JPH06280388A - Construction method for concrete structure - Google Patents

Abstract

PURPOSE:To improve weather resistance of a colored material layer formed by giving arbitrarily designed coloration to projected patterns of the concrete hardened body surface. CONSTITUTION:Concrete is placed between a foam resin form work 2 having a recess part 5 where natural stone-like projected patterns are formed and a foundation material 1, and natural stone-like projected patterns are formed on the surface. A colored material layer which can be connected to a concrete hardened body is formed on the recess part 5 of the form work and the colored material layer is transferred chemically to the concrete hardened body surface by the chemical reaction to color the patterns. The colored material is stuck to the concrete hardened body surface by an adhesive.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for constructing a concrete structure in which the surface of a convex pattern formed on the surface is colored like natural stone.

[0002]

2. Description of the Related Art Since ancient times, it has been customary in Japan to form a stone wall in which natural stones are piled up at a boundary with another person's property.
This stone wall is made up of many natural stones of different shapes and has a Japanese atmosphere.

However, in recent years, it has become difficult to construct a stone wall by a technique that has been used since ancient times due to a shortage of natural stones for forming a stone wall, a shortage of stone wall craftsmen, and the like. Under such circumstances, a concrete structure with a natural stone-like convex pattern formed on the surface is formed by placing concrete using a mold in which various forms are transferred from natural stone to resin foam. However, after the concrete has hardened, the formwork is removed, and the portion of the convex pattern formed on the surface that looks like natural stone is colored in the same way as natural stone to form a pseudo stone wall.

However, it is very difficult to color the concrete surface so that it looks like natural stones at the work site, and if the color is wrong, not only will it create a taste, but it may also destroy the surrounding environment. Further, such a coloring work is very troublesome since it is necessary to manually color each convex projection pattern.

There is also a method in which the concrete itself is colored by adding a pigment or a dye, and the colored concrete is placed. However, this method has the advantage that the pseudo-stone wall has a single color, and thus the goodness of the stone wall is obtained. Often not.

[0006] Further, it has been proposed that the concrete material is poured into the concave portion and the concrete material is permeated into the convex portion of the concrete at the same time as the stone wall is colored by using a formwork in which the concave material is dispersed. Some of them do not have good affinity with kuncrete, and in such a case, coloring durability cannot be ensured.

The pseudo stone wall needs to be colored in the same color scheme as the stone wall made by stacking natural stones, and this pseudo stone wall is used for a very long period of time, and, as much as possible, do not touch it. It is preferable that the initial state be maintained, and development of a method for easily constructing such a pseudo stone wall is desired.

[0008]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for easily constructing a concrete structure which is a pseudo stone wall having an appearance similar to that of a natural stone pile.

[0009]

A first method for constructing a concrete structure according to the present invention is based on a foamed resin mold having a recess in which a projecting pattern like a natural stone is formed by placing concrete. A space for pouring concrete is formed between the materials and arranged, then concrete is poured into the space, and after the concrete has hardened, the formwork is removed to give a natural stone-like appearance to the surface. In a method for constructing a concrete structure having a protruding pattern formed, a colorant layer that can be chemically bonded to the concrete surface is formed in the recess of the foamed resin mold along with the hardening reaction of the concrete. It is a feature that at least a part of the components in the coloring material layer is chemically bonded to the concrete by the hardening reaction of the concrete to color the natural stone-like protruding pattern surface of the concrete structure. It is set to.

The second concrete structure of the present invention
The method of construction is that a concrete foam space is formed between the foundation material and a foam resin mold having a recess in which a natural stone-like protruding pattern is formed by pouring concrete. In the method for constructing a concrete structure in which a natural stone-like protruding pattern is formed on the surface by arranging and then pouring concrete into the space and removing the formwork after the concrete hardens Concrete is placed between the foam resin mold and the foundation material in which the colorant layer and the adhesive layer are laminated in this order, and the colorant layer is used as a natural stone-like projecting pattern of the concrete structure. It is characterized in that it is adhered to the surface of, and the surface of the protruding pattern like natural stone is colored.

[0011]

In the first construction method of the present invention, since the coloring material layer made of a component that can be chemically bonded to the concrete surface is formed in the concave portion of the foamed resin mold in accordance with the hardening reaction of concrete, Concrete is poured, and as the curing reaction proceeds when this concrete hardens, the reactive components in the colorant react with this concrete to form a robust colorant layer on the concrete surface. Therefore, the coloring material layer transferred to the surface of the concrete is integrated with the concrete and thus has very good weather resistance.

According to the second construction method of the present invention, since the coloring material layer is formed in the concave portion of the foamed resin mold through the adhesive layer which can be bonded to the concrete surface due to the hardening reaction of concrete, Concrete is poured, and as the hardening reaction proceeds when this concrete hardens, the adhesive layer that bonds the concrete and the colorant layer reacts to form a robust colorant layer on the concrete surface. Therefore, the colorant layer transferred to the surface of the concrete is integrated with the concrete and thus has very good weather resistance.

Moreover, since such a coloring material layer is formed in advance in a factory, it is possible to design a color like a stone wall in which natural stones are piled up.

[0014]

DETAILED DESCRIPTION OF THE INVENTION The method for constructing a concrete structure of the present invention will be described in detail below with reference to the drawings.

FIG. 1 is a sectional view showing a state in which a mold is assembled in the first construction method of the present invention, and FIG. 4 is a sectional view showing a state in which a mold is assembled in the second construction method. , Fig. 2
FIG. 5 is an enlarged cross-sectional view of the concave portion of the mold in the first construction method, and FIG. 5 is an enlarged sectional view of the concave portion of the mold in the second construction method.

As shown in FIGS. 1 and 2, in the first method of constructing a concrete structure according to the present invention, a space 3 for forming concrete is formed between the foamed resin mold 2 and the base material 1. Place it.

Concretely, the foamed resin mold frame 2 is attached to the reinforcing bars or bolts 8 planted in the base material 1 with nuts 9 or the like.
The concrete pouring space 3 can be formed by forming and fixing with a predetermined space.

The foamed resin mold 2 is made of a foamed resin such as polyethylene, polypropylene, polystyrene, or polyurethane. Particularly in the present invention, it is preferable that the mold is made of polypropylene foam. The formwork made of polypropylene foam has good strength and elasticity as a formwork, and at the time of removing the formwork 2, the colorant layer has good releasability from the surface of the formwork. is there.

As shown in FIGS. 1 and 2, the foamed resin mold 2 is provided with a recess 5 so that a natural stone-like projecting pattern can be formed on the surface of the concrete which has been cast and hardened. There is.

Foam resin mold 2 having the above-mentioned recess 5
Can be manufactured by filling a mold with a resin component and a foaming agent and foaming the same. The mold used at this time has a convex portion that forms the concave portion 5, but this convex portion is preferably formed by transferring from the surface of the natural stone that is actually arranged. For example, a resin is applied to the surface of a natural stone that is actually placed to produce a resin film in which this surface state is transferred, and a mold is formed based on this resin film to form a convex portion on the mold. . In this way, by actually placing natural stones and performing patterning, the surface pattern of the structure will appear natural.

A coloring material layer 6 is formed on the surface of the recess 5 formed in the mold 2. The colorant layer 6 has a resin component that is chemically bonded to the concrete surface as the concrete hardens.

The colorant layer 6 having such characteristics is composed of a pigment and / or dye and a resin.
Pigments and dyes are dispersed. Then, normally, this resin chemically bonds with concrete along with the hardening reaction of the concrete, peels from the surface of the mold 2 and moves to the concrete surface, and a coloring material layer as shown in FIG. 3 is applied to the concrete surface. Form.

Resins that can be chemically bonded to such concrete include reaction-curable resins and thermoplastic resins having polar groups. Examples of the reaction curable resin include epoxy resin (eg, acid anhydride, composition of epoxy resin and catalyst, two-component epoxy resin, one-component epoxy resin), urethane resin, unsaturated polyester and redox. Examples thereof include a composition containing a system catalyst and a composition containing a (meth) acrylic resin oligomer and a redox system catalyst. Of these reaction curable resins, epoxy resins and urethane resins are preferred. Epoxy resin,
The urethane resin has excellent weather resistance, and pigments and the like can be mixed well.

Further, among epoxy resins, by using a one-component curing type resin having a reaction initiation temperature of 60 to 120 ° C., preferably 60 to 100 ° C., the reaction heat at the time of curing concrete can be effectively utilized. You can Also,
Epoxy resin A two-pack type epoxy resin composed of the present agent and a curing agent and having a reaction initiation temperature within the above range is also preferably used. There are various kinds of two-pack type epoxy resins, but an epoxy resin in which the present agent is a bisphenol type epoxy resin and a curing agent is an amine curing agent, a polyamide curing agent or a polysulfide curing agent is particularly preferable.

Further, in the present invention, as the urethane resin,
Solvent-diluted urethane or reactive urethane resin can also be used, and among these, reactive urethane resin is preferable.

The thermoplastic resin having a polar group, specifically, has a softening temperature of a polar group such as -COOH, -NH-,> C = O, and a finyl group of usually 100 ° C or lower, preferably 80 ° C.
It is a resin below ℃. Examples of such thermoplastic resin include graft-modified polyolefin, ABS resin, polystyrene resin, acrylic resin, polyamide resin, POM.
Examples thereof include resins, and of these, graft modified polyolefin, acrylic resin, and polyamide resin are preferable. Such a thermoplastic resin has good weather resistance and also has good affinity with pigments and the like.

The above-mentioned resins forming the colorant layer 6 can be used alone or in combination. The pigment or dye forming the colorant layer 6 together with the resin as described above is not particularly limited, and commonly used pigments and dyes can be used, and also natural stone powder and the like can be used.

Examples of pigments and dyes forming the colorant layer 6 are shown below. Examples of pigments: white inorganic pigments such as zinc oxide, lithopone and titanium oxide, yellow inorganic pigments such as chrome yellow, cadmium yellow and nickel titanium yellow, red inorganic pigments such as red iron oxide, cadmium red and molybdate orange, navy blue and ultramarine blue. Blue inorganic pigments, black pigments such as carbon black, azo pigments, organic pigments such as phthalocyanine.

Examples of dyes: azo dyes, anthraquinone dyes, indigoid dyes, phthalocyanine dyes, carbonium dyes, nitro dyes, quinoline dyes, naphthoquinone dyes. These pigments and dyes can be used alone or in combination. Although these pigments and dyes are dispersed in the resin to form the colorant layer 6, the dispersed state may be uniform or non-uniform. That is, when the coloring material layer 6 is transferred to the concrete surface, the concrete surface to which the coloring material layer 6 is transferred should have an appearance like natural stone, and the pigment or dye is not necessarily uniformly dispersed. You don't have to. Further, when the formwork 2 has a plurality of concave portions 5, the coloring material layer 6 formed in the concave portions should be in a colored state in which the convex portion of the concrete surface has an appearance similar to natural stone, and therefore, The coloring material layer 6 may be colored the same or different.

The blending weight ratio of the resin to the pigment or the like in such a coloring material layer is usually within the range of 1: 9 to 9: 1. The thickness of such coloring material layer is usually 1 μm. It is about 5 mm.

The colorant layer 6 contains the above-mentioned resin and pigment,
Further, if necessary, a mixture to which a solvent or the like is added is applied to the surface of the recess 5 by using a known method such as various coating methods such as brush coating and spray coating, or a coating method utilizing a printing technique such as screen printing. Can be formed by.

The coloring material layer 6 as described above can be directly formed on the surface of the concave portion 5 formed in the foamed resin mold 2, but is preferably formed via the release layer 7. Such a release layer 7 is formed of a release agent such as silicone resin, fluororesin, silicone oil and wax. Particularly, in the present invention, by using a wax having a melting point of 90 ° C. or lower, preferably 90 to 40 ° C., the coloring material layer 6 is removed from the mold 2 by utilizing the heat generated when the concrete hardens. It can be easily released. Examples of the wax having a melting point of 40 to 90 ° C. used here include carnauba wax, wax and paraffin wax.

By using such a wax, the release layer hardly remains on the surface of the coloring material layer 6 which has moved to the concrete surface 10 as shown in FIG. 1 and 2 show a mode in which the mold release layer 7 is provided only in the concave portion 5 of the mold 2, but this mold release layer is provided on the entire concrete contact surface of the mold 2. May be.

The thickness of the release layer 7 is usually 0.1 μm to
It is about 1 mm. The release layer 7 can be formed, for example, by dissolving or dispersing a release agent such as wax in a solvent, applying this to the release layer forming portion of the mold 2, and then removing the solvent. .

The foam resin mold 2 as described above is used as a base material 1.
After forming and arranging the space 3 therein, concrete is poured and cured in the space 3. The concrete used here is not particularly limited, and ordinary concrete which is a mixture of cement such as Portland cement, alumina cement and blast furnace cement, aggregate and water is used. A known admixture may be added to this concrete. For example, calcium chloride or the like for smoothing the concrete surface.

The concrete thus cast hardens in a few hours to a few days. When the concrete hardens, heat is generated and the surface temperature of the mold is usually about 80 ° C. Due to this heat generation, the curing reaction of the reaction curable resin that forms the coloring material layer 5 progresses, and a chemical bond is formed with the concrete that is being cured (for example, with hydroxyl groups, metal ions, etc. in the concrete). It is formed. Further, the thermoplastic resin adheres to the concrete surface while softening, and a chemical bond is formed between the polar group and the concrete.

Further, in the case of having the release layer 7 made of wax, the wax is softened or melted by the heat generated by the hardening of the concrete, so that the release of the coloring material layer 6 from the mold 2 can be performed very easily. To do. Therefore, the colorant layer 6 is reliably transferred to the surface of the concrete 10 when the formwork 2 is removed after the concrete has hardened.

As shown in FIG. 3, in the pseudo stone wall which is the concrete structure thus constructed, the coloring material layer 6 resembling the color tone of the natural stone is formed on the surface of the convex pattern of the natural stone. Since a chemical bonding force is generated between the coloring material layer 6 and the hardened concrete 10 and not merely physical adhesion, the relationship between the coloring material layer 6 and the hardened concrete 10 is High strength.

In the second construction method of the present invention,
As shown in FIGS. 4 and 5, the coloring material layer 16 and the adhesive layer 15 are arranged in this order on the surface of the concave portion 14 formed in the mold 12 similar to the mold in the first construction method. It is stacked.

The coloring material layer 16 is composed of a pigment and / or a dye and a resin, and the pigment and the dye are dispersed in the resin. The resin functions as a binder for the pigment and the dye, and also has the function of ensuring the affinity between the coloring material layer 16 and the adhesive layer. Therefore,
As the resin forming the coloring material layer, a resin having a good affinity with the adhesive layer is used. Such resins include thermoplastics and reaction curable resins, any of which can be used in the second construction method.

Examples of the thermoplastic resin forming the colorant layer in the present invention include polyolefin resins such as polyvinyl chloride, polyethylene and polypropylene, and thermoplastic resins having a polar group. Here, as the thermoplastic resin having a polar group, -COOH, -N
H-,> C = O, having a polar group such as phenyl group, softening temperature is 1
A resin having a temperature of 00 ° C. or lower, preferably 80 ° C. or lower is suitable. Examples of such a thermoplastic resin include graft-modified polyolefin, ABS resin, polystyrene resin, acrylic resin, polyamide resin, and POM resin. Among them, the graft-modified polyolefin,
Acrylic resin and polyamide resin are preferred. Such a thermoplastic resin has a good affinity with the adhesive layer, a good weather resistance, and a good affinity with a pigment or the like.

Examples of the reaction-curable resin which is a resin contained in the colorant layer include epoxy resin (eg, a composition comprising an acid anhydride, an epoxy resin and a catalyst, a two-component epoxy resin, a one-component resin). Epoxy resin), urethane resin, a composition composed of an unsaturated polyester and a redox catalyst, and a composition composed of a (meth) acrylic resin oligomer, a redox catalyst such as an organic peroxide and a metal salt. Examples of the urethane resin include solvent-dilutable urethane and reactive urethane resin.

The above resins forming the colorant layer 16 can be used alone or in combination. The resin in this second construction method is the first
Unlike the resin forming the colorant layer in the above method, it does not have to have reactivity with concrete.

In the second construction method, as the pigment or dye forming the colorant layer 16 together with the resin as described above, those listed in the explanation of the first construction method can be used.

Although these pigments and dyes are dispersed in the resin to form the colorant layer 16, the dyes and pigments may be dispersed uniformly or non-uniformly in the resin. May be. That is, when the coloring material layer 6 is adhered to the concrete surface, the concrete surface to which the coloring material layer 16 is adhered may have an appearance like natural stone, and the pigment or dye is not necessarily required. It need not be evenly distributed. Further, when the formwork 2 has a plurality of concave portions 5, the coloring material layer 6 formed in the concave portions may be in a colored state in which the convex portion of the concrete surface has an appearance similar to natural stone, and therefore, The coloring material layer 6 may be colored the same or different.

The blending weight ratio of the resin to the pigment or the like in such a coloring material layer is usually within the range of 1: 9 to 9: 1. The thickness is usually about 1 μm to 5 mm. The colorant layer 16 can be formed by applying the mixture of the resin, the pigment, and the like, and the solvent and the like, if necessary, to the surface of the recess 4 by using the same application method as described above.

An adhesive layer 15 is provided on the coloring material layer 16 thus formed on the surface of the recess 14. The adhesive layer 15 acts so as to bond the concrete and the coloring material layer, and the resin forming the adhesive layer 15 develops an adhesive force due to the heat generated by the hardening reaction of the concrete so that the surface of the concrete structure is exposed. By adhering the coloring material layer, the coloring material layer as shown in FIG. 6 is colored in the natural stone pattern formed on the concrete surface.

Examples of the adhesive constituting the adhesive layer 15 include an acrylic emulsion adhesive, a latex adhesive, a malein-modified polyolefin adhesive and a reaction curable adhesive. Here, as an example of the reaction curable adhesive, a reaction curable resin used in the coloring material layer can be mentioned.

The adhesive layer 15 is formed on the surface of the concave portion 14 by using a known method such as various coating methods such as brush coating and spray coating, or a coating method utilizing a printing technique such as screen printing. It can be formed by coating on the coloring material layer 16 formed on the.
The thickness of the adhesive layer 15 is usually 1 μm to 5 m.
It is about m.

In the present invention, the coloring material layer 16 can be directly formed in the concave portion formed in the mold, but in order to improve the transferability to the surface of the hardened concrete, it is formed via the peeling layer. Preferably. This release layer 17
Can be formed in the same manner as the release layer in the first construction method described above.

After the foamed resin mold 12 as described above is fixedly arranged in the base material 11 with the bolts 18 and the nuts 19 so as to form the space 13, concrete is poured and hardened in the space 13.

The concrete used here is the same as in the first construction method. When this concrete hardens, heat is generated and the temperature of the mold surface is usually 80 ° C.
It will be about. Due to this heat generation, the curing reaction of the adhesive layer 15 and the coloring material layer 16 proceeds, and a strong bond is formed between the concrete, the adhesive layer, and the coloring material layer. Further, the thermoplastic resin contained in the coloring material layer is
A strong bond is formed with the adhesive layer while softening.

Further, in the case of having the release layer 17 made of wax, the wax is softened or melted by the heat generated by the hardening of the concrete, so that the release of the coloring material layer 16 from the mold 2 can be performed very easily. To do. Therefore, the colorant layer 16 is reliably transferred to the surface of the concrete 20 when the formwork 2 is removed after the concrete has hardened.

In the pseudo stone wall which is a concrete structure constructed in this way, a coloring material layer 16 resembling the color tone of natural stone is formed on the surface of a convex pattern like natural stone as shown in FIG. An adhesive layer 15 is provided between the colorant layer 6 and the hardened concrete 20, and a chemical bonding force is generated between the colorant layer and the adhesive layer and between the adhesive layer and the concrete. Since it is not merely physically attached, the engaging force between the coloring material layer 16 and the hardened concrete 20 is high.

[0055]

According to the method for constructing a concrete structure of the present invention, the coloring material layer can be locked by a chemical bonding force to the convex protrusions such as natural stones formed on the surface of the concrete. . Further, according to the second construction method, the coloring material layer is firmly adhered to the concrete surface by the adhesive layer. Therefore, this colorant layer is stable even when exposed to the weather for a long time. Moreover, such a coloring material layer is designed in a factory before construction so as to be harmonious as a whole stone wall, and is preformed on the foam resin mold, so that it is like a natural stone piled up on a concrete structure. You can easily build a stone wall.

Since such a colorant layer is formed on the surface of the hardened concrete for forming a pattern, the protruding pattern can be colored in a desired color regardless of the background color of the concrete, and the color may be turbid. Is less likely to occur.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a state in which a mold is assembled by the first construction method of the present invention.

FIG. 2 is an enlarged sectional view of a concave portion of a mold.

FIG. 3 is a cross-sectional view showing a state in which a coloring material layer is transferred to the surface of hardened concrete.

FIG. 4 is a cross-sectional view showing a state in which a mold is assembled by the second construction method of the present invention.

FIG. 5 is an enlarged cross-sectional view of a concave portion of the mold.

FIG. 6 is a cross-sectional view showing a state in which a coloring material layer is transferred to the surface of hardened concrete.

[Explanation of symbols]

 1, 11 ・ ・ ・ Foundation material 2, 12 ・ ・ ・ Foam resin mold 3, 13 ・ ・ ・ Space 5, 15 ・ ・ ・ Recess 6,6 ・ ・ ・ Coloring material layer 7, 17 ・ ・ ・ Release layer

Claims (4)

[Claims] 1. A plurality of foam resin molds having recesses in which a projecting pattern of natural stone is formed by pouring concrete by forming a space for pouring concrete between the base material and a plurality of frames. A method for constructing a concrete structure in which a natural stone-like protruding pattern is formed on the surface by arranging, then pouring concrete into the space, and removing the formwork after the concrete hardens, A coloring material layer that can be chemically bonded to the concrete surface is formed on the surface of the concave portion of the resin mold along with the hardening reaction of the concrete, and at least a part of the components in the coloring material layer by the hardening reaction of the concrete. A method for constructing a concrete structure, characterized in that the surface of a natural stone-like projecting pattern of the concrete structure is colored by chemically bonding with the concrete. 2. A plurality of foam resin molds having a concave portion in which a projecting pattern of natural stone is formed by pouring concrete, by forming a space for pouring concrete between the base material and a plurality of foam resin molds. A method for constructing a concrete structure in which a natural stone-like projecting pattern is formed on the surface by placing concrete, then pouring concrete into the space, and removing the formwork after the concrete hardens, Concrete is placed between the foam resin mold and the foundation material in which the colorant layer and the adhesive layer are laminated in this order, and the colorant layer is used as a natural stone-like projecting pattern of the concrete structure. A method for constructing a concrete structure, which comprises adhering to the surface of a concrete stone and coloring the surface of a protruding pattern like natural stone. 3. The method for constructing a concrete structure according to claim 1 or 2, wherein the resin foam mold is made of polypropylene resin. 4. The coloring material layer is formed on the surface of the concave portion of the foamed resin mold via a release layer.
Item 2. A method for constructing a concrete structure according to item 2 or item 2.