JPH07285114A - Manufacture of concrete block - Google Patents

Abstract

PURPOSE:To provide a method of manufacture a concrete block whose surface simulated the roughness and color of a natural stone and which is harmonious with the natural environment. CONSTITUTION:A concrete block is constituted so that an uneven part P-1 in a natural stone shape is provided on a face pallet, an appropriate quantity of mortar M is supplied onto the uneven part P-1, a mortar layer having a uniform thickness is formed on the uneven part by press by a vibration and inertia body 1, the mortar is made to permeate into concrete by supplying the concrete and compacting the same, a block in which unevenness color in the natural stone shape are formed and after curing and hardening, an expressed surface of the block is impregnated with a water-soluble adhesive agent and drying and hardening are made to perform.

Description

Detailed Description of the Invention

[0001]

[Field of Industrial Application] The present invention applies natural stone to the exposed surface of various shapes of concrete blocks for constructing road retaining walls, retaining soil in mountainous areas, revetment of rivers, retaining walls of development areas, boundaries of parks, etc. TECHNICAL FIELD The present invention relates to a method for manufacturing a concrete block having an exposed surface simulating the shape color of a natural stone, which is constructed by using a concrete block whose shape and color are simulated to form a new environment in harmony with the natural environment.

[0002]

2. Description of the Related Art A conventional small or large concrete block has an uneven surface, an uneven smooth surface, or a small uneven rough surface with a mediocre concrete color. It had been.

Even when the exposed surface is formed by using a mortar in which a pigment is mixed with sand cement on the rough surface, cement acres flow out after the concrete hardens, and the dyeing on the exposed surface is also faded, resulting in an unsightly appearance surface. Becomes

Further, the exposed surface has a large water absorbency and is severely deteriorated and lacks in durability, and the mortar layer on the exposed surface due to frost damage has a defect such as a peeling phenomenon and damage. The arranging required labor and time-consuming manual work.

In recent years, concrete blocks, which have been actively developed in recent years and which expose natural stones to the exposed surface, have been developed and produced. However, the collection of the natural stones exposed to the surface is difficult and expensive. Although it is necessary at present, the shape of the stone, the size of the stone, the work of placing the natural stone on the surface pallet to expose it on the block surface, the molding means for forming the joint, and the joint material after hardening There is a problem in that the product cost is inevitably high because it requires a very laborious and laborious work process such as processing.

[0006] Further, there is also a drawback that the natural stones embedded in the hardened concrete after being commercialized come out and fall off, resulting in a decrease in product value. The existing block has a heavy weight and has a problem in construction work.

[0007]

DISCLOSURE OF THE INVENTION The present invention is directed to the natural appearance of the surface of small concrete blocks produced by instant demolding of various shapes used for civil engineering, or large concrete blocks formed by pouring soft concrete into a formwork. Without using stones,
Molded on the concrete exposed surface with natural stone shape and color, and forming the concrete block exposed surface layer that is in harmony with the environment landscape into a fine-density layer, the minimum suitable amount of mortar is formed in a concave-convex shape that matches the natural stone shape. The mortar layer is formed into a uniform thickness from above by pressing and vibration of a loose body such as rubber or plastic, and the mortar layer of this uniform thickness is compacted together with concrete to form a concrete layer during molding. The mortar is infiltrated into the inside to form a concrete layer with mortar infiltrated into a fine density, increasing the strength of the exposed surface, and there is no mortar layer on the exposed surface of the block.
Provided is a method for producing a concrete block which has no water absorption and permeation from the exposed surface, has increased weather resistance, prevents stains, maintains the beauty of the exposed surface, and exerts a strong action effect against frost damage, impact and the like.

[0008]

The present invention solves the above-mentioned problems and drawbacks of the prior art, and pours soft concrete into a compact concrete block or mold which is easy to handle and is molded by hard-mixed concrete in an instant demolding process. The molding surface of a large concrete block is formed into a natural stone shape that is in harmony with the environmental landscape.The molding surface is slightly smaller than the conventional flowable kneading mortar used for surface pallets. Hard sand, mixed mortar with cement, or mixed mortar with sand, cement mixed with pigment for dyeing the exposed surface, or mixed mortar with sand, cement mixed with appropriate amount of resin adhesive liquid, and further glass Supply an appropriate amount of suitable kneading mortar, such as powdered kneading mortar, to a natural stone-shaped uneven ridge-valley surface pallet, and stretch it from above to the lower surface of the pressing plate. Rubber, to form a mortar layer of uniform thickness uneven peak to valley shape entire surface pallet stretch deformable pressing the flexible slow resistant material such as synthetic resin.

[0009] A double structural form frame disclosed by the applicant earlier, in which the composition is removed from the mold by splitting it into left and right parts (Japanese Patent Application No. 5-825385).
No.) or a double structure type integrated formwork, in which the surface pallet having a mortar layer of uniform thickness formed on the surface pallet is placed at the bottom of the formwork in a formwork that horizontally moves laterally and demolds downward. Concrete is supplied from above, and the formwork vibration, pressing force from above, and independent vibration from the bottom of the surface pallet are applied to allow the mortar on the surface pallet to permeate into the concrete layer and reduce the concrete layer on the exposed surface. The block is compacted to a high density, the mold is opened to the left and right, the mold is removed, and the molded block is carried out of the machine.

When applied to a reversing type formwork, the formwork is inverted to feed the material with the exposed surface facing upward, and the curved press plate is lowered from above to temporarily press the top surface of the supplied concrete. To stabilize it, and then turn over the surface pallet with the mortar layer formed on it and press it while applying vibration to the press plate from above to allow the mortar in the surface pallet to penetrate into the concrete layer and expose concrete. The layer is formed into a fine density, the surface pallet is pressed down, the form is reversed, and the surface pallet is attached to immediately remove the mold downward.

Further, in the formwork apparatus for forming a large-sized concrete block to be poured, the four-direction side formwork plate is a formwork which undulates from the bottom as a base point, and the inner bottom of the formwork has irregularities formed in a large natural stone shape. A mold plate for forming a mountain-valley-shaped exposed surface, that is, a surface pallet is placed at the bottom of the mold, and an appropriate amount of kneading mortar that is slightly harder than the conventional kneading is put into the surface pallet, and the mortar upper surface is attached to the press plate. By applying pressure while applying vibration to the stretchable loose body, a mortar layer is formed on the entire surface of the uneven ridges and valleys of the surface pallet with a substantially uniform thickness, and soft kneaded concrete is put on it to cause vibration from the bottom of the surface pallet. Mortar is allowed to permeate into the supplied concrete layer and air bubbles are allowed to escape, compaction is performed, and the mortar is conveyed to the heat curing chamber together with the mold.

For both the small block by immediate mold release and the large block by casting that is cured together with the mold after molding, the surface pallet is peeled off when the curing process is completed, and the block is taken out and the exposed surface of the block is cured separately. Put the resin adhesive liquid in the placed tank, immerse the sponge sheet in this liquid, impregnate the sponge sheet with the resin adhesive liquid, and place it with the exposed surface of the block facing the exposed surface of the block. The resin adhesive solution is absorbed and permeated in, and then this block is taken out, moved to a predetermined place and dried in an open field.

The permeation of the adhesive liquid into the surface layer of the block prevents cement accretion or fading from the concrete layer, prevents deterioration of the concrete, and further strengthens the surface layer of the concrete to prevent frost damage and impact. There is no surface damage due to.

[0014]

According to the present invention, as described above, sand, cement, mortar, or water-soluble resin is provided in the surface pallet concave portion formed so that the exposed surface of the concrete block becomes a rough surface of natural stone-shaped irregularities. Supply a fixed amount of kneading mortar such as sand, cement, mortar mixed with adhesive liquid and glass sand particles, mortar mixed with sand and cement with optional color pigment, and a loose body that can expand and contract from the upper surface of the mortar Various blocks are formed using a surface pallet in which mortar having a uniform thickness is laminated on the entire rough surface of the surface pallet by pressing and slight vibration.

After completion of curing, the surface pallet is peeled off, and the block is placed on the sponge sheet containing the adhesive liquid laid on the bottom surface of the prepared resin adhesive liquid tank and the block exposed surface is faced to dry and cure. The adhesive liquid penetrates into the existing concrete layer to increase the strength of the exposed surface, and the exposed surface is beautiful and prevents water absorption stains. be able to. Therefore, there is no peeling damage due to frost damage on the exposed surface. Further, the method of molding the exposed surface of the concrete block according to the present invention saves the trouble and troubles at all, and the simpler molding method has a work effect which cannot be found elsewhere.

The main features of the present invention are: (a) The first feature is that this mortar is formed as a layer having a uniform thickness by using a minimum amount of kneading mortar on a natural stone-shaped uneven pallet-shaped surface pallet. Technical configuration. (B) The surface pallet on which the mortar layer is formed is compacted together with the concrete, and the mortar layer is infiltrated into the concrete layer during molding to strengthen and re-densify the concrete layer on the block surface. (3) The third characteristic is the technical configuration that peels off the pallet after curing and penetrates the water-soluble resin adhesive into the concrete block surface to enhance strength and weather resistance. is there.

[0017]

Embodiments of the method of the present invention will be described with reference to the accompanying drawings. In the drawings, FIGS. 1 to 6 are embodiment diagrams showing a processing method of a small block molding surface pallet P molded by an immediate demolding method, and FIGS. 7 and 8 show a mold using the surface pallet P. It is an Example figure which shows an example of the shaping | molding method by a frame. 9 and 10 are examples of a method of forming a large concrete block by casting. Further, FIG. 11 and FIG. 12 respectively show examples of the method for treating the exposed surface after molding.

FIG. 1 shows a mortar M that is constantly stirred by a stirring blade (7) from a mortar storage hopper F on a surface pallet (template) P for molding the exposed surface of a concrete block into a simulated stone surface. Figure 3 shows a front sectional view in which a metered quantity is supplied with an extrusion piston (2). Therefore, on the bottom surface of the surface pallet P, a natural stone-shaped uneven peak-valley shape P-1 is formed. Reference numeral (3) in the drawing denotes a piston rod, (4) denotes a cylinder cylinder, and (5) denotes a lid, which prevents the mortar M from flowing down. Also (8)
Shows a conveyor for transferring the surface pallet P from the storage to the molding machine via the hopper F. FIG. 2 is a side view of FIG.

The kneading mortar M used in the present invention is a kneading mortar which is slightly harder than the conventional mortar having a large amount of slump and having a large fluidity, and the compounding thereof is the mortar of the conventional sand cement compounding or the pigment compounding of sand and cement. In the case of the mortar, the pallet having a deep and intense surface with uneven peaks and valleys, sand containing a small amount of a water-soluble adhesive liquid, glass powder particles in cement, and a kneading mortar containing an appropriate amount are used. (Hereafter referred to as mortar.)

FIG. 3 is a pressing machine comprising a loose body (1) which can be expanded and contracted from the upper surface to which the mortar M arbitrarily mixed according to the shape P-1 of the bottom surface of the surface pallet shown in FIG. To a predetermined position, and the mortar M supplied by the vibration and pressing of the loose body (1) is laminated on the uneven ridge-valley surface P-1 of the surface pallet P with the mortar layer M-1 having a uniform thickness. A cross-sectional view is shown. That is, the uneven peak-valley surface P-1
The mortar penetrates into the space between the loose body (1) and the loose body (1), and the mortar layer M-1 having a uniform thickness is formed on the bottom surface of the surface pallet.
-1 is formed. FIG. 4 is a side view of FIG. In the figure, reference numeral (10) is a vibrator (11) for anti-vibration rubber, (12) is a cylinder for moving the loose body (1) up and down, and (13) is for accurately moving the cylinder (12) up and down. It is a guide shaft.

5 and 6 are embodiment diagrams showing a simple method which is carried out manually without using a mechanical supply means for the mortar M, and in FIG. FIG. 6 is a state diagram in which the mortar M is supplied to the surface P-1, and FIG. 6 shows that the surface pallet P is placed on the vibrating table (17) and the loose body is manually operated while vibrating from the bottom by the vibrator (10). By pressing (1), a mortar layer M-1 having a uniform thickness is laminated on the uneven peak-valley surface P-1 on the surface pallet.
In the figure, reference numeral (11) is a vibration proof rubber, (14) is a machine base, and (1)
8) shows a movement preventing piece, and (19) shows a handle of the pressure-relaxing body (1).

FIGS. 7 and 8 show a formwork apparatus,
FIG. 7 shows a split double structure formwork (20), (2
The double structure in which the treated surface pallet P in which the mortar M-1 having a uniform thickness is layered on the surface pallet P for molding the block exposed surface into a natural stone shape in the front cross-sectional view of (0) It is placed on the inner bottom of the split formwork (20) or (20) or on the inner bottom of the integrated double-structured formwork (not shown), and the concrete mixer is put into the formwork vibrator from above. The mortar M-1 layered on the surface pallet is deeply permeated into the concrete pallet by deeply infiltrating the concrete layer C by vibrating by the vibration of (23) and another vibration by the vibrator (24) independent of the bottom surface of the surface pallet. Press board (26)
The concrete block is compacted by pressing, and when the molding is completed, the split molds (20), (20) are opened right and left and immediately released from the mold, and the block B molded from the bottom surface of the pallet is lifted by the elevator device (25). Pusher (2
It is pushed up via 2) and carried out of the machine by the carry-out rod and transferred to the curing. Also, in the case of an integral mold, although not shown, it is demolded downward and transferred to curing as in the conventional case.

FIG. 8 is a double structural type in which the form (27) is attached to the shaft (2
9) is a front cross-sectional view of a reversing mold for reversing the block in the normal direction as shown by the arrow to mold the block. A fixed amount of concrete C is supplied with the exposed surface facing upward, and the press plate (3
0) is lowered by the cylinder (32) and the form (2
7) The concrete C in the above is subjected to primary compaction while applying vibration to the formwork, and the surface pallet in which the mortar M-1 is layered on the surface pallet P in a uniform thickness is inverted on the upper surface of the primary compacted concrete, and the press plate is covered. (30) descends and presses the surface pallet against the press plate while applying independent vibration by the vibrator (10), and also applies vibration to the form by the form vibrator (23), thereby stacking layers in the surface pallet. Mortar M-1 is infiltrated and mixed into concrete C to form a concrete layer with a high density, and a surface pallet (not shown) is pressed down to reverse the mold to form a block into a surface pallet P.
Immediately demold the formwork downward with face down. As shown in the figure, the press plate (30) is easily handled by making the lower surface a curved surface so that the surface pallet P can be easily covered.

Next, a molding process for pouring soft concrete into a mold to mold a large concrete block will be described with reference to FIGS. 9 and 10. Example 9 FIG. 9 is a block showing surface P- having a natural stone-shaped concave-convex mountain-valley shape with an exposed surface on the inner bottom of the mold for molding a large product with soft concrete in which four-sided side-face form plates (34) are undulated. The surface pallet P formed in an appropriate number is arranged in 1 to form a mold, and a fixed amount of mortar M is supplied onto the surface pallet P to form the uneven peak-valley shape P- on the surface pallet from above.
1 is a front cross-sectional view of forming a layered mortar layer having a substantially uniform thickness in accordance with a surface pallet shape by vibrating and pressing an elastic soft loose body (1) corresponding to 1. Reference numeral (10) in the figure
Is a vibrating body (12) of the loose body (1) is a vertically moving cylinder,
(11) is a vibration-proof rubber.

FIG. 10 shows that while the pallet shape P-1 arranged at the bottom of the mold in FIG. 9 is followed by forming the mortar into the uniform thickness layer M-1, the soft concrete is charged and supplied from above. One independent vibration that gives vibration to the bottom surface of the pallet and the formwork gives another independent vertical vibration to the bottom surface of the pallet, and the mortar layer M-1 formed on the input concrete and the surface pallet penetrates into the concrete layer by vibration. It is a front sectional view which inserts and forms a block surface in arbitrary color and fine density. Reference numeral (14) in the drawing indicates a machine frame (1
1) is a vibration proof rubber, and (10) is a form vibrator. F indicates a hopper. Further, the vibration of the mold vibrating machine (10) is caused by the protrusion (36) of the surface pallet mounting table (15) placed on the mold bottom plate (35) on the vibrating table (17). ), The vertical vibration is effectively transmitted to the surface pallet P.

Next, the embodiment shown in FIGS. 11 and 12 will be described. When curing is completed, the concrete block B molded by hard-mixed concrete by the immediate release method and the large concrete block molded by soft concrete by the pouring method peel off the surface pallet P for molding the exposed surface,
Laying a sponge sheet (48) of an appropriate thickness on the inner bottom of a tank (46) containing a resin adhesive solution, which is provided at an appropriate place when the lift (49) is conveyed to a predetermined place with the exposed surface facing downward. Then, the adhesive solution was poured into the sponge sheet (48) up to about a half position of the thickness of the shonji sheet, and the adhesive solution was contained in the sponge sheet (48). Adhesive liquid is permeated into the concrete layer on the surface of the bumps and valleys, and is clamped again by the clamping device of the lift (49), and when it rises, excess water drop of the adhesive liquid on the surface of the block is sponge sheet due to the absorbing action of the sponge sheet. By being absorbed by (48), the concrete exposed surface becomes a uniform adhesive liquid application surface.

The permeation of the adhesive solution into the concrete layer having the convex and concave peaks and valleys of this concrete block penetrates deeply into the concrete layer to strengthen the concrete on the surface of the concrete, and the weather resistance is excellent. It is beautiful to prevent it from peeling off or chipping due to frost damage or impact, and when the exposed surface is dyed it becomes a faded surface or a natural stone shaped exposed surface from which cement acres do not exude from the exposed surface. This surface protection treatment is an outstanding function Produce an effect. FIGS. 11 and 12 show an example of a small block B in which a concrete block is molded by an immediate demolding method, but a large block molded by a pouring method is also used for permeating the adhesive liquid into the exposed surface layer in the same process. Illustration is omitted.

[0028]

According to the present invention, as described above, the minimum amount of mortar is supplied to the surface pallet, and the rubber,
A mortar layer having a uniform thickness can be formed on a complex rough surface by the deformable pressing and vibration of a pressing loose body such as a synthetic resin.

According to the present invention, the mortar layer can be laminated to have any uneven peak and valley shape with a uniform thickness, and the concrete block is molded using the surface pallet. By vibrating independently, it penetrates deeply into the concrete layer and compacts the exposed surface to a compact density. At the same time, the exposed surface is beautiful and a concrete block without a mortar layer is formed.

Then, the water-soluble resin adhesive solution is deeply penetrated into the exposed surface layer which has been further cured to harden the concrete, and the compacted and compacted exposed surface layer is further strengthened and the weather resistance is enhanced. Since it does not absorb water from the exposed surface, it does not seep out cement cement, and the dyeing of the exposed surface with pigment does not depend on the weather and does not fade.

Further, when a concrete block having a high strength on the surface of the block is required depending on the construction conditions, concrete for the surface of the surface is prepared by using a kneading mortar containing sand and cement mixed with fine sandy powder of glass as described above. A concrete block with strengthened layers is obtained.

As described above, according to the present invention, a technical structure for forming a minimum amount of mortar in a layered manner on a surface pallet having a rough surface having an uneven surface and a mortar that has been formed are permeated into the concrete layer to form a concrete layer on the exposed surface. Manufactured by a molding method that features three technical configurations: a finely densified and strong exposed concrete layer, and a concrete exposed surface layer that is strengthened by the penetration of an adhesive liquid to enhance weather resistance and prevent dirt. The concrete block thus produced improves environmental destruction and is in harmony with the environment landscape, and the invention has been epoch-making and has excellent operational effects by reducing the labor and time and streamlining the block production.

[Brief description of drawings]

FIG. 1 is an embodiment diagram showing supply of mortar to a surface pallet.

FIG. 2 is a side view of FIG.

FIG. 3 is a diagram illustrating an example in which a mortar layer is formed on the entire surface of an uneven surface of a surface pallet with a uniform thickness.

FIG. 4 is a side view of FIG.

FIG. 5 is a diagram illustrating an example of manually supplying mortar to a surface pallet.

FIG. 6 is a diagram showing an embodiment in which the surface pallet of FIG. 5 is manually laminated with mortar.

FIG. 7 is a cross-sectional view of a double structure split formwork device.

FIG. 8 is a cross-sectional view of a double-structured normal / inversion type mold.

FIG. 9 is a diagram showing an embodiment of a frame device for forming a large block.

FIG. 10 is an embodiment diagram showing molding of a large block.

FIG. 11 is an embodiment diagram in which the concrete block B is permeated into the water-soluble adhesive liquid.

FIG. 12 is a side view of FIG. 11.

[Explanation of symbols]

 (1) ... Press-releasing body (2) ... Piston for supplying mortar (3) ... Piston rod (4) ... Piston cylinder (5) ... Supply lid (7) ... Stirring blade (8) ... Chain conveyor (10) … Press plate vibrator (11)… Vibration isolation rubber (12)… Vertical cylinder (13)… Guide shaft (14)… Machine stand (15)… Face pallet mount (17)… Vibration table (18)… Movement prevention piece (19) ... Handle (20) ... Double formwork (23) ... Formwork vibrating machine (24) ... Machine frame vibrating machine (26) ... Press plate (27) ... Inversion double formwork (28) ... Inversion Shaft (30) ... Press plate (32) ... Press cylinder (34) ... Side formwork (35) ... Formwork bottom plate (36) ... Surface pallet platform protrusion (46) ... Tank (48) ... Sponge ( 49) ... Lift P ... Surface pallet B ... Block C ... Concrete F ... Wrapper

Claims (1)

[Claims] 1. A bottom surface of a surface pallet for forming an exposed surface of a concrete block is formed into a natural stone-shaped uneven ridge and valley shape, and an appropriate amount of arbitrarily mixed kneading mortar is supplied to this upper surface to deform by pressing. By pressing and vibrating the loose body, mortar with a uniform thickness is layered on the uneven ridge-valley surface of the surface pallet, and the surface pallet with the mortar layered is stored in the formwork device, and the concrete to be supplied and the surface pallet Forming mortar and layered mortar by infiltrating the concrete layer with the vibration of the mold and independent vibration from the back side of the surface pallet and pressure compaction, and transferring the molded concrete block to curing, and curing is completed. Peel off the rear pallet and place it on the adhesive-containing sponge sheet laid on the inner bottom of the water-soluble adhesive liquid tank equipped with a block exposed surface and press the sheet. Then, the adhesive liquid is permeated into the surface layer of the block and the block is lifted from above the sheet to release the pressure on the sheet, and the double action of this sheet absorbs the excess adhesive liquid on the surface of the block to absorb the adhesive. A method for manufacturing a concrete block, which comprises drying.