JPH03247802A - Manufacturing method of mosaic pattern of panel block - Google Patents

Abstract

PURPOSE:To save man-power for construction work of panels by arranging colored and small sized blocks in a form in the shape of an illustrated pattern through a joint filler capable of stripping easily, and subsequently placing mortar, concrete, etc., to make a panel block. CONSTITUTION:In the manufacture of a mosaic pattern of a large sized block, after colored and small sized blocks 3 are arranged in the shape of an illustrated pattern through a joint filler on the bottom plate 2 of a form 1, mortar 5 and concrete 6 are placed to solidify, and the joint filler 4 is stripped and collected. The joint filler 4 is manufactured of a material having soft elasticity and has approximate 2-5mm of the depth thereof. The mortar is approximately 5mm in thickness, and then the concrete 6 is placed. Then, the form is released after curing, and the joint filler 4 is stripped to form a panel block. According to the constitution, a mosaic pattern of a large sized panel 10 is obtained, and the man-power for the construction work of the panel can be saved.

Description

[Detailed Description of the Invention] [Industrial Application Field 1] The present invention is directed to the manufacture of landscape blocks that use a large number of colored small blocks and form and integrate mosaic patterns such as designs and letters on the surface to form panels. It is about the method.

[Conventional technology]

For the sake of landscape beautification, patterns such as designs and letters may be drawn on retaining walls of roads, residential areas, parks, concrete block slopes of coasts, lakes, rivers, embankments, etc., or on road surfaces (in the following cases): There is a way.

■ A method of drawing designs using paint on the surface of blocks such as slopes after construction.

■ A method in which several types of small blocks with different surface colors (such as interlocking blocks) are arranged on a slope to form a mosaic pattern.

[Problem to be solved by the invention 1] The pattern drawn in the above method (■) tends to give a cheap impression to the viewers, lacks a sense of luxury, and is difficult to harmonize with the surrounding landscape, so it is unsuitable as a landscape block. .

In method (2) above, mechanized construction is not possible because the small blocks must be laid out one by one on the slope at the site where the small blocks are laid. As a result, there are problems in that a large number of installation workers are required and that manual work at the installation site is inefficient and takes a long time.

In addition, since there has been a serious shortage of workers in recent years, there is a desire for concrete blocks that can be constructed in a labor-saving manner.

As a way to solve the problems of method ① above.

At a concrete product factory, a method in which several types of small blocks with different surface colors are adhered with adhesive onto a large pre-fabricated concrete slab to form a pattern, and the large blocks are arranged on the slope of the site. is possible. According to this method, the blocks delivered to the construction site are large in size, so mechanized construction is possible. As a result, it is possible to significantly save the labor of the laying worker, and the laying work is also speeded up, shortening the construction period.

[Problem to be solved by the invention] However, this method has the following problems.

(a) When bonding small blocks to a concrete flat plate, if the flatness of the flat plate is poor or the dimensional accuracy of the thickness of the small blocks is insufficient, there may be differences in level between the small blocks forming a mosaic pattern. This is not aesthetically pleasing.

When an instant demolding product such as an interlocking block is used as a small block, the immediate demolding product generally has large dimensional errors in thickness, so unevenness is likely to occur due to differences in level.

(b) It is difficult to maintain a uniform and beautiful gap between the small blocks, that is, the joint spacing.

(C) In order to integrate the flat plate and the small block, a large amount of adhesive is used, but since adhesive is expensive, the cost increases.

[Means for Solving the Problems] The present invention provides a method for forming a mosaic pattern when manufacturing a panel-like large block on the surface of which a mosaic pattern is formed by appropriately arranging a large number of small blocks of several different colors. The small blocks are placed on the bottom plate of a formwork for manufacturing large blocks while interposing a joint material having shrinkability, flexibility, and water permeability in the joints between the small blocks on the surface side of the blocks. Lay them out so that their surfaces are in contact with the bottom plate of the form, pour mortar over the small blocks, and then pour concrete on top of them to a predetermined thickness to form a plate-like body that integrates the small blocks. The concrete is characterized in that it is removed from the mold after hardening, and then the joint material between the small blocks is peeled off and recovered.

[Effect]

The method of the present invention produces the following effects.

(B) The flatness of the surface of the panel block can be ensured.

(b) Since the joints are completely sealed with the compressible, flexible, water-permeable joint material, paste leakage will not occur on the surface even when small blocks with serrations are used.

Wool felt is suitable as the joint material of the present invention.

Wool felt is long wool felt (JIS L).
3201), downy wool felt (JIS A 95
08), Recycled felt (JIS L 3204)
Jute felt (JISL320 3) or the like is suitable. These felts are recovered after being used as a joint material, and when left in steam, they recover to their current state and can be used repeatedly.

(c) Since the joint material is permeable to water, the mortar in the joint area becomes dense and has a beautiful surface due to the drainage action of the surface in contact with the joint material.

(d) It is efficiently manufactured in a factory under conditions of careful quality control, and installation is easy and labor-saving.

[Example] FIG. 1 is a detailed explanatory diagram of the present invention.

(a) A large number of small blocks 3 of different colors are laid out on the bottom plate 2 of a formwork 1 for producing large blocks so that the surfaces of the blocks 3 are in contact with the formwork bottom plate 2. At this time, the small blocks are appropriately arranged so that a mosaic pattern such as a design or a letter is formed on the surface of the large block after completion, and a joint material 4 is inserted between the joints between the small blocks.

(b) Pour mortar 5 over the small blocks 3.

(C) Before the mortar begins to harden, concrete is poured and finished to a predetermined block thickness. At this time, it is preferable to insert mesh-like reinforcing bars 7 into the concrete because this increases the strength of the block.

Next, after performing a predetermined curing and demolding, the joint material between the joints between the small blocks is removed to obtain an integrated panel block 10 as shown in FIG. 2.

In this example, the small block 3 used has a surface area of about 100 to 200 crn'' and a thickness of about 5 to 10 cm.This small block 3 can be manufactured using either concrete pouring or immediate demolding concrete. However, from the viewpoint of production efficiency of small blocks, it is preferable to use an instant demolding method because the production cost is lower.

The surface of the small block 3 can be colored using methods such as mixing pigments into the concrete during the production of the small block, spraying powdered resin onto the surface of the small block after production, or spraying resin-based paint. From the viewpoint of aesthetics, the method of spraying powdered resin is most preferable.

The joint material 4 used between the mutual joints of the small blocks 3 is
It serves to prevent mortar poured later from entering the interface between the formwork bottom plate and the surface of the small block and staining the surface of the small block, and to maintain a constant joint spacing.

Wool felt was used for the joint material. This joint material 4 is made of a soft material with high elasticity so that no gap is created between the joint material and the small block 3, and the cement and sand in the mortar do not seep into the joint material itself. It has enough strength to prevent it from breaking when the block is removed after completion.

The thickness of the joint material 4 (dimension in the joint width direction) is slightly thicker than the desired joint spacing, and the width (dimension in the joint depth direction) is selected depending on the desired joint depth, but generally 2. It is about 5 cm.

The joint material should be inserted below the joints between the small blocks as shown in the figure.

When filling with mortar, it is necessary to fill the spaces between the joints above the joints between the small blocks. If the filling condition is poor, there is a risk that the integrity of the small block will be compromised.

Therefore, using a vibrator and using fine sand for mortar are effective in improving filling properties.

The amount of mortar to be poured is approximately 5 mm from the top of the small block.
The thickness should be about mm.

When felt is used as a joint material, by leaving the removed felt in steam for a while, the felt recovers to its original state and can be used repeatedly.

The panel block 10 manufactured as described above has a large number of small blocks 3 forming a mosaic pattern placed in joint mortar 5 and mortar 5 placed on the back side of the small blocks 3.
and concrete 6 to be completely integrated.

FIG. 3 shows a panel block 10 manufactured according to the present invention.
This figure shows an example of a surface diagram of a slope constructed by combining the above. Slope protection blocks with a mosaic pattern laid out according to the original design on the surface can be constructed beautifully and labor-savingly using large working machines.

〔Effect of the invention〕

It has the following superior effects compared to conventional methods.

■ ■ Because the mosaic pattern panel blocks delivered to the installation site are large in size, mechanized construction is possible, resulting in significant labor savings. In addition, the installation work is speeded up, so
The construction period will also be shortened.

Because the large blocks with mosaic patterns are manufactured at a concrete product factory, they are well managed and the finished mosaic pattern is excellent.

■ Because the small blocks are manufactured by arranging their surfaces so that they are in contact with the bottom plate of the formwork, even if there is a large dimensional error in the thickness of the small blocks, there is no difference in level between the small blocks that form the mosaic pattern after completion. , aesthetically pleasing.

■ Because a compressible, flexible, water-permeable joint material is used between the joints between small blocks, the joint spacing (clearance) is constant even if the small blocks are jagged like interlocking blocks. , the joint surface is beautiful and aesthetically pleasing. Also, the joint material can be used repeatedly.

■ Manufacturing costs are low because expensive adhesives are not used, as is the case with the method of gluing small blocks to concrete slabs.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram illustrating the steps of an embodiment of the method of the present invention,
FIG. 2 is a perspective view of the manufactured mosaic pattern panel block, and FIG. 3 is a perspective view of the magazine. l... Formwork 2... Bottom plate 3... Small block 4... Joint material 5... Mortar 6-... Concrete 10... Panel block

Claims (1)

[Claims] 1 Place the small blocks on the bottom plate of the formwork with their surfaces touching the bottom plate while interposing a contractible, flexible, water-permeable joint material on the surface side of the joints between the colored small blocks that are to form a mosaic pattern. Mortar is placed on the small blocks, concrete is poured on the mortar to form a plate-like body integrating the small blocks, and after the concrete hardens, the small blocks are removed from the mold. A method for manufacturing a mosaic pattern panel block, characterized by peeling and recovering joint material from the joints.