RU65916U1 - DOUBLE LAYER BUILDING PRODUCT - Google Patents

Abstract

The utility model relates to construction, in particular, to the production of building materials, and can be used in the manufacture of products used in landscape design, such as curly stones for paving, etc. A two-layer construction product obtained by vibrocompression includes a decorative front and main layers made of hard concrete mixtures, while the mixture for the main layer contains, wt.%: Cement - 13.1-13.2; gravel with a grain size of 3-10 mm - 39.6-39.9; sand MK 2.5-3.0 mm - 43.4-43.7; water - the rest, for the manufacture of the front layer of the product used hard concrete mixture of the following composition, wt.%: cement - 18.2-18.6; quartz or dolomite flour - 1.1-2.9; decorative placeholder - 71.0-75.8; water - the rest, with a mixture of sand, serpentinite, decorative granite and marble, or a mixture of sand, amphibolite, serpentinite and marble, or a mixture of sand, amphibolite, granite and marble as a filler. The composition of the rigid concrete mixture for the manufacture of the front layer of the product can be introduced pigment in the amount, wt.%, 0.37-0.56. The technical result from the use of the utility model is to improve the decorative and artistic properties of the front surfaces of building products by perceiving them as products made of natural stones while ensuring high performance indicators - strength and durability of the product, including high resistance to surface damage and efflorescence, reduced water absorption, abrasion and ensuring high frost resistance, reducing material consumption and cost (minimizing the amount of pigment used c) the possibility of using not only white but also gray cement without reducing the decorative properties of the product.

Description

The technical field to which the utility model relates.

The utility model relates to construction, in particular, to the production of building materials, and can be used in landscape design - figured stones for paving, etc.

State of the art

For the manufacture of decorative building products, colored architectural concrete is used with high rates of basic physical and mechanical properties during operation, since products made from it are subjected to various external influences (atmospheric precipitation, the effects of variable temperature and humidity, exhaust gases). Currently, the production of concrete paving is widely developed. Two technologies for the production of paving slabs are known: vibrocasting using plasticizing additives and vibrocompression of hard mixtures with low water content.

A decorative and facing building product is known, obtained by the method according to the patent of the Russian Federation No. 2114084, A1, 06/27/98, including the preparation of a decorative-finishing mixture, applying the prepared mixture to a smooth form, laying the product on it and hardening. In this case, the preparation of the decorative-finishing mixture is carried out by mixing cement, sand in a ratio of 1: 1-1: 3, respectively, cement and sand, using sand of the following fractions, wt.% 2-4 mm 55-70; 0.3-1.2 mm 25-30; 0.03-0.1 mm 20-25. Sand is introduced with stirring in series: first, a fraction of 0.03-0.1, then 2-4 and then 0.3-1.2, at the same time, with the introduction of sand of a fraction of 2-4 mm, pigment, water and

superplasticizer, after which the prepared mixture with a layer thickness of 5-50 mm is poured onto a smooth form and the product is placed on the layer of the laid mixture, hardening is carried out for 24-48 hours at 20-23 ° C.

A two-layer construction product is known (RF patent No. 2017908, A1, August 15, 1994), including an external decorative layer and an internal structural layer with reinforcing cage, the layers being made of fine-grained concrete, while the fine-grained concrete of the decorative layer contains the following components, wt.%: Cement 30.4-31.0, silica fume with a specific surface area (20-40) • 10 ³ cm ² / g - 1.5-3.0, quartz sand, fractions: 0.3-0.63 mm 1.5- 2.5; 0.63-1.26 mm 10.0-10.5; 1.26-5.0 mm 38.5-40.5, crushing waste of scaly basalt and colored granite crushed stone, taken in a ratio of 1: 4, fractions: 0.14-0.3 mm 0.5-1.5; 0.3-2.5 mm 1.5-2.5; 2.5-5.0 mm 2.0-3.0, "S-3" superplasticizer based on the sodium salts of the condensation product of naphthalene sulfonic acid with formaldehyde 1.0-1.5, water - the rest, and the fine-grained concrete of the structural layer contains the following components, wt.%: cement 30.0-31.0, quartz sand fractions: 2.2-2.5 mm 38.5-40.5; 1.0-1.15 mm 10.0-10.5; 0.05-0.5 mm 1.5-2.5, silica fume with a specific surface area (20-40) • 10 ³ cm ² / g 1.5-3.0, crushing waste of scaly basalt fractions: 0.14- 0.3 mm 0.5-1.5; 0.3-2.5 mm 1.5-2.5; 2.5-5.0 mm 2.0-3.0, "S-3" superplasticizer based on sodium salts of the condensation product of naphthalenesulfonic acid with formaldehyde 1.0-1.5, water - the rest. A method of manufacturing a two-layer building product according to the aforementioned patent includes applying to the bottom the form of concrete setting retarder, sequential laying of concrete mixtures of decorative and structural layers, installing an internal reinforcement cage, sealing, heat treatment, cooling and opening the textured surface, while after laying the concrete mixture, the decorative layer

layer it is subjected to vertical vibration with a frequency of 950-1500 cycles / min and an amplitude of vertical vibrations of 0.5-0.8 mm for 8-10 s, then the internal armature frame is placed and fixed in the mold and the concrete mixture of the construction layer is laid and compacted with the specified vibration parameters for 4-6 s, after which the surface of the product is closed with a sealing shield-load and heat treatment is carried out.

Also known are technical solutions related to products obtained by vibropressing. The technology of vibropressing consists in the fact that at a vibropress the concrete mixture located in the mold is pressure-affected and preset oscillation modes are set, exciting the concrete mixture to vibrate. The method is highly productive, allows a high degree of automation, makes it possible to produce paving slabs with a colored layer. Using the vibrocompression method makes it possible to produce a two-layer tile with a thin color layer, which reduces the consumption of pigments for coloring and reduces the cost of the finished concrete product.

Known artificial building stone imitating natural stone (RF patent No. 2175913, C2, 11/20/2001), obtained by a method involving the preparation of concrete mixtures, one of which is painted, and the painted mixture is prepared in the form of mixtures of several colors corresponding to the components of the simulated material, loading under conditions of vibration of a layer of unpainted concrete mix into a mold, its preliminary pressing and application of a second layer of a painted mixture, then intermittent loading on the second layer is performed under vibration conditions a sharp box of the third, fourth (and more) layers of the mixtures painted in different colors, and there is a discrete distribution of mixtures of the third and fourth layers. Color mixtures of the third and fourth layers are intermittently using vibrators loaded on the second layer to provide

the color scheme of the surface layer of artificial building stone, characteristic of natural stone.

This technical solution provides an increase in the level of imitation of natural stone, but is not aimed at solving the problem of improving the operational performance of products.

The closest analogue is a vibro-pressed product with a facing layer predominant of semi-dry concrete mixtures, obtained by the method according to the patent of the Russian Federation No. 2097177, C1, 11.27.1997. The method includes laying mixtures in a bottomless matrix, preliminary and final compaction under the influence of vibrational and pressing force pulses of the movable frame and punch of the molding unit, respectively, and removing the molded product. According to this method, laying of semi-dry concrete mixtures is carried out in two stages, alternating the last with preliminary and final compaction processes, while at the first stage of laying, the matrix is filled for 2.0-6.0 with a semi-dry concrete mixture of the main layer under the influence of vibrational pulses, and preliminary compaction is carried out by pressing power pulses of the punch with a specific pressure on the surface of the mixture in the matrix of 120-250 g / cm ² for 3.0-8.0 s to achieve a density that exceeds 1.1-1.2 times the initial field density dry building mixture of the base layer, and at the second stage of laying, fill the matrix with a dry building mixture of the facing layer and perform final compaction for 15-25 with simultaneous effects of vibrational pulses of the moving frame and pressing pulses of the punch with a specific pressure of 200-500 g / cm ² on the surface of a semi-dry mortar.

The closest analogue is aimed at solving, firstly, the task of increasing the density, strength, abrasion, reducing water absorption, frost resistance of the product, and secondly, to reduce the consumption of mineral binder.

However, this technical solution does not provide high operational performance of the product during subsequent bead-blasting or sandblasting of the decorative layer to reveal the texture of the front layer of the product.

Utility Model Disclosure

The problem solved by the claimed utility model is to improve the decorative and artistic properties of manufactured products while ensuring high performance.

For vibrocompression, through which the product is obtained - the closest analogue and the claimed product, the use of semi-dry concrete mixtures with a reduced water-cement ratio (w / c) is characteristic. Reducing the water-cement ratio allows, with a reduced cement content, to manufacture products of high strength with high frost resistance, low water absorption and abrasion. Products made on vibrating presses are characterized by accuracy of geometric dimensions and stability of the main operational parameters.

However, in the well-known technical solutions, the decorative and artistic properties of products are largely determined by the color of the decorative concrete layer, which depends not only on the pigments used, but also on the ratio of water and cement, and the amount of cement in concrete. The higher the ratio of water to cement, the lighter the concrete appears. As a rule, for the manufacture of paving slabs, concrete with a water-cement ratio (w / c) of not more than 0.4 is used.

When using well-known technologies in the manufacture of tiles by vibrocompression, large concrete is required to obtain saturated colors

pigment consumption and the use of, as a rule, white cement. Usually up to 8% of pigments are added to concrete, pigments with good coloring ability can be added from 0.5%.

The problem in the claimed utility model is solved by using the proposed starting ingredients of a semi-dry concrete mixture of the front layer of the building product in combination with the composition of the main layer and the introduction of the operation of opening the texture of the front layer of the product by sandblasting or shot blasting.

A two-layer construction product obtained by vibrocompression includes a decorative front and main layers made of hard concrete mixtures, while the mixture for the main layer contains, wt.%:

Cement - 13.1-13.2 3-10 mm gravel - 39.6-39.9 Sand MK 2.5-3.0 mm - 43.4-43.7 Water - the rest,

For the manufacture of the front layer of the product used rigid concrete mixture of the following composition, wt.%:

Cement - 18.2-18.6

Quartz flour or

Dolomite - 1.1-2.9 Decorative placeholder - 71.0-75.8 Water - the rest,

moreover, as a filler used a mixture of sand, serpentinite, decorative granite and marble, or a mixture of sand, amphibolite, serpentinite and marble, or a mixture of sand, amphibolite, granite and marble.

The composition of the rigid concrete mixture for the manufacture of the front layer of the product can be introduced pigment in the amount, wt.%, 0.37-0.56.

As a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients can be used: sand, serpentinite, decorative granite, marble in a ratio of 1.5: 1.0: 1.7: 1.1 fractions 0.9- 7.0 mm

As a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients can be used: sand, amphibolite, serpentinite, marble in the ratio: 1.0: 1.5: 1.1: 1.2 fractions 0.9 - 7.0 mm, while the mixture introduced a dark brown pigment in an amount of not less than 0.35% of the mass.

As a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients can be used: sand, amphibolite, granite, marble in the ratio: 1.4: 1.0: 1.0: 3.1 fractions 0.9- 7.0 mm, while the mixture introduced a dark brown pigment in an amount of not less than 0.50% of the mass.

A mixture of the following ingredients can be used as a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product: sand, serpentinite, decorative granite, marble in the ratio: 1.3: 1.3: 1.5: 1.0 fractions 0.9 -7.0 mm.

As a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients can be used: sand, amphibolite, serpentinite, marble in the ratio: 1.3: 1.4: 1.0: 1.1 fractions 0.9 - 7.0 mm, while the mixture introduced a dark brown pigment in an amount of not less than 0.55% of the mass.

In the manufacture of a two-layer product, a concrete mixture of the main layer was laid in the matrix for 2.0-6.0 during vibrational movements and compacted with preliminary vibration by pulses with a specific pressure of 120-250

g / cm ² for 0.5-5.0 s, then a concrete mixture of the front layer is laid on top of the concrete mixture of the main layer and finally compacted for 3.0-12.0 with a specific pressure of 110-400 g / cm ² to obtain the density of the material of the product 1.2-1.5 from the initial density of concrete.

The limits of the content of ingredients indicated in the formula of the utility model are due to the following reasons. With a decrease in cement content of less than 0.24-0.26 of the amount of decorative filler, despite the presence of 1-3% quartz or dolomite flour, incomplete and loose filling of the space between the grains of the filler, the formation of pores, and shells are possible. With an increase in cement content (a decrease in the amount of decorative aggregate), the decorative expressiveness of the textured surface of the front layer decreases and the process of exposing the textured surface of the product becomes more time-consuming. The proposed composition of the mixture for the manufacture of the front layer of the product also provides reliable adhesion to the main concrete layer.

The technical result from the use of the utility model is to improve the decorative and artistic properties of the front surfaces of building products by perceiving them as products made of natural stones while ensuring high performance indicators - strength and durability of the product, including high resistance to surface damage and efflorescence, reduced water absorption, abrasion and ensuring high frost resistance, reducing material consumption and cost (minimizing the amount of pigment used c) the possibility of using not only white but also gray cement without reducing the decorative properties of the product.

As a result, the surface of the product exposed by bead-blasting or sandblasting has a high-quality texture, including high decorative expressiveness, finished products made from the proposed

compositions have a texture with a uniformly distributed filler. At the same time, the high operational performance of the products obtained is determined by the low water-cement ratio (0.24-0.30) and the fact that due to the use of quartz or dolomite flour in the mixture (with a content of at least 80% fractions of not more than 0.1 mm), filling during compaction of the mixture during molding, the space between the filler fragments, due to which there are no pores in the front layer of the finished product. The optimally selected composition of the front layer allows you to distribute and pack smaller particles of sand and quartz (or dolomite) flour in the gaps between large-sized filler fractions during the manufacturing process. As a result of this, the optimal macrostructure of the mixtures is formed and this determines low water absorption, abrasion, and high frost resistance of the product.

Known technical solutions, for example, copyright certificate SU 1742066, patent RU 2166037, patent RU 2058893, which use operations (milling, sandblasting) to expose the textured surface of a building product, do not provide an increase in physical and mechanical characteristics while obtaining the desired decorative effect. The claimed utility model (product material - mixtures) was specially developed for subsequent bead-blasting or sandblasting in order to obtain a high density of concrete and the absence of porosity. This is essential not only to reduce water absorption, abrasion and increase frost resistance, but also provides high surface quality, its solidity, tight fit of the filler particles to each other, and the absence of surface defects (porosity, chips) even after shot blasting or sandblasting. Finished products, in addition to a spectacular decorative look and the high performance indicators mentioned above, have a rough, not

slippery surface, which is one of the important operational characteristics of paving slabs.

Utility Model Implementation

The manufacture of vibropressed two-layer building products with a front layer is carried out in a vibropress.

Preliminary, in separate mixers, rigid concrete mixtures of the main and front layers are prepared. After preparation, the mixture is fed into the hopper of the vibrating press. Further, by means of transport trolleys, concrete is delivered to the mold. The matrix presses the technological tray to the vibrating table of the press, after loading the mixture, the punch is lowered into the matrix, and the vibrators of the vibrating table and punch are turned on.

Laying the main and facial layers is carried out in two stages. The concrete mixture of the main layer of the product is laid, after laying the concrete mixture of the main layer, the mixture is pre-compacted, then the concrete mixture of the front layer is laid on top of the main and the final compression process is carried out, while the matrix provides the formation of the walls of the manufactured product. Products are formed on removable technological pallets, which are then fed into holding chambers.

By changing the parameters of the frequency and amplitude of vibration of the vibrating table and punch, filling the matrix with a mixture, set the required modes of compaction of the mixtures, providing high-strength products. The punch may have on its surface a pattern that is imprinted on the front surface of the paving slabs.

The first step in the implementation of the method is the preparation of concrete mixture.

To prepare the main layer of a building product, a concrete mixture of the following composition is used, wt.%:

Cement gray - 13.1-13.2 Gravel fractions 3-10 mm - 39.6-39.9 Sand Mk 2.5-3.0 - 43.4-43.7 Water - the rest

Preparation of the concrete mixture of the base layer is carried out, for example, by mixing 300 kg of M500 cement with 1090 kg of fine aggregate in the form of sand with a particle size module of 2.5-3.0 mm without water supply for 20-50 s. After determining the water-cement ratio (hereinafter - w / c), water is supplied to achieve a w / c of 0.24-0.3.

The front layer of the product is made of concrete mixture of the following composition, wt.%:

Cement - 18.2-18.6

Quartz or dolomite flour with a grain size of not more than

0.1 mm (80%) - 1.1-2.9 Decorative filler with a particle size of 0.9-7.0 mm - 71.0-75.8 Pigment - 0-0.56 Water - the rest

As a filler used a mixture of sand, serpentinite, decorative granite and marble, or a mixture of sand, amphibolite, serpentinite and marble, or a mixture of sand, amphibolite, granite and marble

Preparation of the concrete mixture of the front layer is carried out, for example, by mixing 420 kg of cement M500 with 50 kg of quartz or dolomite flour with a grain size of 0.1 mm (at least 80% by weight of the flour), and 1650 kg of aggregate (marble, decorative

granite, serpentinite, amphibolite, decorative coarse sand, etc.) with the introduction of water to achieve a value of 0.24-0.35.

In the case of using pigment, it is supplied approximately 30 seconds before the cement is supplied. If necessary, hydrophobic, decorative or other additives are introduced. The optimal mixing mode: quartz flour + pigment - 15-20 s; quartz flour + pigment + aggregate - 15-20 s; quartz flour + pigment + aggregate + cement - about 20 s; quartz flour + pigment + aggregate + cement + water + additives - 1-1.5 min. In total - 2-2.5 minutes.

The second stage is the molding process.

By means of metering devices, the concrete mixture of the base layer is firstly laid in the matrix for 2.0-6.0 during oscillatory movements of the transport trolley. Then, by preliminary vibration, the concrete mixture of the main layer laid in the matrix is compacted with pulses with a specific pressure of 120-250 g / cm ² for 0.5-5.0 s until the initial required density is reached. The second stage involves laying on top of the concrete mixture the main layer of the concrete mixture of the front layer and final compaction for 3.0-12.0 with the action of a punch and a vibrating table of the press, with a specific pressure of 110-400 g / cm ² . The density of the material of the product after completion of the final compaction process is 1.2-1.5 of the initial density of concrete.

The third stage is hardening.

Process pallets with molded products are fed into holding chambers. It is allowed to harden products made from the declared mixtures in the conditions of the production room, in such a way that can significantly reduce the cost of heat treatment of products.

Products are removed from technological pallets upon reaching concrete strength of at least 15.0-20.0 MPa (after 5-8 hours), then the released pallets are re-fed to the molding section and the cycle is repeated.

The fourth stage is the opening of the textured surface of the front layer of the product.

Hardened products are subjected to bead-blasting or sandblasting, exposing the textured surface of the product from natural stones. Sandblasting is also possible.

The claimed compositions of the mixtures make it possible to obtain a non-smooth surface of the product formed by the aggregate from a mixture of natural stones, tightly adjacent to each other, without pores and sinks.

The utility model is illustrated by the examples presented in table 1 (the composition of the concrete of the front layer in wt.%).

Table 1 The composition of the mixture for the decorative layer Examples No. 1 Number 2 Number 3 Number 4 Number 5 Cement gray (Oskol) - - - - 18.2-18.4 White cement ("Schurovsky") 18.3-18.6 18.3-18.5 18.4-18.6 18.4-18.6 - Quartz or dolomite flour 2.8-2.9 1,1 2.84-2.88 1,1 1,1 Sand 20.6-20.8 15.5-15.6 18.6-18.8 20,4-20,6 16.5-16.7 Amphibolite - 23.5-23.8 - 18.4-18.6 11.7-11.8 Serpentinite 13.8-13.9 17.4-17.6 18.9-19.1 16.0-16.2 - Decorative granite 23.6-23.9 - 18.4-18.6 - 11.7-11.8 Marble 15.3-15.5 18.3-18.5 14.0-14.2 16.9-17.1 35.8-36.2 Pigment - 0.37 - 0.55-0.56 0.55 Water Rest Rest Rest Rest Rest

Claims (8)

1. A two-layer building product obtained by vibrocompression, including a decorative front and main layers made of hard concrete mixtures, while the mixture for the main layer contains, wt.%: Cement 13.1-13.2 3-10 mm gravel 39.6-39.9 Sand MK 2.5-3.0 mm 43.4-43.7 Water Rest characterized in that for the manufacture of the front layer of the product used hard concrete mixture of the following composition, wt.%: Cement 18.2-18.6 Quartz or dolomite flour 1.1 -2.9 Filler decorative fractions of 0.9-7.0 mm 71.0-75.8 Water Rest moreover, as a filler used a mixture of sand, serpentinite, decorative granite and marble, or a mixture of sand, amphibolite, serpentinite and marble, or a mixture of sand, amphibolite, granite and marble. 2. The two-layer building product according to claim 1, characterized in that the pigment in the amount of 0.37-0.56 wt.% Is added to the composition of the rigid concrete mixture for the manufacture of the front layer of the product. 3. A two-layer building product according to claim 1 or 2, characterized in that as a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients is used: sand, serpentinite, decorative granite, marble in a ratio of 1.5: 1, 0: 1.7: 1.1. 4. The two-layer building product according to claim 1, characterized in that as a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients is used: sand, amphibolite, serpentinite, marble in the ratio: 1.0: 1.5: 1.1: 1.2, while the mixture introduced a dark brown pigment in an amount of not less than 0.35 wt.%. 5. A two-layer building product according to claim 1 or 2, characterized in that as a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients is used: sand, amphibolite, granite, marble in a ratio of: 1.4: 1, 0: 1.0: 3.1, while the mixture introduced a dark brown pigment in an amount of not less than 0.50 wt.%. 6. A two-layer building product according to claim 1 or 2, characterized in that as a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients is used: sand, serpentinite, decorative granite, marble in the ratio: 1.3: 1 , 3: 1.5: 1.0. 7. The two-layer building product according to claim 1 or 2, characterized in that as a filler in the composition of the rigid concrete mixture for the manufacture of the front layer of the product, a mixture of the following ingredients is used: sand, amphibolite, serpentinite, marble in the ratio: 1.3: 1, 4: 1.0: 1.1, while the mixture introduced a dark brown pigment in an amount of not less than 0.55 wt.%. 8. A two-layer building product according to claim 1 or 2, characterized in that during its manufacture a concrete mixture of the base layer is laid in the matrix for 2.0-6.0 s during vibrational movements and is densified by preliminary vibration by pulses with a specific pressure of 120 -250 g / cm ² for 0.5-5.0 s, then a concrete mixture of the front layer is laid on top of the concrete mixture of the main layer and finally compacted for 3.0-12.0 with a specific pressure of 110-400 g / cm ² .