JPH028012A - Manufacture of concrete plate body having shaped three-dimensional decorative surface - Google Patents

Abstract

PURPOSE:To efficiently manufacture a concrete plate body without any pinhole, water honey- come, etc., by a method wherein the surface of a female mold is covered with a heat resistant protective layer, which is produced by forming a mortar-containing backing layer on the rear of a surface layer, so as to leave said protective layer on the surface of a concrete layer by adhesion at demolding. CONSTITUTION:After being coated with releasant, the surface of a female mold is covered with a heat resistant protective layer 13, which consists of a surface layer 11 made of polymer- containing mortar and a mortar-containing backing layer 12 provided at the rear of the layer 11. At this time, after the constitution of the surface layer 11, rolling is applied to the rear of the layer 11 in order to make the bonding area between the surface layer 11 and the backing layer 12 larger. After the solidification of the backing layer 12, reinforcing iron bars 15 and 16 are arranged longitudinally and latitudinally between the inner surfaces of concrete form panels 1 and 2 and the points of intersection of the bars are bonded by fusion and pressure welding for assembly and ready-mixed concrete is placed between said inner surfaces. A concrete plate body is obtained by demolding the concrete form panels 1 and 2 after the solidification of a ready-mized concrete layer. As a result, the protective layer 13 is separated from the female mold 3 and adheringly left onto the ready-mixed concrete layer.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method for manufacturing a concrete plate having a shaped three-dimensional decorative surface constituting the outer wall of a building (house or building).

<Prior art> In this way, a concrete plate having a three-dimensional decorative surface on its surface is manufactured by fixing the female mold of the three-dimensional decorative surface to one inner surface of two formwork panels facing each other on the inner surface. Traditionally, reinforcing bars are arranged vertically and horizontally between the opposing inner surfaces of frame panels, concrete is poured after assembly, and both form panels are removed from the mold after the concrete layer has hardened.

<Problem to be Solved by the Invention> The female mold of the three-dimensional decorative surface fixed to one inner surface of the formwork panel is a molded product made of styrofoam, rubber, or other soft material. For this reason, when assembling reinforcing bars vertically and horizontally between the inner surfaces of opposing formwork panels, the reinforcing bars may come into contact with the female mold and damage the female mold, and sparks may occur when joining the vertical and horizontal intersections of reinforcing bars by melt welding. partially melted.

Since the three-dimensional decorative surface of the model is uneven, when ready-mixed concrete is poured between opposing formwork panels, it is difficult for air and moisture to escape upward along the female mold surface, resulting in pinholes and aggregate separation. A nest (junka), a water avatar, etc. that comes into contact with the surface of the female mold is formed.

Therefore, after demolding the formwork panel, these pinholes,
It was necessary to repair the three-dimensional decorative surface of the concrete plate that had been damaged by junk, water scrapes, etc., and the female part that had been melted by the sparks of melt welding. It takes a lot of work.

<Means for Solving the Problems> Therefore, the present invention provides a surface layer of mortar containing a polymer that contacts the surface of the female mold, and a surface layer of mortar containing a polymer that contacts the surface of the female mold. It is characterized in that it is coated in advance with a heat-resistant protective layer consisting of a mortar-containing backing layer formed on the back side of the concrete layer, and that the protective layer is adhered to and left on the surface of the concrete layer during demolding.

<Example> In the illustrated example, 1 and 2 are large formwork panels made of plywood (veneer board), metal plates, etc., and 3 is one of the formwork panels 2.
This figure shows a female mold 3 of a three-dimensional decorative surface molded from styrofoam, silicone rubber, etc., which is fixed to the inner surface of the mold. The formwork panels 1 and 2 and the female mold 3 have holes arranged in the same manner that face each other when placed side by side, and the cone 4 passed through the holes is screwed into the inner surface of the formwork panel 1 with a nut. Attachment: Pass the short end of the pivot bolt 5 with the flange through the hole in the formwork panel 2 from the inside, and screw the form tie 6 into the part that protrudes from the outside and tighten it. Sandwich the formwork panel 2 between the form ties, and insert the hole in the female mold 3 into the pivot bolt 5.
The female mold is fitted onto the inner surface of the formwork panel 2, and the female mold and the formwork panel 2 are fixed using nails.

To make both formwork panels 1 and 2 face each other with their inner surfaces kept at a predetermined distance, line the vertical and horizontal grouping materials 7 and 7' along the outer surface of formwork panel 1, and attach the outer horizontal grouping materials 7' to each other. Hold the rib washer 8 attached to the form tie 6 and tighten it to the outside surface of the formwork panel 1, and connect the separator 9 screwed onto the cone 4 of the formwork panel l and the pivot bolt 5 with a hexagonal cross-section joint nut or other They are connected by a connecting tool 10.

After assembling reinforcing bars arranged vertically and horizontally at opposing intervals between the formwork panels 1 and 2, ready-mixed concrete is poured, or prior to this, a mold release agent is applied to the surface of the female mold 3 and then a polymer is applied. The surface of the female mold is covered with a heat-resistant protective layer 13 consisting of a surface layer 11 containing mortar and a backing layer 12 containing mortar formed on the back of the surface layer.

The surface layer 11 and the backing layer 12 are preferably formed by spraying with a mortar gun from the viewpoint of work efficiency. That's about it.

The reason why the surface layer 11 contains bomber is to increase the fluidity of the mortar and spread the mortar even to the fine details of the uneven surface of the female mold 3, thereby faithfully reproducing the uneven surface of the female mold 3. If the three-dimensional decorative surface of the manufactured concrete plate is to be colored, pigments may be mixed into the mortar of the surface layer, and fine particles of quartz or slag may be mixed to make it resemble natural stone such as granite. . Once the surface layer 11 is formed in this way, it is preferable to apply a roller to the back surface of the surface layer to form streaks or other irregularities to increase the area of contact with the backing M12. Once the surface layer 11 is solidified, the backing layer 12 is formed.

This backing layer 12 is suitably made of a mortar made of Furukawa reinforced concrete (FRC), which is a mixture of mortar and metal fibers such as glass fibers and metal fibers such as iron fibers (Fig. 2).
However, the entire back surface of the surface layer 11 is covered with a mesh material 14 made of glass fiber, carbon fiber, nylon, iron fiber, etc., and nails or the like are driven into the surface layer 11 in places to secure it.
Ordinary concrete mortar may be sprayed (Figure 3).

After forming the backing layer 12, it is preferable to form streaks similar to those of the surface layer on the back surface of the backing layer 12 to increase the adhesion area with the ready-mixed concrete layer placed between the formwork panels. Further, if necessary, an adhesive that exhibits adhesive strength with the ready-mixed concrete layer may be applied by spraying.

After forming the backing layer 12 in this way and solidifying it, reinforcing bars 15 and 16 are arranged vertically and horizontally between the inner surfaces of the formwork panels 1 and 2, and the intersection points are joined by melt welding to assemble it, and then ready-mixed concrete is poured. Then, once the ready-mixed concrete layer has solidified, formwork panel 1.2
demold and obtain the desired concrete plate.

As a result, the protective layer 13 is peeled off from the female mold 3 and remains attached to the ready-mixed concrete layer.

Of course, it is also possible to arrange a plurality of formwork panels 1 and 2 adjacently in the horizontal direction and pour ready-mixed concrete between them.In that case, the female molds 3 attached to each formwork panel 2 may also be arranged adjacently. , the series of female molds are coated with a series of protective layers 13.

<Effects of the Invention> According to the present invention, the female mold 3 on the inner surface of the formwork panel 2 is covered with a heat-resistant protective layer 13, so that the reinforcing bars 15 and 16 are not brought into contact with the reinforcing bars during reinforcement arrangement and assembly, and are prevented from melting. Do not touch sparks from pressure welding.

The surface layer 11 of the protective layer in contact with the female mold faithfully reproduces the uneven decorative surface of the female mold.

Therefore, what is repaired is only the trace where the pivot bolt 5 has come off, and a concrete plate body having a female-shaped uneven decorative surface and a three-dimensional decorative surface opposite to the female mold can be efficiently manufactured.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of a part of a state in which formwork panels are opposed according to the present invention, the female form thereof is covered with a protective layer, and reinforcing bars are assembled;
Figure 2 is a cross-sectional view of one example of the protective layer, and Figure 3 is a cross-sectional view of another example of the protective layer. The backing layer 13 is a protective layer that collectively refers to the surface layer and the backing layer.

Claims (1)

[Claims] The female mold of the three-dimensional decorative surface is fixed to the inner surface of one of the two formwork panels that face each other on the inner surface, reinforcing bars are arranged vertically and horizontally between the opposing inner surfaces of the formwork panels, and after assembly, concrete is poured. In a method for manufacturing a concrete plate having a three-dimensional decorative surface, in which both formwork panels are removed from the mold after the concrete layer has solidified; pre-coated with a heat-resistant protective layer consisting of a surface layer made of mortar containing a polymer in contact with the surface layer, and a backing layer containing mortar configured on the back of the surface layer,
At the time of demolding, the above protective layer is attached to the surface of the concrete layer,
A method for producing a concrete plate having a shaped three-dimensional decorative surface that is left in place.