JPH0220403B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is capable of forming a concrete product of any three-dimensional shape into a smooth vertical surface and top surface, including the bottom surface, rising and sloped surfaces, without the presence of a mortar layer on the surface, and which is dense and strong. This invention relates to a method for forming concrete products that is excellent in terms of performance and is formed using an immediate demolding method.

Conventionally, when forming secondary concrete products using the instant demolding method, a pallet with mortar spread to an uneven thickness was laid on only the bottom surface, and hard mixed concrete was poured into the formwork. For this reason, only the bottom surface is formed into a smooth surface by the mortar layer, but the top and vertical surfaces have a rough surface with the hard-mixed concrete forming surface exposed. This rough surface has good water absorbency and is inferior in design, and especially when construction is carried out in cold regions, water penetrating the rough surface freezes and causes cracks and damage. Therefore, in the case of building blocks for retaining walls that are generally pyramid-shaped and are commonly used, only the surface that appears on the surface is smooth, and the retaining part that is buried underground is rough. It has a rough surface, and when it is constructed as a retaining wall for a road in a cold region, the water absorbed by the retaining part freezes and expands, causing cracks and damage, weakening the supporting stress, and even with the vibration of a car or a slight earthquake. The phenomenon of collapse often occurred.

In addition, in order to form smooth surfaces including the bottom, rising surfaces, slopes, top surfaces, etc., soft concrete is used, and it is possible to pour this into a formwork and remove it after curing to obtain a product. Since mixed concrete is used, it does not have sufficient strength, and it also requires time because it cannot be demolded immediately.

The present invention was developed in order to solve the drawbacks of the conventional forming method, and it aims to finish any surface of a concrete product into a smooth surface by an instant demolding method, regardless of the shape, and further improves this smooth surface. To provide a method for forming a concrete product that has an extremely fine surface density and excellent strength, and is aesthetically pleasing in terms of design.

In carrying out the method of this invention, as a primary treatment, a surface of a concrete product having an arbitrary shape to expose a smooth surface;
For example, a surface pallet is applied to the bottom, vertical surface, top surface, etc., a mortar layer of average thickness is provided on this surface pallet and compacted, and as a secondary treatment, the surface pallet with this compacted mortar layer formed is immediately demolded. Hard-mixed concrete is placed inside the formwork of a molding machine, and is then vibrated, compressed, and rubbed to infiltrate and mix the moisture-rich mortar layer into the hard-mixed concrete material, compacting it and forming the concrete. To obtain a concrete product that has no mortar layer on the smooth surface of the product and has a smooth surface with fine density and strength, the conventional split molding machine is used as an instant demolding machine used as a secondary treatment. A variety of formwork types, integral formwork types, and inverted formwork types can be used.

The method of the present invention will be explained with reference to the accompanying drawings.
2 and 3 are examples showing a method of compacting and forming a mortar layer on a surface pallet as a primary treatment, and the shape of the surface pallet is not limited to this. Fig. 1 shows a surface pallet formed in an L shape, Fig. 2 a surface pallet formed in a U shape, and Fig. 3 a surface pallet with an opening in a U shape. , FIG. 2, and FIG. 3 have the same system as that in FIG. 1, so they are shown in schematic diagrams.

In Fig. 1, 1 is an L-shaped surface pallet, and 2 is mortar M on this surface pallet 1.
It is a core type that polymerizes while leaving a thickness interval of . 3 is a mortar leak prevention plate attached to the side end of the core mold 2, and 4 is a drainage hole. Reference numeral 5 denotes a surface pallet mounting table and a vibration table, and the surface pallets 1 are coated with a mold release agent from the stacking area and placed on the vibration table 5. 10 is a vibrator provided on the lower surface of the vibrating table 5, and 14 is a vibration-proof rubber which prevents the vibration of the vibrator 10 from being transmitted to the receiving frame 7 within the machine frame. 8 is a lifting cylinder. Reference numeral 11 denotes a cylinder that presses the core mold 2 and moves up and down as shown by the arrow, and a magnet is attached to the tip of the rod to prevent the core mold from shifting due to vibration. Reference numeral 15 denotes a mortar hopper in which mortar M to be adhered and molded onto the surface pallet 1 is stored. 16 is a mortar supply cylinder, 17
18 is a piston plate, 18 is an operating cylinder, and 19 is a closing plate provided at the mortar supply port of the hopper. The closing plate 19 opens and closes as the cylinder 18 operates as shown by the arrows. Reference numeral 13 indicates a chute for pouring mortar M into the space between the face pallet 1 and the core mold 2. Reference numeral 6 in the figure is a conveyor which conveys the surface pallet 1 to which the mortar M has been adhered and molded, as shown by the arrow, to an instant demolding machine.

The mortar layer forming machine for the primary treatment in the present invention has the configuration as shown in the figure, and since the L-shaped surface pallet 1 has an L-shaped cross section as described above, its operation is such that the surface pallet 1 is placed on the mounting table and vibration table 5. The core mold 2 placed on top is fed in from the opposite side by the horizontal cylinder 12, and the surface pallet 1 and the core mold 2 are superimposed as shown by dotted lines in the figure. When the polymerization of the surface pallet 1 and the core mold 2 is completed, the closing plate 19 of the hopper 15 is opened via the supply cylinder 16 by the action of the cylinder 18, and the mortar is poured into the surface pallet 1 and the polymerized surface pallet 1 from above the chute 13. The space between the core molds 2 is filled, and the vibrator 10 is activated at the same time as this filling, and the mortar is compacted with the pressure of the cylinder 11, and the excess water that has floated in the mortar is drained from the drainage hole 4 at the top of the core mold. It is discharged.

In the present invention, a core mold 2 is used for the surface pallet 1 having a vertical surface in the primary treatment, and the mortar is compacted by pressing and vibration. It can be installed in the formwork of an immediate demolding molding machine for secondary processing while remaining adhered to a constant thickness even on vertical surfaces.

Although not shown in FIG. 1, when supplying the surface pallets 1, the supply from the surface pallet stacking place to the surface pallet mounting table 5 is controlled at a constant rate according to the molding capacity of the secondary processing molding machine. Can be supplied automatically in cycles.

Although FIG. 1 particularly shows the molding process for the L-shaped surface pallet 1, the same structure can be used for the U-shaped and open U-shaped surface pallets 1, 1 as shown in FIGS. 2 and 3. Can be processed. That is, in the case of the U-shaped surface pallet 1 shown in FIG. When mortar is supplied from the left and right hoppers 15, 15 and compacted, excess moisture in the mortar overflows from the drain holes 4, 4 on the other side. Also, a mortar layer can be formed on the surface pallet 1 having a U-shaped opening shown in FIG. 3 in the same manner as shown in FIG. The reference numeral 13 in the figure is a chute as in FIG. 1, and the reference numeral 16 is a cylinder for supplying mortar.

The mortar adhesion layer formed on the surface pallet 1 in this way is formed with a constant thickness on the vertical surface, inclined surface, and bottom surface of the surface pallet 1 as shown in FIG. The surface pallet having the adhesive layer is placed in the formwork of an instant demolding machine for secondary treatment, which will be described later, and hard mixed concrete is supplied to it. For this primary treatment, mortar is supplied by pouring as an example, but molding by spraying with a mortar gun is also possible. Mortar is sprayed to the thickness, or water is sprayed and cement powder is sprinkled or sprayed on top of the mortar to absorb excess water content in the mortar and fix the mortar. Also, although not shown, an appropriate amount of water W' is sprayed on the inner surface of the surface pallet 1 without using mortar, and hard mixed concrete with zero slump is poured into this, and the contact between the pallet and the concrete is created by vibration and compression during compaction. While softening the surface to increase fluidity and forming a dense surface, it is formed by directly spraying an appropriate amount of water onto hard mixed concrete with zero slump. For example, by forming an inverted formwork as shown in Figure 7, an appropriate amount of water can be sprayed through the gap that was temporarily compacted during the primary forming process in which the surface pallet is inserted, and a surface pallet without mortar can be inserted from above and overturned, thereby reducing vibration. Compact and form by compression. During this forming process, the slump of the joint surface between the surface pallet and the concrete is altered to increase fluidity, thereby forming the contact surface with the pallet into a dense and water-impermeable surface. When this method is used, no mortar is used at all, no complicated equipment is required, and the product cost is not only low, but also the surface is finished finely and beautifully.

Next, we will discuss the forming of secondary treated concrete products.

The instant demolding type molding machine can be of a split formwork type, an integrated formwork type, or an inverted formwork type, and each type will be explained below.

FIG. 5 shows a split formwork type molding machine. This split formwork type molding machine has a split formwork 20 that is fixed to rods 21 and 21' of cylinders arranged on the left and right and that can be moved on rails 24 and 24'.
20' is provided. The upper surfaces of the formworks 20, 20' are formed so that the opposing two sides are lower 22 by the amount of concrete compaction, and constitute a formwork body as an interval for vibration-sliding compaction, which will be described later. A surface pallet 1 on which mortar M is adhered to a uniform thickness is formed on this form body.
is placed on the vibration mounting table 23. This vibration mounting table 23 is supported by a vibration support table 26, and a vibrator 25 is provided on the vibration support table 26. In this central space, there is a cylinder 30 for lifting up the product, a taper lifting body 32, and a taper It reaches the bottom surface of the surface pallet 1 via the push-up body support 31. In the figure, 29 is a magnet for preventing the surface pallet from moving, and 27 is a vibration-proof rubber.

35 is a hopper in which hard mixed concrete material is stored, 36 is a material supply box for supplying a specified amount of concrete material into the formwork, and 37 is a cylinder for operating the material supply box 36. Also 38 is Hopper 3
It is a closing plate that closes the bottom opening of material supply box 3.
6. Close the bottom of the hopper during movement toward the formwork. 42 is a vibrating sliding plate, and the left and right formworks 20,
20' have a width that corresponds to the width of the stepped portion 22 in two directions at the top of the formwork when the formwork is formed by combining them,
A vibrator 41 is provided on the top surface and is fixed to a sliding plate 45 via a vibration isolating rubber 43. 44 indicates a cylinder that slides on the sliding plate 45; in the illustration, the sliding plate 45
slides in the front-rear direction by the operation of the sliding cylinder 44. 40 indicates a cylinder that moves up and down the vibrating slide device.

The secondary processing, immediate demolding type molding machine of the split formwork type shown in FIG. is moved to form a formwork, and the surface pallet 1 to which the mortar layer M is attached is placed on the vibrating table 23 within the formwork, and in this state, the supply cylinder 37 is operated to open the upper opening of the formwork. Fill the formwork with harder mixed concrete. At this time, the amount of hard mixed concrete supplied is to be supplied up to the upper surface of the step part 22 at the top of the formwork, and at the same time, the lower vibrator 25 and the upper vibrator 41
The diaphragm 42 is lowered by the cylinder 40 while vibrating the upper sliding cylinder 44.
is moved back and forth to press the step part 22 to the lower end. As a result, the sliding plate 42 compacts the upper surface of the concrete by using a combination of vibration, press, and trowel action of back and forth sliding, and the diaphragm 42 is compacted by a synergistic effect with the action of the lower vibrator 25. Step part 2 at the top of the formwork
It descends to the bottom of 2 and compaction is completed. It is important to note here that the vibrator should be started after concrete is filled, to prevent the mortar from falling on the rising surface of the pallet.

When using this compaction method, the mortar material in the mortar layer M of the face pallet 1 permeates and moves into the hard mixed concrete in the formwork together with the moisture content due to the upward and downward vibrations and compaction by pressing. On the inside of the surface pallet 1, the obvious existence of the mortar layer M disappears, and a mixture of hard mixed concrete is exposed. In this demolding, the formwork 20,
20' is opened and a tapered push-up body 32 is raised by a push-up cylinder 30 to fit into a receiving mold 31, and the surface pallet mounting table 23 is raised to take out the product.

In the product from which the curing surface pallet has been removed, the surface of the concrete in contact with the L-shaped surface pallet 1 has a smooth surface due to the presence of a mixture of mortar and concrete material, and the top surface is smooth due to the presence of a mixture of mortar and concrete material. It has a smooth surface for operation. However, although the pallet contact surface is a mortar skin, it is densely formed by mixing concrete and is extremely strong, and unlike conventional mortar surfaces, it does not become brittle and chip or the mortar layer peels off. It is beautiful and water-impermeable.

Next, we will discuss an instant demolding molding machine with an integrated frame for secondary processing. Figure 6 shows a molding machine using the same L-shaped surface pallet 1 as in Figure 5, and the lower vibrator and upper vibrating sliding mechanism are almost the same, so they are denoted by the same reference numerals. .

Reference numeral 20 denotes an integrated formwork, and inside this formwork 20 is formed an L-shaped surface pallet 1 with a mortar layer M adhered thereto.
Load. Steps 22 are provided on two opposing sides of the upper part of the formwork 20, and an upper diaphragm 42 is lowered by the action of the cylinder 40 after the hard mixed concrete material is supplied. 41 is a vibrator, 45 is a sliding plate, and 44 is a cylinder for causing the sliding plate to reciprocate. 36 is a supply box, and 35 is a concrete hopper. Further, the surface pallet 1 is placed on a vibrating table 23 within the formwork 20. 25 is a vibrator, 3
0 is a push-up cylinder that pushes up the molded product and takes it out. 32 is a tapered raised body;
31 indicates a push-up body support. 26 is a support base, and 27 is a vibration-proof rubber.

Even when molding is performed using the integral mold frame type molding machine shown in FIG.
After loading the hard concrete material into the container, the lower vibrator 25 and the upper vibrator 41 are activated to press down the cylinder 40, and the sliding cylinder 44 is activated to move the sliding plate 44 back and forth. When the diaphragm 42 is slid, the upper surface of the concrete in the formwork is compacted by the synergistic action of the vibration, pressing, and sliding troweling actions and the lower vibrator 25, and the diaphragm 42
reaches the lower end of the stepped portion 22 at the top of the formwork, and compaction is completed. Therefore, in the product, the contact surface of the surface pallet is smooth and beautiful, and the upper surface is also formed into a smooth surface by sliding.

FIG. 7 shows an embodiment of an inverted mold type molding machine.

In the figure, reference numeral 20 denotes a mold to which a mortar layer M is attached, and a mold rotating shaft 28 is provided at the center of the side surface, and the mold is removed by rotating as shown by the arrow. (The illustration shows the correct position during molding.) 50 is a demolding plate, which is used as the bottom plate of the formwork when feeding concrete and during molding. A demolding arm plate 51 is fixed to this demolding plate 50 and performs a demolding operation to be described later. 52 is an adsorption magnet provided on the base 60, and when the mold is reversed and demolded, the demolding plate 50
A demolding operation is performed by pressing down the demolding plate 50 which is adsorbed and connected to the demolding arm plate 51 which is fixed to the demolding arm plate 51 . 53
is a surface pallet holding claw that can freely move in and out of the formwork, and is used to stabilize the surface pallet 1 when the formwork is reversed. 54 is hard mixed concrete material C in the formwork 20
The material is supplied and temporarily compacted using a vibrator, and then a U-shaped surface pallet 1 with a mortar layer M attached is formed.
It is a downward U-shaped press-fitting mold for forming a gap into which the concrete C is inserted from above, and is lowered by a cylinder 55 and press-fitted into the concrete C along the inner wall of the formwork 20. Reference numeral 56 denotes a product holder, and when the formwork 20 is reversed and demolded by the demolding arm plate 51, the surface pallet 1 is lifted by the lower cylinder 57.
It is placed on the top surface of the base, and an adsorption magnet 52 is arranged on the side. Reference numeral 58 denotes a conveyor for carrying out the product, and the product, which has been inverted and demolded, is sent to the curing room with the surface pallet still attached.

In an inverted molding machine for secondary processing, concrete is supplied into the formwork 20 and temporarily compacted, and then a downward U-shaped press-fitting die is press-fitted along the inner wall of the formwork to form the mold. A gap is provided between the frame and the concrete material for inserting the surface pallet 1 with mortar, the surface pallet is inserted, and a vibrator (not shown) is operated to perform main compaction.

By forming the product in this way, the contact surface of the surface pallet is similar to the split formwork type and integrated formwork type described above, in which the mortar layer of the surface pallet penetrates into the hard mixed concrete. When the surface pallet was removed, the obvious mortar layer on this surface disappeared and concrete was mixed in, creating a dense, smooth, strong, water-impermeable, and beautiful molded surface. ing.

In the present invention, as mentioned above, the surface pallet used for the primary treatment is formed not only on the bottom surface but also on the rising slopes and vertical surfaces of the side surfaces, and core molds of the same type are placed on this pallet at intervals and polymerized. By filling this gap with mortar and applying compression and vibration to the core mold, a mortar layer with a uniform thickness from which excess moisture has been removed is compacted and adhered to the surface pallet, or a mortar gun is used to After spraying or spraying with water, cement powder can be sprinkled to absorb the water contained in the mortar or the moisture on the wet pallet surface to stabilize the adhesion of the mortar layer. Even if the mortar does not sag, an immediate demolding method using hard mixed concrete is used for the secondary treatment, and the primary treated surface pallets are charged into the formwork of this molding machine. This is then filled with hardened concrete and compacted by vibration and compression.The upper opening surface of the formwork is compacted by pressing and sliding, so the molded product is made of mortar on the contact surface with the surface pallet. The layer moves into the concrete by the action of vibration compaction and mixes with the hardened concrete, and there is no pure mortar layer on the surface, and when the surface pallet is removed after curing, this surface of the molded product becomes dense. Appears as a smooth surface. In addition, the surface of the formwork opening has a dense and smooth surface due to the troweling effect caused by the sliding of the diaphragm, so the product has a smooth surface that is beautiful and has an excellent design.
It is water-impermeable and has excellent strength, and is suitable for products made by laying a surface pallet only on one side of the conventional bottom surface and applying mortar to an uneven thickness, such as a pyramid-shaped retaining wall block. The mortar layer on the surface (bottom surface during molding) was weak and chipped, or the bond between the mortar layer and the concrete layer was poor and often peeled off. In addition, cracks and damage sometimes occurred due to freezing of the retaining portion, but such defects do not occur in the case of the present invention.

The forming machine for secondary processing can be applied to all types of formwork, including split formwork, integrated formwork, and inverted formwork, and is suitable for producing concrete products that are both beautiful and strong. It has a revolutionary effect on molding.

[Brief explanation of drawings]

FIG. 1 is a diagram showing one embodiment of a method for forming a mortar layer in the primary treatment, and FIGS. 2 and 3 show diagrams of another embodiment. Figures 4A, 4B and 4C show perspective views of surface pallets of various shapes to which mortar layers have been adhered. FIG. 5 is a side view of a molding device using split molds for secondary processing, FIG. 6 is a side view of a single frame molding device, and FIG. 7 is a side view of an inverted mold molding device. 1... Surface pallet, 2... Core mold, 4... Drain hole, 5
...Vibration mounting table, 15...Mortar hopper, 20...
Formwork, 23...Formwork vibration mounting table, 25...Lower vibrator, 30...Product thrust cylinder, 35...Concrete hopper, 41...Upper vibrator, 42...Vibration plate, 45...Sliding plate, 50...Removal Template plate, 51... Arm plate for demolding, 52... Magnet for demolding, 54... Press-fit mold for space forming.

Claims (1)

[Scope of Claims] 1. Core molds having the same shape and having drainage holes at the top are placed on the inner surface of a surface pallet having a rising surface including a bottom surface and a vertical surface, and are polymerized at intervals. A primary treatment is performed in which mortar is filled in the spaces between the pallets and the mortar layer is compacted by vibration pressing to adhere to the inner surface of the pallet having rising surfaces including the bottom and vertical surfaces, and the pallet with the mortar layer attached is molded. The mortar layer is placed inside the frame, and hard mixed concrete is supplied and filled into the form, and the mortar layer penetrates into the hard mixed concrete material through vibration pressure and immediate demolding secondary treatment by rubbing the upper formwork opening surface. A method for forming concrete products that eliminates the presence of a mortar layer on the peripheral surface and forms a dense smooth surface. 2. When forming a mortar layer on the bottom, rising surface, or vertical surface of the inner surface of a pallet, stabilize the mortar layer by spraying mortar with a mortar gun or by spraying water and scattering cement powder on top of the mortar. A concrete product forming method according to claim 1, characterized by: 3. A method for forming a concrete product according to claim 1, characterized in that a proper amount of water is sprayed on the three-sided pallet and the hard mixed concrete to form a dense surface. 4. The concrete product forming method according to claim 1, which uses a split formwork type immediate demolding machine as the secondary treatment. 5. The method for forming a concrete product according to claim 1, which uses an instant demolding molding machine with an integrated formwork method as the secondary treatment. 6 As a secondary treatment, an instant demolding machine with an inverted formwork system was used, and a demolding plate was placed on the bottom of the formwork, and hard mixed concrete was poured in. After that, mortar was attached to the inner circumferential surface of the formwork. A press-fitting mold is inserted to form the space for inserting the surface pallet and for spraying an appropriate amount of water to form a space, and the surface pallet is placed over the space. After compaction by vibration pressing, the formwork is reversed and magnetized. The concrete product forming method according to claim 1, wherein the demolding operation is performed by the adsorption action of.