JPWO2016047500A1 - Forming mold for concrete, concrete molded body molded thereby, concrete structure using concrete molded body, method for producing concrete molded body, and method for producing concrete structure - Google Patents

Abstract

Provided is a concrete molding form that can be used repeatedly. The concrete molding form (10) includes a base material (1) and a protective layer (2) provided on at least a part of the surface of the base material (1). The protective layer (2) is a flake. Stainless steel particles (21).

Description

  The present invention relates to a concrete molding form, a concrete molded body molded thereby, a concrete structure using the concrete molded body, a method for producing a concrete molded body, and a method for producing a concrete structure.

  Concrete before solidification (hereinafter, also referred to as “fresh concrete”) has fluidity in which aggregates such as crushed stone and gravel, cement, and water are mixed together. The ready-mixed concrete is prepared by putting ready-mixed concrete into a formwork for concrete molding (hereinafter also referred to as “formwork”), vibrating and compacting the ready-mixed concrete, and then solidifying the ready-mixed concrete. Produced.

  Generally, wood, paper, metal, resin, etc. are known as the material of the mold. Examples of the metal include iron (for example, carbon steel), stainless steel, aluminum, and an aluminum alloy. Of these, aluminum and aluminum alloys are excellent in that they are lightweight and have a relatively high strength.

  However, when the aluminum mold is not subjected to any treatment on its surface, aluminum reacts with the alkali components in the concrete, and the surface condition of the obtained concrete is not smooth, and the finished appearance Will be damaged. Therefore, a coating film as a protective layer or a protective treatment is usually applied to the surface of the aluminum mold.

  For example, Japanese Patent Application Laid-Open No. 2002-327532 (Patent Document 1) discloses an aluminum mold having a surface subjected to alumite treatment and a coating containing an acrylic resin. JP 07-195342 A (Patent Document 2) includes an innermost layer composed of a resin layer containing a (meth) acrylic polymer and an outermost layer composed of a resin layer containing a fluorine- (meth) acrylic copolymer. An aluminum alloy mold having a surface coating layer applied thereto is disclosed.

JP 2002-327532 A JP 07-195342 A

  However, since the conventional formwork as disclosed in Patent Document 1 and Patent Document 2 does not have a high hardness of the coating film formed on the surface of the formwork, when placing ready-mixed concrete on the concrete formwork In addition, the coating film on the surface of the mold is often damaged due to the impact of the aggregate colliding with the surface of the mold or the contact with the vibrator used for vibration. Also, when removing the frame, there may be a scratch or a scratch on site work. As a result of the damage, the scratched portion of the coating film is in a state where the aluminum is exposed, so that the aluminum reacts with the alkali component in the concrete, and the surface condition of the obtained concrete does not become smooth. , The appearance of the finish may be impaired.

  Furthermore, the concrete is in close contact with the formwork, and it takes time to separate (demold) the concrete and the formwork, or the concrete tends to stick to a part of the formwork. For this reason, there has been a problem that a concrete molded body having a desired shape cannot be obtained, and the mold cannot be repeatedly used.

  The present invention has been made in view of the current situation as described above, and an object of the present invention is to use a concrete molding form that can be repeatedly used, a concrete molded body molded thereby, and a concrete molded body. An object of the present invention is to provide a concrete structure, a method for producing a concrete molded body, and a method for producing a concrete structure.

  The concrete molding form of the present invention includes a base material and a protective layer provided on at least a part of the surface of the base material, and the protective layer includes flaky stainless particles.

  In the above concrete forming mold, the base material preferably contains at least one of aluminum and an aluminum alloy.

  In the above-mentioned concrete mold, the protective layer preferably contains 5% by mass or more and 58% by mass or less of flaky stainless particles.

  In the concrete molding form described above, it is preferable that the passing rate of the sieve having a mesh size of 150 μm of the flaky stainless particles is 99.0% by weight or more.

  The present invention also relates to a concrete molded body formed by the above-described concrete molding form and a concrete structure including the concrete molded body.

  The method for producing a concrete molded body according to the present invention includes a step of placing one or more of the concrete forming molds in a desired positional relationship, filling the concrete forming molds with the ready-mixed concrete, and the ready-mixed concrete is solidified. Separating the concrete molded body and the concrete molding form.

  The method for producing a concrete structure of the present invention includes a step of producing a concrete structure using the concrete formed body produced by the method for producing a concrete formed body.

  According to the concrete molding form of the present invention, there is an effect that it can be used repeatedly.

It is a typical sectional view of a formwork for concrete formation of an embodiment. It is a schematic diagram which expands and shows the area | region II of FIG.

[Concrete Forming Form and Manufacturing Method Thereof]
<Construction of concrete molds>
FIG. 1 is a schematic cross-sectional view of a concrete molding form (hereinafter also referred to as “form form”) according to the present embodiment. As shown in FIG. 1, the mold 10 of the present embodiment includes a base material 1 and a protective layer 2 provided on one surface 1 a of the base material 1.

  As shown in FIG. 1, the mold 10 may have any other layer between the base material 1 and the protective layer 2. The other layers in the present embodiment are composed of a first intermediate layer 3 provided on the surface 1a side of the substrate 1 and a second intermediate layer 4 provided between the first intermediate layer 3 and the protective layer 2. Become.

  The shape of the mold 10 is not particularly limited as long as it can form a space in which a desired concrete molded body can be formed. For example, the mold 10 may have a cylindrical shape for the purpose of manufacturing a columnar concrete molded body, and is a plate-like member that draws an arc, and is formed by combining a plurality of plate-like members. The shape which can form a shape may be sufficient.

(Base material)
The material in particular of the base material 1 is not restrict | limited, Wood, paper, a metal, resin (synthetic resin and natural resin), these composite materials, etc. can be used. Examples of the metal include iron (for example, carbon steel), stainless steel, magnesium, magnesium alloy, aluminum, and aluminum alloy. However, aluminum or an aluminum alloy is preferable because it is lightweight, has excellent workability, has a relatively high strength, and is inexpensive. As the aluminum alloy, other contained metals are not particularly limited as long as aluminum which is the main metal is contained. For example, an alloy composed of aluminum and at least one selected from silicon, magnesium, and transition metal is cited. be able to. In the present embodiment, a case where the material of the substrate 1 is aluminum will be described.

  The shape of the substrate 1 substantially matches the shape of the mold 10. The thickness of the substrate 1 is not particularly limited, but is preferably 0.1 mm or more and 50 mm or less, and more preferably 1 mm or more and 5 mm or less. In this case, it is possible to have sufficient strength of the mold 10, and it is possible to maintain light weight and low cost.

(Protective layer)
The protective layer 2 is provided on at least a part of the surface of the substrate 1. For example, the protective layer 2 may be provided on the surface 1a, may be provided on the surface 1b opposite to the surface 1a, may be provided on both surfaces of the surfaces 1a and 1b, and at least concrete. It should just be provided in the surface of the side which contacts. In this embodiment, the protective layer 2 is provided on the outermost surface of the surface 1a of the substrate 1 and is a layer that comes into contact with concrete.

  As shown in FIG. 2, the protective layer 2 includes flaky stainless steel particles 21. Specifically, the protective layer 2 is a layer in which the flaky stainless particles 21 are dispersed in the resin 22 and may contain an additive as an optional component.

  The protective layer 2 preferably contains 5 mass% or more and 58 mass% or less of the flaky stainless steel particles 21. When content of the flaky stainless particle 21 in the protective layer 2 is 5 mass% or more, the protective layer 2 can have high hardness. Thereby, even if it is a case where the impact which the aggregate collided with the surface of the formwork 10 or the impact by contacting with the vibrator used for vibration is suppressed, it can suppress that the protective layer 2 is damaged. Therefore, it is possible to suppress the reaction between the base material 1 and the alkali component in the concrete. In addition, since the flaky stainless particles can be oriented in layers in the protective layer 2 (see FIG. 2), the components in the concrete (permeable components such as alkali components) penetrate in the thickness direction of the protective layer 2. Can be efficiently suppressed. Thereby, the damage of the protective layer by penetration | infiltration of a permeable component, deterioration, and the corrosion of the base material 1 by the contact with a permeable component and the base material 1 can be suppressed.

  On the other hand, when the content of the flaky stainless particle 21 in the protective layer 2 exceeds 58% by mass, the content of the resin 22 is relatively lowered, and thus the frequency of occurrence of cracks in the protective layer 2 tends to increase. . When a crack occurs in the protective layer 2, the hardness of the protective layer 2 decreases, the protective layer may be damaged from the cracked part, and the protective layer 2 may peel off in some cases. In this case, there is a possibility that the reaction between the base material 1 and the alkali component in the concrete cannot be suppressed, and the surface shape of the obtained concrete molded body may not be smooth. The content of the flaky stainless steel particles 21 in the protective layer 2 is more preferably 23% by mass or more and 55% by mass or less.

  The protective layer 2 preferably contains 42 mass% or more and 95 mass% or less of the resin 22. When the content of the resin 22 in the protective layer 2 is 42% by mass or more, occurrence of cracks in the protective layer 2 can be suppressed. When the content of the resin 22 in the protective layer 2 exceeds 95% by mass, the content of the flaky stainless steel particles 21 is relatively lowered, thereby reducing the hardness of the protective layer 2 or constituting the concrete. There is a tendency that the effect of suppressing the permeation of is reduced. The content of the resin 22 in the protective layer 2 is more preferably 50% by mass or more and 70% by mass or less.

  Although the thickness of the protective layer 2 is not specifically limited, For example, it is 10 micrometers or more and 100 micrometers or less. In this case, since the flaky stainless steel particles 21 can be arranged in a plurality of layers in the thickness direction in the protective layer 2, the protective layer 2 can have a higher hardness, and can penetrate the permeable component. Can be efficiently prevented. On the other hand, when the thickness of the protective layer 2 is less than 10 μm, the hardness of the protective layer 2 tends to be insufficient, and when it exceeds 100 μm, workability at the time of forming the protective layer 2 is lowered. Or the cost tends to increase.

  The composition of the flaky stainless steel particles 21 contained in the protective layer 2 is not particularly limited, and examples thereof include known stainless steels such as ferritic stainless steel, austenitic stainless steel, martensitic stainless steel, and biphasic stainless steel.

  In particular, it is preferable to use ferritic stainless steel or austenitic stainless steel in terms of having high corrosion resistance and workability. Among ferritic stainless steels, SUS430, NSS445M2 and NSS447M1 manufactured by Nisshin Steel Co., Ltd. are preferable, and among austenitic stainless steels, SUS304, SUS316, and SUS316L are preferable. Further, NSSURC manufactured by Nisshin Steel Co., Ltd. can be suitably used in that it has high corrosion resistance even in an extremely severe corrosive environment.

  The flaky stainless steel particles 21 may contain inevitable impurities other than stainless steel. However, from the viewpoint of corrosion resistance and workability, the content of inevitable impurities in the flaky stainless steel particles 21 is preferably 1% by mass or less.

  Moreover, it is preferable that the flaky stainless steel particle 21 has a passing rate of a sieve having an aperture of 150 μm of 99.0% by mass or more. That is, the flaky stainless steel particle 21 of the present embodiment is an aggregate of particles having a flake shape, and it is preferable that 99.0% by mass or more of the aggregate pass through a sieve having an opening of 150 μm.

In the present specification, the “passage rate” of the sieve is defined as S1 as the mass of the flaky stainless steel particles before sieving by wet sieving, and S2 as the mass of the flaky stainless steel particles remaining on the sieve after sieving. In this case, it can be obtained based on the following formula (1).
Passing rate (% by mass) = {(S1-S2) / S1} × 100 (1).

  When the passing rate of the flaky stainless steel particles 21 with respect to a sieve having an aperture of 150 μm is 99.0% by mass or more, the flaky stainless steel particles 21 are easily arranged in parallel in the thickness direction of the protective layer 2 in the protective layer 2. The surface of the protective layer 2 can have higher smoothness. If the surface of the protective layer 2 has high smoothness, the surface of the resulting concrete molded body tends to be smooth, and the mold 10 and the concrete molded body can be easily separated.

  On the other hand, when the passing rate of the sieve having an aperture of 150 μm is less than 99.0% by mass, the flaky stainless steel particles 21 protrude from the surface of the protective layer 2 to reduce the surface smoothness of the protective layer 2 or There is a tendency that cavities are easily formed in the layer 2. When the flaky stainless steel particles 21 protrude from the surface of the protective layer 2, cracks are likely to be generated from that portion, and when a cavity is generated in the protective layer 2, the protective layer 2 is easily peeled from the hollow portion. The passing rate of the flaky stainless steel particles 21 through a sieve having an aperture of 150 μm is more preferably 99.9% or more.

The flaky stainless steel particles 21 preferably have a 90% diameter (D ₉₀ ) of volume cumulative particle size distribution of 70 μm or less, more preferably 55 μm or less, and even more preferably 52 μm or less. Also in this case, since the protective layer 2 with fewer defects can be formed, the mold 10 provided with the protective layer 2 can have higher hardness and higher corrosion resistance, and can be used repeatedly with good releasability. An excellent effect can be exhibited.

For the same reason, the 50% diameter (D ₅₀ ) of the volume cumulative particle size distribution of the flaky stainless particle 21 is preferably 1 μm or more and 100 μm or less, more preferably 3 μm or more and 50 μm or less, and more preferably 5 μm or more and 50 μm or less. It is particularly preferably 8 μm or more and 29 μm or less.

  In the present specification, “volume cumulative particle size distribution” means a volume cumulative particle size distribution obtained by measuring the volume average particle size of flaky stainless steel particles. For example, “50% diameter is 1 μm or more and 100 μm or less” is a volume cumulative particle size distribution curve where the vertical axis is the cumulative frequency (%) and the horizontal axis is the particle diameter (μm). Means 1 μm or more and 100 μm or less. Similarly, “90% diameter is 70 μm or less” is a cumulative volume (%) on the vertical axis and a cumulative particle size distribution curve in which the horizontal axis is the particle diameter (μm). It means that it is 70 micrometers or less. The volume average particle diameter can be obtained by calculating the volume average based on the particle size distribution measured by the laser diffraction method.

The flaky stainless particles preferably have an average thickness (t) of 0.01 μm or more and 1.0 μm or less and an average particle diameter (D ₅₀ ) of 1 μm or more and 100 μm or less. More preferably, the average thickness (t) is 0.03 μm to 0.5 μm, the average particle diameter (D ₅₀ ) is 3 μm to 50 μm, and more preferably t is 0.03 μm to 0.33 μm. D ₅₀ is 5 μm or more and 50 μm or less, more preferably t is 0.16 μm or more and 0.33 μm or less, and D ₅₀ is 8 μm or more and 29 μm or less. In this case, since the flaky stainless steel particles are suitably laminated in the thin protective layer 2, for example, in the protective layer 2 having a thickness of 10 μm or less, the labyrinth effect (blocking) against corrosive substances (permeable components) such as alkaline components Effect).

Further, the hardness of the flaky stainless particles is due to the fact that the larger the average particle diameter (D ₅₀ ), the relatively larger the thickness of the flaky stainless particles, and the higher the hardness of each flaky stainless particle. Tend to be higher. For this reason, the mold 10 provided with the protective layer 2 containing the flaky stainless particles satisfying each range of the above characteristics can have higher hardness and higher corrosion resistance, and can be used repeatedly with good releasability. It is possible to exert an excellent effect.

On the other hand, when the average thickness (t) is less than 0.01 μm, it becomes difficult to handle in the manufacturing process, and when (t) exceeds 1.0 μm, it is necessary to increase the thickness of the protective layer 2 for suitable lamination. Occurs. The same problem occurs when D ₅₀ is less than 1 μm and when D ₅₀ exceeds 100 μm.

In the present specification, the average thickness (t) of the flaky stainless steel particles is determined by a water surface diffusion area method (cm ² / g) according to the procedure of JIS K5906: 1998.

In the flaky stainless steel particles 21, the average aspect ratio (D ₅₀ / t), which is the ratio of the average particle diameter (D ₅₀ ) to the average thickness (t), is preferably 5 or more and 500 or less, more preferably. 10 or more and 100 or less.

  When the average aspect ratio is less than 5, the effect of suppressing the penetration of the permeable component in the concrete tends to be insufficient. When the average aspect ratio exceeds 500, the viscosity of the coating material for forming the protective layer 2 is greatly increased, and it tends to be difficult to ensure an appropriate blending amount in the coating material. When the average aspect ratio exceeds 500, the bulk specific gravity of the flaky stainless steel particles 21 is small, so that there are many gaps between the flaky stainless steel particles 21 in the protective layer 2, and as a result, the corrosion resistance of the protective layer 2 is increased. There is a tendency to decrease. This also tends to lower the hardness of the protective layer 2.

  The resin 22 contained in the protective layer 2 is not particularly limited. For example, epoxy resin, polyester resin, alkyd resin, acrylic resin, acrylic silicone resin, vinyl resin, silicon resin, polyamide resin, polyamideimide resin, fluororesin, synthetic resin emulsion , Boil oil, chlorinated rubber, natural resin, amino resin, phenol resin, polyisocyanate resin, urea resin and the like. Moreover, you may combine these resin suitably.

  Examples of the additive optionally contained in the protective layer 2 include a dispersant, an antifoaming agent, an anti-settling agent, a curing catalyst, and a lubricant. In particular, when it is desired to further improve the peelability between the protective layer 2 and the concrete molded body, as a lubricant, polytetrafluoroethylene, ethylene / tetrafluoroethylene copolymer, polychlorotrifluoroethylene, polyvinyl fluoride , Fluoropolymers such as polyvinylidene fluoride, hexafluoropropylene / perfluoro (alkyl vinyl ether) copolymer, fluorinated ethylene polypropylene copolymer, fluorine monomers such as tetrafluoroethylene, silicone oil, molybdenum disulfide, tungsten disulfide, It is preferable to use boron nitride, graphite or the like. This lubricant may adopt an aspect in which it is contained in a layer different from the protective layer 2, and in this case, the other layer may be formed on the surface of the protective layer 2 (the outermost surface in contact with the concrete). .

(Other layers)
The first intermediate layer 3 is a chemical conversion film. By providing the chemical conversion film on the surface 1a of the substrate 1, it is possible to improve the adhesion with the protective layer 2 formed thereon, and the protective layer 2 is temporarily damaged. Also, the reaction between aluminum and the alkali component can be suppressed. The chemical conversion film of aluminum is a chromate film.

  The 2nd intermediate | middle layer 4 is a coating film formed with a well-known coating material, such as undercoat coating material, intermediate coating material, sealing coating material, primer coating material, and coloring coating material. By providing the second intermediate layer 4 between the base material 1 and the protective layer 2, irregularities on the surface of the base material 1 can be corrected or the adhesion of the mold 10 can be improved. .

  In the present embodiment, the mold 10 is a first intermediate layer 3 that is a chemical conversion film between the base material 1 and the protective layer 2 and a second intermediate film that is a coating film formed by conventional coating. Although illustrated about the case provided with the layer 4, the structure of the formwork 10 is not restricted to this. For example, it may not have other layers, and may have only the first intermediate layer 3 or only the second intermediate layer 4 as other layers, or may further include other layers. Also good.

<Manufacturing method of formwork for concrete molding>
The mold 10 of this embodiment can be manufactured by forming the 1st intermediate | middle layer 3, the 2nd intermediate | middle layer 4, and the protective layer 2 in order on the surface of the base material 1 made from aluminum, for example. The shape and size of the base material 1 are appropriately set according to the shape and size of the target concrete molded body.

  The 1st intermediate | middle layer 3 which is a chemical conversion film can be formed by well-known methods, such as a chromic acid film process and a phosphoric acid and chromic acid film process.

  The second intermediate layer 4 can be formed by a known coating method using a known undercoat, intermediate coat, sealant, primer, and colorant.

  The protective layer 2 can be formed using a paint containing at least flaky stainless particles and a resin. The paint includes a solvent-type paint containing a solvent in its components and a powder paint containing no solvent, but it is preferable to use a solvent-type paint from the viewpoint of ease of handling.

  When using a solvent-type paint, the protective layer 2 can be formed by applying the paint on the second intermediate layer 4 to evaporate the solvent in the paint and cure the resin. The coating method of the protective layer 2 is not particularly limited, and known coating (coating) methods such as spraying, brushing, roller, dipping, and other printing methods (ink jet printing, screen printing, gravure printing), and dropping. The law etc. can be used.

  The flaky stainless particles contained in the paint are the flaky stainless particles in the protective layer 2 and can be prepared, for example, as follows.

  First, stainless steel particles (first particles) are prepared using a known atomizing method, crushing method, rotating disk method, rotating electrode method, cavitation method, melt spinning method, and the like. From the viewpoint of manufacturing cost and uniformity, it is preferable to use an atomizing method.

  Next, the prepared stainless particles (first particles) are pulverized by a wet ball mill, a dry ball mill, a bead mill or the like to produce flattened stainless particles (second particles). From the viewpoint of safety and workability, it is preferable to use a wet ball mill. In particular, by using a steel ball having a diameter of ¼ inch or less, it can be efficiently flattened to a target size. The grinding time is preferably 1 hour to 48 hours, more preferably 3 hours to 10 hours.

  The obtained stainless steel particles (second particles) may be used as flaky stainless steel particles, but sieving is performed using a sieve having an opening of 150 μm, and the stainless steel particles (third particles) passing through the sieve are flaked. It is preferable to use as stainless steel particles. The third particles are flaky stainless steel particles having a passage rate of 99.0% by mass or more through a sieve having an opening of 150 μm.

  In the sieving step, a sieve made of stainless steel having a diameter of 200 mm or more and 2000 mm or less may be used. In this case, there is little abrasion and damage of a sieve, and it can be sieved efficiently. Moreover, when the stainless steel particle which passed through the deformation | transformation process is a slurry state, it is preferable to perform a sieving process, after wash | cleaning this slurry with solvents, such as a mineral spirit. The sieve mesh used may be 150 μm or less.

In the above, D ₉₀ of the stainless particles (first particles) is preferably 5 μm or more and 50 μm or less, and more preferably 40 μm or less. In this case, the recovery rate of the stainless particles (third particles) obtained after sieving can be increased. On the other hand, if D ₉₀ of greater than 50 [mu] m, there is a possibility that recovery of obtained after sieving stainless particles (3 particles) or takes a long time may decrease, the sieving step. Further, when the stainless particle (first particle) D ₉₀ is less than 5 μm, the raw material cost becomes high.

Further, D ₅₀ of stainless steel particles produced (first particles) is preferably 2μm or more 20μm or less. Also in this case, similarly to the above, the recovery rate of the stainless particles (third particles) can be increased. In addition, a recovery rate shows the ratio of the mass of the stainless steel particle (3rd particle) finally obtained with respect to the mass of the used stainless steel particle (1st particle). Also, the meaning of D ₉₀ and D ₅₀ of the stainless steel particles, and the calculation method thereof is the same as D ₉₀ and D ₅₀ of flake stainless particles, description thereof will not be repeated.

  The flaky stainless steel particles used in the present invention can be produced by the production method detailed above. In addition, the manufacturing method of the flaky stainless particle used for this invention is not restricted to said each process, Other processes can be included.

  As resin contained in the coating material for forming the protective layer 2, it can select from the resin mentioned above suitably.

  When a solvent-type paint is used to form the protective layer 2, the solvent contained in the paint includes alcohol-based, glycol-based, ketone-based, ester-based, ether-based, hydrocarbon-based organic solvents, water, etc. Can be appropriately selected. In addition, it is preferable that the compounding quantity of the solvent in a coating material is 20 to 80 mass parts with respect to 100 mass parts of resin. When the amount of the solvent is less than 20 parts by mass, the dispersibility of the flaky stainless particles in the paint becomes insufficient, and when the amount is more than 80 parts by mass, environmental pollution due to evaporation of the solvent becomes a problem.

<Effect>
The conventional protective layers described in Patent Document 1 and Patent Document 2 are not sufficiently high in hardness. For this reason, when the ready-mixed concrete is put into the formwork, the protective layer is damaged when the aggregate collides with the surface of the formwork. When the vibration is applied, the aggregate collides with the formwork surface. The protective layer may be damaged. Also, when removing the frame, there may be a scratch or a scratch on site work. When the protective layer is damaged, a concrete molded body having a desired appearance (smooth surface) cannot be obtained, and the mold can not be repeatedly used.

  On the other hand, since the protective layer 2 included in the mold 10 of the present embodiment includes the flaky stainless steel particles 21, the protective layer 2 has higher hardness than the conventional protective layer. For this reason, since damage to the protective layer as described above can be suppressed, a concrete molded body having a desired shape can be manufactured, and furthermore, the mold 10 can be repeatedly used.

  Moreover, since the conventional protective layer made of resin has low hardness, fine cracks that do not affect the shape of the concrete molded body to be produced are likely to occur. When a fine crack is generated in the protective layer, the low hardness of the protective layer is combined with the penetration of an osmotic component such as an alkali component in the concrete from the crack into the protective layer, which causes a large fine crack in the protective layer. There is a risk of growing into damage. In particular, when the base material is aluminum or an aluminum alloy, the alkali component reacts with aluminum to corrode the surface of the base material, and the protective layer itself is peeled off from the base material, which makes it difficult to continue use as a mold. Tend to be.

On the other hand, in the present embodiment, the flaky stainless steel particles oriented in the protective layer 2 can suppress the permeation of the alkali component, and thus can have high corrosion resistance, and thus the above-described problems occur. Can be suppressed. In particular, when the passing rate of the flaky stainless steel particles 21 with respect to a sieve having an opening of 150 μm is 99.0% by mass or more, the flaky stainless steel particles can be arranged more suitably, and thus the above-described problem can be achieved more efficiently. Can be suppressed. The same applies when the D _{90 of} the flaky stainless steel particles 21 is 70 μm or less, the D ₅₀ is 1 μm or more and 100 μm or less, or the average thickness (t) is 0.01 μm or more and 1.00 μm or less. I can say that.

  In the present embodiment, the mold 10 includes a first intermediate layer 3 and a second intermediate layer 4 between the base material 1 and the protective layer 2. Thereby, even if it is a case where the protective layer 2 is damaged, contact with the base material 1 and corrosive components, such as an alkali component in concrete, can be suppressed. Moreover, by having such other layers, the adhesion between the layers of the entire mold 10 can be improved.

[Concrete compact and its manufacturing method]
The concrete molded body of the present embodiment is formed by using the above-mentioned concrete molding form, and examples thereof include concrete columns and walls. The concrete molded body can be produced as follows.

  First, the above-mentioned concrete molding form is placed in a desired positional relationship. At this time, the space formed by the concrete molding form is set so as to match the shape of the target concrete molded body.

  One may be used as the concrete molding form to be arranged, or two or more may be combined as appropriate. In addition, when the shape of a concrete molded object is complicated, for example, when providing a joint groove in a concrete molded object, a joint rod can also be arrange | positioned to the concrete mold.

  Next, the ready-mixed concrete is filled into the placed concrete molding form. Vibrate and compact the filled concrete. After vibration, leave the ready-mixed concrete to solidify. Thereby, a concrete molded object is shape | molded in the formwork for concrete shaping | molding. A release agent may be applied to the surface of the protective layer 2 before filling the ready-mixed concrete.

  Next, the concrete molding form and the concrete molded body are separated. For example, both can be separated by peeling the concrete molding form from the concrete compact.

  By the above, a concrete molded object can be produced using the above-mentioned concrete forming mold.

  The concrete molded body of this embodiment is produced using the above-mentioned concrete molding mold. Since the above-mentioned concrete molding form has a protective layer having high hardness and high corrosion resistance, damage to the surface due to concrete charging and vibration is suppressed. For this reason, the surface of the produced concrete molded object becomes smooth, and can be excellent in an external appearance.

[Concrete structure and manufacturing method thereof]
The concrete structure of the present embodiment includes a molded concrete molded body. That is, the concrete structure only needs to include a concrete molded body, and may include other members. What is necessary is just to produce a concrete structure by employ | adopting a conventionally well-known method except using the formwork for concrete shaping | molding of this embodiment.

  Since the concrete structure of this embodiment is provided with the concrete molding produced using the above-mentioned concrete molding form, the surface becomes smooth and can be excellent in appearance.

  EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated in detail, this invention is not limited to these.

<Production of flaky stainless steel particles>
(Flake stainless steel particle 1)
A spherical stainless steel powder (first particle) having D ₅₀ of 17 μm and D ₉₀ of 37 μm was prepared. The stainless particles (first particles) were put into a ball mill containing a 1/4 inch steel ball and flattened to produce flaky stainless particles (second particles). Next, the flaky stainless steel particles (second particles) were sieved using a sieve having an opening of 38 μm. The pasty flaky stainless particles (third particles) that passed through the sieve were defined as flaky stainless particles 1.

(Flake stainless steel particle 2)
Paste-like flaky stainless steel particles 2 were produced in the same manner as flaky stainless steel particles 1 except that a sieve having 150 µm openings was used instead of the sieve having 38 µm openings.

(Flake stainless steel particles 3)
A flaky shape except that a spherical stainless steel powder (first particle) with D ₅₀ of 3 μm and D ₉₀ of 5 μm was used in place of the spherical stainless steel powder (first particle) with D ₅₀ of 17 μm and D ₉₀ of 37 μm. Paste-like flaky stainless steel particles 3 were produced by the same method as stainless steel particles 1.

<Evaluation of flaky stainless steel particles>
Measure the solid content (% by mass), D ₅₀ and D ₉₀ of the obtained paste-like flaky stainless steel particles 1 to 3, and further sieve the flaky stainless steel particles 1 to 3 using a sieve having an opening of 150 μm. Then, the passing rate of each particle was calculated. The solid content, D ₅₀ and D ₉₀ , and the passing rate were calculated according to the following methods, respectively. The results are shown in Table 1. Table 1 also shows D ₅₀ and D ₉₀ of the first particles and the sieve openings used for sieving the second particles.

(Solid content)
Each paste obtained in a 100 ml beaker was collected and dispersed by adding mineral spirit. Next, this was left still in a dryer and dried, and then allowed to cool to room temperature in a desiccator. And the mass of the residue in a beaker was measured, and solid content (mass%) was computed by following formula (2).

Solid content (mass%) = (W2 / W1) × 100 (2)
(In Formula (2), W1 shows the mass of the paste before drying, W2 shows the mass of the residue after drying and standing_to_cool).

(D ₅₀ and D ₉₀₎
Each sample is prepared by adding 0.25 g of each paste to 10 ml of toluene, and using a particle size distribution measuring device (Microtrac HRA 9320-X100, manufactured by Honeywell), measurement of the particle size distribution in the sample is performed. _D50 and _D90 were calculated.

(Passing rate)
About each obtained paste, the passage rate of the sieve of 150 micrometers of openings was measured by the wet sieving method. Specifically, 30 g of each paste was transferred into a 150 ml beaker, and 100 ml of mineral spirit was gradually added thereto to prepare a sample in which the paste was dispersed. Next, a sieve having an opening of 150 μm was fixed on the collection container (container 1), and the prepared sample was poured onto the mesh of the sieve. Further, the sample remaining in the beaker was washed with a small amount of mineral spirit, and this washing solution was also poured onto the mesh of the sieve.

  Next, mineral spirit was added into a collection container (container 2) having a size capable of accommodating the sieve, and up to about half of the depth was filled with mineral spirit. And the said sieve was put in this container 2, and the sample which remain | survived on the mesh was immersed in the mineral spirit in the container 2 by immersing the mesh | network of the said sieve in the liquid surface of a mineral spirit. In this state, the sieve was vibrated and sieved. Thereafter, the mineral spirit in the container 2 was replaced, and the above sieving operation was performed again.

  The above operation was repeated, and sieving was completed when there was no sample sieving from the mesh of the sieve into the mineral spirit, that is, when there were no more flaky stainless particles passing through the mesh of the sieve. In addition, the presence or absence of flaky stainless steel particles passing through the mesh of the sieve was confirmed visually.

  The sieve with the sample remaining on the mesh was placed in a dryer maintained at 105 ± 2 ° C. and dried, and then allowed to cool. Finally, the dried flaky stainless particles on the mesh were collected, and the passage rate (mass%) of a sieve having an aperture of 150 μm in the flaky stainless particles in the paste was calculated according to the above formula (1).

  In addition, the mass of the flaky stainless particles before sieving is the flaky stainless particles obtained by placing 10 g of the paste in a drier maintained at 105 ± 2 ° C., drying, and then allowing to cool. Mass.

Referring to Table 1, the solid content in the paste containing flaky stainless steel particles 1 to 3 (indicated as Particle 1, Particle 2 and Particle 3 in Table 1 respectively) is 90% by mass, and has an opening of 150 μm. The passing rate of the sieve was 99.9% in all cases. Further, D ₅₀ and D ₉₀ of the flaky stainless steel particles 1 to 3 were as shown in Table 1, respectively.

<Production of formwork for concrete molding>
Example 1
A base material was prepared by preparing a 300 mm × 300 mm (thickness 1 mm) plate of JIS-A1100-H24, which is 1000 series aluminum having a purity of 99.00% or more, and subjecting the surface of the plate to degreasing.

  A hexavalent chromate film (thickness: 1 μm or less) as a chemical conversion film was formed as a first intermediate layer on one surface of the prepared substrate.

  Next, as the second intermediate layer, an intermediate coating was applied on the first intermediate layer by a spray coating method and dried at 120 ° C. for 20 minutes to form an intermediate coating film (thickness: 10 μm). . An epoxy primer (manufactured by Tope Corporation, product name: “Metal Under # 600T”) was used for the intermediate coating.

  Next, a protective layer was formed on the second intermediate layer, and the concrete molding form of Example 1 was completed. The protective layer was formed as follows.

  First, the coating material which mix | blended the main ingredient which consists of a component shown in Table 2, and the hardening | curing agent by the ratio of 4: 1 by mass ratio was prepared. Next, solvent A in Table 2 was added to dilute the paint until the viscosity of the paint became optimum for spray coating. And the coating material after dilution was apply | coated by the spray coating method, and it dried for 30 minutes at 80 degreeC. Thereby, a protective layer (thickness: 40 μm) was formed on the second intermediate layer.

In addition, the solvent A shown in Table 2 consists of the component shown below.
Ethyl acetate: 30% by mass
Butyl acetate: 10% by mass
High boiling point solvent # 100 (manufactured by Gordo Solvent Co., Ltd.): 20% by mass
Xylene: 30% by mass
Acetic acid ethylene glycol monoethyl ether: 10% by mass.

  Moreover, the [solid content ratio] shown in Table 2 is the solid content ratio in each component. For example, the flaky stainless steel particles 1 contained in the main agent are in a paste form, and 90% by mass of the flaky stainless steel particles 1 is a solid content ratio (mass of the flaky stainless steel particles).

(Example 2)
In Example 2, the coating composition comprising the components shown in Table 3 was applied by spray coating, and the protective layer was formed by drying at 80 ° C. for 30 minutes and then baking at 190 ° C. for 20 minutes. In the same manner, a concrete mold was prepared.

The solvent B shown in Table 3 consists of the components shown below.
Butylcellulose: 55% by mass
Methyl ethyl ketone: 45% by mass.

(Example 3)
In Example 3, the same procedure as in Example 1 was performed, except that a surface layer was formed on the protective layer by further applying a lubricant (manufactured by Sagami Co., Ltd., product name: “Sanamold No-2”) with a brush. A concrete molding form was prepared.

Example 4
In Example 4, a concrete molding form was produced in the same manner as in Example 1 except that the flaky stainless particle 2 was used instead of the flaky stainless particle 1 and a surface layer similar to that of Example 3 was formed. did.

(Example 5)
In Example 5, a concrete molding form was produced in the same manner as in Example 1 except that flaky stainless particles 3 were used instead of flaky stainless particles 1 and a surface layer similar to that of Example 3 was formed. did.

(Comparative Example 1)
In Comparative Example 1, the base material of Example 1 (however, the degreasing process was performed) was used as a concrete mold.

(Comparative Example 2)
In Comparative Example 2, instead of the protective layer of Example 1, an acrylic resin paint (product name: “Toa GP Paint” manufactured by Tope Co., Ltd.) was applied to form a protective layer (thickness: 30 μm). Prepared in the same manner as in Example 1.

(Comparative Example 3)
In Comparative Example 3, a protective layer (thickness: 30 μm) was formed by applying a fluororesin paint (product name: “New Garmet # 2000” manufactured by Tope Co., Ltd.) instead of the protective layer of Example 1. Was prepared in the same manner as in Example 1.

<Evaluation of hardness>
The hardness of the surface on which the protective layer of the concrete forming molds of Examples 1 to 5 and Comparative Examples 1 to 3 was formed was measured. The hardness was measured according to JIS K5600-5-4. The results are shown in Table 4.

<Evaluation of peelability from concrete compact>
By placing the concrete forming molds of Examples 1 to 5 and Comparative Examples 1 to 3 as a bottom surface, and placing a wooden mold having an inside dimension of 12 cm long x 20 cm wide x 25 cm high Concrete mold forming structures for pouring ready-mixed concrete were respectively prepared.

  The ready-mixed concrete was poured up to a height of 20 cm into these concrete molding form structures. Thereafter, the poured concrete was vibrated using a vibrator and then left for 5 days to solidify the ready-mixed concrete.

  After that, the concrete mold form is disassembled, and then the concrete mold is peeled from the concrete mold, and the surface condition of the concrete mold after peeling and the surface condition of the concrete mold are visually observed. did. In addition, when the surface state of the concrete molding form was smooth visually, the production of the concrete molded body was repeated using this. The results are shown in Table 4.

  In Table 4, the column “protective layer” indicates the type of flaky stainless particles contained in the protective layer and the type of resin. The column of “Hardness” shows the result of hardness measured by the above method. Of 4H and 2H, 4H has higher hardness.

  As shown in Table 4, the protective layers of the concrete forming molds of Examples 1 to 5 had a hardness of 4H. It should be noted that the hardness measured on the surface side of the concrete molding form of Examples 1 to 5 is the hardness of the protective layer, while Examples 3 and 5 have surface layers, The same hardness (4H) is shown, and it is understood from the fact that the hardness of Comparative Examples 2 and 3 having a protective layer containing no flaky stainless particles is 2H.

  Moreover, in Examples 1-5, even when the same concrete molding formwork is used 10 times repeatedly, the peelability between the concrete molding and the concrete molding form is good, and the surface of the concrete molding form The concrete molded body did not partially adhere to the surface, and both the concrete molded body and the concrete molding form were smooth surfaces. This is presumably because damage to the protective layer due to vibration or the like was suppressed because the protective layer formed on the surface of the concrete molding form of Examples 1 to 5 had high hardness and high corrosion resistance. .

Moreover, it turned out that the protective layer of Examples 1-4 has hardness higher than Example 5. FIG. This was presumed to be due to D ₅₀ of flake stainless particles 1 and 2 used in Examples 1 to 4 is larger than D ₅₀ of flake stainless particles 3 used in Example 5.

  On the other hand, in Comparative Example 1, the surface of the concrete mold was corroded from the first use. In addition, it was difficult to separate the concrete molding form from the concrete molded body, and the surface of the obtained concrete molded body was not smooth. This was presumed that the surface condition of the concrete obtained by the influence was not smooth because corrosion occurred on the surface of the base material due to the reaction of the alkali component in the concrete with aluminum. Further, it was inferred that the concrete and the base material were firmly attached to each other, so that peeling became difficult, and the surface state of the concrete molded body after peeling was not smooth.

  Moreover, in Comparative Example 2 and Comparative Example 3, the first release property was good, and the surface of the obtained concrete molded body was in a smooth state. However, the surface of the concrete molding form was corroded at the stage of repeated use 5 times, and the surface of the concrete molding obtained at this time was not smooth. This is because the protective layer made of resin could function at a stage where the number of repeated use was small, but as the number of repeated use increased, damage to the protective layer due to vibration, slight cracks, etc. were caused. It was speculated that the alkaline component permeated from the location and the corrosion of the base material gradually occurred, causing such a result.

  Although the embodiments and examples of the present invention have been described above, it is also planned from the beginning to appropriately combine the configurations of the above-described embodiments and examples.

  It should be understood that the embodiments and examples disclosed herein are illustrative and non-restrictive in every respect. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  DESCRIPTION OF SYMBOLS 1 Base material, 1a, 1b surface, 2 Protective layer, 3rd 1st intermediate | middle layer, 4th 2nd intermediate | middle layer, 21 Flakes-like stainless particle, 22 Resin.

Claims (8)

A substrate;
A protective layer provided on at least a part of the surface of the base material,
The protective layer is a formwork for concrete molding containing flaky stainless particles.   The formwork for concrete molding according to claim 1, wherein the base material contains at least one of aluminum and an aluminum alloy.   The said protective layer is a formwork for concrete shaping | molding of Claim 1 or Claim 2 which contains the said flaky stainless particle 5 mass% or more and 58 mass% or less.   The formwork for concrete molding according to any one of claims 1 to 3, wherein a passage rate of a sieve having an aperture of 150 µm of the flaky stainless particles is 99.0% by mass or more.   The concrete molded object shape | molded by the formwork for concrete shaping | molding of any one of Claims 1-4.   A concrete structure comprising the concrete molded body according to claim 5. Placing one or more of the concrete molding forms according to any one of claims 1 to 4 in a desired positional relationship, and filling the concrete molding form with ready-mixed concrete;
A method for producing a concrete molded body, comprising: a step of separating the concrete molded body in which the ready-mixed concrete is solidified and the mold for molding concrete.   The manufacturing method of a concrete structure provided with the process of manufacturing a concrete structure using the concrete molding manufactured by the manufacturing method of Claim 7.

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