JPH0686044B2 - Manufacturing method of exterior material pre-attached concrete products - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a concrete secondary product for construction or civil engineering, which is provided with an exterior material such as tile or stone in advance.

[0002]

2. Description of the Related Art The number of works for applying tiles or stones as a decorative exterior material on the surface of a building or for applying tiles or stones as a decorative exterior material to civil engineering concrete products such as parks and roads is increasing year by year.

Further, the number of products in which tiles, stones, etc. are driven into concrete products has been increasing year by year.

In recent years, in building construction work in the construction industry, as a building material for the exterior building as described above, a product in which an exterior material such as a tile or a stone material is preliminarily attached to a concrete PC board or a curtain wall board is produced in a factory. Fastening to steel frames is becoming common in the building industry.

[0005] In addition, in park construction, general houses, etc., construction is performed with pincoin stones, non-slip, etc. attached, with an emphasis on aesthetics.

[0006] In the civil engineering industry, concrete L-shaped retaining walls are used for earth retaining work such as residential land development and road construction. However, if the surface is concrete, there is an aesthetic problem. It is common practice to stack processed stones to make processed products and make them more luxurious.

Conventionally, as a method of driving an exterior material into these concrete products in a factory, as shown in FIGS. 8 (A) and 8 (B), the interior of the concrete product formwork 1 has an exterior material such as tiles. In order to make the joints between the materials A uniform, the exterior material A
The joint plates 2 having a thickness smaller than that of the joint plate 2 are provided in a grid pattern, and the exterior materials A are fitted and arranged in the respective frame-shaped spaces surrounded by the joint plates 2 so that the surface thereof faces downward, and then the concrete B is placed in the formwork 1.
By placing the concrete B and solidifying the concrete B to fix and integrate the exterior material A, and by removing the mold after the solidification of the concrete B, a concrete product C as shown in FIG.
Is what you get.

[0008]

By the way, in the manufacturing method as described above, the adhesion between the exterior material A and the joint board 2 is poor, a gap is generated between the exterior material A and the joint board 2, and the concrete B is cast. It is not possible to completely prevent concrete milk from entering the surface of the exterior material A when installed, and therefore, it takes a lot of work time such as washing the surface of the exterior material A with water after completion of the concrete product, There is a problem that the manufacturing process cannot be rationalized.

Further, in order to solve the above problems,
Paraffin is used instead of the conventional joint board 2, and the joint portion of the exterior material arranged in the mold is formed from a substance that changes from solid to liquid to liquid by temperature change, for example, paraffin (hereinafter referred to as paraffin). However, a method of dissolving and removing paraffin after pouring concrete has been proposed in Japanese Patent Application No. 4-207495, which is a prior application.

According to this method, the exterior material and paraffin are in close contact with each other and concrete milk can be prevented from invading the surface of the exterior material. In this case, when immersed in or in contact with paraffin, the paraffin is absorbed, and the permeated paraffin causes stains on the surface, which causes problems such as color difference after the product is finished.The absorbed paraffin reduces the adhesive strength with concrete. However, there is a risk that the exterior material will peel off. Further, if the paraffin is adhered to the back foot portion of the exterior material when the paraffin is poured, the exterior material inevitably lowers the adhesion strength and makes quality control difficult.

Therefore, in the case of an exterior material having a high water absorption property,
It is impossible to manufacture concrete products by the manufacturing method using paraffin, and it is difficult to thoroughly control quality.

Therefore, an object of the present invention is to reliably prevent concrete milk from entering the surface of the exterior material,
Work such as washing the surface of the exterior material with water is unnecessary, and even if the exterior material is a highly water-absorbing material, it can be used without any problems and a reliable adhesive force can be guaranteed. It is to provide a manufacturing method of a product.

[0013]

In order to solve the above-mentioned problems, a first invention is to provide a casing for an exterior material unit,
Water or hot water in which exterior materials such as tiles and stones are arranged in a specified position with the surface on top and the soles on the bottom, and the interior material is filled up to a predetermined height in the exterior material unit formwork. And then change from solid to liquid or from liquid to solid due to heat change, and pour the liquid material of the substance that separates from the liquid in the above mold into the mold to cool naturally or forcibly. By making the liquid material into a solid state by doing so, a method of forming an exterior material unit in which the back of the exterior material such as tiles or stones is completely exposed by integrating the solid material with the upper part of the liquid of the exterior material is integrated. It was adopted.

In a second aspect of the present invention, an exterior material such as tiles or stones is arranged in a designated frame in a frame for an exterior material unit at a designated position with the front surface facing upward and the back foot portion facing downward. The material up to a predetermined height is immersed in water or hot water poured into the exterior material unit mold, and then changes from solid to liquid or from liquid to solid due to heat change The liquid material of the substance that separates from the liquid is poured into the mold, and the liquid material is solidified by cooling naturally or by force, and the solid material is integrated with the upper part of the exterior material rather than water or hot water. Form the exterior material unit with the exposed soles completely exposed, and place the exterior material unit removed from the formwork inside the concrete product formwork with the backing portion of the exterior material facing up. Concrete is poured into the frame, solidified concrete and exterior materials With integrated, the mold or solid product by applying heat to the product is obtained by employing a method of removing dissolved in the liquid.

In the present invention, water or hot water may be preliminarily impregnated into the outer casing arranged in the outer casing unit frame.

[0016]

[Function] The exterior material is installed in the form for the exterior material unit side by side in a shape instructed according to the type of the concrete product, and the exterior is filled with water or hot water injected into the formwork in advance or after the exterior material is installed. Soak the bottom of the material.

When the exterior material has a high water absorption property, the exterior material is impregnated with water or hot water.

In this state, a liquid material such as liquid paraffin melted in the mold is poured to completely cover the upper part of the exterior material.

Since the liquid material such as paraffin is completely separated from the water or hot water poured into the mold, it does not adhere to the portion of the exterior material immersed in the liquid, and the exterior material has high water absorption. However, since the liquid has been impregnated first, no infiltration occurs inside.

Liquid substances such as paraffin will naturally solidify over time.

When solidifying in a short time, it is forcibly cooled to form an exterior material unit in which the upper portion of the exterior material and paraffin are integrated.

Next, the exterior material units removed from the mold are lined up in the concrete product mold with paraffin down, and concrete is placed thereon.

The concrete covers the back foot portion exposed on the paraffin, and does not penetrate into the paraffin-covered surface side of the exterior material.

The placed concrete waits for solidification at a temperature below the melting temperature of paraffin, and when the concrete solidifies, steam for curing is applied to the concrete. When the curing temperature exceeds the melting temperature of paraffin, the paraffin melts. Then the liquid becomes liquid and paraffin is allowed to flow out of the form by pulling out the plug of the extraction hole provided in the lower part of the form to obtain a concrete product in which the exterior material and concrete are integrated in the form. When is taken out from the mold, a concrete product with an exterior material on the surface is completed. Depending on other circumstances, the paraffin may be removed from the product by removing the product from the mold while leaving the paraffin in a solid state and then raising the temperature with steam or the like.

[0025]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of the present invention will be described below with reference to FIGS.

The drawings exemplify a method for manufacturing a concrete product using a tile a as an exterior material. As shown in FIGS. 1A and 1B, the tile unit formwork 11 includes a large number of tiles a.
Are arranged side by side in a plane, and the tile division gauge 12 is detachably accommodated therein.

The tile-splitting gauge 12 is constructed by assembling a joint plate 13 having a height of about half the thickness of the tile a in a grid pattern so that the tile a can be exactly accommodated in a frame-shaped space surrounded by the joint plate 13. Has been formed.

As shown in FIG. 1 (A), after the tile division gauges 12 are assembled in the tile unit formwork 11, the tiles a are placed in the frame-shaped spaces of the gauges 12 with the surfaces thereof facing upward. Place with the part down.

The tiles a lined up in a plane are kept in a precise joint space around them by the joint plate 13, and the upper half of the tile (a) on the front surface side is projected onto the tile division gauge 12.

Next, as shown in FIG. 2, a liquid 14 such as water or hot water is poured into the tile unit formwork 11 up to the height of the tile split gauge 12, and the lower half of the tile a is poured into the liquid 14. Immerse.

The liquid 14 may be poured into the mold 11 not only after the tile a is arranged, but also before the tile a is arranged.

As shown in FIG. 3, after the liquid 14 is injected, a mesh reinforcing bar 15 serving as a reinforcing material is set inside the tile unit formwork 11 at an appropriate upper position of the tile a.

Next, as shown in FIG.
Pour liquid paraffin 16 melted like
The upper half of the tile a is completely covered with the liquid paraffin 16.

The liquid paraffin 16 floats on the liquid 14 in a state where the liquid paraffin 16 is completely separated from the liquid 14 previously injected into the mold 11.

The liquid paraffin 16 accumulates at a position higher than the tile dividing gauge 12 and flows so as to wrap around the upper half of the front side of the tile a, and is separated from the liquid 14 under the tile dividing gauge 12 in a natural state. Alternatively, it is solidified by forced cooling.

The solidified paraffin 16 is applied to the tile a and the mesh rebar 15 by the adhesive force to the tile a.
To form a tile unit 17.

In this case, the paraffin 16 does not adhere to the lower half of the tile a immersed in the liquid 14 which is the back foot side.

The tile unit 17 formed by solidifying the paraffin 16 is removed from the tile unit mold 11 by taking out the mold, as shown in FIG.

Next, as shown in FIG. 6, a concrete product form 21 that matches the shape of the concrete product is prepared, and a large number of tile units 17 are arranged side by side in this form 21.

In this case, the tile units 17 are arranged with the paraffin 16 on the lower side and the backs of the tiles a on the upper side, and in the illustrated case, the tile units 17 are also arranged on the side surfaces of the mold 21 which is the rising portion. is doing.

Concrete 22 is poured into the form 21 in which the tile unit 17 is arranged, and the surface is finished with a trowel.

The cast concrete 22 gradually hardens, but the paste or the like of the concrete 22 does not flow out to the surface side of the tile a completely sealed by the paraffin 16 and does not stain the surface of the tile a. .

Wait for the concrete 22 to solidify at a temperature below the melting temperature of the paraffin 16, and after the solidification, the concrete 22 is cured with steam or the like.
Above the melting temperature of, paraffin 16 begins to melt and liquefy.

After that, by opening and removing a plug of a hole (not shown) provided on the lower surface of the mold 21, the paraffin 16 flows out of the mold 21, and the tile a and the concrete 22 are integrated in the mold 21. Only the concrete products that have been made remain.

The concrete 22 is joined to the tile a with the foot portion where the paraffin 16 is not attached at all, and fills the joint between the tiles a.
Will be tightly integrated.

After the concrete 22 is cured at a predetermined temperature and for a certain period of time to increase the strength of the concrete 22, the mold is removed to obtain a finished concrete product 23 having the tile a in advance, as shown in FIG.

In the above, in removing the paraffin 16 by melting, the concrete 22 is left to solidify and then the form 21
Alternatively, the concrete product 23 may be demolded, and after the demolding, the paraffin 16 may be melted by heating and recovered.

Although the tile a is exemplified as the exterior material, a stone material may be used, and the concrete product 23 to be formed is a concrete PC plate, a curtain wall, a concrete L-shaped retaining wall, a sidewalk concrete block, concrete in addition to the concrete flat plate as shown. The walls can be raised, and in order to manufacture these, it is sufficient to prepare a concrete product formwork corresponding to each shape and size.

Further, in the above manufacturing method, when a tile or stone having high water absorption is used as the exterior material, the lower half of the exterior material is added to the liquid 14 injected into the mold 11 in the step of forming the tile unit 17. When the paraffin 16 is immersed in the liquid, it is possible to prevent the paraffin 16 from penetrating into the exterior material when the paraffin 16 is poured.
It is possible to prevent the problem that the paraffin 16 peels off the adhesive surface between the outer packaging material 2 and the exterior material, and to prevent the surface of the exterior material from being discolored after the completion of the product due to the permeation of the paraffin.

Further, in the step of forming the tile unit 17, in order to more completely prevent paraffin from being absorbed by the exterior material, the exterior material is immersed in the liquid in advance before being placed in the mold 11 to remove the liquid. You may make it absorb.

[0051]

As described above, according to the present invention, a liquid material such as paraffin is poured into a mold while being immersed in a liquid up to a predetermined height position of the exterior material arranged in the mold for the exterior material unit. Then, the exterior material unit and the solid material are joined together to form an exterior material unit, and this exterior material unit is incorporated into a concrete product formwork, and concrete is placed and solidified in this formwork. After that, since the solid matter is removed by melting it in a liquid state, when molding the exterior material pre-attached concrete product, the surface side of the exterior material is covered with a solid matter such as paraffin, and concrete milk is poured when pouring concrete. It can be surely prevented from penetrating to the surface side of the exterior material, eliminating the need for washing work after the product is completed, cost can be reduced by labor saving and rationalization, and products with a beautiful surface can be manufactured at low cost. Kill.

Further, since the paraffin or the like is injected while the exterior material is immersed in the liquid, the liquid and the paraffin or the like are completely separated, and the paraffin or the like does not penetrate into the surface side of the exterior material to be contaminated. Elimination work is unnecessary.

Furthermore, since the exterior material is immersed in the liquid, even if the exterior material is a highly water-absorbing material, the liquid is absorbed first, so that the paraffin or the like penetrates into the exterior material when the paraffin or the like is poured. It is possible to provide a high-quality product that does not reduce the joint strength between the exterior material and the concrete, can prevent paraffin and the like from seeping out onto the surface of the exterior material, and is free from peeling accidents.

Since the paraffin can be easily molded, no labor is required, and the recovered paraffin can be recovered separately from the water due to the difference in specific gravity from the water. The work of is unnecessary and can be used repeatedly, leading to cost reduction.

[Brief description of drawings]

FIG. 1A is a vertical cross-sectional view in which tiles are set in a frame for an exterior material unit, and FIG. 1B is a plan view of the same.

FIG. 2 is a vertical cross-sectional view in which a liquid is injected into a casing for an exterior material unit.

FIG. 3 is a vertical cross-sectional view in which a mesh rebar is set in a frame for an exterior material unit.

FIG. 4 is a vertical sectional view in which paraffin is filled therein.

FIG. 5 is a vertical cross-sectional view showing demolding of the exterior material unit.

FIG. 6 is a vertical sectional view at the time of molding a concrete product.

FIG. 7 is a vertical cross-sectional view of the completed concrete product.

FIG. 8 (A) is a vertical cross-sectional view showing the production of a conventional concrete product, and FIG. 8 (B) is a plan view of the mold in the same.

FIG. 9 is a vertical sectional view of a conventional concrete product.

[Explanation of symbols] 11 Tile unit formwork 12 Tile split gauge 13 Joint plate 14 Liquid 15 Mesh rebar 16 Paraffin 17 Tile unit 21 Concrete product formwork 22 Concrete 23 Concrete product a Tile

Claims (7)

[Claims] 1. An exterior material such as tiles or stones is arranged in a specified position in the exterior material unit frame with the surface on top and the back foot portion down to a predetermined height position of the exterior material. Is immersed in water or warm water poured into the mold for the exterior material unit, and then changes from solid to liquid or from liquid to solid due to heat change, and of a substance that separates from the liquid in the mold It is possible to form an exterior material unit by pouring the liquid material into the mold and solidifying the liquid material naturally or by forced cooling to integrate the solid material above the liquid of the exterior material and the solid material. A method for manufacturing an exterior material unit for a prefabricated concrete product. 2. An exterior material such as a tile or a stone is arranged in a specified position in the exterior material unit frame with a surface on top and a foot on the bottom, and the exterior material reaches a predetermined height position. Is immersed in water or warm water poured into the mold for the exterior material unit, and then changes from solid to liquid or from liquid to solid due to heat change, and of a substance that separates from the liquid in the mold The liquid material is poured into the mold, and the liquid material is solidified by cooling naturally or by force, and the exterior material unit is formed by integrating the solid material above the liquid of the exterior material and the mold. The exterior material unit removed from the frame is placed in the concrete product formwork with the foot of the exterior material facing up, and the concrete is placed in the concrete product formwork to separate the solidified concrete and the exterior material. Integral and solid by applying heat to the form or product A method for producing a concrete product with an exterior material pre-applied, characterized in that the material is melted and removed. 3. The exterior material arranged in the exterior material unit frame is preliminarily impregnated with water to prevent a substance that changes from a solid state to a liquid state or from a liquid state to a solid state due to a thermal change from entering the exterior material. The method for producing a concrete product with an exterior material pre-attached according to claim 2, which is characterized in that 4. A concrete PC plate manufactured by the manufacturing method according to claim 2. 5. A concrete curtain wall produced by the production method according to claim 2 or 3. 6. A concrete L-shaped retaining wall manufactured by the manufacturing method according to claim 2 or 3. 7. A concrete flat plate or a concrete block for sidewalks and a concrete fence manufactured by the manufacturing method according to claim 2 or 3.