WO2004052604A1 - A method for creating a non-porous fair-face surface when casting concrete - Google Patents

A method for creating a non-porous fair-face surface when casting concrete Download PDF

Info

Publication number
WO2004052604A1
WO2004052604A1 PCT/FI2003/000936 FI0300936W WO2004052604A1 WO 2004052604 A1 WO2004052604 A1 WO 2004052604A1 FI 0300936 W FI0300936 W FI 0300936W WO 2004052604 A1 WO2004052604 A1 WO 2004052604A1
Authority
WO
WIPO (PCT)
Prior art keywords
concrete
formwork
membrane
casting
fair
Prior art date
Application number
PCT/FI2003/000936
Other languages
French (fr)
Inventor
Janne Samuli Naamanka
Original Assignee
Janne Samuli Naamanka
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Janne Samuli Naamanka filed Critical Janne Samuli Naamanka
Priority to US10/536,983 priority Critical patent/US20060006583A1/en
Priority to EP03778360A priority patent/EP1569777B1/en
Priority to DK03778360T priority patent/DK1569777T3/en
Priority to DE60313027T priority patent/DE60313027T2/en
Priority to AU2003285372A priority patent/AU2003285372A1/en
Publication of WO2004052604A1 publication Critical patent/WO2004052604A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
    • B28B7/364—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article of plastic material or rubber

Definitions

  • the present invention relates to a method for creating a non-porous surface when casting concrete.
  • plank formwork has the advantage that the planks absorb water from the surface of the freshly cast concrete and thus blisters are seldom seen on surfaces cast in this way.
  • formwork stripping agent so-called formwork stripping agent
  • the pores arising in a concrete surface come from the collection, in the interface between the formwork and the concrete, of the air that is naturally trapped in the concrete.
  • the pores usually come from the separation of water contained in the concrete mass, as the concrete compacts.
  • the high surface tension of water causes a large angle of contact between a drop of water and the formwork material, which causes the water to separate into large drops against the concrete and thus form a blister in the hardening concrete.
  • fresh concrete must be compacted by vibration, and this is the force that collects the water as drops on the formwork surface.
  • the present invention is therefore intended to create a method, with the aid of which a fair-face surface, of very even quality and without blisters, can be achieved in concrete.
  • the invention is made by using, on the surface of the formwork, a membrane of special material that lies against the concrete being cast, with the aid of which the formation of blisters is prevented.
  • the casting membrane has a three-layer structure, which can comprise a paper-based middle layer and a plastic coating on each side of it.
  • This structure creates a material for the casting membrane that is sufficiently thin and is also sufficiently inelastic and stiff.
  • the paper acts precisely as a stiffener and reduces stretch.
  • a membrane, with a plastic coating only on the side of the membrane that comes against the concrete being cast, is also practicable.
  • the casting membrane according to the invention is manufactured in a conventional manner by coating at least one side of a cellulose-based paper web with a membrane of a suitable plastic, or of a plastic composition. After this, the membrane is subject to an electrical treatment, which is usually termed corona treatment. Its principle is that, by exploiting electrical discharges, the surface of the plastic coating is broken at the micro-level. Naturally, the corona treatment can be performed on both sides of the membrane, in cases in which both surfaces are coated with plastic, but it is performed at least on the surface that lies against the concrete being cast during casting.
  • the aforesaid corona treatment has a positive effect on the surface tension of water. This reduction in surface tension creates precisely a fair-face surface on the concrete that is without blisters and is of an even quality. It is assumed that the excellent casting surface arises because the water in the concrete cast against the formwork can flow in the micro-level passages and does not remain as drops between the concrete and the membrane, which would create blisters in the concrete surface.
  • Figures 1a and 1b show two parallel figures as a series showing the assumed behaviour according to the prior art (Fig. 1a) and the behaviour when using a membrane according to the invention (Fig. 1 b).
  • the reference number 1 represents the membrane according to the invention while number 2 represents the water drop.
  • the reference number 3, represents the angle of contact between the membrane and the drop, which, in the case of a large drop of water is obtuse, while the angle when using a membrane according to the invention is acute and the drop is widely spread.
  • a further additional advantage of the invention that can be mentioned is that, when using a casting membrane according to the invention, there is usually no need to use a separate stripping agent, as the formwork material will detach from the hardened concrete easily and completely.
  • the material according to the invention there is a stiff non-creasing cellulose-based layer of material, usually of paper, surfaced with a plastic membrane.
  • the low surface energy of the plastic membrane would, as such, cause the formation of a water drop as described above and through it the formation of a blister in the concrete surface being created.
  • the surface energy of the plastic membrane can economically and effectively be increased using the said electric discharge treatment, i.e. corona treatment.
  • the plastic surface is treated using an electric current, which causes sparking and forms ozone. Together, these factors increase the energy of the plastic surface and thus reduce the angle of contact between the formwork surface and the water drop to such an extent that a water drop, and through it a pore, cannot form.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Mold Materials And Core Materials (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Aftertreatments Of Artificial And Natural Stones (AREA)

Abstract

A method for creating a non-porous fair-face surface when casting concrete, in which method a casting membrane is used between the concrete being cast and the formwork. The casting membrane is formed at least on the plastic coating lying against the concrete being cast, which coating is treated with an electric-discharge treatment.

Description

Method for creating a non-porous fair-face surface when casting concrete
The present invention relates to a method for creating a non-porous surface when casting concrete.
Concrete being cast copies onto its surface a negative image of the surface structure of the formwork material. In old structures, the pattern of rough-sawn planks used in plank formwork is often visible. Plank formwork has the advantage that the planks absorb water from the surface of the freshly cast concrete and thus blisters are seldom seen on surfaces cast in this way. However, the formwork material must always be treated with so-called formwork stripping agent, which ensures that the formwork will detach from the hardened concrete in one piece, without breaking the new concrete surface. Treatment with stripping agent decisively reduces the planks' water absorption. In present-day concrete technology, the use of plank formwork has diminished considerably. Thus, at present, materials that do not absorb water are used, for example, treated plywood and steel.
The quality of the new concrete surfaces has not come up to expectations, but often leaves much to be desired. Quality requirements have therefore been issued for surfaces, depending on the surface treatment to be given afterwards to the concrete surface, and on the distance from which the concrete surface will be seen. According to the present guidelines issued by the Finnish Concrete Association (Concrete Surfaces, by 40), in the highest quality grade, 20 pores per square metre are permitted on the surface of concrete cast against horizontal formwork. Double this number of pores are allowed in a surface cast against vertical formwork. Keeping the numbers of pores beneath the guidelines generally demands the use of varnished timber formwork. Even then, it is often doubtful whether the surface created will meet the above requirements. It is therefore increasingly uncommon to see surfaces cast against untreated formwork.
Very often, it is imagined that the pores arising in a concrete surface come from the collection, in the interface between the formwork and the concrete, of the air that is naturally trapped in the concrete. However, the pores usually come from the separation of water contained in the concrete mass, as the concrete compacts.
The high surface tension of water causes a large angle of contact between a drop of water and the formwork material, which causes the water to separate into large drops against the concrete and thus form a blister in the hardening concrete. In practice, fresh concrete must be compacted by vibration, and this is the force that collects the water as drops on the formwork surface.
The present invention is therefore intended to create a method, with the aid of which a fair-face surface, of very even quality and without blisters, can be achieved in concrete.
This is achieved in the manner described as characteristic in the accompanying Claims.
In general, it can be said that the invention is made by using, on the surface of the formwork, a membrane of special material that lies against the concrete being cast, with the aid of which the formation of blisters is prevented.
According to one preferred embodiment, the casting membrane has a three-layer structure, which can comprise a paper-based middle layer and a plastic coating on each side of it. The use of this structure creates a material for the casting membrane that is sufficiently thin and is also sufficiently inelastic and stiff. In the casting membrane, the paper acts precisely as a stiffener and reduces stretch. However, a membrane, with a plastic coating only on the side of the membrane that comes against the concrete being cast, is also practicable.
However, coating the casting membrane with plastic on both sides will naturally act as more effective moisture-proofing than a membrane surfaced on one side, as the water in the damp concrete will not swell the paper mass.
The casting membrane according to the invention is manufactured in a conventional manner by coating at least one side of a cellulose-based paper web with a membrane of a suitable plastic, or of a plastic composition. After this, the membrane is subject to an electrical treatment, which is usually termed corona treatment. Its principle is that, by exploiting electrical discharges, the surface of the plastic coating is broken at the micro-level. Naturally, the corona treatment can be performed on both sides of the membrane, in cases in which both surfaces are coated with plastic, but it is performed at least on the surface that lies against the concrete being cast during casting.
The aforesaid corona treatment has a positive effect on the surface tension of water. This reduction in surface tension creates precisely a fair-face surface on the concrete that is without blisters and is of an even quality. It is assumed that the excellent casting surface arises because the water in the concrete cast against the formwork can flow in the micro-level passages and does not remain as drops between the concrete and the membrane, which would create blisters in the concrete surface.
The above behaviour of a drop is also illustrated in the accompanying drawings, in which Figures 1a and 1b show two parallel figures as a series showing the assumed behaviour according to the prior art (Fig. 1a) and the behaviour when using a membrane according to the invention (Fig. 1 b). The reference number 1 represents the membrane according to the invention while number 2 represents the water drop. The reference number 3, on the other hand, represents the angle of contact between the membrane and the drop, which, in the case of a large drop of water is obtuse, while the angle when using a membrane according to the invention is acute and the drop is widely spread.
The use of the said casting membrane permits the process of casting large units, without creasing or folding. Practical experiments have shown that the method actually works excellently and that with its aid a fair-face surface of excellent quality can be obtained.
A further additional advantage of the invention that can be mentioned is that, when using a casting membrane according to the invention, there is usually no need to use a separate stripping agent, as the formwork material will detach from the hardened concrete easily and completely. In the material according to the invention, there is a stiff non-creasing cellulose-based layer of material, usually of paper, surfaced with a plastic membrane. In a normal situation, the low surface energy of the plastic membrane would, as such, cause the formation of a water drop as described above and through it the formation of a blister in the concrete surface being created. However, as stated above, the surface energy of the plastic membrane can economically and effectively be increased using the said electric discharge treatment, i.e. corona treatment. In corona treatment, the plastic surface is treated using an electric current, which causes sparking and forms ozone. Together, these factors increase the energy of the plastic surface and thus reduce the angle of contact between the formwork surface and the water drop to such an extent that a water drop, and through it a pore, cannot form.

Claims

Claims
1. A method for creating a non-porous, fair-face surface, when casting concrete, in which a casting membrane is used between the concrete being cast and the formwork, characterized in that the casting membrane is formed of a plastic coating, which is treated using an electrical discharge treatment, at least on the surface against the concrete being cast.
2. A method according to Claim 1 , characterized in that the electrical discharge treatment is a so-called corona treatment.
3. A method according to Claim 1 , characterized in that a casting membrane is used on the surface of the formwork, which is formed of a cellulose-based layer, on both sides of which is a plastic coating, which is corona treated, at least on the surface lying against the concrete.
PCT/FI2003/000936 2002-12-10 2003-12-08 A method for creating a non-porous fair-face surface when casting concrete WO2004052604A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US10/536,983 US20060006583A1 (en) 2002-12-10 2003-12-08 Method for creating a non-porous fair-face surface when casting concrete
EP03778360A EP1569777B1 (en) 2002-12-10 2003-12-08 A method for creating a non-porous fair-face surface when casting concrete
DK03778360T DK1569777T3 (en) 2002-12-10 2003-12-08 Process for creating a non-porous glossy wall surface when casting with concrete
DE60313027T DE60313027T2 (en) 2002-12-10 2003-12-08 Process for producing a nonporous smooth plaster surface when pouring concrete
AU2003285372A AU2003285372A1 (en) 2002-12-10 2003-12-08 A method for creating a non-porous fair-face surface when casting concrete

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI20022173A FI20022173A0 (en) 2002-12-10 2002-12-10 Method for providing a non-porous clean casting surface in concrete castings
FI20022173 2002-12-10

Publications (1)

Publication Number Publication Date
WO2004052604A1 true WO2004052604A1 (en) 2004-06-24

Family

ID=8565059

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/FI2003/000936 WO2004052604A1 (en) 2002-12-10 2003-12-08 A method for creating a non-porous fair-face surface when casting concrete

Country Status (9)

Country Link
US (1) US20060006583A1 (en)
EP (1) EP1569777B1 (en)
AT (1) ATE358562T1 (en)
AU (1) AU2003285372A1 (en)
DE (1) DE60313027T2 (en)
DK (1) DK1569777T3 (en)
ES (1) ES2283843T3 (en)
FI (1) FI20022173A0 (en)
WO (1) WO2004052604A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2789439A1 (en) 2013-04-09 2014-10-15 Niels Pieter Gerard Nieuweboer Method for manufacturing a variety of esthetic concrete surfaces using metal molds and a magnetic substrate
JP2019078163A (en) * 2019-01-09 2019-05-23 清水建設株式会社 Form for concrete molding and its manufacturing method

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2071454A5 (en) * 1969-12-30 1971-09-17 Joos Pierre Vibrated concrete moulds - lined with resiliennt (silicone rubber) - sheeting giving a smooth surface finish
US4112173A (en) * 1975-02-04 1978-09-05 Champion International Corporation Concrete module unit
JPS5628971A (en) * 1979-08-16 1981-03-23 Koyo Sangyo Co Panel for concrete form and manufacturing method of said panel
EP0375924A2 (en) * 1988-12-14 1990-07-04 Cartiere Saffa S.A. Process for producing coated papers and coated cardboards endowed with barrier properties against the migration of water vapour, and so obtained products
JPH11254416A (en) * 1998-03-10 1999-09-21 Asahi Chem Ind Co Ltd Skin material for concrete form and concrete form
JP2003268924A (en) * 2002-03-14 2003-09-25 Nisshoku Corp Implement embedded in mortar or concrete

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3454688A (en) * 1965-06-15 1969-07-08 Ici Ltd Process for the production of formed gypsum castings

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2071454A5 (en) * 1969-12-30 1971-09-17 Joos Pierre Vibrated concrete moulds - lined with resiliennt (silicone rubber) - sheeting giving a smooth surface finish
US4112173A (en) * 1975-02-04 1978-09-05 Champion International Corporation Concrete module unit
JPS5628971A (en) * 1979-08-16 1981-03-23 Koyo Sangyo Co Panel for concrete form and manufacturing method of said panel
EP0375924A2 (en) * 1988-12-14 1990-07-04 Cartiere Saffa S.A. Process for producing coated papers and coated cardboards endowed with barrier properties against the migration of water vapour, and so obtained products
JPH11254416A (en) * 1998-03-10 1999-09-21 Asahi Chem Ind Co Ltd Skin material for concrete form and concrete form
JP2003268924A (en) * 2002-03-14 2003-09-25 Nisshoku Corp Implement embedded in mortar or concrete

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Week 198119, Derwent World Patents Index; Class A93, AN 1981-33496D, XP002990417 *
DATABASE WPI Week 199950, Derwent World Patents Index; Class A93, AN 1999-584745, XP002229181 *
PATENT ABSTRACTS OF JAPAN vol. 2003, no. 12 5 December 2003 (2003-12-05) *

Also Published As

Publication number Publication date
EP1569777B1 (en) 2007-04-04
DE60313027T2 (en) 2007-12-13
US20060006583A1 (en) 2006-01-12
DE60313027D1 (en) 2007-05-16
EP1569777A1 (en) 2005-09-07
AU2003285372A1 (en) 2004-06-30
DK1569777T3 (en) 2007-07-16
FI20022173A0 (en) 2002-12-10
ATE358562T1 (en) 2007-04-15
ES2283843T3 (en) 2007-11-01

Similar Documents

Publication Publication Date Title
EP2910385B1 (en) Method for producing decorative panels
EP1569777B1 (en) A method for creating a non-porous fair-face surface when casting concrete
WO2008131005A1 (en) Structural panels
KR20100050689A (en) Complexity water-proof layer structure using the perforation sheets, and perforation sheets, and construction method of complexity water-proof layers using thereof
DE05111659T1 (en) Floor coverings with wooden slats on a substrate, method for dressing the substrate and use of studded slab
DE102015013405B4 (en) Method and device for filling at least one perforated artificial brick
DE2305797A1 (en) Concrete casting wooden shuttering panel - having a planar layer of plastics
EP0708210B1 (en) Brick
DE202007010293U1 (en) baseplate
RU2593296C2 (en) Coating layer with low tensile properties for use in wear resistant laminate
KR200193121Y1 (en) Uroform having replacement pannel
DE102004018135B4 (en) Method and molding device for producing porosity foam concrete moldings
EP0945563B1 (en) Shuttering for producing concrete items
DE102008059364A1 (en) Building sound insulating slab for body sound-absorbing wall bearing for vibration technical decoupling of base plate for building wall, has joint section for simplified buckling of sound insulating slab
US6991206B1 (en) Concrete block mold with improved stripping ability
CN2716393Y (en) Floor board unit structure
JP2004225376A (en) Concrete placing form
KR101861969B1 (en) Concrete interception wall having good durability
DE102004024249A1 (en) Shaped sound-absorbing material, comprises protein-containing foamed biopolymers, plant fibers or partially mineralized plant fibers
KR20100107941A (en) Manufacturing method of plywood for using waste board and plywood thereof
JP2605793B2 (en) Curing method of hydraulic cement composition
JP2001152661A (en) Regenerated form by wood chip
DE281315C (en)
KR200344083Y1 (en) Synthesic sheeting of bridge using prestressed concrete beam
JPH1161780A (en) Structure of groin dam

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NO NZ OM PH PL PT RO RU SD SE SG SK SL TJ TM TN TR TT TZ UA UG US UZ VN YU ZA ZM ZW

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): BW GH GM KE LS MW MZ SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LU MC NL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG

121 Ep: the epo has been informed by wipo that ep was designated in this application
WWE Wipo information: entry into national phase

Ref document number: 2003778360

Country of ref document: EP

ENP Entry into the national phase

Ref document number: 2006006583

Country of ref document: US

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: 10536983

Country of ref document: US

WWP Wipo information: published in national office

Ref document number: 2003778360

Country of ref document: EP

WWP Wipo information: published in national office

Ref document number: 10536983

Country of ref document: US

NENP Non-entry into the national phase

Ref country code: JP

WWW Wipo information: withdrawn in national office

Country of ref document: JP

WWG Wipo information: grant in national office

Ref document number: 2003778360

Country of ref document: EP