JPS63299901A - Molding of concrete product wherein natural stone is exposed on surface - Google Patents

Abstract

PURPOSE:To obtain a concrete product having excellent surface of natural stones, by piling up natural stones in two layers or more on the inner face of a palette in a form, filling sand particles in gaps of the stones, spraying thereon water, tightening and hardening a hard-kneaded concrete on these stones, then aging it and taking it out from the form. CONSTITUTION:A box-shaped palette 1 where stones 2 and 3 and sand particles 4 are filled and water is sprayed is placed in a form 20 and a specific amt. of concrete is therein fed. The concrete is tightened and hardened by applying vibration of a vibrator 6 and lowering a press plate 22 to mold a block. Just after the molding, the block is taken out from the form and the palette 1 is removed after aging. Stones 3 of the upper layer where water was fed on its surface and stones 2 of the lower layer are divided at the line C-C and a block B on whose surface natural stones 3 are exposed can be obtained. Stones constituted of natural stones in the block B exhibit durability and natural appearance, have no water absorbing property and do not break when being frozen.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention enables the surface (decorative surface) of a concrete product to be formed by embedding blocks of natural stones of various sizes and shapes into the concrete surface depending on the purpose and place of use of the product. , concerning a method of forming concrete products that reveals natural stone on the surface depending on the environment.

Conventionally, the methods for forming a decorative surface on the surface of a concrete product to match the environment include (a) pasting an uneven plate made of synthetic resin, rubber, etc. on a surface pallet, forming a concrete product, and creating a decorative surface; (b) A method of forming a concrete product by interposing a concrete mixture of natural stone or a similar material in a sandwich shape, and after hardening, this natural stone or a concrete mixture is
A method of dividing to obtain a concrete product with two natural stone surfaces.

(c) A method in which large and small natural stone blocks are placed inside pallets and concrete is poured directly into the blocks to form them.

However, in method (a), the molded surface formed by an uneven plate made of synthetic resin or rubber is a natural stone pseudo surface made of concrete itself, so time and time elapse. This has the disadvantage that it not only weathers and corrodes and becomes unsightly, but also deteriorates due to its high water absorption.Also, in the method of breaking in the middle layer of the opening, the surface divided into two parts is It has the disadvantage that cracks occur due to the shock of water and water absorption increases.In addition, there is a risk that such water-absorbing surfaces may freeze in cold regions and fall onto the construction site, causing damage and collapse. Furthermore, in the method (c) of laying large and small natural stone blocks on the inner surface of the pallet and directly pouring concrete, the natural stone blocks become embedded in the concrete during compaction. Natural stone blocks are not represented.

The present invention was developed in order to solve the above-mentioned drawbacks of the conventional method of expressing a natural stone surface on a concrete surface. The stones are piled up in layers, and natural sand grains are vibrated and filled into the gaps between the stones up to a predetermined upper surface position. After water is sprayed, a fixed amount of hard mixed concrete is supplied onto the stone and compacted by vibration and compression. In the case of block examples as shown in Figures 2 and 3, which will be described later, the product is removed from the mold and cured, and in the case of a product as shown in Figure 4, the formwork is cured and then palletized. By removing or demolding, the stone block embedded in the concrete and the stone block in the pallet or formwork are divided into two parts, and the natural stone block embedded in the concrete becomes a concrete product. The result is a concrete product formed on a natural stone surface that has an uneven surface that is incomparably superior to conventional products.

To explain the molding method of the present invention with reference to the accompanying drawings, FIGS. 1 and 2 show a block molding method of the formwork straight type or formwork sliding type using a box-shaped pallet;
The figure shows a block molding method using a mold reversal type. FIG. 4 shows another embodiment of a method of forming a plate block.

In Figure 1, (1) shows a deep box-shaped pallet, (2) and (3) show natural stone blocks of mixed sizes, and (2) shows the underlying stone layer. , (3) shows the upper stone layer, and in the figure, 1-1 is simply stacked in two layers,
In reality, it is complexly laminated into several layers. (4) is the sand grains that fill the voids of the natural stone blocks (2) and (3), and the stone blocks and sand grains are densely packed into the pallet (1) by the vibration of the vibrator (6). , the sand grain (4) layer is the upper layer of stone blocks (3
) is filled up to the A-A line, leaving the exposed surface. (5
) is a diaphragm, and (7) is a vibration-proof rubber that supports the diaphragm.

Further, (8) indicates a machine base, and (9) indicates a nozzle that sprays an appropriate amount of water to supply moisture to the surface filled with stone blocks and sand grains. Figure 2 shows a cross-sectional view of a block molding form, where ■ is a formwork that opens and closes from side to side, and inside this formwork a pallet (1) sprayed with water as shown in Fig. 1 is placed. do. (6) is the vibrator attached to the molding machine, (to)
(4) is a product projection rod, (B) is a vibration support stand, and (4) is a press plate.To explain the molding method used in this example, the mold First in Yayanai
A box-shaped pallet filled with stone blocks (2) and sand grains (4) shown in the figure and sprayed with water is arranged, a fixed amount of concrete is poured in, and a vibrator (6) is used to excite and press. The concrete is compacted and formed into blocks by the descent of the board,
Immediately demold the mold and send it to the curing room with the box-shaped pallet (1) placed there. When the pallet (1) is removed after curing, the exposed part of the upper layer of stone blocks (3) whose surface has been supplied with water is concrete. The lower stone mass (2) is in the sand grain layer (4), so it remains at the bottom of the pallet and is attached to the block side.
Block B is obtained by dividing along line -C and having natural stone blocks (3) exposed on the surface shown in FIG. In Figure 5 (
4) shows some of the sand grains attached to the concrete surface.

In this molding, the concrete is softened at the part that comes into contact with the hard mixed concrete that is thrown in to spray and supply water to the upper stone (3), and the stone is firmly attached and will never come off.

Figure 3 shows an example of a block molding formwork with inverted demolding.As shown in the figure, a certain amount of concrete is poured into the inverted formwork, and a vibrator gives primary vibration to the concrete. Once compacted, natural stone blocks (21, (3) are stacked in two or more layers evenly on the surface of this compacted concrete, and the voids between these stone blocks (2) and (3) are stacked. Either fill sand grains up to the top of the stone and spray an appropriate amount of water onto the stone mass and sand grains to penetrate, or spray water onto the top of the concrete to create a wet surface before supplying the stone mass. , place a regular plate-shaped pallet (1) on top of it, compress it downward to a certain height regulation position using the upper surface of the pallet (1) as a press plate, and start the vibrator (roller).
Next, vibration is applied to form the block, and then the pallet (
1) and turn the formwork over using the reversing axis) and remove it together with the pallet (1). After curing and hardening, remove the pallet to form the stone block (2).

(3) Divided into two along the l-1U-C line, the upper layer stones remain on the pallet with sand, and the lower layer stones are buried in the surface of block B to reveal natural stones as shown in Figure 5. Block B is obtained. In the figure, reference numeral (C) indicates an adjustment screw for regulating the compression height, (9) indicates a water spray nozzle, (B) indicates a pressing cylinder, and (B) indicates a guide rod.

Figure 4 shows an example of molding a plate-shaped block. A pallet (2) of the formwork (E) is removably attached, and large and small natural stone blocks (2) are placed on this pallet (4). ), (3)
Pour and stack two or more layers of sand grains (4) into the voids of these stone layers up to the A-A line position where the top surface of the upper stone layer (3) is exposed while vibrating the vibrator (6). Then, spray water at a high rate on the top surface, and then pour concrete from above.
The vibrator (6) is started and vibrated, and the press plate is lowered to compact and form the concrete to a certain height.After forming, hard knead the concrete 11. In this case, place it on a pallet (4), demold it, and cure it.

This forming method can also be used with soft concrete, but in this case, it is cured in the form. After demolding, by removing the pallet 1-(2), the exposed part of the upper layer of the stone block (3) is embedded in the concrete and adheres to the block side, and the lower layer of the stone block (2) and the mineral sand grain layer ( 4) Since it is inside, it remains on the bottom plate and is divided into two parts along the line C--C in the figure, resulting in a concrete product as shown in Figure 6 in which the natural stone is exposed. In the figure, (5) is the diaphragm, (7) is the anti-vibration rubber, (
8) indicates the machine base. Also, (9) is a water spray nozzle, (b)
The symbol indicates the cylinder for the press, the symbol for the cylinder guide rod, and the symbol for the adjustment screw to adjust the height of the press.

Although this Figure 4 shows a concrete product in the form of a flat plate, it is not limited to this shape (any shape may be used, and even if the product is in the form of a flat plate, if it is large, the formwork may be split). It is also possible.

The natural stone blocks appearing on the concrete surface of the present invention provide moisture to the contact surface with the hard-mixed concrete to improve adhesion to the concrete, so they do not peel off even after hardening. (Also, since the sand layer contains water, it is hard and there is no penetration of compacted mortar.In addition, as mentioned above, the present invention has natural stone blocks and sand grain surfaces all over the surface of the concrete product. It has a natural color, and it is completely sealed and has no water absorption, so it is completely different from conventional concrete-colored products, and even when used in cold regions, it does not freeze and deteriorate. There is no damage.Also, during molding, the presence of a sand grain layer makes it extremely easy to peel off the pallet, and the stamping when peeling off the pallet prevents damage to the pallet or product, and the pallet is easy to clean and wash. The process is efficient, and the stone blocks and sand grains left in the pallet can be reused.This is an outstanding method for forming concrete products that reveals natural stone on the surface.

[Brief explanation of the drawing]

Figure 1 shows an in-line drawing of a box-shaped pallet filled with natural stone blocks, Figures 2 and 3 are example diagrams showing the block forming method, and Figure 4 shows the manufacturing method of flat plate products. An example diagram is shown. Further, FIGS. 5 and 6 each show a cross-sectional view of the product. (1)...Pallet (2), (31...Natural stone block (4)...Sand grain layer (6)...Vibrator (9)
... Spray nozzle - ... Adjustment screw (4) ... Formwork patent applicant Kunio Watanabe review, 'AZ Fig. 1 Fig. 2 Fig. 3rl! J Figure 4 Figure 5 Figure 6 → 6 Procedural Amendment C Spontaneous) August 4, 1982 Patent Application No. 136382 of 1988 2 Title of Invention Method for forming concrete products that makes natural stone appear on the surface F Relationship with the case of the person making the amendment Patent applicant T-18 Sengen Kamimachi, Fuji City, Shizuoka Prefecture Table Date of amendment order Voluntary 5, number of inventions increased or decreased by amendment O a Column for detailed explanation of the invention subject to amendment (1 ) 41 The scope of claims is amended as follows. L A deep box-shaped pallet with drainage pores on the bottom.Using nine pallets, put natural stones of appropriate size and small size into the pallets using Mukubarare, and compact them by shaking the pallets. The stones are stacked in two or more layers, and sand grains are filled into the voids between the stacked stones while being vibrated to a thickness of about ten times the thickness of the upper layer of stones. A pallet is placed at the bottom of the forming frame, a certain amount of hard-mixed concrete is poured into the core mold, and the concrete is compacted and formed by applying compression and vibration, and the exposed natural stones and sand grains are buried in the concrete. The pallet is removed from the mold after curing, and the pallet is removed and embedded in concrete to separate the natural stone and sand grains from the natural stone and sand grains that remain inside the pallet. A molding method that reveals natural stone. 1. In a concrete formwork that is formed by inverting the formwork, a certain amount of hard mixed colloid is put into the formwork, the concrete is compacted by compression and vibration, and then a natural mixture of various sizes is applied to the top surface of the concrete formwork. Inject stones and stack them in two or more layers, fill the gap between the stones with sand grains lower than the top surface of the upper layer of stones, and spray an appropriate amount of water on the surface of the skeleton stones and sand grains to overturn the pallet. The compaction plate is lowered to press the pallet and compact it by applying vibration, and the stones and sand grains in the lower layer are embedded in the concrete in the required amount according to the regulations of the compaction plate, and the excess water is poured into the hard mixed concrete in the lower layer. After infiltration and compaction, the pallet is held down and the formwork is rotated forward to remove the mold. After curing, the pallet is removed and the natural stone and sand particles embedded in the concrete and the natural stone and sand particles left inside the pallet are removed. A forming method for revealing natural stone on a concrete surface as claimed in claim IK, characterized in that sand grains are separated into particles. A pallet with drainage holes is attached to the bottom of the upper and lower open formwork in a removable manner, and natural stones of appropriate sizes are placed in the formwork and compacted by shaking the formwork. The stones are stacked in two or more layers, and after the sand grains are filled into the voids between the stacked stones while vibrating to a thickness of about 10 times the thickness of the upper layer, an appropriate amount of water is sprayed onto the exposed stone surface. A certain amount of hard-mixed concrete is poured into the formwork, compacted and formed by applying compression and vibration, and the exposed natural stone and sand grains are embedded in the concrete, which is then removed from the mold together with the pallet and left to cure. The natural stones and sand particles embedded in the concrete are separated from the natural stones and sand particles remaining in the pallet by removing the pallet after the pallet. A molding method that reveals (2) Page 7, line 2 of the specification “indicates a let,”
``(1)' refers to the pores for water drainage provided in the bottom plate of the pallet (1), and a large number of holes are drilled on the entire surface as shown in the figure.'' (3) On page 9, line 10 of the specification, next to ``As a wet surface,'' it says, ``Excess water permeates into the hard mixed concrete below.''
join. (4) Replace “Ballen + lO” in line 6 on page 10 of the specification with “
Pallet Q with many pores Cυ′ for draining water on the bottom plate
υ” I corrected. (5) Insert between lines 11 and 12 of the same page in the specification: ``Excess water is discharged from the nine pores C1)' in the pallet to densify the sand grains.'' (618A Hosobara, page 11, 2nd line from the bottom, ``Hard and firm'', followed by ``Furthermore, excess water from spraying permeates and drains through the pores for draining water provided at the bottom of the pallet, making the sand grain layer denser.'' (7) On page 12 of the specification, line 7, ``It never happens.'' is followed by ``Even if soft concrete is used, there is no mortar on the natural stone surface.'' 8) In the drawings, Figures 1 and 4 will be corrected as shown in the attached drawings. that's all

Claims (1)

[Scope of Claims] 1. Natural stones of various sizes are put into a deep box-shaped pallet, and the pallet is vibrated and compacted to form two or more layers. After filling the gap with sand particles while vibrating to approximately 1/2 the thickness of the upper layer of stones, spraying an appropriate amount of water onto the exposed stone surface and placing the pallet at the bottom of the molding frame, A certain amount of hard mixed concrete is poured into the formwork, compression and vibration are applied to compact and form the concrete.
After embedding the exposed natural stones and sand grains in concrete, they are removed from the mold along with the pallet, and after curing, the pallet is removed and the natural stones and sand grains embedded in the concrete are mixed with the natural stones and sand grains remaining in the pallet. A molding method that makes natural stone appear on the concrete surface. 2. In a concrete formwork that is formed by inverting the formwork, a certain amount of hard mixed concrete is poured into the formwork, the concrete is compacted by compression and vibration, and natural stones mixed in size and small are poured on top of the concrete. The stones are stacked in two or more layers, and the gaps between the stones are filled with sand grains lower than the top surface of the stones in the upper layer, and an appropriate amount of water is sprayed on the surfaces of the stones and sand grains to overturn the pallet, and the compaction plate is The pallet is lowered and compacted by pressing the pallet and applying vibration, and after embedding the required amount of stones and sand grains in the concrete according to the regulations of the compaction plate and compacting, the pallet is held down and the formwork is rotated in the normal direction. Claim 1, characterized in that after demolding and curing, the pallet is removed and the natural stones and sand grains embedded in the concrete are separated from the natural stones and sand grains remaining in the pallet. A molding method that makes natural stone appear on the surface of concrete. 3. A pallet is removably attached to the bottom of a formwork with an open top and bottom, and natural stones mixed in sizes as appropriate are placed in the formwork, and the formwork is vibrated to compact and stack into two or more layers. After filling the gaps between the stacked stones with sand grains while vibrating them to approximately 1/2 the thickness of the upper layer of stones, an appropriate amount of water is sprayed onto the exposed stone surface and poured into the formwork. The concrete is compacted and formed by applying compression and vibration, and the exposed natural stones and sand grains are embedded in the concrete, and then demolded together with the pallet, and after curing, the pallet is removed. The molding for making natural stones appear on the concrete surface according to claim 1, characterized in that the natural stones and sand grains embedded in the concrete are separated from the natural stones and sand grains remaining in the pallet. Method.