JPH11182031A - Concrete facing form and face execution of concrete surface making use thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To have durability in concrete casting with slope as well as horizontal casting and vertical casting on the surface of a concrete structure and to accurately transcribe specific architectural design and pattern, etc., bringing out a taste of natural stone. SOLUTION: A plurality of recesses for forming specific architectural designs and patterns are formed on the surface of concrete on the side to cast concrete of a facing form in order to form specific architectural designs and patterns on the surface of a concrete structure, a pattern layer 4 consisting of dry film formed of a mixture of nonaqueous resin binder and natural aggregate is formed on the surfaces of recesses. Inorganic aggregate having particle size larger than 1 mm or fiber is fixed to the pattern layer 4 by means of an optional device.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative formwork for concrete and a method for decoratively applying a concrete surface using the formwork. The term "concrete" used in the present invention includes so-called curable materials that harden after a chemical reaction such as mortar, stucco, gypsum, synthetic resin, in addition to ordinary concrete that hardens by a chemical reaction between cement and water. You. In the present invention, the aggregate used for the production of the decorative formwork is the same as sand, gravel, crushed stone, etc., which is mixed with a binder such as a cement paste to form a concrete or mortar when combined with water and hardened to form concrete or mortar. Without being fixed to the decorative formwork,
After the concrete is cast, a part of the hardened concrete is buried and fixed to the surface of the concrete, and the concrete has a function of expressing a natural stone pattern and texture. Therefore, the terms relating to the particle size, particle size, etc. used for the aggregate in the present invention do not always exactly follow the terms stipulated in the Architectural Institute of Japan: Building Construction Standard Specifications / Commentary JASS 5 Reinforced Concrete Work, or JIS. Absent.

[0002]

2. Description of the Prior Art Conventionally, on the surface of various buildings,
Mortar spraying, concrete, tiles, natural stones, bricks, etc. with various designs such as stucco finish patterns are used. In addition, the fence is made of stone quarry, quarry, quarry, brick, piled with concrete tiles or stones, sprayed with mortar, artificial stone, or the like. These outer walls and fence works require expensive materials themselves or special skills such as plasterers and masons. For this reason, the technique of applying various design patterns such as various masonry patterns, brick patterns, and chipping patterns on the surface of concrete at the same time as placing concrete has been widely adopted. It is referred to as a decorative formwork, as distinguished from a formwork used for concrete subjected to bare finish or concrete for direct finish.

[0003] The decorative formwork is mounted on a formwork dam which is mainly composed of a dam plate, a shoring work, and a fastening material. The concrete form is cast, hardened, and then released. Therefore, the decorative mold has good mold releasability from concrete, high strength, high mechanical strength of the mold itself, etc., and good design precision, that is, accurate transfer of the concave and convex pattern of the design. It is required that the texture of natural stone be given and that the durability be good.

Conventionally, as a technique for transferring a pattern of natural stone or the like to the surface of concrete using a decorative form, there is a method using a form to which pigment powder is adhered. There is a fatal drawback of discoloration due to rainfall and the like. As another conventional technique, there is a method of using a mold to which a powder of natural stone colored with a pigment is adhered. However, in this conventional technique, the particle diameter of natural stone is generally small, so that it does not bite into concrete. There is a drawback that the natural stone powder is stained with the pigment, and the original texture is impaired.
Further, as another conventional technique, there is a method using a formwork coated with a mixture of natural stone powder and a resin binder. Many variations are possible for this conventional technology by combining it with a resin binder with excellent durability.
Although it is expected as a landscape material, the surface in contact with concrete becomes smooth after spraying, has a drawback of poor biting into concrete, lack of pattern due to poor transfer, peeling after construction, etc. . As described above, the prior art of transferring a pattern such as natural stone to the surface of concrete using a decorative form has drawbacks to be improved.

[0005]

SUMMARY OF THE INVENTION Accordingly, a main problem to be solved by the present invention is to provide a method of transferring a pattern such as a natural stone on a concrete surface using a decorative form.
It is impossible to manufacture a decorative mold that is durable and can accurately transfer a predetermined design pattern or the like that reproduces the texture of natural stone.

Another problem to be solved by the present invention is that it has not been possible to establish a construction method which is durable and accurately transfers a predetermined design pattern or the like which reproduces the texture of natural stone on the surface of concrete. That is. Further problems and advantages to be solved by the invention will be clarified below.

[0007]

In general, a concrete-manufactured product has a relatively small cross-sectional dimension, a complicated shape, and many rebars and various embedded objects. Therefore, in order to obtain a solid and uniform concrete molded product, it is necessary to increase the mixing water amount and make the concrete with a large slump. On the other hand, if the unit water volume is excessive, the excess water will breathe and move on the surface of the formwork, and the surface layer of concrete in contact with the formwork will become a fragile layer containing a large amount of moisture, and as a result, the aggregate will be separated. Or the phenomenon of insufficient adhesion of the coating material to the concrete is caused.

[0008] Conventionally, for the concrete for building, the unit amount of water has been regulated by the Architectural Institute of Japan, "Building Construction Standard Specification JASS 5 Reinforced Concrete Work". Also, with the recent development of fluidizers and high-performance water reducing agents, Although high quality concrete products with good fluidity can be obtained with a small amount of water, construction (transportation and casting of concrete), especially when forming complex and subtle design patterns such as natural stone patterns on concrete, From the ease, large slump,
In other words, there is a strong tendency that concrete with a large unit water volume is preferred. Therefore, it is difficult to eliminate the defect that the aggregate is separated or the adhesion of the coating material to the concrete is insufficient only by controlling the unit water amount.

The present inventors have pointed out that it is difficult to eliminate the defect that the aggregate is separated or the coating material is insufficiently fixed to the concrete only by controlling the unit water amount. Attention was focused on improving these defects with aggregate size.

[0010] Accordingly, the present invention, which is a means for solving the problem, is a decorative formwork for forming a predetermined design pattern on the surface of a concrete molded article, which is formed on the side where concrete is cast. A plurality of concave and convex portions for forming the predetermined design pattern on the surface of concrete,
A pattern layer that is fixed to the surface of the concave portion and is made of a dry film formed of a mixture of a water-insoluble resin binder and a natural aggregate and that expresses a predetermined pattern, and is fixed to the pattern layer. This is a decorative formwork composed of inorganic aggregates and / or fibers. .

[0011] The decorative formwork of the present invention has a plurality of concave and convex portions for forming a predetermined design pattern on the surface of the concrete, on the side of the decorative formwork body on which the concrete is cast,
Next, the natural aggregate is fixed to the entire surface of the concave portion, or a part thereof, by any means to form a pattern layer, and then the particle diameter of the pattern layer is 1 mm or more by any means. It is manufactured by fixing fibers.

The mold body used in the decorative mold of the present invention is made of, for example, a foam of a thermoplastic synthetic resin such as a polystyrene resin, a polypropylene resin, a polyethylene resin, a polyurethane resin, a polyvinyl chloride resin, a polyvinylidene chloride resin, or These foams are selected from a combination of materials. The expansion ratio should be determined in consideration of various conditions such as workability, workability of concrete placement, and cost, but is preferably in the range of 14 to 50 times.

The concave and convex pattern for forming a predetermined design pattern on the concrete surface of the decorative formwork of the present invention, which is formed on the side where concrete is cast, can be easily formed by any means. For example, it can be performed by roughing, rough carving, and finishing, which are one of ordinary engraving techniques.

[0014] The entire surface of the concave and convex pattern formed on the side of the decorative formwork of the present invention where concrete is cast,
Alternatively, examples of the natural aggregate fixed to a part thereof include river sand, river gravel, mountain sand, mountain gravel, land sand, land gravel, sea sand, sea gravel, volcanic gravels, and the like.

[0015] The entire surface of the concave portion of the concavo-convex pattern formed on the side of the decorative formwork of the present invention where concrete is cast,
Alternatively, the pattern layer in which the natural aggregate fixed to a part thereof is blended may be formed by a dry coating by applying a resin paint in which the natural aggregate is mixed with a water-insoluble resin binder such as an acrylic copolymer emulsion by an arbitrary method. It is formed. At this time, it is possible to adjust the type, particle size, particle size, etc. of the natural aggregate according to a desired pattern, and / or to make subtle changes by spraying a plurality of combinations of paints having different colors and textures. it can. In the production of the decorative formwork of the present invention, if a mold release agent is applied as necessary in forming the pattern layer, the decorative formwork can be easily removed after concrete placement.

The inorganic aggregate fixed to the pattern layer of the decorative formwork of the present invention is a natural inorganic aggregate such as crushed stone produced by crushing rock or cobble stone, for example, granite crushed stone, or an artificial aggregate such as ceramics. The particle size is preferably a sphere or polyhedron that remains on a 1 mm sieve and passes through a 5 mm sieve.

The inorganic aggregate used in the decorative formwork of the present invention may be formed by any means, for example, spraying, before the resin binder in the paint applied for forming the pattern layer is dried and formed into a film. It is embedded in the resin binder by an attaching method. In this case, in the case of a handmade work by special order, it can be embedded manually. In this way, the inorganic aggregate temporarily held by the resin binder is fixed to the dried film after the resin is dried and formed into a film. By setting the particle size of the inorganic aggregate to 1 mm or more, the inorganic aggregate is sufficiently embedded in the dried film resin, integrated, and does not fall off.

Further, by setting the particle size of the inorganic aggregate used in the present invention to 1 mm or more, the inorganic aggregate can be bitten by a structure having a higher strength inside the surface layer of the concrete which is weakened by the influence of breathing water. After the concrete hardens, it is integrated with the concrete and does not fall off.
Since a part of the entire length of the inorganic aggregate is buried in the pattern layer, if the inorganic aggregate is 1 mm or less, it may be insufficiently bitten into concrete and fall off. On the other hand, when the inorganic aggregate is 5 mm or more, it rebounds when sprayed onto the pattern layer, so that not only a sufficient amount of the inorganic aggregate cannot be attached, but also the solid weight of the inorganic aggregate due to its own weight. Strength drops and falls. As a result of the experiment, the particle size of the inorganic aggregate was 1 mm or more, preferably 1.5 mm or more.
To 4 mm.

The decorative formwork of the present invention can also be manufactured by fixing fibers three-dimensionally by any means, instead of inorganic aggregates, before the pattern layer is dried and hardened. The types of fibers used in the present invention are natural fibers, synthetic fibers,
Alternatively, inorganic fibers may be used, and when classified according to the production method, monofilaments, bundled fibers, or twisted yarns may be used.

The fibers used in the present invention are 1 mm to 3 mm.
It is a chopped strand cut to 0 mm. If the fiber is 1 mm or less, the fiber does not reach the concrete structure, while if it is 30 mm or more, the fiber collapses horizontally due to the lateral pressure at the time of concrete casting. Do not reach.

The fibers used in the present invention are preferably monofilaments having a diameter of 20 to 1000 microns or bundled fibers. If the fiber diameter is less than 20 microns, the fibers will fall down horizontally due to the lateral pressure during concrete casting, and will not reach the concrete structure. on the other hand,
When the fibers are 1000 microns or more, the fibers are not sufficiently fixed to the pattern layer and are not fixed to a three-dimensional random structure. In the present invention, when a so-called non-woven fabric manufactured by three-dimensionally entangled fibers instead of fibers is used, the thickness and length of the fibers are not restricted. Thus, the term "fiber" as used in the present invention encompasses nonwovens.

In order to apply a decorative surface to the concrete surface using the decorative formwork of the present invention, first, a concrete formwork dam, which is mainly composed of a dam, a shoring, and a binding material, is applied to the dam. Attach by predetermined means. Weir plate
If it is made of wood, it is nailed, and if it is made of steel, aluminum alloy, plastic, or paper, it is attached with double-sided adhesive tape. Next, a curable material selected from mortar, concrete, plaster, gypsum, synthetic resin, and the like is filled into the voids formed by the decorative formwork and the formwork for the concrete skeleton construction, and after the curable material is cured, it is removed. When molded, any design pattern is accurately transferred to the concrete surface.

Hereinafter, the present invention will be described in detail with reference to Examples and Comparative Examples.

Example 1 A foamed polystyrene form "Swalite Foam" manufactured by Hiroshima Kasei Co., Ltd. was used as the main body 2 of the decorative form. A mold release agent 3 manufactured by Nippon Preston Co., Ltd. was sprayed on the surface of the mold body 2 which comes into contact with concrete.
Then, a pattern coating layer 4 was formed by spraying a mixed coating of natural stone fine powder and an emulsion “Celagrany w” (manufactured by Yamamoto Ceramics Co., Ltd.) at a blowing air pressure of 4 kg / cm ² to an average thickness of 2 mm. . The surface on which "Celagrany w" was sprayed had a resin in a floating state, and the unevenness of the surface was slight. Before the resin is dried and formed into a film, granite aggregate 5 (manufactured by Hitachi Crushed Stone Co., Ltd.) that passes through a 2 mm sieve and passes through a 3 mm sieve is sprayed in a dry state,
It was fixed in the dry resin. The decorative formwork thus manufactured was attached to the concrete form dam board 1, and the concrete was cast in a state of standing up for 3 minutes and removed from the mold 4 days later. There is no poor transcription,
The adhesive strength of the transfer portion was 11 kg / cm ² .

[0024]

Example 2 A foamed polystyrene mold "Swalite Foam" manufactured by Hiroshima Kasei Co., Ltd. was used as the main body 2 of the decorative mold. A mold release agent 3 manufactured by Nippon Preston Co., Ltd. was sprayed on the surface of the mold body 2 which comes into contact with concrete.
Then, a pattern coating layer 4 was formed by spraying a mixed paint “Celagrany w” (manufactured by Yamamoto Ceramics Co., Ltd.) of fine natural stone powder and an emulsion at a spray air pressure of 4 kg / cm ² to an average thickness of 2 mm. . Was. “Celagrany
The surface to which "w" was sprayed was in a state where the resin was in a floating state, and the unevenness of the surface was slight. Before the resin was dried and formed into a film, it had a diameter of 500 microns and a length of 9 mm. ARC fiber 6 (manufactured by Nippon Electric Glass Co., Ltd.) was sprinkled and fixed thereon, and the decorative form produced in this manner was mounted on the concrete form dam board 1 and kept standing for 3 minutes. Pour concrete and 4
When the mold was removed after a day, there was no transfer failure of the sprayed pattern layer 4, and the adhesive strength of the transferred portion was 10 kg / cm ² .

[0025]

Example 3 A foamed polystyrene mold "Swalite Foam" 2 manufactured by Hiroshima Kasei Co., Ltd. was used as a body of a decorative mold. A mold release agent 3 manufactured by Nippon Preston Co., Ltd. was sprayed on the surface of the mold body 2 which comes into contact with concrete.
Then, a pattern coating layer 4 was formed by spraying a mixed paint “Celagrany w” (manufactured by Yamamoto Ceramics Co., Ltd.) of fine natural stone powder and an emulsion at a spray air pressure of 4 kg / cm ² to an average thickness of 2 mm. . Was. “Celagrany
The surface to which "w" was sprayed was in a state in which the resin was floating, and the unevenness of the surface was slight. Before the resin was dried and formed into a film, the three-dimensional stitched nonwoven fabric base net 7 (Japan) (Made by Stucco Co., Ltd.) and fixed.The thus-prepared decorative formwork was attached to the concrete form dam plate 1, and the concrete was poured in a state of standing up to the corobi for 3 minutes and then removed 4 days later. When it was molded, the sprayed pattern layer 4
No transfer failure, adhesive strength of transfer part is 10kg / c
It was m ^2.

[0026]

Comparative Example A foamed polystyrene mold "Swalite Foam" 2 manufactured by Hiroshima Kasei Co., Ltd. was used as the body of the decorative mold. A mold release agent 3 made by Nippon Preston Co., Ltd. was sprayed on the surface of the mold 2 which comes into contact with concrete. Then, a mixed paint “Celagrany w” (manufactured by Yamamoto Ceramics Co., Ltd.) of a natural stone fine powder and an emulsion is sprayed at an air pressure of 4 kg / cm ^{2 so as} to have an average thickness of 1.5 mm to form the pattern layer 4. Formed. Was. “Celagrany
The surface to which "w" was sprayed was in a state where the resin was in a floating state, and the unevenness of the surface was very small. 4 days after casting, the pattern layer 4 sprayed was hardly transferred to the concrete surface.
Only the part that was thinly fixed at the time of spraying was transferred.
The adhesive strength of this part was 5 kg / cm ² .

[0027]

Since the decorative mold of the present invention has the above-described structure, the following effects can be obtained. Design patterns formed on the surface of concrete objects,
For example, a stone wall pattern has a natural stone aggregate embedded partially on its surface and is firmly fixed, and furthermore, an inorganic aggregate such as granite aggregate is fixed, so that the texture of the natural stone itself as a whole is accurately Is expressed. Since the inorganic aggregate is partially embedded and firmly fixed to the surface of the concrete model, it does not fall off even after hardening of the concrete, and a predetermined pattern with high durability is exhibited. The shape of the natural stone, the inorganic aggregate expressing texture, is fixed to the surface of the pattern layer as a dry film of a mixture with, for example, a water-insoluble resin binder. Since it does not separate from the surface, it is durable not only for horizontal casting and vertical casting, but also for concrete casting with corobi (inclined), and accurately transfers predetermined design patterns etc. that reproduce the texture of natural stone be able to.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a first embodiment of the present invention.

FIG. 2 is a sectional view showing a second embodiment of the present invention.

FIG. 3 is a sectional view showing a third embodiment of the present invention.

FIG. 4 is a sectional view showing a comparative example.

[Explanation of symbols]

 Reference Signs List 1 damper of concrete formwork 2 decorative formwork body 3 mold release agent 4 pattern layer 5 granite aggregate 6 fiber 7 nonwoven fabric base net

Claims (5)

[Claims] 1. A decorative formwork for forming a predetermined design pattern on a surface of a concrete molded article, wherein the decorative formwork is formed on a side where concrete is cast and forms the predetermined design pattern on the surface of concrete. A plurality of concave and convex portions for making, a pattern layer which is fixed to the surface of the concave portion, and which comprises a dry film formed from a mixture of a water-insoluble resin binder and a natural aggregate, and which exhibits a predetermined pattern, And a decorative form made of inorganic aggregates and / or fibers fixed to the pattern layer. 2. The method according to claim 1, wherein the inorganic aggregate remains on a 1 mm sieve.
The decorative form of claim 1, wherein the form is selected from the group consisting of natural stones, crushed ceramics, ceramic balls, and mixtures thereof passing through a 5 mm sieve. 3. The decorative formwork according to claim 3, wherein the fibers are monofilaments having a diameter of 20 to 1000 microns or chopped fibers cut into bundles of 1 to 30 mm. 4. The decorative formwork according to claim 3, wherein the fibers are nonwoven fabrics. 5. A method for decoratively constructing a concrete surface using a decorative formwork, wherein (a) a decorative formwork for forming a predetermined design pattern on a surface of a concrete molded article, wherein the concrete is A plurality of concave and convex portions formed on the side to be cast and for forming the predetermined design pattern on the concrete surface, fixed to the surface of the concave portion, a water-insoluble resin binder and a natural aggregate A decorative layer composed of a dry film formed from a mixture of the above and a pattern layer exhibiting a predetermined pattern, and an inorganic aggregate and / or fiber fixed to the pattern layer; , Mortar, concrete plaster, gypsum, synthetic resin, etc. The curable material selected from the above is filled in the voids formed by the decorative formwork and the formwork for concrete skeleton construction, and the curable material is cured, and then (c) removing the decorative formwork A method of applying makeup to the surface of concrete consisting of: