JPH0667566B2 - Method for manufacturing concrete plate having a three-dimensional decorative surface - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for producing a concrete plate body having a three-dimensionally shaped decorative surface that constitutes the inner and outer walls and retaining walls of a building (house or building).

<Prior Art> As described above, the concrete plate body having the modeling three-dimensional decorative surface on the surface is fixed to the female mold of the modeling three-dimensional decorative surface on one inner surface of the two mold panels facing each other on the inner surface. Reinforcing bars are arranged vertically and horizontally between the opposing inner surfaces of the frame panel, assembled, and then concrete is poured. After the concrete layer is solidified, both mold panel panels are demolded, and the conventional manufacturing is performed.

<Problems to be Solved by the Invention> The female mold having a three-dimensional decorative surface fixed to one inner surface of the panel of the mold is a molded product made of expanded polystyrene, rubber, or other soft material. For this reason, when the reinforcing bars are assembled vertically and horizontally between the inner surfaces of the facing form panels, the reinforcing bars come into contact with the female mold and damage the female mold, and sparks are generated when the vertical and horizontal crossovers of the reinforcing bar are joined by fusion welding. Partially melted in.

And since the three-dimensional modeling decorative surface is uneven, if you put a fresh concrete between the opposite mold panels, it is difficult for air and moisture to escape upward along the surface of the female mold, so the pinhole and aggregate will separate. Nests (junkers), water avatars, etc. are formed on the part that contacts the female surface.

Therefore, after demolding the form panel, these pinholes,
It is necessary to repair the part of the three-dimensional decorative surface of the concrete plate body that transferred the female part that was scratched by jean, water avatar, etc., rebar, or melted with sparks of melt pressure welding, which is very difficult. It is troublesome.

<Means for Solving Problems> Therefore, according to the present invention, a mortar panel in which a surface layer is formed of a mortar containing a polymer is formed on a female die surface of a three-dimensionally shaped decorative surface, and the mortar panel is peeled from the female die to form an opposing pair. Between the inner surface of the formwork panel and the surface of the mortar panel, the surface layer being opposed to one of the inner surfaces of the formwork panel, the mortar panel being separated from the inner surface of the formwork panel and being detachably fixed. A foaming resin layer is filled between them by injecting and foaming a foaming resin, and a fresh concrete is placed between the mortar panel and the other mold panel, and the mortar panel is adhered to the solidified fresh concrete layer and left. Then, the mold frame panels and the foamed resin layer are removed from the mold.

<Example> A female die 2 having a female surface of a three-dimensionally shaped decorative surface to be expressed is fixed on a suitable plate 1, a mold release material is applied to the surface of the female die 2, and then a surface layer of mortar containing a polymer is applied. The surface of the female mold is covered with 3 and the backing layer 4 containing mortar.

From the viewpoint of work efficiency, it is preferable that the surface layer 3 and the backing layer 4 are formed by spraying with a mortar gun. The thickness of the surface layer 3 is about 2 to 5 mm, and the thickness of the backing layer 4 is about 5 to 20 mm.
It is a degree.

The inclusion of the polymer in the surface layer 3 not only enhances the strength of the mortar, but also lowers the water absorption rate of moisture from the outside after curing, and enhances the fluidity of the mortar to even the fineness of the irregularities on the surface of the female mold 2. This is to spread the mortar and faithfully reproduce the uneven surface of the female mold. And, when the molded three-dimensional decorative surface of the manufactured concrete plate is colored, a pigment is mixed in the mortar of the surface layer, and in order to resemble natural stone such as granite, quartz, fine particles of slag, etc. are mixed. Good. When the surface layer 3 is formed in this manner, a roller is applied to the back surface of the surface layer 3 to form irregularities such as lines to form a line, and the backing layer 4
It is preferable to increase the contact area with. When the surface layer 3 is solidified to some extent, the backing layer 4 is formed.

The backing layer 4 is preferably a fiber reinforced concrete (FRC) mortar in which fibers, for example, glass fibers, metal fibers such as iron are mixed, but the entire back surface of the surface layer 11 is made of glass fibers, carbon fibers, nylon, While covering with the mesh material 5 made of iron fiber or the like, nails or the like may be hit and fixed to the surface layer 3 in places, and ordinary concrete mortar may be sprayed.

When the backing layer 4 is formed, the same streaks as those of the surface layer are formed on the back surface thereof, or metal lines, various fibers, meshes, etc. are embedded in the backing layer 4 to place the backing layer 4 between the formwork panels to attach it to the ready-mixed concrete layer. Should be raised.

In this way, the backing layer 4 is formed, and when it solidifies, both layers 3 and 4 are peeled off from the surface of the female mold 2 as a mortar panel 6, and the mortar panel 6 is opposed to each other, and fresh concrete is placed between them. Surface layer 3 on the inner surface of one side 8 of a large formwork panel 7 or 8 made of a pair of plywood (plywood) or metal plate.
To face each other, and a small distance between them so as to be detachably fixed.

As is well known, the form panels 7 and 8 are provided with holes facing each other in the same arrangement when they are vertically arranged.

Therefore, at the beginning of making the mortar panel 6, holes are formed in the female die 2 and, if necessary, the plate 1 in the same arrangement as the form frame panels 7 and 8, and the holes are used to mold the surface of the female die 2 with plastic. The attached piece 9 is attached, and the surface layer 3 and the backing layer 4 of the mortar panel 6 are formed on the stepped piece in the stepped piece 9, and the small diameter portion 9 ′ of the piece is attached to the back of the backing layer 4. When the mortar panel 6 is protruded and peeled off from the surface of the female mold, the mortar panel 6 is provided with a holed recess 10 at a position corresponding to each hole of the formwork panels 7, 8 Then, this is used as a means for detachably fixing to the form panel 8.

That is, the nut 12 is screwed into one end of the shaft foot bolt 11, and the one end is penetrated through the hole at the bottom of the recess 10 of the mortar panel to bring the nut 12 into contact with the bottom of the recess 10 and project from the hole. A coupling tool 13 such as a joint nut having a hexagonal cross section is screwed into this portion to sandwich the bottom of the recess 10 with the coupling tool 13, and the short other end having the collar 11 'of the shaft foot bolt 11 is the formwork panel 8
Through the hole from the inner surface, and screw the fortie 14 into the part protruding to the outer surface to tighten it to narrow the frame panel between the collar of the shaft foot bolt and the foam tie, or to the inner surface of the frame panel 7. Fixes the cone 15 passed through the hole with a nut. Since the mortar panel 6 is uneven, the nut 12 screwed into one end of the shaft foot bolt 11 adjusts the distance from the collar 11 'at the other end in accordance with the position of the mortar panel 6 to form the form panel 8. The mortar panel 6 can be fixed in parallel with the inner surface as a whole. Since the surface of the stepped piece 9 that contacts the female die 2 needs to be machined in accordance with the surface of the female die, it is preferable to mold the foamed resin or the like that is easy to machine.

Then, the vertical and horizontal flaps 16 and 16 'are arranged along the outer surface of the form panel 8, and the outer horizontal flap 16' is held by the rib washer 17 attached to the foam tie 14 and is attached to the outer surface of the form panel 8 by a nut. At the same time as tightening, the other end of the separator 18 whose one end is screwed to the cone 15 of the form panel 7 is connected to the connecting tool 13 such as the joint nut, so that the two molds 7 and 8 are opposed to each other.

Reinforcing bars 19, 20 are arranged vertically and horizontally in opposite intervals between the formwork panels 7 and 8 and assembled, and urethane foam resin is injected between the inner surface of the formwork panel 8 and the mortar panel 6 to foam.
The space between them is filled with the foamed resin layer 21, and then an adhesive is applied to the surface of the mortar panel 6 if necessary, and green concrete is cast between the inner surfaces of the mortar panel 6 and the form panel 7. The foamed resin layer 21 backs up and supports the lateral pressure and impact applied to the mortar panel 6 by placing the fresh concrete. In addition, the lower surface between the mortar panel and the mold panel for injecting the foamed resin,
Both side surfaces may be appropriately closed, and a release agent may be applied to the back surface of the mortar panel 6 in advance to reduce the adhesive force with the foamed resin layer 21.

Then, when the ready-mixed concrete layer 22 is solidified, the rib washer 17 is removed, the flap material 16, 16 'is removed, the form tie 14 is removed, the form panel 8 and the foamed resin layer 21 are peeled off from the mortar panel 6, and the shaft foot bolt is also removed. Remove 11 and remove. Also, the formwork panel 7
Is removed from the ready-mixed concrete layer 22 by removing the mounting nut of the cone.

As a result, the mortar panel 6 is adhered and left on the ready-mixed concrete layer.
22 gives a concrete plate.

Of course, a plurality of formwork panels 7 and 8 may be laterally adjacent to each other and a fresh concrete may be placed between them, but in that case, the mortar 6 attached to each formwork panel 8 is also adjacently connected. The injection and foaming of the foamed resin are performed integrally between the mold frame panels 8 ... And the mortar panels 6 ...

<Effect of the Invention> According to the present invention, the surface layer 3 of the molded mortar panel 6 brought into contact with the female mold 3 faithfully reproduces the concave-convex decorative surface of the female mold.

And, 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 placed, even if the reinforcing bars come into contact when the reinforcing bars are arranged and assembled, the melt welding There is no problem even if you receive a spark. In addition, the foamed resin layer filled between the formwork panel and the mortar panel adheres to and reinforces the mortar panel, and since the formwork panel and the mortar panel are integrated, the lateral pressure and Effectively prevent the mortar panel from cracking or chipping due to impact.

Therefore, it is necessary to repair the depression 10 formed in the mortar panel.
It is possible to efficiently manufacture a concrete plate body having a three-dimensional shaped decorative surface opposite to the female concave-convex decorative surface.

[Brief description of drawings]

The drawings show one embodiment of the present invention. FIG. 1 is a sectional view of a state in which a mortar panel is being molded, and FIG. 2 is a sectional view of a state in which ready-mixed concrete is placed. Is a female type, 3 is a surface layer, 6 is a mortar panel, 7 and 8 are formwork panels, 21
Indicates a foamed resin layer, and 22 indicates a green concrete layer.

Claims (1)

[Claims] 1. A mortar panel in which a surface layer is formed of a mortar containing a polymer is formed on the surface of a female mold of a three-dimensional molding surface, and the mortar panel is peeled from the female mold. The surface layers are opposed to each other, and the mortar panel is detached from the inner surface of the form panel and is detachably fixed,
A foam resin is injected between the inner surface of the mold panel and the surface of the mortar panel to foam the resin layer, thereby filling a foam resin layer therebetween, and a fresh concrete is placed between the mortar panel and the other mold panel. A method for producing a concrete plate having a three-dimensional decorative surface, comprising adhering the mortar panel to a solidified green concrete layer and leaving the mortar panel to demold the mold panel and the foamed resin layer.