JP5613933B1 - Method for producing replicas of antique bricks using lightweight concrete - Google Patents

Abstract

An object of the present invention is to provide a method for producing a replica of an antique brick that reproduces the individual shape and color of the brick to be replicated using lightweight concrete. A mortar paste colored in advance and lightweight concrete are poured in two stages and cured while applying vibration to a transfer mold imitating a brick to be replicated. According to this method, a faithful replica of an antique brick made of lightweight concrete can be produced without using a spray gun. [Selection] Figure 1

Description

  The present invention relates to a method for producing a replica of an antique brick using lightweight concrete.

  Brick is often used for historic buildings and antique-style buildings. And bricks have the charm that after a long period of time, the corners and the surface are worn away by weathering, and color irregularities occur, creating a unique atmosphere. Therefore, a method of manufacturing a newly manufactured brick so as to have a weathered feeling from the beginning has been proposed.

  One example is the publication of JP-A-7-97251 (hereinafter referred to as “Patent Document 1”). In Patent Document 1, in the firing step of the unfired brick, first, the first step in which the temperature in the kiln is sintered at a high temperature of 1050 ° C. to 1080 ° C., and then the supply of air sent into the kiln is reduced to 1100. In the second step of high-temperature sintering from ℃ to 1200 ℃, all or part of the brick surface is obtained in a reducing atmosphere to obtain a baked brick that is slightly darker than normal red brick, and the baked brick is put in a drum. There is disclosed a method for producing period colored bricks, which comprises a third step of obtaining a brick with a corner worn away by adding a mixture of an abrasive such as sand and water and stirring. With this method, bricks with a weathered atmosphere can be produced from the beginning.

However, bricks manufactured by this method have the disadvantages that they are heavy and hard to construct, as are common bricks.
Furthermore, there are the following problems when repairing an existing building using bricks while maintaining its original shape. The first is that the color of bricks is determined by the soil used as the raw material, so it does not have the same color as existing buildings. Second, it is not possible to produce individual replicas that have the same shape and color as the original brick. And if the building to be renovated is an important cultural property, it is not allowed to add the same material. This is because the use of materials that cannot be distinguished between before and after refurbishment in order to take over the building for future generations is prohibited in principle.
From the above, the invention of Patent Document 1 is a brick whose surface is worn after production, and therefore cannot solve these problems.

Japanese Patent Application Laid-Open No. 2002-154856 (hereinafter referred to as “Patent Document 2”) discloses a method of manufacturing a pseudo rock panel with waste glass mortar. This is a pseudo-rock panel by preparing a silicone mold molded from natural stone or sculpture, spraying waste glass-based fresh mortar with a commercially available mortar gun and air compressor, and removing the mold after the mortar is cured. It is a method of manufacturing.
Further, in Japanese Patent Application Laid-Open No. 51-98117 (hereinafter referred to as “Patent Document 3”), a cement gun mortar containing foam aggregate and fine aggregate on the inner surface of an elastomer mold having an uneven pattern is spray gun. And spraying with reinforcing material mixed, forming a plate with the required thickness, demolding after curing, applying epoxy resin adhesive, spraying and bonding metal powder, made of cement with a metal-like surface A method of manufacturing a lightweight decorative building material is disclosed.

JP-A-7-97251 Japanese Laid-Open Patent Publication No. 2002-154856 JP-A 51-98117

However, the invention of Patent Document 2 is mainly intended to produce a shaped object that imitates a natural object, and the invention of Patent Document 3 is intended to produce a lightweight decorative incombustible building material made of cement having a relief-like metal-like surface. As intended, these inventions do not make it possible to produce individual replicas that have the same shape and color as the original brick. Moreover, since the invention of patent document 2 and patent document 3 has the process of spraying mortar etc. with a spray gun on the inner surface of a formwork, a manufacturing process is complicated.

  Accordingly, an object of the present invention is to provide a method of manufacturing a replica of an antique brick that reproduces the shape and color of each brick to be replicated using lightweight concrete.

  In order to achieve the above object, the method for producing a replica of an antique brick according to the present invention is to pour and harden the mortar paste colored in a transfer mold imitating the brick to be replicated and lightweight concrete in two stages. Is characterized by producing a replica of antique bricks.

That is, the present invention is a first step of making a transfer mold including a side surface of a replication target brick using a mold material,
A second step of making a plurality of mortar pastes each having a different color by mixing and stirring light and fine aggregate having a diameter of less than 3 mm with water, cement, and moisture so that each one does not fall apart, and a pigment;
A portion of the mortar paste arbitrarily selected from the plurality of mortar pastes is mixed with a lightweight coarse aggregate in a dried state having a diameter of 3 mm to 30 mm, and the lightweight coarse aggregate floats on the surface without absorbing moisture. and a third step of making the lightweight concrete and the stirring of the degree to come,
A fourth step of making a mortar layer by mixing the plurality of mortar pastes while mixing the transfer mold, or by gently mixing once or twice and pouring into the transfer mold;
A fifth step of making a lightweight concrete layer by placing the lightweight concrete on the mortar layer;
A sixth step of re-vibrating the transfer mold;
A seventh step of making a replica of the brick by curing the mortar layer and the lightweight concrete layer;
An eighth step of removing a brick replica from the transfer mold;
Have
The mixing ratio of the cement and the lightweight fine aggregate in the second step is 1: 1 to 2 in volume ratio,
The mixing ratio of the cement and the water is 1 to 0.25 to 0.5 in mass ratio,
The mixing ratio of a part of the mortar paste arbitrarily selected from the plurality of mortar pastes in the third step and the lightweight coarse aggregate is 1: 0.5 to 5 in the volume ratio. This is a method for producing a replica of a lightweight concrete antique brick.

The antique brick manufacturing method of the present invention is the method of casting a lightweight concrete after pouring a plurality of mortar pastes having different colors while applying vibration without forming a lightweight concrete at a time, and forming a mortar layer. The vibration is applied again. This prevents adverse effects when placing lightweight concrete from the beginning, that is, lightweight aggregates and air are biased on the surface of the manufactured antique brick replica, and the finished surface is in a bubble-like form. Yes. As a result, the finished surface including the side of the replica of the antique brick is formed to be exactly the same as the brick to be replicated, and the lightweight aggregate is biased on the back side of the replica of the antique brick. At this time, the amount of the mortar paste poured into the transfer mold is preferably less than half of the capacity of the transfer mold. Usually, it waits for spontaneous curing, but it can also be accelerated by steam with steam.

And by mixing multiple mortar pastes with different shades, or lightly mixing once or twice, and pouring into a transfer mold, it is possible to more reliably prevent uneven color due to aging of bricks and unevenness of fire when firing old bricks. Can be reproduced.

Furthermore, if the diameter of the lightweight fine aggregate is less than 3 mm, the affinity with water and cement is good and the diffusion is evenly distributed, and the unevenness of the transfer mold can be faithfully reproduced. Further, if the diameter of the light rough aggregate is 3 mm or more and 30 mm or less, the moisture is not easily absorbed up to the air layer of the light rough aggregate, and the light rough aggregate is unevenly distributed on the upper surface when the lightweight concrete is placed. The replica of the antique brick produced in this way will become lighter as it gets closer to the back side while maintaining a firm texture on the surface. If you compare it to food, the surface will be crisp and the inside will have a slightly fluffy finish.

  The method for producing a replica of a lightweight concrete antique brick according to the present invention is such that a lightweight concrete or air is applied to the surface of a finished antique brick replica by casting the lightweight concrete after pouring mortar paste onto the transfer mold surface. Is biased, and the finished surface is prevented from becoming a bubble-like mode. As a result, the finished surface of the replica of the antique brick is formed exactly like the brick to be replicated, and the light weight aggregate is biased on the back side of the replica of the antique brick so that the overall weight can be reduced. is there.

FIG. 1 is an explanatory view showing a manufacturing process of a replica of an antique brick. FIG. 2 is a perspective view showing a state in which a transfer mold is filled with a brick to be duplicated and wax. FIG. 3 is a perspective view showing a state in which the transfer mold is filled with silicone rubber. FIG. 4 is a perspective view of the transfer mold. FIG. 5 is a cross-sectional explanatory view showing a manufacturing process of a replica of an antique brick.

  A method of easily manufacturing a lightweight concrete replica that faithfully reproduces the brick to be replicated will be described with reference to the drawings.

  FIG. 1 is a process diagram of an embodiment of the present invention, in which S110 to S180 indicate a first process to an eighth process, respectively. 2 is a perspective view of a transfer mold filled with bricks and wax to be replicated, FIG. 3 is a perspective view of a transfer mold filled with Sicicorn rubber, FIG. 4 is a perspective view of the transfer mold, and FIG. It is sectional explanatory drawing which showed the manufacturing process of the replica of an antique brick.

First step (S110): As shown in FIG. 2, a base for laying a melted wax 14 on the bottom of a box-shaped transfer mold 10 that can be dismantled such as wooden or iron is buried. Then, about half of the brick 12 to be copied is buried in the foundation. Thereafter, as shown in FIG. 3, silicone rubber 20 containing a curing agent as a shaping material is poured into the transfer mold 10 and cured. Next, the transfer mold 10 is disassembled, and the wax 14 and the brick 12 to be copied are removed from the silicone rubber 20 to form a transfer mold 30 as shown in FIG. In this embodiment, the use of wax 14 as a base realizes cost reduction.
In addition, although the transfer mold 30 of the present embodiment is created as a set of six bricks to be replicated, the number of bricks in one set of the transfer mold 30 is arbitrary. However, if the size is about the size of a brick, the limit is 6 pieces per set. If the number is larger than this, distortion may occur at the time of demolding, and a brick replica may be broken.

  The transfer mold 30 is created by a known method as described above. Then, a release agent is applied to the surface of the transfer mold 30. A release agent is not always necessary, but if the release agent is not applied, the probability of damaging the duplicated product at the time of release is increased. In this embodiment, the back side of the brick is not duplicated, but the entire transfer mold including the back side can be made by a known method. As the shaping material, wax, urethane rubber, rubber, gypsum, sand, clay and the like can be used in addition to silicone rubber.

Second step (S120): Lightweight fine aggregates 1-2 are mixed with Portland cement or white cement volume ratio 1, and further pigment is added for coloring. The amount of the pigment is adjusted while looking at the hue.
Add water to make mortar paste. The amount of water added is in the range of 0.25 to 0.5 water with respect to cement 1 in terms of mass ratio. The smaller the amount of water with respect to the cement, the stronger the finished brick replica, but the surface texture will be softer, so the amount of water will be adjusted according to the desired texture. A plurality of mortar pastes having different colors, that is, a plurality of A materials are produced by the same operation.

At this time, if the weight is further reduced, bubbles may be generated in the mortar with aluminum powder, an air set or the like. In addition, when the finished product is used outdoors, a concrete water repellent may be added to the mortar paste.
The lightweight fine aggregate used here is a glass foam or pearlite having a diameter of less than 3 mm, a baked shell, a polystyrene foam or the like. Each of these lightweight fine aggregates has such a degree of moisture that it does not fall apart. Let the mortar paste produced | generated above be A raw material.

Third step (S130): Next, generation of the B material will be described. Select any A material from a plurality of A material made in the second step, this time making B material lightweight concrete mix diameter 3mm or more rough aggregate thereto. At this time, A material and coarse aggregate are mixed lightly. The coarse aggregate is used in a dry state, and lightly mixing means mixing so that the coarse aggregate does not absorb moisture and floats on the surface of the A material. This is because, by mixing lightly in this way, it is possible to reduce the weight by enlarging the voids in the material and increasing the air layer.

Since the A material plays a large role as a binder, the mixing ratio at the time of generating the B material is 0.5 to 5 that is a light rough aggregate with respect to the A material 1 in volume ratio. Here, the lightweight coarse aggregate may be as large as about 30 mm in diameter, and is a glass foam or perlite, a baked shell, a polystyrene foam, or the like.
In this way, the material A plus the light rough aggregate is designated as material B. This completes the preparations. Subsequent steps will be described with reference to FIG.

Fourth step (S140): Next, the generated plurality of A materials are poured into the transfer mold 30 while being vibrated without being mixed or lightly mixed . At this time, it is possible to vibrate well by using a table vibrator or hitting the transfer mold 30 with a hammer.
By applying vibration, a smoother finished surface is formed on the finished surface of the transfer mold 30 than a thin aggregate. This effect eliminates the need to spray with a spray gun first. Further, by using a plurality of A materials, it is possible to reproduce the color unevenness of aged deterioration that cannot be expressed by one color and the unevenness of firing at the time of brick firing. Note that the amount of the A material to be poured is less than half of the capacity of the transfer mold 30. After the A material is filled, the mortar layer 40 is formed as shown in FIG.

  Fifth and sixth steps (S150, S160): Thereafter, the B material is poured into the transfer mold 30. At this time, the B material is poured into the central portion of the transfer mold 30 and then adjusted using a trowel or the like while keeping the upper surface horizontal. Then apply vibration again. After filling with the B material, the state becomes as shown in FIG. 5C, and the lightweight concrete layer 50 is formed on the mortar layer 40.

  In this way, by a series of operations that are poured into the A material and the B material, the outer side is tightly packed, but there is an air layer inside, so that both securing of the texture and weight reduction can be realized.

  Seventh and Eighth Steps (S170, S180): The mortar layer 40 and the lightweight concrete layer 50 in the transfer mold 30 are naturally cured, and after being cured, they are taken out from the transfer mold 30 to complete a brick replica 60. A state in which the brick replica 60 is taken out from the transfer mold 30 is shown in FIG. It is also possible to accelerate the curing by spraying water vapor when curing. In addition, when the manufactured replica is used outdoors, a water repellent is applied to the surface of the replica. After that, it is cured and stored for about 6 weeks until the strength of the concrete comes out.

  Any type of transfer can be copied, so it can be applied not only to replicas of antique bricks, but also to replicas of a wide variety of tangible objects such as old stone statues, weathered natural stones, and original ceramics.

10 Transfer Form 12 Brick to be Replicated 14 Wax 20 Silicone Rubber 30 Transfer Mold 40 Mortar Layer 50 Lightweight Concrete Layer 60 Antique Brick Replica

Claims (1)

A first step of making a transfer mold including the side of the brick to be replicated using a mold material;
A second step of making a plurality of mortar pastes each having a different color by mixing and stirring light and fine aggregate having a diameter of less than 3 mm with water, cement, and moisture so that each one does not fall apart, and a pigment;
A portion of the mortar paste arbitrarily selected from the plurality of mortar pastes is mixed with a lightweight coarse aggregate in a dried state having a diameter of 3 mm to 30 mm, and the lightweight coarse aggregate floats on the surface without absorbing moisture. and a third step of making the lightweight concrete and the stirring of the degree to come,
A fourth step of making a mortar layer by mixing the plurality of mortar pastes while mixing the transfer mold, or by gently mixing once or twice and pouring into the transfer mold;
A fifth step of making a lightweight concrete layer by placing the lightweight concrete on the mortar layer;
A sixth step of re-vibrating the transfer mold;
A seventh step of making a replica of the brick by curing the mortar layer and the lightweight concrete layer;
An eighth step of removing a brick replica from the transfer mold;
Have
The mixing ratio of the cement and the lightweight fine aggregate in the second step is 1: 1 to 2 in volume ratio,
The mixing ratio of the cement and the water is 1 to 0.25 to 0.5 in mass ratio,
The mixing ratio of a part of the mortar paste arbitrarily selected from the plurality of mortar pastes in the third step and the lightweight coarse aggregate is 1: 0.5 to 5 in the volume ratio. To make a replica of lightweight concrete antique brick

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