FR2697015A1 - Compsns. and processed for fabricating ornamental masonry - with the appearance of natural stone, marble and granite - Google Patents

Abstract

A compsn. is claimed for the fabrication of a material with a decorative appearance from a base of sand, cement, water and pigments which imitates the appearance of a natural stone, in which the dosage of its main ingredients is as follows: 60 percent finely sifted sand; 40 percent cement; a third to a sixth of mixing water; 1 to 6 percent of oxides by wt. With a third of mixing water and 1 percent oxide the compsn. produces the appearance of marble. With a sixth of mixing water and 6 percent oxide the compsn. produces the appearance of granite. With a part mixed with a third of water and a part mixed with a sixth of water the compsn. produces the appearance of stone. Pref. the method of using the materials to fabricate decorative objects is also claimed in which the objects are produced by casting in a horizontal plane with the aid of a plastic cladding of 2 to 3 mm thick on which the mixt. of materials are applied. USE/ADVANTAGE - The compsn. is used to produce a decorative material that imitates the appearance of natural stone, marble and granite for casting into various objects, such as funeral monuments, garden ornaments, flower boxes, kitchen worktops, etc. The material has a number of advantages including price, reliability, resistance, maintenance, realistic sensation to touch, elimination of treatment after casting and the elimination of firing.

Description

 The present invention relates to a composition and methods for the manufacture of objects in particular based on concrete, mortar or plaster. It also relates to the objects manufactured by the processes.

 Nowadays, when we talk about concrete, it immediately comes to mind "environment". Multiple efforts are made every day to protect nature. In addition, in the Leisure Society where we live today, color is becoming more and more important.

 The object of the invention is to integrate concrete, mortar or plaster objects into nature by giving them an appearance of decorative natural stone.

 I1 is known to use oxides to tint the exterior ornaments in concrete, such as balusters, coping, pavers, etc ... but we do not use the combination of oxide mixtures to find the decorative effect of the veins marble for example, and we do not know any process to find the appearance of granite.

 In addition the existing tinted materials are of a raised cost price.

 In addition, there are known processes based on various resins or cooking based on terracotta: many kitchen worktops, for example, imitating marble, are on the market, they are based on resin and use totally different techniques and materials.

 The invention aims to solve the problems of the prior art with a material based on Breton, mortar, plaster or other composition in use in the building.

 A first problem to solve was to be able to imitate marble or granite or any other colored decorative stone while being accessible to all budgets and to be able to use the applications of the process as well outside as inside.

 A second problem was to obtain a smooth and shiny surface without the contribution of a machine (sandstone or other) by an appropriate formwork release.

 It was also necessary to solve these problems taking into account the requirements of reliability, resistance, maintenance, without forgetting the aesthetic result sought.

All these goals are achieved with the composition for the manufacture of a material of decorative appearance based on sand, cement, water, pigments, in particular imitating the appearance of a natural stone characterized in that the dosage of the main materials is substantially the following
- 60% fine sieve sand,
- 40% cement
- from one third to one sixth of mixing water,
- from 1% to 6% of oxides by weight
Depending on the amount of mixing water and / or the dosage of pigments, a material with the appearance of marble, granite, a decorative stone is obtained.

 The invention and the various methods of implementation will be better understood using the following description.

The composition and the method according to the invention have different variants for
- imitation of marble,
- imitation of granite,
- stone imitation from any country,
- manufacture of pavements or other flat objects,
- manufacture of vertically cast objects.

For the manufacture of pavements and other flat objects, the molding is done on a horizontal plane but with the following differences depending on the aesthetic effect sought
The manufacturing is carried out on a horizontal plane with the addition of a plastic coating of 2 to 3 mm thick on which we apply the mortar or concrete mixtures previously worked with oxides of iron, zinc or chromium or other pigment, the dosage of cement, sand, gravel, mixing water, varies according to the veins or colors sought.

To obtain a "marble" effect, the percentages of materials are substantially on the order of
- 60% fine sieve sand
- 40% cement (black, gray or white)
- A third of mixing water
- 1% oxides by weight
When formwork is removed, the appearance of marble is given.

To obtain the appearance of granite, the production is carried out on a horizontal plane without the addition of special coatings on which the mixtures are applied in the same way as above except that the concrete or mortar paste is more consistent. I must
- 60% sieved fine sand
- 40% cement (black, gray or white)
- One sixth of mixing water
- 6% oxides by weight
After stripping and after 28 days of drying, this production is sanded by a sandstone to give it the appearance of granite.

 To obtain the appearance of the decorative stone, the production is carried out on a horizontal plane with the addition of a plastic coating of 2 or 3 mm thick on which the mortar or concrete mixtures previously worked with oxides are applied. of iron, zinc or chromium.

 The difference between imitation marble and imitation stone is when mixing. Part of the dough is deposited with a third of mixing water, the other part with a sixth of mixing water so as to bring out more intense contrasts and more structured veins during the release. Thus in formwork the appearance of the stone is given.

 For all applications where the mixtures are poured vertically, the technique is a little different. To keep the desired appearance, you have to wait for the prepared dough to set before adding the next.

It should be known that any oxide is not fixed until after eighteen months and that existing products can be added, either during the preparation, or after a month of total drying, namely:
For exterior: water repellent: surface hardener, varnish ...

 For the interior: liquid wax, tint, sealer.

 In addition, each of these products can be reinforced, either by iron or by fibers.

 By way of non-limiting example of application, the following is described the manufacture of a kitchen worktop with imitation of a tricolor marble, for example blue, white and black with the dimensions: 2 times 2 meters length and 0.60 m width with reservation for sink bowls.

 1st stage: Take the exact measurements and calculate, if necessary, according to a false squaring; in this case the height will be 3 cm.

 2nd step: prepare two frames (wood, plastic or resin), which once turned over can receive the preparations.

 Indeed, for problems of laitance, resistance and finished appearance, it is imperative to pour the preparation where the finish is below (provide the reservation for the sink).

 3rd step: this work plan has no shoe on the back.

Its frames are coated on their inner periphery, with a plastic sheet by gluing which will give the smooth and shiny appearance on the edges.

 4th step: these frames are placed on a sheet of counterplate that is flat and level on which a plastic sheet of the desired dimensions is placed (this sheet has a protective film that is removed at the last moment (dust and other ).

 5th step: we arrive at the dough preparation stage.

For the desired effect, the composition is substantially as follows
- 65 Kgs of fine sand,
- 6 Kgs of white cement,
- 10 Kgs of gray cement,
- 27 kgs of molten cement,
- 120 Grs of white oxide,
- 200 Grs of unalterable blue oxide,
- 140 Grs of blue oxide from France,
- 500 Grs of black oxide,
- 1 Kg of water repellent.

 Note that the mixtures can be done manually or mechanically.

 6th step: The water added to the preparation must give a smooth paste of the same consistency as that used by the masons for the squirting on a plastered wall.

 Iron, zinc and chromium oxides are mainly used. The color charts exist in the form of references and the color palette either by mixing the oxides between them, or by the number of shades of the manufacturer.

 The latter also indicates the usual dosage for conventional uses. Namely for example 250 Grs of oxide for 25000 grs of mortar or concrete.

 For the process according to the invention, the dosages are significantly different if it is white, gray or black cement. After various tests the resistance threshold of oxide-mortar or concrete ratio is at equivalent weight. This also indicates that the maximum coloring is reached well before saturation and shows a similar color between all the cements (white, gray or black). We also demonstrate that the starting color is 1 gram per 10 grams varying according to the nature of the cement.

The order of preparation of the dough is as follows
1 "- 6 Kgs of white cement + 8 Kgs of sand + 120 Grs of white oxide (dry mixed) then the mixing water.

 2 "- 10 Kgs of gray cement + 14 Kgs of sand + 200 Grs of unalterable blue oxide (dry mixed) then the mixing water.

 3 - 7 Kgs of molten cement + 11 Kgs of sand + 140 Grs of blue oxide of France (dry mixed) then the mixing water.

 4 "- 20 Kgs of molten cement + 32 Kgs of sand + 500 Grs of black oxide (dry mixed), then the mixing water.

 7th step: These preparations must be mixed to avoid lumps when pouring. In this specific case, it is advisable to run from lightest to darkest.

 a) pour together the preparation (1) and (2) "6th step" slightly at an angle to the length, spaced 30 to 40 cm apart.

 b) do not vibrate, then pour the preparation (3) on the edges and sides of the preparations (1) and (2).

 c) do not vibrate, then pour the preparation (4) into the empty spaces.

 Note that this step flows over a thickness of 1.5 cm. We will repeat the above-mentioned operations, after one hour before the total setting of cements and oxides for an ambient temperature of 20. We can arm, either with iron fibers or wire mesh on the 1st casting part.

 8th stage: the drying of the whole varies according to the regions and the seasons. However, after approximately 48 hours, demoulding is possible, vertically and in one piece to avoid scratches and contact with plastic.

 The worktop is thus produced, smoothed, shiny, waterproof, in imitation marble. Its resistance is obtained after 28 days. Vitrification is also possible.

 Its cost price is extremely competitive.

The applications are numerous and in particular and not limited to in the following fields
- Local and regional authorities: creation of flower boxes, flowerbeds, terminals, etc.

 - Funerary monuments: tombstones, steles ...

 - Individuals: garden table, bench, patio in the form of slabs, enclosure walls ... and, for the interior, work plan for the kitchen, bas-reliefs on the walls, desk, coffee table, furniture, etc ...

The advantages are numerous compared to the state of the prior art, in particular
- Price of raw materials,
- Reliability,
- Resistance,
- Interview,
- Sensation of true to the touch,
- No treatment after demolding,
- No cooking.

Claims (10)

1. Composition for the manufacture of a material of decorative appearance based on sand, cement, water, pigments, in particular imitating the appearance of a natural stone, characterized in that the dosage of the main materials is substantially as follows  - 60% of fine sieved sand,  - 40% cement,  - From a third to a sixth of mixing water,  - From 1% to 6% of oxides by weight. 2. Composition according to claim 1 characterized in that it presents demoulding the appearance of marble with a dosage of one third of mixing water and 1% of oxides by weight. 3. Composition according to claim 1 characterized in that it has the demoulding appearance of granite with a dosage of one sixth of mixing water and 6% of oxides by weight. 4. Composition according to claim 1 characterized in that it has the appearance of stone release from the mold and in that it comprises a part tempered with a third of water and a part tempered with a sixth of water. 5. Composition according to any one of claims 1 to 4 characterized in that it further comprises at least one component taken from the list (water repellant, surface hardener, varnish, liquid wax, tinted wax, sealer). 6. A method of manufacturing objects characterized in that it implements the composition according to any one of the preceding claims. 7. Object manufacturing process characterized in that it implements the composition according to claim 2 and that the manufacturing is carried out on a horizontal plane with the addition of a plastic coating of 2 to 3 mm d 'thickness to which mortar or concrete mixtures previously worked with iron, zinc or chromium or other pigment oxides are applied. 8. A method of manufacturing objects characterized in that it uses the composition according to claim 3, in that to obtain the appearance of granite, the manufacture is carried out on a horizontal plane without the addition of special coating on which the mixtures are applied and in that when formwork is removed and after 28 days of drying, this production is sanded by a sandstone to give it the appearance of granite. 9. Object manufacturing process characterized in that it uses the composition according to claim 4, in that the manufacturing is carried out on a horizontal plane with the addition of a plastic coating of 2 or 3 mm d '' thickness to which mortar or concrete mixes are applied and in that one part of the paste is deposited with one third of mixing water, the other part with one sixth of mixing water so as to bring out the demolding of more supported contrasts and more structured veins.  10. Object made of decorative material based on sand, cement, water, pigment, characterized in that it is manufactured by any of the methods of claims 6 to 9.