JPH02103103A - Preparation of natural stone concrete product - Google Patents

Abstract

PURPOSE:To enhance mass productivity and to sufficiently correspond to a large-sized product or a concrete product of every kind by a method wherein sealing aggregate and decorating aggregate are thrown on the bottom part of a retaining mold having a required shape to be vibrated and concrete is subsequently thrown in the mold to perform ageing and demolding. CONSTITUTION:Sealing aggregate 5 and decorating aggregate 4 are thrown in a retaining mold. The throwing order of both aggregates can be appropirately selected like simultaneous throwing, throwing in the order of the sealing aggregate and the decorating aggregate or the throwing in the order of the decorating aggregate and the sealing aggregate according to a line or working procedure. When the shape of the bottom part or surface plate of the retaining mold is set to the shape shown by a numeral 1, simultaneous throwing or either one of the appropriate throwing methods is selected to make it possible to easily obtain an excellent concrete product. By vibrating the decorating and sealing aggregates 4, 5 thrown on the surface plate 1 or bottom part of the retaining mold, the decorative aggregate 4 is arranged on the bottom part. Next, when water is emitted in a showerlike manner from above, water is drained through the holes 3 of the surface plate or bottom part and the sealing aggregate 5 present above the decorating aggregate 4 are sunk by water and the bonding surface with concrete of said aggregate 5 above the decorating aggregate 4 is washed with water and the bonding with concrete becomes certain. Thereafter, concrete is thrown in the retaining mold and, after ageing, a product is obtained by demolding.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention is utilized in a method for producing concrete products, more particularly in a pouring method. This article relates to manufacturing methods for various surface-decorated concrete products.

[Conventional technology]

Conventionally, methods for manufacturing concrete products with natural stone exposed on one surface include embedding natural stone in the surface before the concrete hardens, or fixing natural stone etc. with ice on a pallet and then applying concrete-81 mortar etc. A method of pouring (Utility Model Application Publication No. 60-191405), concrete is poured over the decorative aggregate, pressurized, vibrated, cured, and then the faults are separated and the laminated state is exposed on the decorative surface. The manufacturing method of the product (Japanese Patent Laid-Open No. 53-136028) is that the surface of a concrete block is decorated, concrete is poured into a mold, decorative gravel is scattered on top of the concrete, and it is vibrated.

There is a method for producing a pressurized concrete block having decorative gravel on the surface (Japanese Patent Application Laid-open No. 158206/1983).

In addition, a method for manufacturing surface-decorated concrete products using the pouring method has been desired.

[Problem to be solved by the invention]

However, with methods such as embedding natural stone before concrete hardens or fixing natural stone with ice, the natural stone tends to peel off after installation.

Also, JP-A-53-136028, JP-A-58-
Even if the method of Publication No. 158206 is used, when using large aggregates such as natural stone as a surface decorative material, the natural stone and concrete do not bond well and the natural stone easily peels off. It was also impossible to combine both at the same time.

In addition, all conventional methods are relatively small.

It can only be used for decorative aggregates with a certain shape, and cannot be used for large decorative aggregates or decorative aggregates of various sizes. It was only very limited.

Furthermore, in the conventional method, the bare surface of the concrete is inevitably exposed at the joints, giving the product an artificial atmosphere.

Therefore, the present applicant and others previously filed an application for a method for manufacturing a concrete product whose surface is decorated by exposing the aggregate (Japanese Patent Application No. 142,813/1982).

However, the method applied by the present applicants made it possible to manufacture finished concrete products with natural stone exposed on the surface, but it was not possible to manufacture concrete products mechanically and in mass production of natural stone concrete products. Desiring the development of a method and a device for manufacturing the same, the applicant filed an application for a method and device for manufacturing concrete products that mechanically and mass-produce exposed concrete blocks made of natural stone (Japanese Patent Application No. 315822/1982). .

Furthermore, in manufacturing these decorative surface concrete products, the applicant is concerned with the amount of filler aggregate and the size of the decorative aggregate, since the conventional face plates are not structured to anticipate the input of filler aggregate. There was a limit to the amount of mortar that could be added.

In addition, with the conventional shape of the face plate, it is necessary to apply vibration each time a closing aggregate, a decorative aggregate, etc. are introduced, and a plurality of vibrating devices are required, which is uneconomical.

Furthermore, depending on the type of decorative aggregate, it is necessary to change the order in which filler aggregate and decorative aggregate are added, and it is not easy to rearrange the order in which they are incorporated on the -degree line.

Further, when the decorative aggregate or filler aggregate was introduced on the line, it was difficult to clean the surface of the decorative aggregate.

In addition, since the pouring method uses soft concrete, it is necessary to adjust the amount of filler aggregate, but this adjustment was difficult with conventional faceplates that do not predict the filler aggregate. .

Furthermore, when vibration is applied after adding filler aggregate or decorative aggregate, depending on the type of decorative aggregate, the decorative aggregate may move around a lot, and the more time it takes for compaction, the denser it becomes. However, the vibration may cause the aggregate for sealing to rise and enter the air bubbles in the concrete.

Furthermore, some conventional manufacturing methods cannot adequately handle large-sized products and various concrete products.

The present invention allows the amount of decorative aggregate, filler aggregate, and mortar to be freely adjusted, reduces the number of vibrators on the line, and allows the decorative aggregate to be appropriately positioned. It is an object of the present invention to provide a method for forming surface decorative aggregate that can be used economically and effectively in the production of various concrete products.

[Means to solve problems]

Therefore, as a result of intensive research to provide a method for manufacturing concrete blocks that can surface-dress natural stone, especially in the pouring method, the present inventors found that the shape of the face plate installed at the bottom of the formwork or the shape of the bottom of the formwork was changed from the conventional one. From the plate shape of
A box is provided at the bottom, and the top surface has a tapered projecting surface.

In addition, if necessary, provide multiple drainage holes on the bottom.
After putting filler aggregate and decorative aggregate into the bottom or face plate of the formwork of the desired shape, vibrating it, then showering water from the top, then adding concrete, curing and removing the mold. Flat plates, curb blocks, U-shaped covers, pedestrian and roadway boundary blocks, large stacked blocks, concrete retaining walls, stacked blocks.

completed the present invention based on the knowledge that an unprecedented and superior surface decorative concrete product can be obtained by reblocking, pouring, on-line using this method, or by manual method.

Although one drawing will be described in detail below, the present invention is not limited thereto.

FIGS. 1A, B, C, D, E, and F are diagrams showing the manufacturing process of the present invention, where l indicates the bottom of the face plate or any formwork, and the bottom of ■ has the box body 2. The upper surface has a tapered projecting surface.

Moreover, a formwork of an arbitrary shape is provided on the side of this 1.

Depending on the purpose of the product, this formwork can be used, for example, as a flat plate, a curb block, a U-shaped lid, a U-shaped lid, a pedestrian path boundary block,
Large stacking blocks, concrete retaining walls, stacking blocks,
For example, reblocking is used.

The depth of the box body is appropriately determined depending on the material of the decorative aggregate, the material, etc.

In addition, even if you do not use the formwork bottom or face plate shaped like 1, filler aggregate,
A surface-decorated concrete block can also be manufactured by adding a decorative aggregate, applying vibration, and then pouring concrete.

However, it is preferable to provide a drainage hole 3 at the bottom as shown in FIG.

Filling aggregate and decorative aggregate are introduced into the formwork, either at the same time, or in the order of closing aggregate and then decorative aggregate, or decorative aggregate and then decorative aggregate. It can be selected as appropriate depending on the calculation line and work procedure, but if the shape of the bottom of the form or the face plate is made into the shape shown in 1, it is possible to easily obtain an excellent concrete product even when simultaneously charging or selecting an appropriate charging method. Can be done.

By applying vibration to the decorative aggregate and closing aggregate placed in the face plate or the bottom of the mold, the decorative aggregate is aligned with the bottom.

Next, when water is radiated from the top in a shower shape, the water escapes from the hole 3 at the bottom of the face plate, but the filler aggregate that was at the top sinks to the bottom due to the water, and the decorative aggregate The surface that joins the upper concrete is washed with water,
Ensures a secure bond with concrete.

At this time, if a water-soluble adhesive is added together with water, the binding of the closing aggregate will be more secure, and the decorative aggregate will also be less likely to move during the work.

After that, a product is obtained by pouring concrete and molding after curing.

These operations can also be performed on line.

As the filler aggregate used in the present invention, sand, soil, slag, ore, natural stone shavings, synthetic resin, etc. may be used, and aggregates smaller than the size of the surface decorative aggregate used may be used. Although it is determined as appropriate depending on the type of aggregate used for surface decoration, viscous aggregate for sealing is preferable.

In addition, aggregates for closures can be selected from a variety of colors in order to harmonize with decorative aggregates1.For example, granite shavings may be used for granite, or materials with completely opposite colors may be used. may be used, and can be selected as appropriate depending on the location where the concrete product will be used, the purpose of installation, etc.

Since the degree of protrusion of the surface decorative aggregate after completion can be adjusted depending on the amount of filler aggregate, the supply amount may be adjusted depending on the purpose.

Concrete is selected as appropriate depending on the purpose.

When using the pouring method, it is preferable to use soft concrete, and when using the demolding method, it is preferable to use hard mixed concrete.

〔effect〕

INDUSTRIAL APPLICABILITY According to the present invention, by simply making improvements to a conventional production line, it can be applied to various molding machines such as instant demolding type and pour molding type.

By using filler aggregate, aggregates of various sizes can be pressurized uniformly, and even small decorative aggregates hidden behind large aggregates can be reliably bonded to the concrete surface, unlike conventional methods. Therefore, only small particles of the surface decorative material do not fall off, and the degree of protrusion can be sufficiently adjusted.

In addition, the filler aggregate prevents the decorative aggregate from shifting until the molded product is cured, and further protects the decorative surface during transportation.

Furthermore, the surface of the concrete is not exposed at the joints, and the appropriately selected filler aggregate is adhered to the joints, making it possible to obtain a natural stone exposed concrete product that is a natural product as a whole. It is possible to manufacture concrete products using natural stone at low cost.

In addition, conventionally, products using natural stone were often constructed on-site, but with the present invention, concrete products can be manufactured at the factory using formwork of any shape. Work becomes easier.

Furthermore, by using the formwork bottom or face plate shaped as shown in Figure 1, decorative aggregate and filler aggregate can be added at the same time, so there are no restrictions on the number of vibrations or on the line. .

In addition, machine costs can be reduced by reducing the number of vibrators on the line, and appropriate vibrations can be applied, so decorative aggregates can be positioned appropriately and The order in which filler aggregate is added can be freely set.

Moreover, since these can be introduced at the same time, costs can be reduced.

Furthermore, conventionally, when decorative aggregates are bonded to concrete, the bonding becomes poor when dirt accumulates, but since the bonding surface is sprayed with water in a shower, the bonding becomes reliable.

In addition, even if the bottom of the formwork has protrusions, protrusions, or unevenness, by using closing aggregate, pressure will be applied evenly when the decorative aggregate and concrete are bonded, and any It is also possible to obtain a concrete product with an excellent surface finish made from natural stone.

Furthermore, since a variety of surface decorations can be used on one surface, various designs can be created by combining them, so when used for residential land development, stone walls, and landscaping work, the natural texture and individuality can be used as companions. It is possible to recreate a beautiful style, and it can also be used for embankments, riverbeds, riverbeds, etc. in national parks and other parks.
When used in civil engineering works such as tunnel entrances and exits, it also harmonizes with the natural environment and can contribute to environmental protection.

After curing, the surface pallet is removed from the mold and at the same time, the closing aggregate other than that attached to the concrete is removed, and the surface of this is treated with water or air to obtain the concrete product of the present invention.

At this time, in the past, the surface was treated by polishing or scraping, but with the present invention, an extremely clean finished product can be obtained just by lightly spraying air or water, eliminating the pollution caused by waste as in the past. I won't wake you up.

[Example] Production example 1 (manufacture of large stacked blocks) Viscous sand was applied to the bottom of the formwork of a large stacked block measuring 800 mm in length x 1250 mm in width to a thickness of about 50 mm as filler aggregate. Then, after 50 to 450 mm of Kai stone was added as a surface decorative aggregate, vibration was applied until the Kai stone sank into the filler aggregate.

Next, from the top of the formwork, 151 kg/m3 of water and 3 cm of cement were added.
20kg/m', fine aggregate 776kg/m', coarse aggregate 10
84kg/m”, admixture 3.2%, water-cement ratio 45.
8% concrete with a slump of 7.8 cm was poured into the concrete, and it was evenly vibrated with a rod vibrator without touching the decorative aggregate, and then vibrated throughout as a finishing touch.

After that, reinforcing bars were inserted before the concrete hardened, and after curing and demolding, a large stacked concrete block with a surface decoration as shown in Figure 3 was obtained.

After 14 days, a 500 g weight was dropped from a height of 30 cm onto the surface of the protruding part of the surface decorative aggregate held horizontally, and the surface decorative aggregate was peeled off.

Although cracks, bulges, wrinkles, etc. on the bonded surface were visually observed, no abnormalities such as peeling or cracks were observed.

Production example 2 (manufacture of car walkway blocks) At the bottom of the formwork of a flat plate measuring 300 mm in length and width, a box is provided at part a, the top surface has a tapered projecting surface, and water drains with a diameter of 5 mm are placed on the bottom at intervals of 3 cm and 1 lll. At the bottom of the formwork with holes of 60 to 10
At the same time, 0 mm Hanaoka rock was introduced, and the decorative aggregate was caused to sink to the bottom of the box by vibration.

Thereafter, a shower of water was sprayed from the top until the top of the decorative aggregate was exposed from the filler aggregate and the filler aggregate sank to the bottom of the box.

Next, concrete according to Production Example 1 was poured, compacted by vibration, cured, and demolded to obtain a natural stone surface decorative concrete flat plate.

Thereafter, an impact test was conducted according to Production Example 1, but no abnormality was observed.

Production example 3 (manufacture of concrete boundary blocks) length 250
In creating a concrete boundary block of 600mm wide x 180mm wide, fill the bottom of the formwork with the exposed surface facing down, and add filler aggregate as granite shavings of 1 to 100mm.

Granite with a thickness of 50 to 300 mm was introduced, and vibration was applied until the granite sank into the filler aggregate.

Next, concrete was poured from the top of the formwork with 161 kg/m of water, 324 kg/m of cement, 798 kg/m of fine aggregate, 1060 kg/m of coarse aggregate, a water-cement ratio of 50°0%, and a slump of 15 cm. , dedicated vibrator
Then, vibration is applied evenly without touching the decorative aggregate, and then as a finishing touch, vibration is applied from the entire surface to tighten it and tighten it.
After curing and demolding, a natural stone surface decorative concrete boundary block shown in Fig. 4 was obtained.

Ta.

Thereafter, an impact test was conducted according to Production Example 1, but no abnormality was observed.

Production example 4 (manufacture of tension rib blocks for seawall) Length 350mmX
At the bottom of the formwork of a 350mm horizontal revetment rib block, a box is provided at the bottom, the top surface has a tapered projecting surface, and drainage holes with a diameter of 3.5mm are provided at 2cm intervals on the bottom. 100% as surface decorative aggregate at the bottom of the formwork.
~500mm of Teppei stone was put in, and then shavings of Hanaoka stone made into a viscous material was put in at the bottom to a thickness of about 30mm as a filler aggregate, and then a shower of water was added from the top. Water was sprayed until the top of the filler aggregate was exposed from the filler aggregate and the filler aggregate sank to the bottom of the box.

Next, from the top of the form, water: 179 kg/m", cement: 320 kg/m", fine aggregate: 840 kg/m3, coarse aggregate: 971 kg/m', water-cement ratio: 56%.

A slump of concrete with a thickness of 21 cm was poured into the concrete, and it was evenly vibrated with a rod vibrator without touching the decorative aggregate, and then vibrated throughout the concrete as a finishing touch.

After curing and demolding, a revetment rib block was obtained.

After 14 days, an impact test was conducted according to Production Example 1, and no abnormality was observed.

Production Example 5 (Manufacture of L-shaped block) An L-shaped block form with the side where the surface decorative aggregate is exposed is placed on the bottom, and viscous sand is placed at the bottom as a filler aggregate to a thickness of 50 m.
m, and then add 1 as surface decorative aggregate.
After adding 50 to 700 mm of snakestone, vibration was applied until the snakestone sank into the filler aggregate.

Next, concrete was poured from the top of the form according to Production Example 4, and it was evenly vibrated with a bar vibrator so as not to touch the decorative aggregate, and then vibrated throughout as a finishing touch.

Thereafter, after curing and demolding, a one-surface decorative concrete block was obtained.

After 14 days, an impact test was conducted according to Production Example 1, but no abnormalities such as peeling or cracking were observed.

Manufacturing example 6 (Manufacturing of lid for reinforced concrete U type) JIS-
In the production of A5334 reinforced concrete U-shaped lids, on the bottom of the formwork of the required shape.

A box was provided at the bottom, the upper surface had a tapered protruding surface, and the bottom of the form had drainage holes with a diameter of 10 mm at 5 cm intervals. ~100 mm of Hanaoka rock was simultaneously introduced, and the decorative aggregate was sunk to the bottom of the box by vibration.

Thereafter, a shower of water was sprayed from the top until the top of the decorative aggregate was exposed from the filler aggregate and the filler aggregate sank to the bottom of the flute body.

Next, from the top of the formwork, 121 kg/m3 of water and 2 cm of cement were added.
88kg/m3, fine aggregate 697kg/m3, coarse aggregate 12
43 kg/m', water-cement ratio 42%, slump 2
cm of concrete is poured, and it is vibrated evenly using a vibrator without touching the decorative aggregate.Afterwards, as a finishing touch, vibration is applied to the entire surface, and the concrete is compacted, cured, and
The mold was removed to obtain a natural stone surface decorative lid for reinforced concrete U-shape.

Thereafter, an impact test was conducted according to Production Example 1, but no abnormality was observed.

Production example 7 (manufacture of special concrete products) 1300m long
At the bottom of the formwork of a large block product measuring 1000 mm wide x 250 mm thick, a box is provided at the bottom, the top surface has a tapered protruding surface, and drainage holes with a diameter of 10 mm are provided at 1 cm intervals on the bottom surface. At the same time, one side of the formwork is decorated with a pattern in which a plurality of teppei stones are arranged at appropriate intervals, and the bottom of the formwork is filled with 100% of the surface decorative aggregate.
~ 500mm of Teppei stone was put in, and then viscous Teppei stone shavings were put in the bottom to a thickness of about 30mm as a filler aggregate, and then a shower of water was poured from the top. Water was sprayed until the top of the filler aggregate was exposed from the filler aggregate and the filler aggregate sank to the bottom of the box.

Next, from the top of the formwork, 179 kg/m3 of water and 3 cm of cement were added.
20kg/m', fine aggregate 840kg/m3゜coarse aggregate 97
1kg/m', water-cement ratio 56%, slump 21cm
concrete was poured in, and it was vibrated evenly using a rod vibrator without touching the decorative aggregate, and then as a finishing touch, vibration was applied throughout.

After curing and demolding, a large concrete product as shown in FIG. 5 was obtained, the top surface of which was decorated with iron pebbles, and a portion of the side surfaces decorated with iron pebbles patterns.

After 14 days, an impact test according to Production Example 1 was conducted and no abnormality was observed.

[Brief explanation of drawings]

1A, B, C, D, E, and F are views showing one embodiment of the manufacturing process of the present invention, FIG. 2 is a plan view showing one embodiment of the face plate, and FIGS. FIG. 4 is a diagram showing an embodiment of a large decorative concrete block with a surface, FIG. 4 is a diagram showing an embodiment of a natural stone surface decorative concrete boundary block, and FIG. 5 is a diagram showing an embodiment of a large concrete product. Figure 1 (A) (D) (E) ζ (C) (F)

Claims (5)

[Claims] (1) A method for manufacturing natural stone concrete products, characterized in that filler aggregate and decorative aggregate are poured into the bottom of a formwork of a desired shape, vibration is applied, and then concrete is poured, and the mold is removed after curing. A method for manufacturing natural stone concrete products. (2) In the manufacturing method of natural stone concrete products, filler aggregate and decorative aggregate are poured into the bottom of the formwork of the desired shape, water is then poured from the top in a shower-like manner, and then concrete is poured and cured. A method for manufacturing natural stone concrete products characterized by molding. (3) The bottom part of the formwork is a bottom part or a face plate having a tapered projecting surface on the top surface of the box body and having a plurality of holes in the bottom surface. Method of manufacturing natural stone concrete products. (4) The method for producing a natural stone concrete product according to any one of claims 1, 2, and 3, wherein the filler aggregate is viscous. (5) The formwork is a flat plate, curb block, U-shaped cover, pedestrian road boundary block, large stacked block, concrete retaining wall,
5. The method for producing a natural stone concrete product according to claim 1, wherein the stacked blocks are reblocks.