JPH0613164B2 - Manufacturing method of concrete molding - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a concrete formed body such as an outer wall body, a retaining wall block, a sheet pile, and a gutter lid in a building or the like.

<Prior art> Both concrete molded products with a three-dimensional decorative pattern on the surface and flat molded concrete products without such a three-dimensional decorative pattern have conventionally been arranged with vertical and horizontal reinforcing bars inside facing molds. Then, the concrete was placed between the forms while vibrating the form with a vibrator, and the form was removed by the solidification of the placed concrete, and the concrete compact was demolded.

<Problems to be solved by the invention> When the molded product to be manufactured is large, even if the fresh concrete is placed under the vibration of the mold, the bubbles and excess water in the ready-mixed concrete come out from the surface of the ready-mixed concrete. Niku, especially the surface of the molded body (the vertical outer surface looking at the molded body) has a three-dimensional decorative pattern, and the vertical inner surface of one of the molds becomes an uneven female mold for expressing the above pattern. If so, the tendency is large. As a result, air bubbles and water avatars are left on the surface of the molded body, which impairs the appearance and water bubbles generated inside the concrete layer may damage the molded body from the inside due to repeated freezing and thawing in cold regions. Even there.

In addition, a plastic gear-shaped or ratchet-shaped spacer made of plastic is fitted to the reinforcing bars that are arranged vertically and horizontally inside the mold to keep the distance from the inner surface of the mold almost constant. Since the teeth or claws come into contact with the inner surface of the mold, the teeth or claws are exposed on the surface of the molded body, impairing the appearance of the surface of the molded body, and plastic and concrete have different expansion and contraction rates due to temperature. There is a risk that a crack will occur between the spacer and the concrete and moisture will enter from there to corrode the reinforcing bar, or the molded body will be damaged by repeated freezing and thawing of the moisture.

<Means for Solving the Problem> Therefore, in the method for producing a concrete molded body of the present invention, a polymer mortar kneaded with a polymer emulsion adhesive for cement and a water reducing agent is sprayed on the inner surface of a mold forming the surface of the molded body. To form a surface layer, then spraying or pouring fiber-containing polymer mortar mixed with the same polymer mortar and kneaded to form a protective layer of a predetermined thickness on the back of the surface layer, after curing the protective layer, By placing a spacer attached to the reinforcing bar on the back of the protective layer, the reinforcing bar is separated from the back of the protective layer to arrange longitudinally and laterally, and then concrete is poured, and the surface layer, the protective layer and the concrete layer made of ready-mixed concrete. It is characterized by integrating.

And to express a three-dimensional decorative pattern on the surface of the molded body,
The inner surface of the mold forming the surface to be molded may be a female mold having a three-dimensional decorative pattern expressed on the surface.

<Embodiment> In FIG. 1, reference numeral 1 denotes an outer mold 1 for molding a large L-shaped retaining wall having a vertical frame 2 for molding a vertical portion of the retaining wall and a horizontal portion. It consists of a horizontal mold part 3 for molding,
In order to express a three-dimensional decorative pattern on the outer surface of the vertical portion of the retaining wall, the inner surface 2'of the vertical wall 2a of the vertical frame 2 has a female shape of the above-mentioned three-dimensional decorative pattern and is uneven. The upper and rear surfaces (right surface) of the vertical frame 2 of the outer mold 1 are open, and the upper surface of the horizontal frame 3 is open.

To mold the retaining wall, cement and sand are uniformly kneaded with a polymer emulsion adhesive for cement, such as epoxy emulsion adhesive, acrylic emulsion adhesive, vinyl acetate emulsion adhesive, and then water reducing agent (fluidizing agent). (Also referred to as an agent) and further kneaded, and the polymer mortar thus obtained is pumped by a pump to a gun, and compressed air supplied to the gun is applied to the entire inner surface 2'of the vertical wall of the vertical mold part. Spray and make the surface layer 4. During this spraying, the polymer mortar entrains air, but collides with the inner surface of the vertical mold part and emits air, so that no bubbles are generated at the boundary with the inner surface 2 '. Further, since a water reducing agent is mixed, it has fluidity even if the water content is small, and it is suitable for spraying, and since it does not contain excess water, no blistering occurs. still,
Prior to spraying, a mold release agent such as silicone oil is applied and placed on the inner surface 2'of the vertical wall of the vertical mold part.

The thickness of the polymer mortar sprayed once on the entire inner surface of the vertical wall of the vertical mold part is about 2 to 3 mm, and the surface layer 4 may be formed by one spray or several sprays. You can make it.

Spraying a thin layer of mortar containing ordinary cement, water, and sand in this way causes it to dry rapidly and cause a dry-out phenomenon, which prevents it from solidifying.However, when the cement is kneaded with a polymer emulsion adhesive, the inner surface of the mold becomes 2 '. In addition to the increase in the adhesive strength, the resin film is formed on the surface of the sprayed layer, and the film prevents abrupt drying, so that the dry-out phenomenon does not occur.

Next, glass fiber, carbon fiber,
A polymer mortar containing fibers mixed with metal fibers, resin fibers, aramid fibers, etc. is sprayed on the back surface of the surface layer 4 to be adhered to form the reinforcing layer 5.

To prepare this fiber-containing polymer mortar, the fibers are mixed with a polymer emulsion adhesive for cement, and the adhesive is permeated into the interstices between the fibers that make up the fiber bundle (multifilament) to bond the individual fibers. The mixture is coated with an agent to protect the fibers from the alkalinity of the cement, cement and sand are added to the mixture of the adhesive and the fibers thus obtained, and the mixture is uniformly kneaded, and then a water reducing agent is further added and kneaded.

The reinforcing layer 5 made of fiber-containing polymer mortar attached to the back of the surface layer 4 improves the mechanical properties of the surface layer 4 by the mixed fibers, for example, by moving the formwork to construct a building wall. When inserting, the surface layer 4 attached to the inner surface of the formwork is prevented from being chipped or cracked, and when the reinforcing bars are next arranged longitudinally and laterally, the reinforcing layers touch the surface layer and the surface layer is chipped, Prevents cracking. The thickness of the surface layer 4 is about 2
~ 5 mm, the thickness of the reinforcing layer 5 is about 3 ~ 10 mm, the reinforcing layer 5
Also, the spray thickness of one time is 2-3 mm, and it is made by one spray or several sprays.

The amount of the polymer emulsion adhesive for cement used with respect to cement and sand is determined based on the concentration of the resin contained in the adhesive.

For example, cement 0.6 is mixed with sand 0.6, and 100 parts by weight of the polymer emulsion adhesive has a resin concentration of 100 parts by weight.
If it is 48%, use about 20 parts by weight, and use 3% water reducing agent.
Parts by weight, 3 to 5 parts by weight of fibers are used to make the fiber-containing polymer mortar.

The reinforcing layer 5 is preferably sprayed before the surface layer 4 is solidified, but may of course be sprayed after the surface layer is solidified.

In this way, when the reinforcing layer 5 is solidified, a plastic gear-shaped or ratchet-shaped spacer 7 is fitted on the reinforcing bar 6, and the outer periphery of the spacer 7 is brought into contact with the back surface of the reinforcing layer 5 to arrange the reinforcing bar 6 vertically and horizontally. Reinforcing, joining the crossovers of the rebars by melt pressure welding, and then closing the back surface of the vertical mold part 2 on the outside 1 and the upper surface of the horizontal mold part 3 with the inner mold part 8 and opening the vertical mold part 2. The ready-mixed concrete 9 is cast from the upper surface and solidified (FIG. 2).

Vertical wall 8'of inner mold 8 with respect to vertical wall 2a of vertical mold 2
For the connection, the palletizer 10 originally attached to the vertical wall 2a by a well-known cone or the like is placed, and the shaft foot bolt 11 attached to the vertical wall 8'by a well-known rib washer, foam tie or the like via a flap material is used to joint nut 12. And so on. Further, the reinforcing bars 6 are arranged vertically and horizontally inside the horizontal form part 3 of the outer formwork 1 and the crossing parts thereof are joined together. The bottom surface of the bottom of the retaining wall block formed by the horizontal form part 3 is Since the surface does not become the surface when the block is viewed, the spacer 7 fitted to the reinforcing bar contacts the bottom surface of the horizontal form part 3 to arrange the bar.

Then, when the cast ready-mixed concrete 9 is solidified, the molds 1 and 8 are demolded, the shaft foot bolts 11 and the cones are removed, and the removed traces are filled with mortar for repair.

In order to color the surface layer 4, a pigment of a desired color is mixed with the polymer mortar, and in order to mimic natural stone such as granite, fine particles of quartz, slag, etc. are mixed with the polymer mortar.

Since the outer formwork of the above-described embodiment has the inner surface 2a forming the surface of the block on the upright vertical wall 2 ', the reinforcing layer 5 is formed by spraying, but the reinforcing layer 5 may be formed by lengthening.

The formwork 13 shown in FIG. 3 is used to form, for example, the outer surface or the inner surface of the wall of a building, and the inner surface 13 'is a female mold of a three-dimensional decorative pattern to be expressed on the wall and is uneven. .

The formwork 13 is placed horizontally on the floor as shown and the inner surface 13 'is sprayed with polymer mortar to form a surface layer 14. Then, a reinforcing layer 15 is formed on the surface layer 14 by incorporating a fiber-containing polymer mortar. Since the reinforcing layer 15 is not formed by spraying, it suffices to pour the required amount of the fiber-containing polymer mortar so that the reinforcing layer having a predetermined thickness can be obtained from the beginning.

After the reinforcement layer 15 is solidified, it is transported to the site where the building wall is to be constructed, and it is built vertically, and as described above, the spacer fitted to the reinforcing bar is abutted on the back of the reinforcing layer 15 to arrange the reinforcing bar vertically and horizontally. Then, the intersecting parts are joined, the shaft foot bolts of the pair of molds are connected by the separator 10, the joint nut 12, etc., and the ready-mixed concrete is set in the space between both molds to harden.

Since the surface layer 14 is protected by the reinforcing layer 15, it will not be chipped or cracked when the formwork 13 is transported to the site and vertically assembled.

<Effect of the Invention> According to the present invention, the surface of the concrete molded body is formed of polymer mortar, and bubbles and water avatars are not generated. And since the spacer fitted to the reinforcing bar that is buried inside the molded body does not appear on the surface of the molded body, it does not damage the appearance of the surface, and it also prevents the infiltration of moisture that corrodes the reinforcing bar or damages the molded body from the inside. Can be completely prevented.

[Brief description of drawings]

The drawings show an embodiment of the present invention. FIG. 1 is a cross-sectional view showing a state in which a surface layer and a reinforcing layer are formed on the inner surface of an L-shaped retaining wall block molding frame, and FIG. 2 is a mold of FIG. Sectional view of the ready-mixed concrete placed in the frame, Figure 3 is an enlarged sectional view taken along the line III-III in Figure 2, and Figure 4 shows the surface layer and the reinforcement layer on the inner surface of the building wall molding formwork. It is sectional drawing of the state made. In the figure, 2 and 13 are formwork, 2'and 13 'are inner surfaces thereof, 4 and 14 are surface layers, 5 and 15 are reinforcing layers, 6 is a reinforcing bar, 7 is a spacer, and 9 is a spacer.
Indicates ready-mixed concrete.

Claims (2)

[Claims] 1. A surface layer is prepared by spraying a polymer mortar kneaded with a polymer emulsion adhesive for cement and a water reducing agent onto the inner surface of a mold forming the surface of a molded body, and then fibers are mixed with the same polymer mortar. By spraying or pouring the kneaded fiber-containing polymer mortar to form a protective layer of a predetermined thickness on the back of the surface layer, after hardening the protective layer, a spacer attached to the reinforcing bar is brought into contact with the back of the protective layer. A method for producing a concrete formed body, characterized in that reinforcing bars are arranged in the vertical and horizontal directions apart from the back of a protective layer, and then fresh concrete is poured to integrate the surface layer, the protective layer and the concrete layer made of fresh concrete. 2. The method for producing a concrete molded body according to claim 1, wherein the inner surface of the mold forming the surface to be molded is a female mold having a three-dimensional decorative pattern expressed on the surface. Method for manufacturing concrete moldings.