JPH028005A - Manufacture of concrete plate body having shaped three-dimensional decorative surface - Google Patents

Abstract

PURPOSE:To prevent a mortar panel from cracking and chipping by a method wherein the mortar panel is adherently left onto a ready-mixed concrete between the mortar panel and the other concrete form panel and, after that, both the concrete form panels and a foamed resin layer are demolded. CONSTITUTION:After the surface of a female mold 2, which has a female surface consisting of a shaped three-dimensional decorative surface and is above a plate 1, is coated with releasant, the surface of the female mold is covered with a surface layer 3 made of polymer- containing mortar and a mortar-containing backing layer 4. In the resultant mortar panel 6, recesses 10, each of which is equipped with a hole, are made at positions corresponding to the respective holes of concrete forms 7 and 8 so as to be attachably fixed to the concrete form panel 8. The concrete form panel 7 is assembled so as to set against the concrete form panel 8 so as to pour and expand foaming urethane resin between the inner surface of the concrete form panel 8 and the mortar panel 6 in order to form a foamed resin layer 21 by filling. After that, ready-mixed concrete is placed between the mortar panel 6 and the inner surface of the concrete form panel 7. After the solidification of the ready-mixed concrete layer 22, the concrete form panel 8 and the foamed resin layer 21 are separated from the mortar panel 6 and at the same time the concrete form panel 7 is peeled off the ready-mixed concrete layer 22 by dismantling the mounting nuts of cones.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method for manufacturing a concrete plate having a shaped three-dimensional decorative surface constituting the outer wall of a building (house or building).

<Prior art> In this way, a concrete plate having a three-dimensional decorative surface on its surface is manufactured by fixing the female mold of the three-dimensional decorative surface to one inner surface of two formwork panels facing each other on the inner surface. Traditionally, reinforcing bars are arranged vertically and horizontally between the opposing inner surfaces of frame panels, concrete is poured after assembly, and both form panels are removed from the mold after the concrete layer has hardened.

<Problems to be Solved by the Invention> The female mold of the three-dimensional decorative surface fixed to one inner surface of the formwork panel is a molded product made of styrofoam, rubber, or other soft material. For this reason, when assembling reinforcing bars vertically and horizontally between the inner surfaces of opposing formwork panels, the reinforcing bars may come into contact with the female mold and damage the female mold, and sparks may occur when joining the vertical and horizontal intersections of reinforcing bars by melt welding. partially melted.

Since the three-dimensional decorative surface of the model is uneven, when ready-mixed concrete is poured between opposing formwork panels, it is difficult for air and moisture to escape upward along the female mold surface, resulting in pinholes and aggregate separation. A nest (Junka), water avatar, etc. that comes into contact with the surface of the female mold is formed.

Therefore, after demolding the formwork panel, these pinholes,
It was necessary to repair the three-dimensional decorative surface of the concrete plate that had been damaged by jumpers, water avatars, etc., or the female part that had been damaged by reinforcing steel or melted by the sparks of melt welding. It takes a lot of work.

<Means for Solving the Problems> Therefore, the present invention forms a mortar panel in which a surface layer is formed using mortar containing a polymer on the female mold surface of a three-dimensional decorative surface, and peels it off from the female mold, and The surface layer is placed opposite to the inner surface of one of the pair of formworks, the mortar panel is separated from the inner surface of the formwork, and is removably fixed, and a foaming layer is provided between the inner surface of the formwork and the surface of the mortar panel. By injecting resin and foaming, a foamed resin layer is filled in between.
The method is characterized in that ready-mixed concrete is placed between the mortar panel and the other formwork panel, the mortar panel is attached to and left on the solidified ready-mixed concrete layer, and both formwork panels and one foamed resin layer are removed from the mold. .

Example: A female mold 2 having a female surface of a three-dimensional decorative surface to be expressed is fixed on a suitable board 1, a mold release agent is applied to the surface of the female mold 2, and then a mortar containing a polymer is applied to the surface of the female mold 2. A surface layer 3 and a backing layer 4 containing mortar cover the surface of the female mold.

The surface layer 3 and the backing layer 4 are preferably formed by spraying with a mortar gun from the viewpoint of work efficiency, and the thickness of the surface layer 3 is about 2 to 5 ml, and the thickness of the backing layer 4 is about 5 to 201 ml. It is.

The purpose of including the polymer in the surface layer 3 is to increase the fluidity of the mortar and spread the mortar even to the fine details of the uneven surface of the female mold 2, thereby faithfully reproducing the uneven surface of the female mold 2. If the three-dimensional decorative surface of the manufactured concrete plate is to be colored, pigments may be mixed into the mortar of the surface layer, and fine particles of quartz or slag may be mixed to make it resemble natural stone such as granite. good. Once the surface layer 3 is formed in this manner, it is preferable to apply a roller to the back surface of the surface layer to form streaks or other irregularities to increase the area of contact with the backing layer 4. It consists of 3 surface layers.

Once solidified, the backing layer 4 is formed.

This backing layer 4 is preferably made of fiber reinforced concrete (FRC) mortar made by mixing mortar with fibers such as class fibers or metal fibers such as iron, but the surface layer 1
The entire back side of 1 is covered with a mesh material 5 made of glass fiber 8-1 carbon fiber, nylon, iron ta, III, etc., nails etc. are nailed here and there to the surface layer 3, and ordinary concrete mortar is sprayed. Good (Figure 3).

After forming the backing layer 4, it is preferable to form streaks similar to those of the surface layer on the back surface of the backing layer 4 to increase the adhesion area with the ready-mixed concrete layer placed between the formwork panels.

In this way, the backing layer 4 is formed, and once it has solidified, both layers 3 and 4 are peeled off as one piece from the surface of the female mold 2 to form a mortar panel 6, and this mortar panel 6 is placed facing each other,
In the meantime, a pair of large formwork panels 7 and 8 made of plywood (veneer board), metal plate, etc., to be cast as ready-mixed concrete, are made to face each other with a surface layer 3 on the inner surface of one side 8, and can be attached and detached with a slight distance between them. Fix it.

As is well known, formwork panels 7 and 8 are provided with holes that face each other or are arranged in the same arrangement when placed side by side.

Therefore, at the beginning of making the mortar panel 6, holes in the same arrangement as the form panel 7.8 are made in the female mold 2 and, if necessary, in the plate 1, and these holes are used to form steps made of plastic on the surface of the female mold 2. The surface layer 3 and the backing layer 4 of the mortar panel 6 are formed on the stepped piece 9 in the stepped piece 9, and the small diameter portion 9' of the piece is made to protrude from the back side of the backing layer 4. , when the mortar panel 6 is peeled off from the surface of the female mold, a recess 10 with a hole is formed in the mortar panel 6 at a position corresponding to the hole in the formwork panel 7.8, where the stepped piece 9 was removed; This is used as a means for removably fixing it to the formwork panel 8.

That is, a nut 12 is screwed onto one end of the pivot bolt 11,
One end of the nut 12 is passed through a hole at the bottom of the depression 10 of the mortar panel, and the nut 12 is brought into contact with the bottom of the depression 10.
A connecting tool 13 such as a hexagonal joint nut with a hexagonal cross section is screwed into the part protruding from the hole, and the bottom of the recess 10 is sandwiched between the nut 12 and the connecting tool 13. By inserting the form tie 14 into the hole 8 from the inner surface and screwing it into the part that protrudes from the outer surface and tightening it, the form panel is sandwiched between the collar of the shaft foot bolt and the form tie, and the form tie 14 is inserted into the inner surface of the form panel 7. The cone 15 passed through the hole is fixed with a nut. 1. Since the mortar panel 6 is uneven, the nut 12 screwed onto one end of the pivot bolt 11 may be attached to the flange 11' at the other end depending on its position.
The distance between the mortar panel 6 and the mortar panel 6 is adjusted so that the mortar panel 6 can be fixed in a parallel manner as a whole from the inner surface of the formwork panel 8. Further, since the surface of the stepped piece 9 that comes into contact with the female mold 2 needs to be processed to match the surface of the female mold, it is preferable to mold it from a foamed resin that is easy to process.

Then, on the outer surface of the formwork panel 8, vertical and horizontal batten materials 16, 16 are placed.
' along the outside horizontal butter material 16' form tie 14
The separator 18 is held by the rib washer 17 attached to the plate and tightened with a nut on the outer surface of the formwork panel 8, and the other end of the separator 18, one end of which is screwed onto the cone 15 of the formwork panel 7, is connected to the connecting tool 13 such as the joint nut. Then, the two formworks 7 and 8 are opposed to each other.

Reinforcement bars 19, 2 are provided at opposing intervals between the formwork panels 7 and 8.
0 are arranged vertically and horizontally, foamed urethane resin is injected and foamed between the inner surface of the formwork panel 8 and the mortar panel 6, the space between them is filled with a foamed resin layer 21, and then the mortar panels 6 are assembled as necessary. Adhesive is applied to the surface of the mold panel, and ready-mixed concrete is poured between the inner surfaces of the mortar panel 6 and the formwork panel 7. lateral pressure applied to the mortar panel 6 due to pouring of ready-mixed concrete;
The foamed resin layer 21 backs up and supports the impact. In addition, the lower surface and both sides between the mortar panel in which the foamed resin is injected and the formwork panel are appropriately closed, and a release agent is applied to the surface of the mortar panel 6 in advance to improve the adhesion with the foamed resin layer 21. It is better to keep it small.

When the ready-mixed concrete layer 22 is solidified, the rib washer 17 is removed and the batten material 16.16' is removed, the form tie 14 is removed, and the formwork panel 8 and the foamed resin layer 21 are attached to the mortar panel 6.
At the same time, remove the pivot bolt 11 and remove it. Further, to attach the cone to the formwork panel 7, remove the nut and peel it off from the ready-mixed concrete layer 22.

As a result, a concrete plate is obtained by attaching the mortar panel 6 and leaving the ready-mixed concrete layer 22.

Of course, a plurality of formwork panels 7 and 8 may be arranged horizontally adjacent to each other, and ready-mixed concrete may be poured between them, but in that case, the mortar 6 attached to each formwork panel 8 may also be arranged adjacently, Injection and foaming of the foamed resin are performed integrally between the connected formwork panels 8 and the mortar panels 6.

<Effects of the Invention> According to the present invention, the surface layer 3 of the mortar panel 6 molded in contact with the female mold 3 faithfully reproduces the uneven decorative surface of the female mold.

Since this mortar panel is fixed to the inner surface of one of the pair of formwork panels 7 and 8 between which the ready-mixed concrete is cast, even if the reinforcing bars come into contact with each other during assembly, melt welding will not occur. Even if it receives sparks, there will be no problem. In addition, the foamed resin layer filled between the formwork panel and the mortar panel adheres to the mortar panel and reinforces it, so the mortar panel is prevented from cracking or chipping due to lateral pressure or impact during pouring of ready-mixed concrete. effectively prevent.

Therefore, what needs to be repaired is the depression 1 formed in the mortar panel.
It is possible to efficiently manufacture a concrete plate body having only the 0 part, and having a female-shaped uneven decorative surface and a shaped three-dimensional decorative surface opposite to the female mold.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, and FIG. 1 is a sectional view of a mortar panel being formed, and FIG. 2 is a sectional view of ready-mixed concrete being poured. In the figure, 2 is a female mold, 3 is a surface layer, 6 is a mortar panel, and 7
and 8 indicate a formwork panel, 21 a foamed resin layer, and 22 a ready-mixed concrete layer. Figure 1 Procedures Arika 1 official book (spontaneous) Figure 2 May 27, 1986

Claims (1)

[Claims] A mortar panel in which a surface layer is formed using mortar containing a polymer is molded on the female mold surface of the three-dimensional decorative surface, and the mortar panel is peeled off from the female mold, and the surface layer is made to face the inner surface of one of the opposing molds. A mortar panel is separated from the inner surface of the formwork and removably fixed, and a foamed resin layer is filled between the inner surface of the formwork and the surface of the mortar panel by injecting and foaming the foamable resin. and placing ready-mixed concrete between the mortar panel and the other formwork panel, adhering and leaving the mortar panel on the solidified ready-mixed concrete layer, and removing both formwork panels and the foamed resin layer from the mold. A method for producing a concrete plate having a three-dimensional decorative surface.