JPH091516A - Manufacture of decorative concrete block - Google Patents

Abstract

PURPOSE: To provide an industrial manufacturing method of a decorative concrete block of a good appearance, beyond the surface of which large and small stones having various shapes and the like are exposed. CONSTITUTION: Solgel material prepared by melting cement hydration reaction retarding component 4 in water-soluble gelled material is employed as shaping agent 3. Under the condition that comparatively larger native stone, crushed stone, dressed stone and either one or composite one of burned matter as brick, tile and the like 2 are planarly arranged on the bottom face of a mold 1. The shaping agent 3 under sol state is poured in thin gap part and, after the gelation of the shaping agent, mortar 5 mixed with comparatively smaller decorative aggregate 6 is poured on the shaping agent. When necessary, concrete 7 is backingly placed on the aggregate. After the hardening of the concrete, the from is separated and the shaping agent at the surface of a block and unhardened portion of the surface of the mortar contacting with the shaping agent are washed off by being brushed with high pressure water. Thus, a concrete block with exposed lump finish of stone or the like under the condition that the gap part has exposed finish of decorative aggregate (broken stone chip).

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in the surface finishing method for concrete decorative blocks.

[0002]

2. Description of the Related Art As a method of exposing a relatively large-sized stone material, etc., an embedding method is used before the concrete is hardened, or the stone material is fixed in a mold with a modeling solution such as an agar solution, paraffin, or a thermoplastic resin. After that, the method of placing concrete, holding stones etc. on the pallet with the sealing aggregate,
There is a method of crimping to concrete immediately after placing.

On the other hand, as a method of exposing and exposing relatively small-sized stones, etc., concrete or mortar is sprayed on the surface of the mortar before it is hardened, and mortar is removed by washing during hardening of mortar mixed with stones. There is also a method of applying a hydration reaction delaying component of cement to the block decorative surface of the mold to remove the mortar by washing and removing after curing and demolding.

[0004]

However, the method of embedding a relatively large-sized stone material or the like before the hardening of concrete, which is an exposed finishing method, is difficult to control technically and industrial productivity cannot be expected. Agar solution such as stones in the mold,
In the method of fixing with a shaping agent such as paraffin or thermoplastic resin, the concrete surface in the gap portion has a simple mortar surface finish in appearance. In the method of holding with the sealing aggregate, the concrete surface in the gap is uneven in appearance and it is difficult to secure quality.

The exposed finish of a stone material or the like having a relatively small shape is limited to a certain size and the exposed finish of a combination of large and small shapes is impossible.

[0006]

Means for Solving the Problems Accordingly, the present inventors have:
Focusing on the combination of a water-soluble gelling agent and a water-soluble cement hydration reaction delaying component for exposed finishing of relatively small stones, among the modeling agents for holding relatively large stones, etc. As a result of research, we have completed a method of manufacturing exposed exposed blocks of mixed sizes such as stone.

According to the present invention, a water-soluble gelling material in which a certain amount of a water-soluble cement hydration reaction delay component is dissolved in a sol state is used as a modeling agent, and a stone material having a relatively large shape on a horizontal surface of a mold,
Alternatively, fired materials such as tiles and bricks are appropriately arranged, and the prepared modeling agent is injected into the gaps thereof, and after gelling, the stone materials or the fired materials are held. Then, a mortar containing a relatively small amount of decorative aggregate (seed stone) or a mortar containing general-purpose aggregate is placed on the entire surface of the modeling agent to a certain thickness or more, and if necessary concrete Lining.

After the concrete has developed a strength capable of demolding the mold, the mold is demolded and the molding agent on the block surface and the mortar on the uncured portion of the mortar surface in contact with the molding agent are washed with high pressure water or brushed. Removed by washing or composite washing, stone material, or fired material and decorative aggregate (seed stone),
Or, a large and small exposed exposed block such as a general-purpose aggregate is manufactured.

The water-soluble gelling material here is an agar aqueous solution, a gelatin aqueous solution, or a cellulose aqueous solution, and the water-soluble cement hydration reaction delay component is mainly a monosaccharide, a disaccharide, a trisaccharide, or a mixed saccharide of a tetrasaccharide or more. Any one of those containing oxycarboxylic acid and its derivative as a main component, those containing lignin sulfonic acid and its derivative as a main component, or a mixture thereof. This is the same component as that of Japanese Patent Application Laid-Open No. 4-369510 "Concrete immediate demolding block surface processing method and cement hydration reaction retardant for same" according to the prior application of the present inventor.

The exposed depth of a relatively large stone material or a fired material such as tile or brick is the injection amount (thickness) of the gelling material.
Controlled by, relatively small shape decorative aggregate (seed stone),
Or the exposure depth of general-purpose aggregate is the injection amount (thickness) of gelling material
It is controlled by the amount of retarding component in the gelling material per contact area between the mortar and aggregated mortar. That is, the injection amount of gelling material uniquely determines the exposure depth of relatively large stones, tiles, or bricks, and the concentration of the delay component in the gelling material and the injection amount are relatively small amounts of cosmetic bone. Affects the exposure depth of wood (seed stone) or general-purpose aggregate, and the higher the concentration and the larger the injection amount, the greater the exposure depth.

[0011]

The exposed stone material and the decorative block in which the shapes of the seed stone and the like are mixed can be finished in a wider range more naturally and artificially by selecting the stone material and the seed stone. That is, it is a manufacturing method that can obtain a product with a wide variety of variations in terms of landscape.

When a relatively large-sized stone material and a relatively small-sized makeup aggregate are made of the same material having the same size and the same processed shape, a more natural makeup in which the shadow due to the size of the exposure depth is emphasized It becomes a finishing block. Naturally, when a relatively large-sized stone material and a relatively small-sized decorative aggregate are made of the same material by differently processing size and shape, the decorative block is natural but has a good taste.

When the material of the relatively large-sized stone and the material of the relatively small-sized decorative aggregate are different, depending on the choice of the stone, the contrast is emphasized by the color tone, the shape, etc. together with the shadow, and the stone material It becomes a landscape block with many variations that make the most of its flavor and luxury. The change in these variations changes in appearance depending on the depth of exposure of a relatively small-sized decorative aggregate or the like. The deeper it is, the more natural and large the shadow, and the shallower the mortar surface is exposed.
Smaller shadows and more artificial.

This exposure depth can be easily controlled by controlling the concentration of the water-soluble cement hydration reaction delay component dissolved in the water-soluble modeling agent.

[0015]

EXAMPLES The present invention will be specifically described based on examples, but the present invention is not limited thereto. Example 1 As shown in FIG. 1A, a steel mold 1 (600 × 600)
Granular crushed stones 2 (50 to 60 mm) are randomly arranged on the bottom surface of (80 mm), and then, as shown in (b), agar sol liquid modeling agent 3 (industrial Agar powder 1%) for crushed stones with a thickness of 5 mm
So that it is poured and cooled, and the modeling agent is gelled,
Fix the crushed stone 2.

The water-soluble cement hydration reaction delay component is a mixture of the main components of mixed sugars in a 0.5% agar sol solution. Next, as shown in (c), a mortar 5 containing granulated crushed stone as a seed stone 6 is cast so as to have a thickness of about 20 mm so as to cover the surface of the modeling agent 3. The composition of mortar containing granulated crushed stone is as follows.

Granulated crushed stone (12 mm) 1250 parts Silica sand 350 parts Cement 420 parts Water 230 parts Next, as shown in (d), the backing concrete 7 is cast to the mold height, and the concrete can be removed from the mold. After curing until the strength is fully developed, the mold is demolded as shown in (e), the bottom surface of the mold becomes a block surface, and the surface is covered with the modeling agent 3.

As shown in (f), the modeling agent on the block surface and the mortar on the uncured portion of the mortar surface in contact with the modeling agent are removed by high pressure water cleaning, brushing cleaning, or the like.
The decorative block finished in this way consists of crushed stones 2, seed stones 6, and lining concrete 7.
It is more attractive than the natural stone with its complex depth of exposure and the emphasis on shading. Example 2 Plate-shaped flat iron stones (80 to 200 × 40 mm) were randomly arranged on the bottom surface of a steel mold (600 × 600 × 80 mm),
The agar sol liquid having the above concentration in which 0.3% of the main component of the mixed saccharide is dissolved is poured into the gap between the iron flat stones so as to have a thickness of 15 mm and gelled to fix the crushed stone.

Next, a mortar containing 5 mm or less of general-purpose aggregate is cast so as to cover the surface of the modeling agent so as to have a thickness of about 20 mm. The mortar composition with general-purpose aggregate is as follows. River sand 1100 parts Silica sand (5 mm or less) 430 parts Cement 500 parts Water 270 parts Then, as in Example 1, a backing concrete is poured, and after the curing and demolding, the modeling agent on the block surface and the uncured mortar part are washed. Remove. The finished decorative block had a natural contrast between iron flat stone and general-purpose aggregate. Example 3 A fired brick (70 × 220 × 50 mm) was placed on a bottom surface of a steel mold (600 × 600 × 100 mm) in a core horse step pattern having a joint width of 25 mm, and 2 main components of oxycarboxylic acid and its derivative were placed. % Of the agar sol having the above-mentioned concentration is poured into the space between the fired bricks so as to have a thickness of 12 mm, and gelled to fix the bricks.

Next, a mortar containing 5 mm of black crushed stone is cast so as to cover the surface of the modeling agent so as to have a thickness of about 20 mm. The composition of mortar containing black crushed stone is as follows. Black granulated crushed stone (5 mm) 1280 parts Silica sand 330 parts Cement 420 parts Water 230 parts Next, in the same manner as in Example 1, lined concrete is cast, and after hardening and demolding, a modeling agent for the block surface and an uncured mortar part. Are removed by washing. In the finished decorative block, fired bricks regularly embedded in relatively small-sized black crushed stone had a more artificial and high-class appearance.

[0021]

INDUSTRIAL APPLICABILITY The method of the present invention can be manufactured by the conventional casting method for concrete regardless of the size of the block shape, requires no special equipment, has a high-class feeling, is of high quality and has high added value. It has the excellent effect of being able to manufacture landscape makeup block products with many variations.

[Brief description of the drawings]

FIG. 1 is a diagram showing a process of the present invention, (a) is a diagram showing a process of arranging a relatively large natural stone or the like in a mold, and (b) is a process of injecting a modeling agent in a sol state. FIG. 6 (c) is a diagram showing a step of injecting mortar mixed with a relatively small-sized makeup or general-purpose aggregate, (d) is a diagram showing a concrete lining step, and (e) is a demolding step. Fig. (F) is a diagram showing a cleaning step,

[Explanation of symbols]

 1: Steel form, 2: Stones (of relatively large shape), 3: (Water-soluble) modeling agent, 4: (Water-soluble cement hydration reaction) retarder, 5: (Seeds of relatively small shape) Mortar with stone, 6: Seed stone (of relatively small shape), 7: (lining) concrete

Claims (3)

[Claims] 1. A natural stone having a relatively large shape on a bottom surface of a mold serving as a block surface, using a sol-gel material obtained by dissolving a cement hydration reaction delay component in a water-soluble gelling material as a modeling agent.
Crushed stone, shape-processed stone, and either bricks, fired products such as tiles, or a composite is placed in a planar shape, the sol-state modeling agent is injected into the gap, after gelling of the modeling agent Mortar mixed with a relatively small amount of decorative aggregate (seed stone) is poured, and if necessary, concrete is lined, and after the concrete is hardened, the mold is demolded, and the block surface modeling agent, And the uncured part of the mortar surface in contact with the modeling agent is removed by washing with high-pressure water brushing, etc., so that the exposed part of the decorative aggregate (seed stone) becomes the exposed part of the aggregate, even though the mass of stone etc. is exposed. A method for manufacturing a decorative concrete block, which is characterized by the above. 2. A sol-gel material obtained by dissolving a cement hydration reaction retarding component in a water-soluble gelling agent is used as a modeling agent, and a relatively large natural stone is formed on the bottom surface of a mold serving as a block surface.
Crushed stone, shape-processed stone, and either bricks, fired products such as tiles, or a composite is placed in a planar shape, the sol-state modeling agent is injected into the gap, after gelling of the modeling agent Inject mortar mixed with general-purpose aggregate of relatively small shape, line the concrete if necessary, and after the concrete is hardened, remove the mold and use it as a modeling agent for the block surface and a modeling agent. A decorative concrete block characterized in that the uncured portion of the mortar surface that comes into contact with it is removed by washing with high pressure water, brushing, etc. Manufacturing method. 3. The shaping agent is an agar aqueous solution, a gelatin aqueous solution,
A certain amount of a water-soluble delay component is dissolved in a sol state in an aqueous solution of cellulose or the like, and the delay component is a monosaccharide, a disaccharide, a trisaccharide, or a mixture of tetrasaccharides or more as a main component, oxycarboxylic acid. An acid and its derivative as a main component, a lignin sulfonic acid and its derivative as a main component, or a mixture, wherein the modeling agent is gelated after being injected into a lump gap of a stone material or the like. The method for producing a decorative concrete block according to claim 1 or 2.