JPH07276322A - Form for concrete product and manufacture of colored pattern concrete product - Google Patents

Abstract

PURPOSE:To efficiently manufacture a colored pattern concrete product in which colored particulate matter (layer) is not peeled and which has excellent weather resistance and stability for a long period. CONSTITUTION:A form 1 comprises colored particulate matter 5 in which non- hydraulic organic powder is colored with metal sulfate and/or reaction product of the sulfate with alkaline substance and which is disposed on a surface of a concrete plated side. A method for manufacturing a colored pattern concrete product 7 comprises the steps of placing concrete in the frame 1, curing to harden it, and transfer embedding the matter 5 in the surface of the concrete.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a concrete casting side surface of a form of colored granules obtained by coloring a non-hydraulic inorganic powder with a metal sulfate and / or a product of a metal sulfate and an alkaline substance. And a method for producing a concrete product having a colored pattern on the concrete surface by using the mold for concrete product arranged in.

[0002]

2. Description of the Related Art Concrete products are used in large quantities in the fields of construction and civil engineering, but in recent years, due to the growing harmony with nature and the increasing interest in landscape, natural stone stone walls, natural stone, etc. There has been a strong demand for colored pattern concrete products similar to the above.

A conventional method for producing a colored pattern concrete product is to add a pigment to cement, sand,
Mix with aggregate material, concrete material such as water, put in the mold,
A method of curing and curing, a method of coating a surface of a product with a paint or pigment emulsion of a predetermined color by brushing, spraying, or the like are known. Further, as the mold, there has been generally used a steel type which is or is not coated with a release agent, an iron type such as stainless steel, a plastic type such as hard urethane or a wood type. However, the method of mixing with the above-mentioned raw materials not only requires a large amount of pigment, but also has a drawback that the coloring effect cannot be obtained unless expensive white cement is used, and it is difficult to produce a natural hue. In the case of the method of applying a coating material, it takes time and effort to remove stains and deposits on the coated surface, and since this method only physically adheres the colored particles to the product surface, In addition to easy peeling, poor weather resistance, etc., since a large amount of organic solvent is used, there are problems in handling and safety and hygiene.

In addition to the above-mentioned method, JP-A-48-
Japanese Patent No. 68620 proposes a method of coloring and coloring by applying an aqueous solution of a metal sulfate such as manganese sulfate and iron sulfate to the surface of a cement product. Since this method uses a chemical reaction, the drawbacks of the method can be improved, but it takes a long time for the color tone to stabilize due to changes in color over time, and poor color development. However, there is a problem in that it is necessary to color the product after producing the concrete product, and further after removing the stains and deposits on the product, and this method also has room for improvement.

Further, Japanese Patent Application Laid-Open No. 5-253909 discloses that
As a method for forming a colored uneven pattern on the concrete surface, a decorative mat in which colored granules obtained by adhering cement powder to crushed natural stone particles etc. are distributed on the surface is used, and a concrete granule is cast. A method of transfer-embedding on the surface of the glass has been proposed. Since cement powder is used in this method, the concrete surface is easily affected by the color peculiar to cement, and it is difficult to give a natural tint.

[0006]

DISCLOSURE OF THE INVENTION In view of the above points, the inventors of the present invention can improve the problems (1) to (3), have a good surface finish, are difficult to peel off, and have a concrete pattern having a colored pattern excellent in weather resistance for a long time. To develop a manufacturing method for the product, and especially to improve the poor coloring, stability of the color tone, and the troublesomeness of the coloring operation after the manufacturing using the metal sulfate. Overlaid. As a result, a colored granule obtained by coloring the non-hydraulic inorganic powder with a metal sulfate and / or a reaction product of a metal sulfate and an alkaline substance is used on a concrete placing side surface. The inventors have found that the problems can be solved by placing a concrete in this mold to cure and harden it, and transferring and embedding the colored granules on the concrete surface.

[0007]

According to the present invention, a non-hydraulic inorganic powder is colored on the surface of concrete frame on which concrete is cast with a metal sulfate or a reaction product of a metal sulfate and an alkaline substance. The colored product is arranged so that it can be transferred and embedded on the surface of the concrete that has been cast.

Further, according to the present invention, a colored granular material obtained by coloring a non-hydraulic inorganic powder with a metal sulfate and / or a reaction product of a metal sulfate and an alkaline substance is arranged on the surface of the concrete casting side. The present invention relates to a method for producing a colored pattern concrete product, which comprises casting a concrete in a mold to cure and cure the color granular material and transferring and embedding the colored granular material on the concrete surface.

There are no particular restrictions on the type, shape, size, etc. of the concrete product to which the method for producing a concrete product frame and a colored pattern concrete product of the present invention can be applied. Panel, block, pile,
There are poles, fume tubes, masonry plates, tanks, concrete buildings, structures, etc., and it is a concrete product that uses a formwork such as a masonry formwork and a centrifugal molding formwork. For example, it can be applied to both.

In the present invention, the form is colored by coloring non-hydraulic inorganic powder with metal sulfate and / or a reaction product of a metal sulfate and an alkaline substance on the concrete casting side surface of the form. The granular material is arranged so as to be transferable and buryable on the cast concrete surface. The concrete casting side surface shape of the mold, in other words, the design transfer surface may be flat, uneven or curved.

As the non-hydraulic inorganic powder, any inorganic powder that does not harden by kneading with water can be used. Specifically, obsidian, mica, granite, calcite, blast furnace slag, silica fume, fly ash, silica sand, silica stone, calcium carbonate, talc, bentonite, clay, zeolite, perlite, diatomaceous earth,
Powders of kaolin, alumina, titania, zirconia and the like can be mentioned. These non-hydraulic inorganic powders may be used alone or in combination of two or more. The particle size (average particle size) of the non-hydraulic inorganic powder is 0.01 μm to 10 m.
m, preferably 0.1 μm to 5 mm.

In the present invention, as the metal sulfate, a water-soluble metal sulfate, preferably a water-soluble metal sulfate selected from the group consisting of 1B group, 6B group, 7B group and 8 group is used. Specific examples of the metal sulfate include water-soluble metal sulfates such as copper sulfate, chromium sulfate, manganese sulfate, iron sulfate, cobalt sulfate and nickel sulfate. The metal sulfates may be used alone or in combination of two or more. When the metal sulfate is used as an aqueous solution, the concentration is appropriately selected from the range of 2% by weight (anhydrous basis) to the saturated concentration or less, preferably 5 to 30% by weight in consideration of the color tone. In general, the lower the concentration, the lighter the color tone, and the higher the concentration, the darker the color tone.

Examples of the alkaline substance include hydroxides of alkali metals such as sodium hydroxide, potassium hydroxide and lithium hydroxide, carbonates of alkali metals such as sodium carbonate, potassium carbonate and lithium carbonate, sodium bicarbonate and bicarbonate. Alkali metal bicarbonates such as potassium and lithium bicarbonate, alkaline earth metal hydroxides such as magnesium hydroxide and calcium hydroxide, alkali metal silicates such as sodium metasilicate and potassium metasilicate, and pyrophosphoric acid. Examples thereof include sodium and potassium pyrophosphate. Among these, sodium hydroxide and salts such as sodium hydroxide, sodium carbonate and sodium metasilicate are preferable. The amount of the alkaline substance used varies depending on the strength of the alkalinity, the type and amount of the non-hydraulic inorganic powder, the amount of the metal sulfate, etc., but is an amount sufficient for the metal sulfate to react with the alkaline substance and develop color. It suffices if it is present, and normally, it is appropriately selected and used from the range of 0.5 to 4 mol per mol of the metal sulfate.

In the present invention, the coloring treatment with the metal sulfate and / or the reaction product of the metal sulfate and the alkaline substance is generally carried out by mixing an aqueous solution of the metal sulfate and / or an aqueous solution of the metal sulfate with an alkaline substance. And / or a method of spraying (spraying) the suspension onto a non-hydraulic inorganic powder, a method of mixing and / or kneading the two, a method of immersing the non-hydraulic inorganic powder in the solution and / or suspension, and Is performed by a method such as adding an alkaline substance later depending on the degree of coloring. By the coloring treatment, the metal sulfate and / or the reaction product adheres to or is impregnated in the non-hydraulic inorganic powder to obtain a colored granule having a unique color formed by the metal sulfate. The particle size (average particle size) of the colored particles is 0.05 μm to 10 mm, preferably 0.15.
The one having a thickness of μm to 5 mm is suitable.

In the mold of the present invention, the colored particles are arranged so that they can be transferred and embedded on the concrete surface on which they are cast. When arranging so that transfer embedding is possible, a method of spray-spraying a solution of the pressure-sensitive adhesive after arranging the colored particles on the surface of the mold so that a predetermined pattern is formed, and forming an adhesive layer on the surface of the mold. , How to place colored granules on it,
Further, a method of embedding a part or all of the colored granular material in the pressure-sensitive adhesive layer by applying pressure or the like is adopted. As an adhesive, concrete is applied during the process of placing concrete and curing it.
It is preferable that the adhesive force is reduced and reduced or dispersed due to moisture, alkali content, etc. in the material. Specific examples thereof include methyl cellulose, polyvinyl alcohol, water glass, and a two-component acrylic pressure-sensitive adhesive.

In the present invention, the colored pattern concrete product is a colored granular material obtained by coloring non-hydraulic inorganic powder with a metal sulfate and / or a reaction product of a metal sulfate and an alkaline substance. It is manufactured by casting a concrete on a mold disposed on the surface of the installation side, curing and curing, and transferring and embedding the colored granular material on the surface of the concrete. When the concrete is cast and cured by curing, the adhesive strength of the pressure-sensitive adhesive is reduced, reduced, or dispersed, and the colored particles are fixed by transfer-transfer embedding on the cast concrete side. When the frame is removed, a clean and clean concrete product having a colored pattern similar to that of a natural product can be obtained.

The colored pattern concrete product is
The residual fine voids on the concrete surface, which are generated when the ordinary concrete material is cast, are filled with colored particles, so that there is no formation of pit-like fine irregularities due to the residual fine voids.
The concrete surface is in a good finished state. In particular, this effect becomes remarkable in the manufacture of colored concave-convex pattern concrete products.

The curing by curing is preferably carried out by steam curing. The temperature at that time is preferably 40 to 90 ° C, preferably 60 to 80 ° C, and the relative humidity is selected from the range of 60 to 98%. The steam curing time is 0.5 hours or more, usually 1 to 8 hours. In addition, steam curing may be followed by air curing.

[0019]

Embodiments of the present invention will now be described with reference to the drawings. Figure 1
FIG. 3 is a schematic cross-sectional view showing an example of the formwork for the concrete product of the present invention. FIG. 2 is a cross-sectional view of a concrete product form of the present invention in which concrete material is cast. FIG. 3 is a state diagram in which the colored pattern concrete product is taken out from the concrete product frame of the present invention.

A steel product frame 1 for concrete products has a product design transfer surface 2 on its surface (concrete material placement surface side).
And a flat back surface 3. In addition, in FIG. 1, the product design transfer surface 2 is shown as a flat surface, but the product design transfer surface 2 may have an uneven shape similar to natural stone, or may have a modeling pattern such as animals and plants. After the stains on the mold 1 are wiped off with a brush and a cloth, an adhesive layer 4 is formed by brush-coating the product design transfer surface 2 with an aqueous solution of carboxymethylcellulose having a concentration of 20% by weight at a rate of 100 g / m ^2. Let

Calcium carbonate powder (average particle size: 1
(8 μm) was sprayed with an aqueous solution of iron sulfate having a concentration of 15% by weight to give yellowish brown colored particles of calcium carbonate 5
(Average particle size: 18.2 μm) was obtained. Next, a colored granular material 5 of calcium carbonate is sprayed and adhered to the adhesive layer 4 of the mold 1 by a spray gun to make a concrete product mold, and then a concrete material 6 is cast and 70 Dehumidification (Fig. 3)
(Arrow direction of arrow) to obtain a colored pattern concrete product 7 having a colored granular material (layer) 5 similar to a natural product on the product design surface 8. This colored pattern concrete product 7 does not peel off the colored granular material (layer) 5 even if it is left outdoors for one year or more, no white flower phenomenon is observed, and the surface retains a yellowish brown color at the time of manufacturing. Was there. The surface of the colored pattern concrete product 7 had no fine irregularities due to residual fine voids generated when the concrete material was cast, and was in a smooth and good finished state.

[0022]

EFFECTS OF THE INVENTION According to the concrete product form of the present invention and the method for producing a colored pattern concrete product using the form, removal of stains and adhering substances when coloring after producing the concrete product It is possible to easily and efficiently produce a colored pattern concrete product which is free from color development defects, peeling of colored particles (layers) and the like and has excellent long-term weather resistance and stability and a good surface condition. Further, since the colored particulate matter (layer) of the colored pattern concrete product of the present invention suppresses permeation of moisture and carbon dioxide gas from the outside, it is possible to prevent the white bloom phenomenon and neutralization.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view showing an example of a concrete product formwork of the present invention.

FIG. 2 is a block diagram of the concrete product form of the present invention.
FIG.

FIG. 3 is a state diagram of a colored pattern concrete product taken out from the concrete product mold frame of the present invention.

[Explanation of symbols]

 1 Formwork 2 Product Design Transfer Surface 3 Back Surface 4 Adhesive Layer 5 Colored Granular Material 6 Concrete Material 7 Colored Pattern Concrete Product 8 Product Design Surface

Claims (2)

[Claims] 1. A colored granule obtained by coloring a non-hydraulic inorganic powder with a metal sulfate and / or a reaction product of a metal sulfate and an alkaline substance on the concrete-casting surface of a mold,
A mold for a concrete product, which is arranged so that it can be transferred and buried on the surface of the concrete that has been cast. 2. A form in which colored granules obtained by coloring non-hydraulic inorganic powder with a metal sulfate and / or a reaction product of a metal sulfate and an alkaline substance are arranged on the surface of a concrete casting side. A method for producing a colored pattern concrete product, which comprises casting a concrete, curing and curing, and transferring and embedding the colored granules on the concrete surface.