EP1254988A1 - Process and die for making floor coverings having an aged appearance - Google Patents

Abstract

The invention relates to a method for producing a floor covering with the appearance of aged paving. This method comprises at least the following steps which consist in: a) delimiting the surface of the ground (5) to be covered and humidifying it, or vice versa; b) covering said surface with a uniform layer (C) of a mixture of cement, sand, latex and water; c) applying a film (3) of plastic material, preferably translucent or transparent, to the top of the layer thus deposited, so that it prevents gas bubbles resulting from the chemical reaction of the constituents of the mixture; d) removing the film (3) from said layer, before said mixture has finished setting. <IMAGE>

Description

The present invention relates to a method for producing a flooring with the appearance of an aged paving.

It also relates to a matrix for its implementation.

In a preferred embodiment, this method makes it possible to obtain a covering that looks like paving.

It is relatively common to carry out road works aimed at placing pavers on the ground, even in areas that did not have them before.

As an example, these blocks are used to delimit a passage for pedestrians, cover the surface with an island of gyratory direction, etc.

In most cases, carrying out this work requires removing the asphalt already in place on the ground, in the area where it is to be laid pavers.

We then proceed with the installation of a concrete slab intended to constitute the support base for the pavers.

These are placed on a layer of mortar, which is applied on the slab. The joints separating the pavers are also filled with mortar.

On the aesthetic level, such a process has largely proven itself.

However, the work to be carried out is tedious and requires lots of manpower. In addition, their cost price is high.

In addition, the materials in place (asphalt, foundation material, concrete slab, pavers, mortar) have different properties, especially on the plan expansion characteristics. In addition, it is very difficult to ensure the sustainability of their mutual bond.

Water infiltration in the joints and at the place of the different connections of the materials used, the repeated passage of vehicles which causes pressure and vibration, the freeze-thaw cycles cause important degradations can appear.

We can see that the pavements are sagging, the joints are slamming, the connection with the asphalt breaks up, the concrete slab cracks and the materials of foundation are destabilizing.

We then understand that it is necessary to carry out new works, the implementation of which is as important as that of the original works, to obtain a paving of correct appearance and behavior.

US-A-3,930,740 (BOWMAN) describes tools to form patterns on the surface of a layer of fresh cement, in the form of stone slab with any outline.

In one embodiment, more precisely described with reference in FIGS. 15 to 19, a sheet of plastic can be placed on the layer of cement made of polyethylene, one millimeter thick.

It should be noted that the use of this plastic sheet is a option which allows better rounding of the edges and angles of the printed pattern than it would be if the plastic were removed.

It is also specified that this plastic sheet is smooth enough to remove air pockets that could form in below.

Ultimately, the patterns formed in the cement layer give this one the aspect of a pavement whose surface is regular, which distinguishes it from a aged paving, the main characteristic of which is to show irregularities in surface, distributed randomly.

US-A-5,447,752 (COBB) relates to a process to form decorative patterns on a surface.

This process consists of pickling a surface with a solution based of water and muriatic acid, brushing said surface and then ridding it of said solution, to place a plastic network therein, having patterns formed by a plurality of openings corresponding to the patterns to be created, to apply a layer of a composition made up of water, and of several materials in the openings of said network and at a thickness which is not greater than that of this network, at remove the network from the surface before the composition has set, the network removed from the surface leaving voids which constitute separations between neighboring tiles made of the material.

It is easy to understand that this process is tedious to implement work, especially due to the delicate installation and removal of the network.

The present invention aims to provide a solution to these problems.

More specifically, it aims to propose a process which allows to get rid of practically all the works listed above, by working directly on the ground already in place, especially when it is a mix road.

It also aims to propose a process which can suit both outside and inside to constitute in this case a paving to replace traditional tiling.

a) délimiter la surface du sol à recouvrir et humidifier celle-ci, ou inversement ;

b) recouvrir ladite surface d'une couche uniforme d'un mélange de ciment, de sable, de latex et d'eau ;

c) appliquer sur le dessus de la couche ainsi déposée, un film de matière plastique, de préférence translucide ou transparent, de manière à ce qu'il empêche l'échappement à l'air libre des bulles de gaz résultant de la réaction chimique des constituants du mélange ;

d) enlever le film de ladite couche, avant que ledit mélange ait fini sa prise.

The present invention therefore provides a method for producing a floor covering having the appearance of aged paving, which comprises the steps which consist in:

a) delimit the surface of the ground to be covered and moisten it, or vice versa;

b) covering said surface with a uniform layer of a mixture of cement, sand, latex and water;

c) applying a plastic film, preferably translucent or transparent, to the top of the layer thus deposited, so that it prevents the gas bubbles resulting from the chemical reaction from escaping into the open air constituents of the mixture;

d) removing the film from said layer, before said mixture has finished setting.

By the expression "paving" is meant both a floor covering in one piece, similar to that obtained by pouring a concrete screed, that a covering consisting of an assembly of joined plates, more or less large dimensions.

By the expression "aged paving" is meant that this paving presents irregularities on its surface, distributed randomly.

Finally, the term "apply on top of the layer" means the fact of pressing said film against it;

These definitions are valid for the whole of this request, including claims.

When the soil on which the layer is applied is an asphalt road, there is no longer any problem of water infiltration, as it cannot flow than on the surface of the paving and the asphalt. Similarly, we no longer find ourselves confronted with problems of segregation and degradation of the materials used.

The layer thus deposited constitutes a unitary assembly which is strongly linked to the ground and which has very high impact resistance qualities and vibrations, even in the case of repeated passage of heavy vehicles.

As will be detailed later in the description, the constituents of cement chemically react with latex to cause gas evolution at the surface of the layer. Because this layer is coated with a plastic film, these clearances remain confined to the surface of the layer. After removal of the film, this results in the presence of bubbles and blisters on the coating which contributes to giving it an aged appearance.

• l'étape a) de délimitation de la surface consiste à poser sur le sol un cadre ou un coffrage ;
• à l'étape b), on fait glisser une règle sur la face supérieure dudit cadre ou coffrage pour uniformiser l'épaisseur de ladite couche ;
• à l'étape b), ledit mélange comporte, pour 100 parties en poids sec de ciment :
  • environ 133 à environ 137 parties en poids sec de sable, et de préférence environ 135 ;
  • environ 14 à environ 16 parties en poids sec de latex, et de préférence environ 15 ;
  • environ et au plus 25 parties d'eau ;
• à l'étape c), on utilise un film fin et déformable, de préférence un film de polyéthylène ;
• ledit film a une épaisseur inférieure ou égale à 30 millièmes de millimètres.

Furthermore, according to other advantageous but non-limiting characteristics of this process:

• step a) of delimiting the surface consists of placing a frame or formwork on the ground;
• in step b), a rule is dragged on the upper face of said frame or formwork to standardize the thickness of said layer;
• in step b), said mixture comprises, per 100 parts by dry weight of cement:
  • about 133 to about 137 parts by dry weight of sand, and preferably about 135;
  • about 14 to about 16 parts by dry weight of latex, and preferably about 15;
  • about and at most 25 parts of water;
• in step c), a thin and deformable film is used, preferably a polyethylene film;
• said film has a thickness less than or equal to 30 thousandths of a millimeter.

In a preferred embodiment, between steps c) and d), we strongly presses on the surface of said film a matrix, so as to form surface of the layer and, preferably at least over part of its thickness, footprints similar to the contours of paving stones and paving slabs.

The plastic film then has a second function here. he prevents, when the matrix is pressed in order to form imprints, that it does not stick to the surface of the layer and does not remove part of the mixture, when withdrawal.

This technique of delimiting pavers or slabs is also suitable both for interior and exterior cladding.

• on met en oeuvre l'étape d) aussitôt après avoir réalisé lesdites empreintes ;
• ledit mélange comprend également des adjuvants, notamment des colorants et des matériaux aptes à améliorer l'adhésion de ladite couche ;
• après que ledit mélange ait fini sa prise, on procède à au moins un traitement de surface de ladite couche, ce traitement étant notamment choisi dans le groupe suivant : ponçage, cirage, application d'une résine, martelage ;
• l'étape d'humidification du sol est remplacée par une étape de dépôt d'une couche d'accrochage.

According to other characteristics of the process:

• step d) is implemented immediately after having made said imprints;
• said mixture also comprises adjuvants, in particular dyes and materials capable of improving the adhesion of said layer;
• after said mixture has finished setting, at least one surface treatment of said layer is carried out, this treatment being chosen in particular from the following group: sanding, waxing, application of a resin, hammering;
• the soil moistening step is replaced by a step of depositing a bonding layer.

The invention also relates to a matrix for the implementation of this process.

• la figure 1 est un schéma en perspective destiné à illustrer la première étape du procédé, consistant à délimiter la surface du sol à recouvrir,
• la figure 2 est un schéma illustrant la mise en oeuvre de la deuxième étape du procédé ;
• la figure 3 est un schéma illustrant la mise en oeuvre de la troisième étape du procédé ;
• la figure 4 est une vue en perspective d'un outil formant matrice, utilisé pour réaliser des empreintes à la surface de la couche ;
• la figure 5 est une vue analogue au schéma de la figure 3, illustrant la mise en oeuvre de l'empreinte ;
• la figure 6 est une vue en coupe partielle de la couche appliquée au sol et de l'outil de la figure 4 ;
• les figures 7 et 8 sont des schémas d'empreintes aptes à être réalisées avec un autre type d'outil ;
• la figure 9 est une vue du dallage ainsi réalisé, encore recouvert d'un film de plastique et délimité par un cadre ;
• la figure 10 est une vue du dallage après que les constituants de la couche mince aient fini leur prise.

Other characteristics and advantages of the invention will appear on reading the detailed description which follows of a preferred embodiment. This description will be made with reference to the accompanying drawings in which:

• FIG. 1 is a perspective diagram intended to illustrate the first step of the method, consisting in delimiting the surface of the ground to be covered,
• FIG. 2 is a diagram illustrating the implementation of the second step of the method;
• FIG. 3 is a diagram illustrating the implementation of the third step of the method;
• Figure 4 is a perspective view of a die tool used to make impressions on the surface of the layer;
• Figure 5 is a view similar to the diagram of Figure 3, illustrating the implementation of the imprint;
• Figure 6 is a partial sectional view of the layer applied to the ground and the tool of Figure 4;
• Figures 7 and 8 are diagrams of imprints suitable for being made with another type of tool;
• Figure 9 is a view of the paving thus produced, still covered with a plastic film and delimited by a frame;
• FIG. 10 is a view of the paving after the constituents of the thin layer have finished setting.

The example of embodiment described below, with reference to the drawings attached, relates to the production of a coating placed on an asphalt road, and having the appearance of a set of pavers of non-uniform shape and appearance. Such paving is for example intended to constitute a pedestrian crossing.

We will now refer to FIG. 1 as regards the first step of the process of the invention. This consists in delimiting the surface of the soil to cover and moisten it.

Soil S here consists of a bituminous-based asphalt, of the type commonly used for road surfaces.

Preferably, this soil S is properly cleaned , either by brushing or by means of a pressurized water jet, to rid it of any dust and any pollutant.

When the cleaning has been carried out by brushing, the soil S is then slightly moistened. By this is meant that water is spread over the ground, so as to leave traces of moisture but, in no case, puddles.

We then proceed to delimit the surface A to be covered. In the example here, this delimitation consists in placing a frame 1 on the ground. This is formed by four bars 10 and 11, simply placed on the ground. The two bars 10 delimit the transverse edges of the surface, while the bars 11 delimit the longitudinal edges. The surface therefore constitutes a rectangle. Of course, any other geometric shape is possible.

We can naturally reverse the humidification and delimitation.

In the event that the soil is very degraded, the humidification step can be replaced by an operation of depositing a bonding layer, by example based on bitumen and / or latex.

Whether the process of the invention is implemented outdoors or in interior, the delimitation of the surface can be done by itself by elements already in place of the location. So when it comes to tiling in a room, the delimitation is naturally made by the walls which frame the room.

Bars 10 and 11 used here have for example a few millimeters thick (especially four or five) and preferably the same thickness.

In a particular embodiment not shown, the bars 10 and 11 can be joined to each other to form a formwork in one piece.

The second step b) to the process consists in covering said surface Has a uniform layer of a mixture of cement, sand, latex and water.

The cement used is a cement of type CPJ-CEM II / B 32.5 R marketed by LAFARGE.

The sand is fine, clean and dry. Its particle size is for example less than or equal to 2 mm.

The latex is used dry or in the form of a dispersion in water. The one sold under the reference OXILATEX 2 by the company PIERI is suitable perfectly.

• environ 133 à environ 137 parties de sable, et de préférence environ 135;
• environ 14 à 16 parties de latex, et de préférence environ 15 ;
• environ et au plus 25 parties d'eau.

The mixture used advantageously has the following proportions, per 100 parts by dry weight of cement:

• about 133 to about 137 parts of sand, and preferably about 135;
• about 14 to 16 parts of latex, and preferably about 15;
• about and at most 25 parts of water.

Except, of course for water, the proportions given above are dry weight data.

In order to carry out the mixing, the various constituents can be gathered at the last moment. However, sand and cement may already be premixed and packaged in bags, while latex and water are pre-stored in cans.

The mixture may optionally contain other adjuvants. As non-limiting, there may be mentioned coloring matters (yellow, red, blue, black, etc.), synthetic fibers capable of improving the bonding of the various constituents and the cohesion of the mixture, pozzolans capable of limiting chemical reactions to cement breast, silica fumes, etc.

In order to carry out the mixing, the various constituents are by example poured into a mixer with vertical axis and low speed up to obtaining a uniform paste.

In the next step of the process, the surface A is covered with a layer C of said mixture.

The dough is for example spread with a trowel. Insofar as the bars 10 and 11 have the same thickness, it is then possible to apply to their upper face 110, a rule 2 which is moved longitudinally in the direction of the arrow a.

A uniform layer C is then obtained consisting of said mixture.

In the next step of the process, a plastic film is applied to the top of layer C. This is referenced 3 in Figure 3. It is for example a polyethylene film. We float this film (arrows f ) so as to press it perfectly against layer C.

As explained above, the constituents of cement and latex, in presence of moisture, react chemically causing releases gaseous which rise to the surface of the layer. The presence of a film pressed against the latter prevents the gas bubbles thus formed from escaping into the open air.

When you want to obtain a paving in one piece, you before the mixture has finished setting, the film 3 is then removed.

The gas bubbles previously generated can then escape. However, because they remained confined to the surface of the layer, they mark the top of it by forming surface hollows more or less regular, randomly distributed, which gives the paving an aged appearance.

The film 3 is preferably, as explained below, transparent or translucent. It must be neither too thin to be able to be pierced, nor too rigid to be able to be locally deformed. A film with a thickness less than or equal to 30 thousandths of a millimeter is perfect.

When the covering is intended to have the appearance of a whole pavers or paving slabs, the process continues to be implemented from the way explained below.

After applying the film 3 on layer C, we strongly press on the surface of the film a matrix, so as to form on its surface and, preferably at least over part of its thickness, imprints similar to the contours of pavers or paving slabs.

An example of such a matrix is shown in Figure 4. This matrix 4 consists of a rectangular frame 40, for example metallic, consisting of an assembly of transverse 41 and longitudinal 42 flat rods arranged on edge. The rods 41 are connected to each other by a handle 43 associated with two connecting branches 44 which constitute a bridge over the frame 40. The outline of the latter corresponds for example to that of a format block standard.

The implementation of this step is illustrated in FIGS. 5 and 6. By successively applying the matrix 4 on the layer C step by step, the neighboring elements 5 whose contour is similar to that of pavers are formed on the surface of the covering. .

By pressing on the matrix, grooves 6 are formed which separate the "false blocks" two by two 5. Of course, the depth of these grooves depends on the degree of depression of the matrix. It is possible to push it in until it comes to a stop against the ground S.

The grooves thus formed are visible through the transparent film or translucent.

During this operation, the function of the film 3 is to prevent the frame 40 of the matrix from sticking to the layer C by removing, during its removal, a fraction of it.

Of course, to make the imprints on the surface of the layer, you can use any other tool than the one in figure 4.

Thus, it is possible to use a 4 ′ matrix (FIG. 7) capable of delimiting at the same time three “false paving stones” P ₁ , P ₂ , P ₃ . FIG. 8 shows the contours of another matrix 4 "capable of delimiting at the same time six" false blocks " P ₁ to P ₆ .

In another embodiment, a suitable matrix can be used to form imprints of various dimensions, for example with circular outline, in rhombus, etc.

Not only does the floor covering thus obtained have the appearance of a paving carried out in the traditional way, but obtaining irregularities on its surface gives it an aged appearance which suggests that it has been produced for many years.

The film 3 is then removed (arrow g , FIG. 9) immediately after having completed the production of the impressions. This removal operation allows the release of gas emissions.

The removal can be postponed to prevent the hardening of the layer is affected by the external environment (rain, strong sunshine, wind supported, ...). In any case, it takes place at the latest before the layer has finished his catch.

When the layer C has completed its setting, it is then possible to withdraw the frame 1. The network R of "false paving stones" 5 thus obtained has surface irregularities 50 and 51. Those referenced 51 are due to the abovementioned gas emissions. They are distributed randomly. The irregularities 50 are for example due to the fact that prior to the removal of the film 3, a pad, not shown, was firmly applied to the surface thereof, so as to mark the surface of the layer C with imprints of shapes complementary to those it presents on its surface.

About twelve hours after removal of the film 3, one can walk on the network R. After 24 hours, a light vehicle can move there without causing any damage. Finally, after 48 hours, any type of vehicle can run on it.

This network presents perfect coherence and perfect behavior in the weather, whatever the weather variations.

When this technique is used for an interior coating, it is possible to carry out one or more treatment (s) of the surface of the network R. It can be, for example, sanding, waxing, application of a resin, a hammering treatment, etc.

Claims (12)

Process for producing a floor covering having the appearance of an aged paving, characterized in that it comprises the following steps which consist in: a) delimit the surface of the soil ( S ) to be covered and moisten it, or vice versa; b) covering said surface ( S ) with a uniform layer ( C ) of a mixture of cement, sand, latex and water; c) applying a film (3) of plastic material, preferably translucent or transparent, on top of the layer ( C ) thus deposited, so that it prevents gas bubbles from escaping to the open air resulting from the chemical reaction of the constituents of the mixture; d) removing the film (3) from said layer ( C ), before said mixture has finished setting. Method according to claim 1, characterized in that step a) of delimiting the surface consists in placing on the ground a frame (1) or a formwork. Method according to claim 2, characterized in that in step b), a rule (2) is slid over the upper face of said frame or formwork to standardize the thickness of said layer ( C ). Method according to one of claims 1 to 3, characterized in that in step b), said mixture comprises, per 100 parts by dry weight of cement: about 133 to about 137 parts by dry weight of sand, and preferably about 135; about 14 to about 16 parts by dry weight of latex, and preferably about 15; about and at most 25 parts of water. Method according to one of claims 1 to 4, characterized in that in step c), a thin and deformable film (3) is used, preferably a polyethylene film. Method according to claim 5, characterized in that the said film (3) has a thickness less than or equal to 30 thousandths of a millimeter. Method according to one of claims 1 to 6, characterized in that between steps c) and d), a matrix (4, 4 ′, 4 ") is strongly pressed on the surface of said film (3), so as to form on the surface of the layer ( C ) and, preferably at least over part of its thickness, imprints (5) similar to the contours of paving stones and paving slabs. Method according to claim 7, characterized in that step d) is implemented immediately after having made said imprints (5). Method according to one of Claims 1 to 7, characterized in that the said mixture also comprises adjuvants, in particular dyes and materials capable of improving the adhesion of the said layer. Method according to one of claims 1 to 9, characterized in that after said mixture has finished setting, at least one surface treatment of said layer ( C ) is carried out, this treatment being chosen in particular from the group next: sanding, waxing, applying a resin, hammering. Method according to one of claims 1 to 10, characterized in that the step of moistening the soil is replaced by a step of depositing a bonding layer. Matrix for implementing the method according to one of claims 7 to 11, characterized in that it comprises a frame (40), in particular rectangular, associated with a grip handle (43).

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