JPH0316979A - Ceramics-coated concrete and production thereof - Google Patents

Abstract

PURPOSE:To obtain the title concrete with improved debonding resistance by forming a ceramic coating layer on the surface of concrete followed by heating to melt said layer to penetrate the resulting melt into the asperities of the concrete surface to effect fusing. CONSTITUTION:Firstly, cement. aggregate and water are mutually kneaded into a molded concrete slab. Second, a vitrifiable ceramic material such as clay comprising (A) as the major component, SiO2 and Al2O3 and (B) TiO2, Fe2O3, CaO, MgO, K2O and Na2O, or a mixture comprising feldspar, silica, magnesite or dolomite and TiO2 is ground and made into an aqueous solution, which is then applied on the surface of the concrete slab to form a ceramics coating layer ca.70mum thick. Thence. the coating layer is irradiated with e.g. carbon dioxide laser for ca.3sec. to effect baking. Thereby, said coating layer, due to the heat, is melted and penetrated into the asperities of the concrete surface to effect fusing on the concrete; also, the heat due to the above heating is transmitted into the concrete and the heating is stopped prior to its breakage, thus resulting in great adhesive force between the coating layer and the concrete surface.

Description

DETAILED DESCRIPTION OF THE INVENTION "Field of Industrial Application" The present invention relates to concrete whose surface is coated with a ceramic coating layer and fired, and a method for producing the same.

"Prior Art" Ceramic-coated concrete comprising concrete and a ceramic coating layer containing a ceramic material that covers the surface of the concrete is well known. The above-mentioned ceramic coating layer is usually provided as a tile, and the tile is bonded onto the concrete with an adhesive such as mortar, or the two are bonded together by pouring concrete onto the tile.

In addition, it has been known that a panel-shaped ceramic coating layer larger than the tile is baked or manufactured, and then concrete is poured (Japanese Patent Publication No. 62-291).
2. : No. 22. Report), ``Problem to be solved by the invention'' As mentioned above, in the conventional ceramic-coated conurete, the ceramic coating layer and the coureate were manufactured separately, and then the two were bonded together. .

Therefore, the ceramic coating layer is required to have at least enough rigidity to prevent itself from being damaged, which increases the thickness and weight, which causes an increase in cost. This also increases costs as additional work is required, and since the ceramic coating layer and concrete are bonded together, there is a risk of the ceramic coating layer peeling or cracking, or water leaking between the two. There was a risk that it would happen.

In order to solve these problems, it is possible to directly burn a ceramic coating layer onto the concrete, but in the past it was thought that such a method was practically impossible.

In other words, even if an unfired ceramic coating layer is formed on the surface of concrete, and only the ceramic coating layer is fired, the concrete will also be heated at the same time, and the concrete will generally generate moisture at temperatures above 80°C. , Occurrence of release of contained calcareous matter at 120~+000'C,
Explosion occurs above 240'C, 300-825℃
Organic or inorganic gases are generated at temperatures above 580°C, tortoiseshell-shaped cracks occur at temperatures above 1200°C, and melting occurs at temperatures above 1200°C. As described above, concrete heated to the temperature at which the ceramic coating layer is fired cannot be used for structural purposes such as architecture and civil engineering because it becomes dangerous.

Holes, cracks, peeling, etc. occur in the ceramic coating layer and the surface ceramic coating layer due to the above-mentioned effects of heating the concrete, and the adhesion between the concrete and the ceramic coating layer weakens, and the concrete and ceramic coating layer deteriorates. Cracks and peeling occurred due to differences in expansion and contraction rates between the layers, so the product was not in a usable condition.

"Means for Solving the Problems" In view of the above-mentioned circumstances, the present invention provides a ceramic-coated concrete comprising concrete and a ceramic coating layer containing a ceramic material, which covers the surface of the concrete. Alternatively, the present invention provides a ceramic-coated concrete characterized in that the heat of the ceramic-coated concrete melts and penetrates into the irregularities on the surface of the concrete and is fused to the concrete.

The present invention also provides a method for forming a ceramic coating layer containing a ceramic material on the surface of concrete, heating the ceramic coating layer, and burning the surface side of the ceramic coating layer by the heating. At least the part of the layer that is in close contact with the concrete is melted and penetrates into the irregularities on the surface of the conuret to fuse it, and the heating is stopped before the heat generated by the heating is transmitted to the concrete and damages the concrete. The present invention provides a method for manufacturing ceramic-covered concrete, which is characterized by:

"Operation" According to the manufacturing method of the present invention described above, when the non-burnt ceramic coating layer formed on the surface of concrete is heated and burnt, the heat from the heating is transferred to the concrete. Since the heating is stopped before the concrete is damaged, the concrete will not be affected by the adverse effects of heat, and the concrete can be used for construction.
It is clear that it can be used for structural purposes such as civil engineering.

In addition, the ceramic coating layer must be melted at least to the extent that the part of the ceramic coating layer that is in close contact with the concrete {
Because of this heating, it is possible to sufficiently burn out the surface side of the ceramic coating layer, and the melting of the above-mentioned close contact part of the ceramic coating layer prevents the close contact part from penetrating into the unevenness of the concrete. It becomes strongly fused.

In this way, a non-burning ceramic coating layer is applied to the concrete surface! }> By heating this,
At the same time as the ceramic coating layer is fired, the ceramic coating layer can be brought into contact with the concrete without damaging the concrete due to heat, which eliminates the need for baking and bonding work as in the past, and is quick and easy. It can be manufactured at low cost.

In addition, in the ceramic-coated concrete manufactured by the above-mentioned manufacturing method, the adhesive portion of the ceramic coating layer melts and penetrates into the unevenness of the concrete and is fused. Compared to when concrete is poured over the covering layer, the two are now in much closer contact,
Therefore, great adhesion can be obtained. As a result, it is possible to prevent separation and cracking between the two, and moreover, it is possible to prevent water from leaking between the two.

Furthermore, since the ceramic coating layer is bonded to the concrete by burning, the strength of the ceramic coating layer can be made to depend on the strength of the conurete.
Therefore, the thickness of the ceramic coating layer is, for example, 70u.
The thickness can be extremely thin, such as m.

In the method of the present invention, the heating for burning the ceramic coating layer is relatively instantaneous, and a laser xenon heater or the like can be used as the heating means. When firing the ceramic coating layer with these heating means, if the heating means has high capacity and the area of the ceramic coating layer is small, or the thickness of the ceramic coating layer is extremely thin, Although the entire surface can be heated at once, if the area of the ceramic coating layer is large, heating a part of the ceramic coating layer and moving the heated part to the entire area of the ceramic coating layer can be used. , the entire surface of the ceramic coating layer can be sintered.

As mentioned above, the conditions for the above heating are that the surface side of the ceramic coating layer is burnt by the heating, and that the parts of the ceramic coating layer that are close to the concrete are melted and penetrate into the irregularities on the surface of the concrete. It is necessary that the heat generated by the heating is not transmitted to the concrete and damage the concrete.

Ru.

Heat is transferred from the surface side of the ceramic coating layer to the concrete side, so if heating is stopped before the concrete is damaged, the degree of firing will change in the depth direction if the ceramic coating layer is thick. . However, if the ceramic coating layer is extremely thin, it is possible to sinter the entire ceramic coating layer substantially uniformly without damaging the concrete by appropriately setting the heating time or ceramic material. is possible.

Examples of the above-mentioned concrete include CaO, SiOz
, ^12Q3, Fe203@Cement paste made of boltland cement and water, sand, gravel,
Using inorganic concrete, which is made by gluing aggregates such as crushed stone and forming rock-like blocks into molds? can do. In this inorganic concrete, reinforcing bars, glass fibers, carbon fibers, graphite, carbon grains, and other inorganic or organic materials can be added as necessary, and further treatments such as foaming and steam curing can be applied depending on the application. can be administered. It is also possible to use organic concrete.

The ceramic material contained in the ceramic coating layer is, for example, mainly composed of SiO2, Al203,
TiO■, F[! 203, CaO, M90, K2
0, N. Clay containing a small amount of a2o and the like and having a grayish-white firing color can be used. Furthermore, as an alkali-resistant ceramic material, it is possible to use feldspar and quartz with additions of magnesand or dolomite containing M90 as a main component and Ti (h), if necessary.

It is clear that various other well-known ceramic materials can be used, such as blast furnace cement.
It is desirable to use ceramic materials that vitrify.

Is the ceramic coating layer limited to a single layer? Instead, the ceramic coating layer is composed of multiple layers.
i. By doing so, various functions can be added. For example, it is possible to create depth of color by coloring each layer, or to create a special color by overlapping colors. It is also a layer that adheres to the surface of the concrete.
High adhesion strength can be easily obtained by selecting materials that take into account only the adhesion strength with concrete. Furthermore, if a metal oxide such as TjO is added to the required layer, the layer can be used as a heat ray reflective layer.
In addition, if the melting point of each layer is set so that it decreases from the surface side of the ceramic coating layer to the concrete side, burning in the depth direction will be easier, so the burning energy per thickness of the ceramic coating layer will be reduced. can be reduced.

Furthermore, by appropriately selecting the materials for each layer and their ratios, each layer can be used as a waterproof layer, or as a buffer layer to buffer the difference in thermal expansion coefficient from concrete and prevent cracking and peeling. Alternatively, it is also possible to provide an adhesive layer for adhering the N layers having the various functions described above to each other. Note that each layer does not necessarily all contain a ceramic material, and it is sufficient that at least one layer contains a ceramic material.

"Example" Next, a specific method for producing ceramic-coated concrete according to the present invention and the ceramic-coated concrete obtained thereby will be described.

(Example 1) In FIG. 1, 1 is concrete, and 2 is a ceramic coating layer consisting of a single layer containing a ceramic material that covers the surface of this concrete 1.

The concrete 1, heating means for firing, and ceramic materials are as follows.

○Conuret precast concrete 1] 12 Compressive strength 500K 9/cm Dimensions 740mm (vertical) x 600mm (horizontal) x
150mm (thickness) ○Heating means carbon dioxide laser Rated output 200W ○Ceramics material Weight feldspar
60 lithium carbonate
8 barium carbonate 16
Limestone 4 years old Rin
3 silica
10 Copper oxide 1 The above ceramic materials were pulverized and mixed using a total of 500c+7j pole mill, then made into an aqueous solution, and the aqueous solution was evenly spread over the surface of the concrete 1 by a spraying method and dried.

Burning or output 30W/O. The ICm carbon dioxide gas laser was sequentially moved in the vertical and horizontal directions of the ceramic coating layer 2 to irradiate the entire surface of the ceramic coating layer 2, and a portion was irradiated for 3 seconds.

As a result, it was confirmed that the ceramic coating layer 2 was fired and melted into the irregularities on the surface of the concrete 1 by the heat thereof, and was fused to the concrete 1. In this state, the adhesion between the concrete 1 and the ceramic coating layer 2 was extremely good, and the adhesion strength was sufficient to lift the concrete plate with a rubber vacuum hanger adsorbed to the ceramic surface.

The surface of the ceramic coating layer 2 has no cracks or holes, has a blue smooth luster, and has a thickness of 70 g.
A ceramic coating layer of m was obtained. The properties of the ceramic coating layer include a softening temperature of 750°C, a Mohs hardness of about 7 degrees,
It has been confirmed that the pressure resistance is 11000K9/ci.

Further, the temperature change of the concrete 1 during burning was continuously monitored using a 5 mmf trowel thermocouple thermometer below the fusion surface, and as a result, it did not reach 80°C. Therefore, as a matter of course, Concrete 1 had no discoloration, explosion, falling off, cracking, etc., nor did it become neutral, and the compressive strength test according to J Engineering SA1107 using the core polling method was confirmed. As a result, no decrease in strength was observed.

(Example 2) Example 2 was the same as Example 1 except that the heating means was different from Example 1.

In Example 2, a reflective xenon heater equipped with three xenon tubes each having a rated output of 10 Kw was used as the heating means. When firing the ceramic coating layer 2 with the xenon heater, a width of 600 mm was fired at the same time, and the heater was moved in the longitudinal direction of 740 mm to continue firing uniformly. The burning time for a total length of 740mm is
The time was approximately 18 minutes and 30 seconds.

In Example 2, the same results as in Example] were obtained, and the difference from Example 1 was that the Mohs hardness of the ceramic coating layer 2 was approximately 6.5 degrees, and the pressure resistance was IO800K. 9/cm'.

(Example 3)? In Example 3, as shown in FIG. 2, the ceramic coating layer 2 covering the surface of the concrete 1 is composed of four layers 3 to 6.

In Example 3, the ceramic material of the group shown in Example 1 was ground and mixed using a pole mill, and 500
9 was used as the first layer 3 of the ceramic coating layer 2.

Further, a frit was manufactured from the ceramic material of the composition shown in Example 1, and the frit was again pulverized and mixed using a pole mill. and the above ceramic material 50
9 mixed with 500q% of frit is used as the second layer 4 of the ceramic coating layer 2, and the frit 5009 is mixed with TiO
2159@ was mixed as the third layer 5 of the ceramic coating layer 2. The TiO2 mentioned above is mixed for the purpose of reflecting heat rays.

Moreover, the fourth layer 6 of the ceramic coating layer 2 is used as an adhesive layer that adheres to the surface of the concrete 1. , gray-white, water-based, paste-like thermosetting inorganic adhesive 1 5 16 5009 was used 6 When shaping the ceramic coating layer 2 in Example 3, first the fourth layer 6 was prepared in Example 1. Spread it evenly on the surface of the same concrete 1 using the spraying method and dry it,
Next, the third layer 5 was uniformly spread on the surface of the fourth layer 6 by a spraying method and dried. Similarly, after the second layer 4 is uniformly spread on the surface of the third layer 50 by a spraying method and dried, the first layer 3 is evenly spread on the surface of the second layer 4 by a spraying method and dried. . The melting point of the ceramic coating layer 2 laminated in this manner is the highest in the first layer 3 and gradually decreases as the fourth layer 6 is reached.

For firing the ceramic coating layer 2, as in Example 1, the carbon dioxide laser was sequentially moved in the vertical and horizontal directions of the ceramic coating layer 2 to irradiate the entire surface of the ceramic coating layer 2, and the same portion was irradiated for 3 seconds. The output was 70W/O. I cm.

As a result, it was confirmed that the fourth layer 6 of the ceramic coating layer 2 melted into the unevenness of the concrete surface due to heat and was firmly fused to the concrete 1.

In this state, the adhesion between the concrete 1 and the ceramic coating layer 2 was extremely good, and the adhesion strength was sufficient to lift the concrete plate with a rubber vacuum hanger adsorbed to the ceramic surface C.

Furthermore, there are no cracks, holes, etc. on the surface of the ceramic coating layer 2. , blue smooth glossy, thickness 20
A ceramic coating layer of 0 um was obtained. The properties of the ceramic coating layer include a softening temperature of 730°C and a Mohs hardness of approximately 7.
The compressive strength was confirmed to be 10,700K 9/crri'.

The ceramic coating layer 2 of Example 3 required less burning energy per thickness of the ceramic coating layer and had a smoother surface finish than the single-layer ceramic coating layer of Example 1. .

Further, the heat ray reflectance of the ceramic coating layer 2 was improved by 62% due to the inclusion of TiOz.

Furthermore, in Example 3, the temperature change of the concrete during firing was measured using a heat 17 1 8 thermocouple thermometer 5 mm below the fused surface! ! Despite continuous monitoring, the temperature never reached 80°C, and no damage to the concrete was observed.

"Effects of the Invention" As described above, according to the manufacturing method of the present invention, the unfired ceramic coating layer formed on the surface of the Conch I notebook can be fired as it is, so that the ceramic coating layer can be fired as is. It does not require the work of firing the layers or the work of adhering the fired ceramic coating layer to the concrete, and can be manufactured in a short time and at low cost. When performing a burning command, the heating is stopped before the heat from the heating is transmitted to the concrete and damages the concrete, so the effect is that the concrete will not be affected by the negative effects of the heat. I can do it.

In addition, since the ceramic-coated concrete manufactured by the manufacturing method of the present invention is heated to the extent that at least the part of the ceramic coating layer that is in close contact with the concrete is melted, the part of the ceramic coating layer that is in close contact with the concrete is melted and It penetrates into the unevenness of the surface and is firmly fused. Therefore, compared to the conventional method of firing the ceramic coating layer and then pouring concrete on the ceramic coating layer, it is possible to bring the two into much closer contact and obtain a greater adhesion force. This makes it possible to prevent separation and cracking between the two, as well as prevent water from leaking between the two.

In addition, since the ceramic coating layer is bonded to the concrete by firing, the strength of the ceramic coating layer can be made to depend on the strength of the concrete 1.
Therefore, it is possible to obtain the effect that the thickness of the ceramic coating layer can be made extremely thin to reduce the overall weight.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view of ceramic-coated concrete showing one embodiment of the present invention, and FIG. 2 is a cross-sectional view of ceramic-coated concrete showing another embodiment. 1...Concrete 2...Ceramics coating layer 3-6-...Layer 1st Fi! J

Claims (2)

[Claims] (1) In ceramic-coated concrete comprising concrete and a ceramic coating layer containing a ceramic material that covers the surface of the concrete, the ceramic coating layer is fired and uses its heat to form unevenness on the surface of the concrete. 1. A ceramic-coated concrete characterized in that the ceramic-coated concrete melts into the concrete and is fused to the concrete. (2) After forming a ceramic coating layer containing a ceramic material on the surface of concrete, the ceramic coating layer is heated, and the surface side of the ceramic coating layer is fired by the heating, and the ceramic coating layer is bonded to the concrete. melting at least the adhesion part and allowing it to penetrate into the irregularities on the surface of the concrete and fuse it;
A method for producing ceramic-coated concrete, characterized in that the heating is stopped before the heat generated by the heating is transmitted to the concrete and damages the concrete.