JPH0310806A - Forming method for concrete product and surface decorative forming plate - Google Patents

Abstract

PURPOSE:To prevent a decorative material and a joint filling material from peeling off by covering the joint filling material for decoration on both or either of the rear surface of the positioned decorative material and the rear surface of a sealed base and then laminating given concrete in a form and bonding integrally the decorative material, the joint filling material and laminated concrete. CONSTITUTION:Surface sealer aggregates 12 are laid on a surface pallet 2 in the laminated state, and decorative materials 11 are sealed on the surface pallet by being buried in the first sealer aggregates 12. Then, decorative joint filling materials 13 constituted of high molecular resin added to decorative sand composed of the mixture of serpentine sand and silica sand mixed therein are laid thinly in the laminate form the rear surface side of the sealer aggregates 12 filling spaces among the decorative materials 11 and moved to a forming form 1. While a vibrator 3 is started in the forming form 1, a material feeding hopper 6 is advanced and ultra-stiff consistency concrete 14 is fed from the upper surface of the frame. Then, the upper surface is finished in the given shape by pressure vibrating the same by means of a press plate 4, and then a release rod 5 is lifted up to release a block upwardly. The released block A is transferred to a curing chamber.

Description

[Detailed Description of the Invention] <Industrial Application Field> This invention relates to a method for tearing a concrete product to expose decorative gravel or decorative materials on the surface of the concrete product, and a method for tearing a concrete product in which a connecting hook is embedded in the back of a concrete forming plate. The present invention relates to a surface decorative molded board for products.

<Conventional technology> Decorative materials or surface patterns on the surface of concrete products? Forming methods include a wet method in which the cosmetic material is exposed to the surface by washing with water using a hardening retardant or abrasive, and a dry method that does not use water, such as chiseling or shot blasting.

Furthermore, recently, Japanese Patent Application Laid-Open No. 1983-1980 (1986), in which decorative materials were buried in filler sand,
No. 3902 has been developed.

In this method, the decorative material to be exposed on the surface is placed in a sand layer spread on a formwork or surface pallet so that it does not move, and is fixed, then concrete is poured from the back and compacted, and the mold is removed immediately. Afterwards, after curing and hardening, the surface pallet is removed and unnecessary grain sand is removed to expose the decorative materials and patterns on the surface.

<Problems to be solved by the invention> Filler sand is spread on the bottom of the formwork or surface pallet, gravel and materials for surface decoration are placed on top of it, and cemented carbide concrete is poured from the back side. When compacting with vibration and pressure,
Due to the diversification of decorative materials used for surfaces, if the decorative material has many irregularities, it is necessary to spread the sealing sand in a layer to the thickness of the protruding layer, otherwise the decorative material placed on the surface may vibrate and move during pressure molding. In addition, the concrete poured from the back leaks through the decorative material on the surface and is exposed.Also, the decorative material and concrete with filler sand are used to bond the concrete, but with cemented carbide concrete with low moisture content, hardening is not sufficient. The problem is that the filler sand that forms the surface due to wind and rain after construction is easily peeled off and the concrete surface is exposed, spoiling the landscape.

In addition, when using expensive cosmetic materials with different colors to increase added value, the eye sand that forms the surface together with the cosmetic materials must be harmonized with each color, so a large amount of eye sand must be used each time. This increases the production cost and requires replacing the grain sand used for each type of cosmetic material, which has become a bottleneck in the pre-treatment process for laying out the cosmetic materials.

The present invention is a cosmetic joint material that also serves as filler sand that is compatible with various types of decorative materials. A method in which the exposed part to be formed is filled in advance and bonded, and the joint material is formed in such a way that the exposed decorative material and the joint material do not peel off after the application and the exposed decorative material and the joint material peel off. The purpose of this invention is to provide a concrete unit forming plate that is easy to form.

<Means for Solving the Invention> In order to achieve the above object, the manufacturing method of the present invention does not require a decorative material to be exposed on the bottom of the formwork or on the surface pallet. When placing
The first layer in which the cV'i material is buried and fixed, and the superficial aggregate (
sand)? : It is a good idea to use a joint material as a second layer filler aggregate that also serves as a decorative surface with different properties that match the decorative materials used.

Then, even when using various different decorative materials, the first layer of filler aggregate, which is common to all, is supplied to the pretreatment process line and laid in layers on the formwork or surface pallet, and the decorative materials are applied to the first layer. Eyes with a color that harmonizes with the decorative material that is buried and fixed in the upper aggregate layer and then exposed on the surface, and that have a color mixed with a predetermined proportion of resin etc. to enhance the bonding strength and sound with the concrete being poured. The adhesive is filled between the decorative materials and in the areas where the surface is to be formed.

After completing the pre-treatment process in this way, the carbide comfleet mixer was introduced from the back and vibrated.

Pressure molding is performed.

Due to this rL, there is no movement of the decorative material even during vibration pressurization, and the bond between the cemented carbide concrete poured from the back and the joint filler, which also serves as the decorative material and the second filler aggregate layer, is strengthened, resulting in surface cracking after curing and hardening)? When the first layer of aggregate is removed, the entire decorative surface is firmly bonded to the surface by a surface-decorative joint material that matches the decorative material used, and is also integrally connected to the concrete on the back. .

This invention solves the problem in which the decorative material buried in the filler aggregate (sand) layer conventionally moves during molding or the poured concrete is exposed due to peeling of the filler aggregate layer. The back surface of the first filling aggregate layer is coated with a joint material that has a bonding strength that also serves as a decoration that matches the surface decorative material, which can also be called the second filling aggregate layer, to integrate each decorative material. This prevents the decorative material embedded in the first filler aggregate layer from moving during molding, and prevents the poured concrete from leaking to the surface, creating decorative joints that harmonize with the decorative material that is exposed to the surface after curing and hardening. A natural stone pattern can be obtained without peeling even after construction, and environmental conservation can be achieved.

In this way, the present invention separates the first filler aggregate layer and the second filler aggregate layer, which also serves as a decorative joint material, so that the decorative material, the decorative joint material, and the backing concrete are firmly solidified as one body. It is.

In addition, for blocks with decorative surfaces that have connecting hooks buried in the back of the block, the lower part should be fixed to the foundation base using a rooting stand, and then the blocks should be stacked in several stages using connecting fittings before concrete is poured all at once. This allows for significant labor savings.

<Example> Next, a method for manufacturing a concrete block having a decorative material of the present invention and an embodiment of a molded plate will be described with reference to the drawings.

Figures 1 to 7 show cases in which powdered fine aggregate is used as a base for fixing decorative materials on a surface pallet, and a top aggregate layer for sealing is also applied to the gaps between the decorative materials. This is an example showing the process of immediate demolding, in which the decorative material of natural stone is laid and buried on top of it, and the decorative material of natural stone is exposed on the surface after curing and hardening.
1 is a mold for immediate demolding, 2 is a surface pallet, and 11 is a decorative material to be exposed on the surface.

12 is the first filling aggregate layer, 13 is the second filling aggregate that also serves as a decoration, 14.24 is the cemented carbide concrete and the connecting hook, 18 is the pouring form, and 25 is the Styrofoam insulation. It is a board.

Figures 10 to 13 show an embodiment of the pouring method in which the molded plate is removed from the formwork after the concrete has hardened.

The joint material that is used as a decorative material to be filled between the decorative materials mentioned here is a mixture of general decorative mortars, borax with pigment added, and fine aggregate obtained by crushing the cosmetic materials used, and cement. It shall include mortar or concrete mixed with a binder such as a resin or a binder.

Now, the surface VC! ! An example of an instant demolding method using coarse aggregate obtained by crushing river gravel with sepenite as a fixing base will be described as a decorative material to be released.

First of all, the first filler aggregate 12 consisting of grain size 0.51X~3~ is laid in a layer to a thickness of about 25% on the pallet 2, and the upper surface is rubbed flat, and then the first filler aggregate 12 with grain size 25~~40 is laid on the surface pallet 2. As shown in FIG. 2, the decorative material is fixed to the surface pallet by embedding the snake stone in the first filler aggregate 12 as shown in FIG.

Subsequently, decorative joint material with resin of Batebasa is mixed with decorative sand mixed with 2KfVc silica sand and 0.5Kf'a' of silica sand, which is used as a decorative material exposed on the surface. 13? : As shown in Fig. 3, the filling aggregate 12 filling the gaps between the buried decorative materials 11 is covered with a thin layer to prevent it from leaking to the surface when long concrete is poured from the back side. In this way, cosmetic resin-containing joint material 1 is prepared in the pretreatment process.
3 coated surface L/t2fj! :Move to molding frame 1.

Demolding rod 5Vc feeder on the top of the formwork Pallet 2
is stopped at a predetermined position on the lower surface 8 of the formwork by lowering the demolding rod, and when the insertion board 10 is pushed in from the rear double-length side of the formwork, the vibrator 3 is started and the material supply hopper 6 moves forward to remove the formwork. Cemented carbide concrete 14 is supplied from the upper surface 9, and the upper surface is pressurized and vibrated formed by the press plate 4 to finish it into a predetermined shape, and then the demolding rod 5 is raised as shown in FIG. 7 to form the block. Remove from the mold upward.

The demolded block A is placed on a product transport rack (not shown) VC by the take-out fork 7 and transported to the curing room.On the other hand, the demolding rod 5Vc is moved to the next pre-treated n-sided pallet 2.
When the material is supplied, the demolding rod 5 descends within the formwork 1, the surface pallet stops at a predetermined position within the formwork, and the above-mentioned forming operation is repeated.In this case, the material is fed from the top of the formwork. The cemented carbide putty pasa concrete is vibrated and pressurized so that the decorative material and the concrete are firmly joined together through the decorative resin-containing joint material 13.

Then, on the surface of block A after initial curing (when the let 2 is removed and the first filler aggregate 12 is removed, a joint filler 13 of crushed grains of the same color that matches the snakestone is formed on the surface, which is natural. A surface of a concrete block that is similar to the surface of a stone can be obtained.0 Although the embodiment of instant demolding using the surface pallet of the present invention has been described above, the bottom surface 16 of the surface pallet 2 is not necessarily flat and can be easily seen. In order to prevent the upper aggregate layer 12 from moving due to vibrations, it is possible to make an uneven shape as shown in FIG. 9, or to use a material with an uneven bottom surface depending on the size of the decorative material used and the burial interval. Good 0 The joint material 13 that also serves as ground surface decoration is not necessarily limited to the crushed particles of the cosmetic material used, but can also be mixed with pigments, surface strength, and admixtures that increase waterproofness depending on the size of the cosmetic material, application location, etc. Any material that can be compacted together with the main body of the product, such as mixing fibers or fibers, is acceptable. Figure 8 shows a fixing base made of a shell filled with powdered glass beads, which makes it easy to peel off after curing. be.

FIG. 10 shows an example in which a concrete unit molding plate B with connecting holes 24 embedded in the back side is formed by the pouring method, and it is laid on the bottom 19 of the pouring form 18 and placed on top of the nine-stop aggregate layer 12. After embedding the decorative material of Teppei stone 26 on almost the entire surface, covering the back side of the filler aggregate layer 12 with hard kneaded decorative joint material 13 made of pigmented cement mortar mixed with polymer, and then connecting hooks 24. The polymer cement mortar is placed on the upper surface of the joint material 13 and fixed in the formwork 18, and then moved onto the vibrating table 21 as shown in FIG. After pouring concrete 23 of about 5 increments while applying vibration, the upper surface is finished by protruding a part of the connecting hook 24 into which the mounting fitting is inserted.

After curing and hardening, the formwork clamping fittings 20 are released and the product is taken out.The filler aggregate layer 12' and feathers remaining on the surface decorative surface are removed to expose the decorative surface with the outline of the teppei stone standing out. be able to.

Above, we have explained one example of the immediate demolding method and the pouring method using the pouring formwork 18, but in both cases, the back side of the first filler aggregate layer is filled with the joint material 13 which also serves as a decoration and then laminated. This prevents the concrete from leaking to the surface or the decorative material from moving during molding, and also allows the decorative material, joint material, and concrete body to be firmly connected through the joint material that also serves as a decoration.

FIG. 14 shows a case where a decorative material is exposed on the upper and lower surfaces of a product using soft concrete, and the slump yong concrete 23 is molded from the back side of the pretreated decorative material 11 on the lower surface of the formwork 18 in the manner described above. Pour the concrete so that the top surface of the frame is completely covered, and when the fluidity of the concrete decreases and the specified hardness is achieved, fill the concrete so that the surface of the decorative material protrudes from the top surface of the concrete. 13 is filled and the cosmetic material is exposed directly.

Alternatively, the decorative material 11 is buried in the fixing base E or the filler aggregate layer 12Vc in advance and the surface pallet 2 applied to the joint material 13' is covered with the upper surface concrete and cured integrally, and after curing and curing, it is removed from the formwork. Then, the upper and lower surface pallets 2 may be removed and the filler aggregate may be removed to allow the cosmetic material to be sprayed out on both sides0.Furthermore, the fixing base E for fixing the cosmetic material is a flexible body that is easily removable. Powder or gas inside the shape.

The cosmetic material may be fixed by filling it with a liquid or the like and deforming it to act as a cosmetic material.

FIG. 15 shows how a foamed polystyrene board 25 for heat insulation is combined with the back surface 27 of the concrete molded board B to form a wall surface for external heat insulation.

The foamed polystyrene used for heat insulation to be combined on the back side does not necessarily have to be in the form of a plate; instead, wet particles such as foamed polystyrene particles with a low specific gravity coated with a binder containing a hydraulic resin are used to make them fluid. A waterproof coating 28 may be sprayed onto the degraded slump concrete 23 and then uniformly applied to form a non-concrete and concrete V-body in a laminated manner.

In this way, by laminating and solidifying multiple different types of concrete and non-concrete in a formwork, it is possible to manufacture high value-added concrete products with excellent surface cosmetics, heat insulation, strength, and light weight. It is.

In addition, the connecting hook 24 buried in the back side also has the width 17 of the molded plate.
If you bury it in a vertical position that is closer to the inside from each end for the length of 4, even when the upper tier is lined up on top of the lower tier with potato joints, the upper tier will be shifted sideways by 1/2 of the width and the upper tier will be placed on top of the lower tier. ! Even when they are lined up at a broken joint, they interfere with each other and can be assembled firmly, making it possible to construct a safe and economical retaining wall using lightweight composite boards.

Effectiveness> The exposure molding method for cosmetic materials of the present invention is divided into a base for fixing the cosmetic materials and a joint material that also serves as a cosmetic, so it is possible to use the same fixing base for materials with large irregularities and many types of cosmetic materials with different colors. Since it can be used, there is no need to replace it, and a decorative joint material can be applied to the surface to match the decorative material used to form nine decorative surfaces.

Furthermore, after application, the surface decoration can be formed as originally planned without peeling of the surface decoration due to wind and rain.

[Brief explanation of drawings]

Figures 1 to 7 are partial front cross-sectional views of the instant demolding method using a surface pallet according to the present invention, and Figures 8 and 9 show a fixing base in the form of a hollow body filled with powder and undulations. Figure 10 is a diagram showing the process of the pouring process, and Figure 11 is a cross-sectional view of the molded plate, and Figures 12 and 13 are diagrams showing another example in which the shape is applied. A cross-sectional view and a plan view of the integrally solidified spear frame, and Figure 14 shows the product N when the decorative material is exposed on both sides.
FIG. 15 is a cross-sectional view showing the implementation status of the external heat insulation wall, and FIG. A: Laminated block, C: Insulating molded plate, E: Fixing base, 1: Formwork,
11... Cosmetic material, 12... Filling aggregate layer, 15... Surface, 17... Uneven portion,
24... Connecting hook, 26... Teppei stone, 29... Made of solid wood, 30... Glass pieces, 31... Basic base , 32...
・Stand for roots.

Claims (8)

[Claims] (1) Fix the decorative material laid in the formwork. Place the decorative material to be exposed on the surface on the base. Concrete is poured from the back of the placed decorative material and compacted. After the concrete has cured and hardened, the decorative material is placed on the base. In the manufacturing method of concrete products that removes the fixation base of the material, the back of the fixed decorative material and the back of the fixation base, or either one of them, is coated with a decorative joint material, and then the specified concrete is laminated within the formwork. A method for forming concrete products, which is characterized by combining decorative materials, joint materials, and laminated concrete into one piece, and exposing the decorative materials to the surface after curing and curing. (2) Decorative material laid out in the formwork is fixed on the base with the cosmetic material exposed on the surface fixed, the back of the fixing base or either side is coated with a cosmetic joint material, and then placed inside the formwork. A method for forming a concrete product, which is characterized by laminating concrete in a predetermined manner on the top surface of the laminated concrete, shaping the top surface of the laminated concrete into a desired shape, supplying a decorative material, and compacting the concrete so as to expose the decorative material on the top and bottom surfaces. (3) The method for forming a concrete product according to claim 1 or 2, characterized in that the base on which the decorative material is fixed is an aggregate layer made of powder or granules. (4) A claim characterized in that the decorative material is buried in an aggregate layer spread on a surface pallet in advance, covered with joint material, and then supplied to the top or bottom of the form, compacted, and immediately removed from the form. A method for forming a concrete product according to item 1 or 2. (5) Claim 1, 2 or 3, characterized in that the concrete to be laminated is soft concrete with slump.
Method for forming concrete products as described in section. (6) The method for forming a concrete product according to claim 4 or 5, wherein the decorative material exposed on the surface is natural stone. (7) A concrete molded plate whose front and back parts have approximately the same height, and from which protruding hooks protrude in pairs to lock and fix connecting fittings for vertically stacking molded bodies. The surface decorative molded board is characterized in that the decorative material exposed on the surface is exposed by removing an unnecessary sealing aggregate layer laid in the formwork after the concrete hardens. (8) The decorative material is natural stone and is approximately 1/5 to 1/5 of the thickness of the molded board.
8. The surface decorative molded board according to claim 7, characterized in that a surface decorative material having a thickness of 2 mm is embedded therein.