JPH0686045B2 - 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 is suitable for the production of concrete secondary products for construction and civil engineering in which exterior materials such as tiles and stones are attached in advance, and in particular, concrete secondary products having rising and bending portions. It relates to a manufacturing method.

[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. 9 (A) and 9 (B), the exterior of tiles or the like is provided inside the concrete product formwork 1. 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.
Is cast, and the concrete B is solidified to be fixedly integrated with the exterior material A, and the concrete B is solidified and then released from the mold to obtain a concrete product C as shown in FIG.

[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. When installed, it is not possible to completely prevent concrete milk from entering the surface of the exterior material A. 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. However, 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. However, the exterior material is made of a material having a high water absorption property such as porcelain tile or granite. 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 was impossible to manufacture concrete products by the manufacturing method using paraffin.

Further, in the conventional manufacturing method, since it is necessary to arrange the exterior materials in a plane and pour concrete, it is impossible to manufacture a concrete product having a rounded rising portion and a bent portion. It is also difficult to thoroughly implement quality control.

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 can be eliminated, and even if the exterior material is a highly water-absorbing material, it can be used without any problems, and it is possible to use the rounded rising parts and bent parts. An object of the present invention is to provide a method for manufacturing a concrete product with an exterior material pre-attached, which can be integrally molded and can ensure a reliable adhesive force.

[0014]

In order to solve the above-mentioned problems, a first invention is to provide a casing for an exterior material unit,
Water or warm 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 exterior material up to a predetermined height is poured into the exterior material unit formwork. And then change from solid to liquid or from liquid to solid by heat change, and pour a liquid material with physical properties that separates from the liquid in the mold into the mold, and the surface of this liquid A flexible sheet with a magnet embedded in it is stacked, and the liquid is solidified by cooling naturally or by force, and the tile above the liquid of the exterior material is integrated with the solid and the flexible sheet. This is a method of forming an exterior material unit in which the back foot of the exterior material such as stone or stone is completely exposed.

According to a second aspect of the present invention, an exterior material such as tiles or stones is arranged in a designated position in a form for an exterior material unit at a designated position with the front side facing up and the foot portion down. The height position is immersed in water or warm water injected into the casing for the exterior material unit, and then changed from solid to liquid or from liquid to solid due to heat change, and with the liquid in the form A liquid material of a substance to be separated is poured into a mold, and a flexible sheet having a magnet embedded is placed on the surface of the liquid material, and the liquid material is solidified by natural or forced cooling. The exterior material unit is formed by integrating the solid material and the flexible sheet above the above liquid, and the exterior material unit removed from the formwork is attracted to the concrete product formwork by the magnet of the flexible sheet. Fixedly placed by the A method of placing a cleat and integrating the solidified concrete with the exterior material, applying heat to the mold or product to dissolve the solid matter into a liquid state, and separating and removing the flexible sheet was adopted. It is a thing.

In the present invention, water or warm water may be previously impregnated into the exterior material arranged in the exterior material unit frame.

[0017]

[Function] The exterior materials are arranged in the form for the exterior material unit in the shape instructed according to the type of concrete product,
The lower part of the exterior material is immersed in water or hot water that has been poured into the mold in advance or after the exterior material is installed.

When the exterior material has a high water absorbing property, the exterior material is impregnated with water or warm water. In this state, a melted liquid material such as paraffin is poured into the mold to completely cover the upper part of the exterior material, and a flexible sheet in which a magnet is embedded is placed on the liquid material.

Since the liquid substance such as paraffin is completely separated from the liquid injected into the mold, it does not adhere to the portion of the exterior material immersed in the liquid, and even the exterior material having high water absorption property is first formed. Since it is impregnated with liquid, 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 the paraffin and the flexible sheet are integrated.

Next, the exterior material units removed from the formwork are arranged in the formwork for concrete products with the flexible sheet facing down, and fixed to the formwork with a magnet embedded in the flexible sheet, and then placed on top. Pour concrete into the.

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 mold by pulling out the stopper of the extraction hole provided at the bottom of the mold, the exterior material and concrete are integrated in the mold and separated from the flexible sheet. The obtained concrete product is obtained, and if this is taken out from the mold, the concrete product with the exterior material preliminarily attached to 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.

During the production of the concrete product,
Since the flexible sheet is overlapped with the paraffin, the exterior unit can bend the exterior unit in an arc shape without causing breakage or breakage in the paraffin, and thus has a rising or bending portion having a radius. It can be attached along the inner surface of the formwork, which makes it possible to produce a concrete product having raised and curved portions having a radius.

[0026]

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 the 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 form 11, the tiles a are placed in the respective frame-shaped spaces of the gauges 12 with their surfaces facing up. Place with the part down.

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

Next, as shown in FIG. 2, a liquid 14 having a specific gravity larger than that of paraffin and separated from paraffin is poured into the tile unit frame 11 to the height position of the tile split gauge 12 by using water or hot water, and the tile is separated. The lower half of a is immersed in the liquid 14.

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 of being completely separated from the liquid 14 previously injected into the mold 11.

After the paraffin 16 is poured, a flexible sheet 18 in which a magnet 17 is embedded is laid on the paraffin 16.

The flexible sheet 18 is made of a rubber plate or a material having the same effect and is formed in such a size as to cover the entire surface of the paraffin 16, and the magnets 17 are embedded in an appropriate arrangement.

The liquid paraffin 16 accumulates at a position higher than the tile-division 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-division gauge 12 in a natural state. Alternatively, it is solidified by forced cooling.

The solidified paraffin 16 is integrated with the tile a, the mesh reinforcing bar 15 and the flexible sheet 18 by the adhesive force to the tile a to form a tile unit 19.

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

The tile unit 19 formed by solidifying the paraffin 16 is removed from the tile unit frame 11 as shown in FIG.

Next, as shown in FIGS. 6 and 7, a concrete product form 21 suitable for the shape of the concrete product is prepared, and a large number of tile units 19 are arranged side by side in the form 21.

In this case, the tile unit 19 is arranged such that the flexible sheet 18 is on the bottom and the backs of the tiles are on the top.
The magnet 17 embedded in the flexible sheet 18 attracts it to fix it to the form 21.

In the illustrated case, the formwork 21 is provided with a rising portion 22 having a radius, and the tile unit 19 is attached by bending it in an arc shape along the inner surface of the rising portion 22.

Since the tile unit 19 has a structure in which the flexible sheet 18 is laminated on the paraffin 16, the flexible sheet 18 prevents the paraffin 16 from being cracked or broken at the time of bending, and the rising portion 22. Bending along the rounded shape can be done without any problems.

Concrete 23 is poured into the form 21 in which the tile unit 19 is arranged, and the surface is finished with a trowel.

The cast concrete 23 gradually hardens, but the paste or the like of the concrete 23 does not flow out to the surface side of the tile a completely sealed with the paraffin 16 and does not stain the surface of the tile a. .

Waiting for the concrete 23 to solidify at a temperature not higher than the melting temperature of the paraffin 16, and after solidifying the concrete 23 with steam or the like, the curing temperature is paraffin 16
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 23 are integrated in the mold 21. The concrete product and the flexible sheet 18 separated from the concrete product remain.

The concrete 23 is bonded 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 23 is cured at a predetermined temperature and for a certain period of time to increase the strength of the concrete 23, if the mold is removed, as shown in FIG. 24 finished products are obtained.

In the above, in removing the paraffin 16 by melting, the concrete 23 is left to solidify and then the form 21
Alternatively, the concrete product 24 may be demolded, and the paraffin 16 may be heated and melted after the demolding to be recovered.

Further, although the tile a is exemplified as the exterior material, a stone material may be used, and the concrete product 24 to be formed is not only the concrete flat plate as shown but also a concrete PC plate, a curtain wall, a concrete L-shaped retaining wall, a sidewalk concrete block, concrete. 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, in the step of forming the tile unit 19, the liquid 14 injected into the mold 11 is filled with the lower half part of the exterior material. 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 3 and the exterior material, and to prevent the appearance of different color on the surface of the exterior material after the product is completed due to the permeation of the paraffin.

Further, in the step of forming the tile unit 19, in order to more completely prevent paraffin from being absorbed by the exterior material, the exterior material is dipped in the liquid in advance before being placed in the mold 11. You may make it absorb.

[0056]

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, a flexible sheet with a magnet embedded on its surface is stacked, paraffin is solidified, and the exterior material and the solid material and the flexible sheet are combined to form an exterior material unit. Since it was incorporated into the product form and fixed with a magnet, concrete was poured into this form to solidify it, and then the solid matter was removed by melting it in liquid form. When molding the product, the surface side of the exterior material is covered with a solid material such as paraffin, and concrete milk can be reliably prevented from permeating into the surface side of the exterior material during concrete pouring, thus eliminating the need for washing work after product completion. , It can reduce the cost by labor saving and rationalization of work, a beautiful product of the surface can be manufactured at low cost.

Further, since the paraffin or the like is injected in a state where 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 and the paraffin or the like is prevented. Elimination work is unnecessary.

Further, since the exterior material is immersed in the liquid, even if the exterior material has a high water absorption property, 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.

Furthermore, since the exterior material unit is provided with a flexible sheet in which a magnet is embedded on the surface of paraffin, it can be fixed by the magnet when it is placed in the concrete product form, and a stable placement state can be obtained. At the same time, the flexible sheet can prevent cracks and breaks when paraffin is bent, which allows the exterior material unit to bend freely, making it possible to manufacture concrete products that have rounded rises and bends. Become.

Since the paraffin can be easily molded, no labor is required, and the recovered paraffin can be recovered separately from water due to the difference in specific gravity from 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 an enlarged vertical sectional view of a main part of the same.

FIG. 8 is a vertical cross-sectional view of the completed concrete product.

FIG. 9 (A) is a vertical cross-sectional view showing the production of a conventional concrete product, and FIG. 9 (B) is a plan view of the mold in the same.

FIG. 10 is a vertical sectional view of a conventional concrete product.

[Explanation of symbols]

 11 Tile Unit Formwork 12 Tile Split Gauge 13 Joint Board 14 Liquid 15 Mesh Rebar 16 Paraffin 17 Magnet 18 Flexible Sheet 19 Tile Unit 21 Concrete Product Formwork 22 Standing Part 23 Concrete 24 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 hot water poured into the casing for the exterior material unit, and then changes from solid to liquid or from liquid to solid due to heat change, and separates from the liquid in the form A liquid material having physical properties is poured into a mold, and a flexible sheet having a magnet embedded is stacked on the surface of the liquid material, and the liquid material is solidified by natural or forced cooling. A method of manufacturing an exterior unit for an exterior material pre-attached concrete product, comprising forming an exterior material unit by integrating an upper part with a solid material and a flexible sheet. 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 hot water poured into the casing for the exterior material unit, and then changes from solid to liquid or from liquid to solid due to heat change, and separates from the liquid in the form A liquid material having physical properties is poured into a mold, and a flexible sheet having a magnet embedded is stacked on the surface of the liquid material, and the liquid material is solidified by natural or forced cooling. The exterior material unit is formed by integrating the upper part with the solid material and the flexible sheet, and the exterior material unit removed from the formwork is fixedly placed in the formwork for concrete products by adsorption of the flexible sheet by a magnet. The concrete in the concrete product formwork. An exterior characterized by placing and solidifying the solidified concrete and an exterior material, and applying heat to the mold or the product to dissolve the solid matter into a liquid state and separate and remove the flexible sheet. Method for manufacturing pre-mounted concrete products. 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.