JPH0872027A - Surface concrete plate and forming method thereof - Google Patents

Abstract

PURPOSE: To provide a surface concrete slab having fine external appearance caused by orderly arranged stones and being employed for efficiently producing the wall of a building with favorable finish and its forming method. CONSTITUTION: A surface concrete slab 10 consists of plate-like formed concrete, which serves as a concrete form and forms the front surface part of a building by being fixed with green concrete or mortar placed on the rear surface side thereof. The front surface of the concrete is formed in the unevenness represented by the orderly arranged surface of stones by a forming mold. Concretely, granular matters 17 made of hard durable substance such as stone dust, crystal flakes or the like are transferred from the molding surface adhered by coating material 13 to the front surface of the concrete together with the coating material 13 and fixed onto the front surface of the concrete under the condition that the coating material 13 adheres to the surfaces of the granular matters 17.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface concrete plate and a method for forming the same.

[0002]

2. Description of the Related Art As an example of a construction method for forming a wall of a building made of concrete, there is a lining method for covering a slope when forming a bank for a river bank. Conventionally, in this conventional lining method, first, leveled concrete is spread and averaged to an average thickness of about 5 cm on a slope (for example, a slope of 20%) on which the embankment is adjusted to a ruler section. Next, a concrete foundation formed below the slope is used as a foundation, and a vertical frame (having a cross section of about 30 cm × 30 cm) extending in the vertical direction is provided along the slope of the slope. The vertical frames are arranged with a predetermined width interval in the extension direction of the river. Then, concrete is struck on the entire surface of the intermediate portion between the vertical frames to a thickness of about 20 cm to cover the slope, thereby forming slope concrete. Since the work of hitting the sloped concrete has a gentle slope, it is usually a construction without using the surface formwork. Therefore, it is difficult to perform sufficient compaction. Moreover, the surface is finished by a skilled worker (or plasterer) after the concrete is appropriately hardened. The concrete structure thus formed needs to be heat-recovered and cured during the winter when the temperature is low, and it is necessary to be careful so that the surface is not roughened.

Further, when forming a wall body having a steep slope for hitting concrete, or when forming a vertical wall body,
There is a construction method that uses surface formwork. In this construction method, first, a surface mold made of a steel plate or the like is held with a predetermined gap from the surface of the facing mold or the substrate surface of the building. Next, fresh concrete or mortar is filled in the voids and solidified, and then the surface formwork is removed. Normal,
Due to insufficient air and water removal from the surface formwork, the surface is not shaped properly and the concrete surface is manually finished.

[0004]

However, in the above-mentioned conventional construction method, the concrete wall surface is usually finished by hand into a simple flat surface. Therefore, there is a problem in that the appearance is dry and tasteless and the scenery is not beautiful. It should be noted that, in order to finish the surface of the building beautifully, skilled workers assemble stone materials or fix stone materials with mortar, but the problem is that construction efficiency is poor and construction costs are high. there were. Further, in the construction method using the surface formwork described above, it is necessary to remove the arranged surface formwork, and the construction efficiency is poor.

Therefore, an object of the present invention is to provide a surface concrete plate which has a beautiful appearance such that stones are lined up and is used for forming a wall of a building with good finish and efficiency, and a forming method thereof. It is in.

[0006]

In order to achieve the above object, the present invention has the following constitution. That is, the present invention is
In the surface concrete plate that is molded into a plate shape by concrete and acts as a concrete formwork, and is fixed to fresh concrete or mortar that is placed on the back side to form the surface part of the building, the concrete surface side is a molding die Is formed into an uneven shape like a surface where stones are arranged, and on the concrete surface, a granular material made of a hard and durable material such as stone powder or crystal fragments is formed from the mold surface of the molding die adhered with a paint. It is characterized in that the paint is transferred and fixed together with the paint, and the paint adheres to the surface of the granular material.

Further, since the paint is a transparent paint,
The gloss of the coating film formed by the paint makes it possible to give the particle a unique luster. Furthermore, since the coating material is an acrylic coating material, the surface of the granular material can be easily and appropriately provided with gloss, and the surface of the stone material can be appropriately imitated.

Further, a lath net is exposed and fixed on the back surface so as to be surely fixed to the poured concrete or mortar, and the lath net is provided in a predetermined direction so as to serve as a passage for discharging air and water. Since the plurality of extending ribs with grooves are provided, the front surface concrete plate can be suitably integrated with ready-mixed concrete or mortar that is cast on the back surface.

Further, according to the present invention, silicone rubber is applied to a rough original surface formed by arranging stones and the like and cured to obtain a silicone rubber layer, and the shape of the silicone rubber layer is retained. As described above, a mold for a surface concrete plate is also provided, which comprises a reinforcing layer formed by applying a liquid resin material over the silicone rubber layer and curing the resin material. The reinforcing layer can be preferably formed of reinforced plastic or urethane.

Further, according to the present invention, a step of applying silicone rubber to a rough original surface formed by arranging stones and the like and curing the silicone rubber to form a silicone rubber layer, and a liquid layer overlaid on the silicone rubber layer. And a step of separating the reinforcing layer and the silicone rubber layer from the original surface, and a method for producing a surface concrete plate molding die, comprising: There is also

Further, according to the present invention, a mold surface of a silicone rubber layer of a molding mold having a silicone rubber layer obtained by applying a silicone rubber to a rough original surface formed by arranging stones etc. A step of applying a paint that acts as an adhesive material, a step of adhering a granular material made of a hard durable substance such as stone powder or crystal fragments to the mold surface to which the adhesive material is applied, and molding the surface concrete plate Having a step of pouring fresh concrete into a mold to cure it, transferring and adhering the particulate matter to the surface together with the adhered paint, and a step of disassembling the molding die for the surface concrete plate and taking out the surface concrete plate There is also a method for forming a surface concrete plate characterized by

[0012]

According to the surface concrete plate of the present invention, the concrete surface side is formed in an uneven shape, and the granular material is transferred and fixed together with the paint from the mold surface of the molding die adhered by the paint. The paint is attached to the surface of the granular material. For this reason, even though it is a concrete plate, it is possible to obtain a beautiful appearance in which stones are lined up, and the surface of the building can be beautifully finished in the view. In particular, since the paint adheres to the surface of the granules, the gloss of the coating film formed by the paint can give the luster of the granules, and the surface of the stone material can be appropriately imitated.

Further, according to the method for molding a surface concrete plate of the present invention, silicone rubber is applied to the surface of the original shape, and an adhesive material is applied to the mold surface of the silicone rubber layer obtained by collecting the mold.
The particulate matter adhered to the mold surface by the adhesive material is transferred and fixed on the surface concrete plate side together with the adhered paint. That is, since the mold surface is made of silicone rubber, the paint can be peeled off favorably. Therefore, the granular material in the state where the paint adheres to the surface can be transferred and fixed to the surface of the surface concrete plate, so that the stone surface can be appropriately imitated.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment of the present invention will be described in detail below with reference to the accompanying drawings. FIG. 1 is a sectional view showing an embodiment of a surface concrete plate according to the present invention. Also, FIG.
FIG. 3 is a partially enlarged view of FIG. 1. Surface concrete plate 10
Is molded into a plate shape (rectangular in this embodiment) by concrete and acts as a concrete formwork,
It adheres to the ready-mixed concrete or mortar that is placed on the back side to form the surface of the building. Reference numeral 12 denotes a concrete forming portion, and a surface portion 16 is provided on the surface side of the concrete forming portion 12 (the surface side of the surface concrete plate 10).
However, it is formed in a concavo-convex shape like a surface where stones are arranged by a molding die. For example, as shown in FIG. 7, the surface portion 16 in which cobblestones are arranged is formed of concrete.

On the concrete surface of the surface portion 16,
As is apparent from the enlarged view of FIG. 2, the granular material 17 made of a hard and durable substance such as stone powder or crystal fragments is transferred and fixed together with the paint 13 from the mold surface of the molding die adhered by the paint 13. ing. By forming the mold surface of the molding die with a material having good releasability such as silicone rubber, the paint 13 is preferably peeled off from the die surface and transferred. Then, the granular material 17 is held by the mortar paste in the concrete, and is firmly fixed to the concrete surface by the hardening of the mortar paste. At this time, since the mortar paste cannot enter the close contact portion between the granular material 17 and the coating material 13 and the close contact portion between the mold surface and the coating material 13, the surface of the granular material transferred and exposed on the concrete surface is a coating film of the coating material. Appears in a glossy state covered by. In addition, 23 is a joint.

As the paint 13, a transparent acrylic paint can be used, the luster of the coating film can give a luster peculiar to the granular material, and the stone surface can be appropriately imitated. In this example, a transparent acrylic paint mainly using toluene and xylene as a diluent was used. The coating film of this transparent acrylic paint has water resistance, acid resistance, and alkali resistance, and has sufficient hardness, strength, adhesion and durability. Therefore, the acrylic coating film attached to the surface of the granular material 17 is not easily detached. Acrylic paints are preferable because they are easy to handle. By the way, as an example, the application amount of the acrylic paint is set to 0.5 to 1.0 kg / m ² as a standard. The specific gravity of this acrylic paint is 0.93 ± 20 ° C
It is 0.03. Instead of the acrylic paint, it is also possible to use vinyl chloride-based, silicone-based, vinyl acetate-based, acrylic urethane copolymer, epoxy-based, or fluorine-based paint. These paints are selected and used according to the mold surface shape of the molding die, the amount of rock powder to be attached, the particle size and the like. It is also possible to use a colored paint (including a paint with a transparent color), and the appearance of the surface concrete plate can be selectively produced.

As the granular material 17 used to imitate natural rock formation or rock surface, base rock fragments, crystalline rock powder, or rock formation rocks can be used for each imitation rock type. The size of the stone powder or the stone pieces depends on the desired specifications of the concrete surface, but normally, the outer size (particle size) of about 0.5 to 10 mm is used. It is possible to use the one in which the concentration of the granular material 17 having a particle size of about 4 mm is increased by sieving,
It is preferable in terms of adhesion of the coating material to the mold surface (particularly the uneven surface) of the granular material 17 and workability. In order to express the desired rock surface and the color tone of natural stone, the particle size distribution of stone powder or the like may be selected, or various stone powders or stone fragments may be appropriately mixed. Also, since natural stones often have spots of mottled rock crystals, the production of these spots is
Particles with a particle size of around 10 mm may be optionally used. Further, the types of rocks imitated on the concrete surface are mainly igneous rocks, metamorphic rocks, and mixed rocks (for example, granite, diorite, gabbros, diabase, etc.). These rock facies, as a granular material of stone powder or stone fragments for imitating rock surface, minerals of the above rocks, phenocrysts or crystal fragments as the main material, slag iron oxide, glass fragments and other hard durable substances as secondary materials It is also possible to do so.

Next, the back side of the surface concrete plate 10 fixed to the ready-mixed concrete or mortar to be placed will be described. When the fresh concrete or mortar is filled between the surface concrete plate 10 and the surface of the base material of the building, the lath net 14 is exposed and fixed on the back surface so as to be firmly fixed to the base material of the building. ing. Reference numeral 18 denotes a wire mesh, which is inserted and integrated when forming the concrete molded portion 12 to reinforce the surface concrete plate 10. The wire mesh 18 is formed by arranging reinforcing bars in a grid pattern. Since the surface concrete plate 10 is reinforced by the lath net 14 and the wire mesh 18 as described above, it is thin and light and has strong strength.

FIG. 3 is a plan view showing the shape of a lath net 14 provided with grooved ribs fixed to the back surface of the concrete molding portion 12, and FIG. 4 is a sectional view taken along line AA of FIG. 1
Reference numeral 5 denotes a grooved rib, and a plurality of ribs are formed on the lath net 14. The grooved rib 15 is formed by bending a portion of the lath net 14 which is not formed in the net shape in the present embodiment into a U-shape. As shown in FIG. 5, the plurality of grooved ribs 15 extend in a predetermined direction (in the present embodiment, a direction that becomes the vertical direction when used), and are formed in parallel at predetermined intervals. The plurality of grooved ribs 15 are filled with fresh concrete or mortar between the back surface of the surface concrete plate 10 and the surface of the base material of the building, and when the surface concrete 10 is adhered to the base material, air and water are used. It becomes a passage for discharge. In particular, since water has a property of easily flowing to the groove portion and flowing out, the grooved rib 15 suitably discharges water. As a result, the surface concrete 10 plate can be reliably fixed to the base material of the building. In addition, it goes without saying that the grooved rib 15 improves the strength of the lath net 14. Further, by forming the grooved ribs 15, it is possible to prevent the lath net 14 from being curved and to form it in a flat plate shape.
Therefore, it is possible to easily fix the lath net 14 to the back surface of the concrete molding portion 12 in a planar manner.

FIG. 5 is a partial sectional view showing the back surface of the surface concrete plate 10 and its internal structure. Further, FIG. 6 is a view on arrow B of FIG. A lath net 14 provided with a plurality of grooved ribs 15 is fixed so as to be exposed on the entire back surface of the concrete molding portion 12. In addition, a wire mesh 18 is provided over the entire surface inside the concrete molding portion 12. Further, 19 is a corner reinforcing bar,
Similar to the wire mesh 18, it is arranged at a corner of the concrete molding portion 12 so as to reinforce the concrete molding portion 12.

Reference numeral 20 is an insert screw, and a female screw portion is provided so that a bolt can be screwed therein. A plurality of insert screws 20 (three places in this embodiment) are provided at predetermined intervals so that they can be used when the surface concrete plate 20 is suspended and transported. Reference numeral 22 is a pin portion, and a pin-shaped protrusion is formed on one side surface of the surface concrete plate 10. Further, 24 is a pin fitting portion,
It is provided on the side surface opposite to the side surface on which the pin portion 22 is provided. The pin fitting portion 24 is provided with a recess so that the projection of the pin portion 22 can be fitted therein. Therefore, if the pin portion 22 of another surface concrete plate 10 is fitted to the pin fitting portion 24, the adjacent surface concrete plate 10
Can be easily joined on the same surface.

FIG. 7 is a front view showing an embodiment of the surface shape of the surface concrete plate 10. The surface concrete plate 10 of the present embodiment is formed by a molding die in a cobblestone imitation shape in which a plurality of cobblestones are arranged. Not limited to this embodiment, it can be molded into various shapes. For example, it can be formed into a rough stone imitation, a hexagonal imitation, a simple flat pattern, or a step shape. Reference numeral 21 is an air vent hole, which acts as a flow path for letting air escape when the fresh concrete or mortar is filled in the gap between the surface concrete plate 10 and the base of the building. FIG. 8 is a view taken in the direction of arrow C of FIG. 7, and shows a pin fitting portion 24 provided on the side surface of the surface concrete plate 10.
Is shown. FIG. 9 is a perspective view showing a socket fitting 24a for forming the pin fitting portion 24. In this socket fitting 24a, a straight pipe portion is vertically provided on a rectangular plate material, and the rectangular plate material side of the straight pipe portion is opened to form a recess of the pin fitting portion 24. FIG. 10 is a perspective view showing a pin fitting 22a for forming the pin portion 22. Pin-shaped projections are vertically provided on both sides of the rectangular plate member, and one of the tapered projections is provided so as to be fitted into the recess of the pin fitting portion 24. The other protruding portion is a portion embedded in the concrete molding portion 12.

Next, the surface concrete plate 1 of the above-mentioned embodiment
The production of 0 will be described. First, a procedure for manufacturing a molding die for a surface concrete plate (hereinafter, may be simply referred to as a mold) used for forming the surface concrete plate 10 will be described by taking an example of forming a surface portion in a cobblestone pattern. A plurality of cobblestones are arranged and fixed within a predetermined size of the surface concrete plate to be manufactured so as to be a cobblestone imitation.
(See FIG. 11). The surface of this original shape 68 (a sampling surface for taking a cobblestone imitation mold) is cleaned by washing with water. The release agent is applied to the collection surface of the cobblestone imitation. As the release agent, Terradide MO-S manufactured by Terada Co., Ltd. can be used. The components of this release agent are 5 to 10% of silicone resin and paraffin resin, and 90% of xylene and methylene dichloride.
~ 95%. Dry the release agent. The release agent is used
This is because the silicone rubber originally has a non-adhesive property in order to improve work efficiency, and it is not necessary to use the silicone rubber when the silicone rubber has sufficient time to cure. A silicone rubber (a mixture of a main agent and an appropriate amount of a curing agent mixed and stirred) is applied by brush or the like to a uniform thickness (for example, 5 mm) or more on the sampling surface coated with the release material. Cure the silicone rubber. Depending on the characteristics of the silicone rubber, it cures when left at 20 ° C. for about 2 hours.
In this way, the silicone rubber layer 70 is formed as shown in FIG. Silicone rubber has excellent fluidity and can flow to small areas for precise molding. It is also highly elastic and can be used to mold complex shapes and undercuts. A glass mat formed of glass fibers in a mat shape is cut into a predetermined size and laid on the cured silicone rubber layer. At this time, the glass mat is laid so that the glass mat completely covers the entire surface along the unevenness of the sampling surface. A resin (such as an epoxy resin obtained by mixing and stirring an appropriate amount of a curing agent with the main component) is applied by brush or the like so that the glass mat is permeated into the glass mat. During this work, the air is vented so that no air remains between the silicone rubber layer 70 and the glass mat. In the same procedure, the glass mat and the resin are overlapped and reinforced, and as shown in FIG.
Reinforced plastic layer (F
RP layer) is formed. After the FRP layer is hardened (it hardens at 20 ° C for about 24 hours), first the FRP layer (FRP
Mold 72), silicone rubber layer (silicone rubber mold 70)
Peel in order. With the FRP mold 72 and the silicone rubber mold 70 integrated, the surface concrete plate 10
A mold member for molding the surface of the. The silicone rubber mold 70 has sufficient durability and toughness as a mold for concrete products, is sufficiently economical to be used several hundred times or more, and is economical.

An example of the procedure for molding the surface concrete plate 10 shown in FIG. 1 using the mold member formed as described above will be described below. First, the position where the workbench is placed is leveled, and the workbench made of steel is reinforced by square timbers so as to withstand the weight of concrete and installed so that it is horizontal. The mold member formed as described above is horizontally installed on the workbench with the mold inner surface (hereinafter, referred to as a mold surface) for molding the uneven surface portion 16 of the surface concrete plate 10 facing upward. That is, as shown in FIG. 13, the silicone rubber mold 70 is on the upper side of the FRP mold 72.
Is placed in a steel box-shaped mold 74 so that the lower side is on the lower side. The mold 74 is formed such that the bottom plate and the side plate are disassembled and disassembled. A transparent acrylic paint is applied to the mold surface of the silicone rubber mold 70 on the portion corresponding to the stone imitation surface (the portion corresponding to the joint is not coated as much as possible), and the stone powder 76 is sprinkled by hand or by a jet power machine. The stone powder 76 used is
As described above. The transparent acrylic paint used in this example is dried to such an extent that it can be taped at room temperature for 2 hours, but in order to allow stone powder to sufficiently adhere to the mold surface and to enable ready-mixed concrete to be poured. The drying time may be about 30 to 40 minutes. Further, when the coating material is applied to the portion corresponding to the joint of the mold surface and the stone powder 76 is attached, it may be scraped off with a spatula or the like. Furthermore, it is also possible to apply a method in which paint is applied to the entire surface of the mold, and a pattern paper prepared in advance is attached to the portion corresponding to the joint as a masking, and then stone powder 76 is sprinkled and adhered. The insert screw 20 (female screw portion) is set at a predetermined position on the mold surface with a bolt. A rebar such as the wire mesh 18 is installed, and the insert screw 20 is fixed to the rebar or the like so as to be surely positioned at a predetermined place. Further, the metal fitting for forming the air vent hole 21 is fixed with a bolt. In addition,
Since the lath net 14 is installed after placing concrete, the lath net 14 is cut according to the size of the mold. Before pouring concrete, it is confirmed that the mold size and the setting in the mold are completed, and the fresh concrete 78 is chute-cast as shown in FIG. For compaction, use a high-frequency vibrator, etc. to make tight concrete. In addition,
In order to preferably transmit the vibration of the high frequency vibrator, the mold 74 may be supported by a spring. FIG. 14 is a cross-sectional view showing a state of the upper portion of the mold member and the surface portion 16 of the surface concrete plate when the fresh concrete 78 is compacted. Transparent acrylic paint 7 on the surface of silicone rubber mold 70
Stone powder 76 fixed by 7 is raw concrete 78
It is integrated with. The top surface of the concrete thus cast (the back surface of the front surface concrete plate 10) is horizontally finished, and the lath net 14 is installed thereon. The lath net 14 is fixed to the front surface of the concrete plate 10 in an exposed state. Regarding the curing of the surface concrete plate 10, all of the workbench and the molding die are surrounded by a sheet for wet curing in order to prevent rapid drying and temperature change due to direct sunlight, wind and the like. Also,
When the average daily temperature is 4 ° C or less, heat retention curing is performed, and to prevent freezing and thawing of concrete, the workbench and mold are all surrounded by sheets and kept warm and heated. It is usual that the surface concrete plate 10 is removed from the mold on the fourth day or later after the placing.
(Fig. 15) is completed. At this time, since the silicone rubber has a high peeling property, the surface concrete plate 10 can be peeled almost by the weight of the mold members (the silicone rubber mold 70 and the FRP layer 70). Therefore, no special peeling work is required. That is, the transparent acrylic paint 77 is peeled off from the mold surface of the silicone rubber mold 70, transferred and fixed to the surface concrete plate side together with the stone powder 76, and the transparent acrylic paint 77 is attached to the surface of the stone powder 76. In addition,
The mold for the surface concrete plate should be cleaned and reused. After the demolding, the surface of the silicone rubber mold 70 has no dry matter of acrylic, no film, etc., and almost no deposits of concrete lumps remain, so that it is kept clean. Therefore, the surface of the silicone rubber mold 70 can be easily cleaned with a suction type cleaner. The concrete molding part 1
In order to reinforce the surface portion 16 of 2, it is preferable to mix glass fiber with concrete.

In the above embodiment, when forming the concrete plate forming die, the work of forming the original shape of natural stone or the like has been described, but the existing slope or wall can be used as the sampling surface to take the die. . That is, natural concrete stone, Nodama cobblestone, Machichi stone, rubble stone as a material for masonry, stone retaining work, earth retaining wall, concrete retaining wall, or decorative concrete with stone plate fitted to make up makeup. It is possible to take a surface concrete plate as a sampling surface such as a wall surface or a concrete wall surface with an artistic art pattern. A method of taking a prototype of the surface concrete plate on the spot without moving the prototype in this manner is hereinafter referred to as a skin mold method. According to this skin molding method, it is possible to easily take the mold of the surface concrete plate on site, and the surface concrete plate can be molded by the mold.
In other words, spherical projections and depressions due to the existing cobblestone arrangement, geometrical arrangement of shiraishi (quadrilateral) and fracture surfaces and joints of stones,
A prototype can be easily sampled from an irregular arrangement of embedded stone materials, a curve of an art pattern, a striped pattern, etc., and the surface of a surface concrete plate can be suitably formed by the prototype.

According to the surface concrete plate formed by the above molding die and molding method, the following effects can be obtained. In addition, the granular material made of hard and durable substances such as stone powder of natural rocks and crystal fragments is sprinkled on the mold surface by hand or by injection type power machine, and raw concrete is placed and fixed on the surface. You can create a rock surface that is very similar to. That is, the surface of the surface concrete plate,
It is possible to imitate natural rock formations and patterns that are composed of natural rock-forming minerals and natural providence. The scattered stone powder or the like is temporarily attached to the mold surface with a paint (for example, acrylic paint). Therefore, although the mold surface has irregularities, the adhesive force allows the stone powder or the like to be adhered substantially uniformly. Since the mold surface is formed of a silicone rubber layer having excellent releasability, stone powder and the like can be easily separated from the mold surface when the surface concrete plate is released from the mold together with the paint. Therefore, the surface of the surface concrete plate can be appropriately formed in a state where stone powder and the like are fixed together with the paint. Furthermore, the paint is applied to the mold surface and the stone powder is sprinkled by a hand-spreading or jet-type power machine, but the present invention is not limited to this, and stone powder or the like to which the paint is adhered can also be spread and adhered to the mold surface.

Next, a method of copying the molding die for the surface concrete plate will be described. When it is necessary to mass-produce concrete boards, or when it is necessary to store the prototype for a long period of time, duplicate the original shape (having a surface shape in which stones are lined up) based on the mold formed by the skin mold method. In addition, it is possible to duplicate a large number of molding dies by using the duplicate original form. That is, in order to mold the duplicate prototype 80, first, a mold formed by the skin molding method is used as shown in FIG.
As shown in 6, it is formed by pouring gypsum. The original copy (gypsum type) 80 is a gypsum material and water (for example, a weight ratio of 2 :).
1) and a suitable amount of sisal fiber for reinforcement. As shown in FIG. 16, a mold member composed of a silicone rubber layer and an FRP layer is put in a mold frame 74 (made of wood or the like) to form a mold, and the kneaded plaster is poured into the mold. After the hardening, the plaster mold is removed from the mold and inverted to complete the replica master 80.

Next, the replica prototype 8 formed as described above
A method of molding a molding die using 0 will be described. First,
As shown in FIG. 17, the completed replica prototype 80 is formed into a form 7
While fitting in 4, the mold release agent for plaster is applied to the surface. An appropriate amount of the main component of silicone rubber and a curing agent are mixed. The amount of curing agent used will increase or decrease depending on the temperature. The mixed silicone rubber is stirred for a predetermined time with a stirrer, poured on a gypsum surface treated with a release agent to a thickness of about 5 mm, and applied. As described above, the silicone rubber layer is formed in the same manner as in the case of taking a prototype, but a glass mat may be used as a reinforcing material. That is, a glass mat is attached as a reinforcing material to the silicone rubber film that has been poured, and a silicone rubber layer (silicone mold 82) is formed by reinforcing the silicone rubber with the glass mat.

Next, urethane is poured onto the completely cured silicone mold 82 and cured. Urethane is cast by mixing an appropriate amount of a main agent and a curing agent. The urethane compound material is thoroughly stirred and cast into rubberized urethane. At this time, the mold 74 is completely sealed to prevent urethane from leaking out. Further, it is preferable to apply a mold release material to a portion of the inner surface of the mold frame 74 where the urethane contacts. However, since the cured silicone rubber has high releasability, it is not necessary to treat the mold surface of the silicone mold 82 with a release agent. After curing the urethane, the urethane layer (urethane type 8
4) Then, the silicone rubber layer (silicone mold 82) is removed in this order. The thickness of the urethane mold 84 is about 4 cm, and the thickness of the mold member is about 5 together with the thickness of the silicone mold 82.
It will be about cm. In this way, many molds can be molded.

A surface concrete plate can be molded by the mold in which the silicone mold 82 is reinforced by the urethane mold 84 as in the method shown in FIG. That is, as shown in FIG. 18, a urethane mold 84 and a silicone mold 82 are set in this order in a wooden or metal mold frame 74, and fresh concrete 78 is poured. At this time, an acrylic paint is applied to a required portion of the upper surface of the silicone mold 82, and the stone powder 76 of natural rock and crystal fragments are sprinkled by hand or by a jet power machine. Also, structurally required steel lath steel, wire mesh, corner reinforcing bars, joining metal fittings, etc. are inserted. As the material of the member forming the mold, the silicone mold 82 having excellent releasability as described above is used as the inner mold,
Although the urethane type 84 is used as the backup material, the present invention is not limited to this, and other resin materials or the like can be used. The backup material is formed because the silicone rubber has a high weight unit price, which reduces the cost and also reduces the weight.

Next, as an example of the construction using the surface concrete plate 10, regarding a river embankment (construction of a slope), FIG.
This will be described with reference to FIGS. FIG. 19 is a side cross-sectional view of the slope of the embankment in which the imitation stone surface is formed. Also,
20 is a view taken in the direction of arrow D in FIG. 19, and FIG.
It is a -E sectional view. Reference numeral 30 denotes leveling concrete, which is laid and leveled to a predetermined thickness on the slope of the embankment. Surface concrete plate 10 is leveled concrete 3
It is fixed by the filled concrete 34 filled with the surface of 0. In this construction example, the two surface concrete boards 10 are joined by the construction joint portion 35. In the construction joint portion 35, the pin portion 22 is fitted into the pin fitting portion 24, and is preferably continuous so that the surface of the surface concrete plate 10 is not displaced. A concrete foundation 32 is provided with a vertical frame 36 extending vertically along the slope of the slope with the foundation as a foundation. As shown in FIG. 19, the vertical frame 36 has a reinforcing bar 38 for reinforcing it. Further, FIG. 22 shows a case where the slope is formed stepwise. The structure of this embankment is different only in the shape of the surface concrete plate 10a formed in a stepped shape.
Others are the same as the case of the above-mentioned boulder imitation. By thus setting the surface concrete plate in various shapes, the surface of the embankment can be easily formed into a desired pattern.

Next, as a concrete example of the construction method using the surface concrete board 10, a construction method of a slope on a river embankment (a method of lining) will be described with reference to FIGS. 23 to 29. First, as in the case of the conventional lining method, leveled concrete is spread and leveled to an average thickness of about 5 cm on a slope (for example, a slope of 20%) on which the embankment is adjusted to a ruler section. Next, using the concrete foundation 32 as a foundation, a vertical frame 36 (having a cross section of about 30 cm × 30 cm) extending in the vertical direction is provided along the slope of the slope. The vertical frames 36 are arranged with a predetermined width interval in the extending direction of the river. The bolts 40 are attached to the insert screws 20 (three places) integrally fixed to the surface concrete plate 10 (Fig. 2).
3). A hanging wire 41 is attached to the bolt 40, and the surface concrete plate 10 is lifted by a crane (not shown) (FIG. 24). Between the two vertical frames 36, the surface concrete plate 10 is installed by a crane (not shown) at the installation location on the mounting bracket 42 set on the vertical frame 36 for installing the surface concrete plate 10 (FIG. 25). . A holding member 46 (H-shaped steel) dedicated to the float of the surface concrete plate 10 is fixed by using a set metal fitting 45 fixed on the upper surface of the vertical frame 36 at the center in the width direction. The jack member 48 (wooden square) is inserted into the gap between the holding member 46 and the surface concrete plate 10 (FIG. 26). The gap between the surface concrete plate 10 and the leveling concrete 30 is filled with fresh concrete 34a (or mortar). Since this gap is, for example, about 15 cm and has a gradient of 1: 2, it is cast by pouring concrete or a concrete pump car (FIG. 27). Fresh concrete 3 filled with lath net 14 on the back surface of front surface concrete plate 10 by high frequency vibrator 50
The adhesion of 4a is improved, and it is formed into tight concrete (FIG. 28). It should be noted that the surface concrete plate 10 has an air vent hole 21, and the state of mortar blown out from the air vent hole 21 is confirmed to compact the concrete. Finally, the air vent hole 21 and the end 21a are filled with mortar (FIG. 29), and then cured.

FIG. 30 is a sectional view for explaining the details of the mounting bracket 42, the set bracket 45 and the holding member 46. The mounting bracket 42 is made of steel, and is screwed and fixed to a screwing portion provided at a predetermined height position on the side surface of the vertical frame 36. The surface concrete plate 10 is placed on the mounting bracket 42. The set fitting has an upper portion protruding from the upper surface of the vertical frame 36 as a bolt portion 45a, and a lower portion inserted into the vertical frame 36 as an anchor portion 45b.
The anchor portion 45b is formed in an L shape, and is formed so as not to come out of the vertical frame 36. Using this bolt portion 45a, the holding member 46 is fixed via a pipe member so as not to float up.

As described above, according to the construction method using the surface concrete of the present invention, the fresh concrete is filled and placed between the back surface of the surface concrete plate and the base of the building such as leveled concrete. As a result, the surface concrete plate is fixed to the base body, and the wall of the building is integrally formed.
Since the surface concrete plate acts as a formwork, concrete pouring, compaction and curing can be rationalized. Since there is no need to remove the formwork, it is possible to rationalize construction and shorten the construction period. Further, since the surface concrete plate is a factory product, the quality can be made uniform, and the quality of the wall surface of the building such as sloped concrete can be improved. That is, compared to the general construction method, the step of finishing the slope by a skilled worker can be omitted,
Curing can also be performed relatively easily without paying attention to the protection of the surface, which saves labor and shortens the finishing process, resulting in a significant improvement in work efficiency. Furthermore, the surface concrete plate is
It is a secondary product of the factory, and its shape and dimensions can be changed according to the place of use and application. In the above embodiments, the rectangular surface concrete plate has been described, but the present invention is not limited to this. Further, since a natural stone pattern, a mosaic or the like can be easily processed on the surface, a more beautiful and functional wall surface can be formed, and environmental problems can be addressed.

Further, when the surface concrete board 10 of the present invention is used to form a wall body having a steep slope for hitting concrete or a wall body perpendicular to the ground,
It is effective to provide the anchor reinforcing bars 52 on the surface concrete plate 10. An example of construction when constructing a steep wall is shown in FIGS. 31 and 32. 31 is a sectional view of the embodiment of the wall body, and FIG. 32 is a view of the embodiment of FIG. A plurality of anchor reinforcing bars 52 are fixed to the surface concrete plate 10 so as to project from the back surface. The surface concrete plate 10 is supported by a support member 54 at a predetermined slope. The backside concrete plate 56 is vertically supported by the vertical pipe 58 and the horizontal pipe 59 on the ground. The gap 60 between the front concrete plate 10 and the rear concrete plate 56 is also held by the spacing support member 64 (round separator) arranged between the insert screw portion 62 and the anchor rebar 52. As described above, in order to maintain the space between the front surface concrete plate 10 and the back surface concrete plate 56, a steel plate or the like is used in a conventional mold assembly method (a space between mold frames is It can be diverted from PECON (for holding and fixing), round separator, steel pipe and round pipe. That is, the anchor reinforcing bars 52 are used as fastening ends, and the surface concrete 10 can be suitably fixed in combination with the conventional method.

Further, as is clear from FIGS. 31 and 32, the surface concrete boards 10 can be connected by fitting the convex portions 10b and the concave portions 10c provided on the side surfaces. Similarly, the back surface concrete plates 56 can be assembled by fitting the convex portions 56a and the concave portions 56b provided on the side surfaces. Then, by filling the void 60 with concrete, the surface concrete plate 10 can be reliably integrated with the wall body. Since the anchor rebar 52 is used, the concrete or mortar filling the void 60 and the concrete plate are more firmly fixed to each other.

The anchor rebar 52 is used for the following reason. If the slope of the wall is gentle, the weight of the surface concrete plate 10 and the lath net 14 with ribs 14
The adhesive action of does not cause the surface concrete plate 10 to separate from the filled concrete. On the other hand, when the slope of the wall is steep or the wall is perpendicular to the ground, the lath net 14 (thin steel plate) and concrete are different materials, and the lath net 14 is effective as concrete. Although the shape of the surface concrete 10 is not adhered to the surface concrete 10, the surface concrete 10 may be separated and separated at the surface to be adhered. To prevent this, surface concrete board 1
Anchor rebar 52 is embedded in No. 0 and fixed to concrete or mortar filled in the void. Even if the wall has a gentle slope, the adhesion can be further improved by using the anchor reinforcing bar 52.

In the above-mentioned embodiments, the construction relating to the revetment of rivers has been mainly described, but the present invention can also be utilized when forming walls of various buildings. For example, it can be applied to the decorative wall of a building. Further, the present invention can be effectively utilized not only when constructing a new wall body but also when repairing a wall body such as an existing revetment. Although various preferred embodiments of the present invention have been described above, the present invention is not limited to these embodiments, and many modifications can be made without departing from the spirit of the invention. That is.

[0039]

According to the surface concrete plate of the present invention,
The concrete surface side is formed in an uneven shape, and the granular material such as stone powder is transferred and fixed together with the paint from the mold surface of the molding die adhered by the paint on the concrete surface, and the paint is applied to the surface of the granular material. It is attached. For this reason, even though it is a concrete plate, it is possible to obtain a beautiful appearance in which stones are lined up, and the surface of the building can be beautifully finished in the view. In particular, since the paint adheres to the surface of the granular material, it is possible to give a luster, and the stone surface can be appropriately imitated. Further, according to the method for molding a surface concrete plate of the present invention, since the mold surface is formed of silicone rubber, the paint can be suitably peeled off. Therefore, it is possible to transfer and fix the particulate matter in a state in which the paint adheres to the surface of the surface concrete plate, and it is possible to easily manufacture the surface concrete plate imitating the stone surface. As described above, according to the present invention, it is possible to suitably obtain a surface concrete plate that has a beautiful appearance in which stones are lined up and that can form a wall of a building with good finish and efficiency. Has a great effect.

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of a surface concrete plate according to the present invention.

FIG. 2 is an enlarged cross-sectional view showing details of a surface portion of the embodiment of FIG.

FIG. 3 is a plan view of a lath net.

4 is a cross-sectional view taken along the line AA of the lath net shown in FIG.

5 is a back view of the embodiment of the surface concrete plate of FIG. 1. FIG.

6 is a view on arrow B of the embodiment of FIG.

FIG. 7 is a front view of the embodiment of FIG.

FIG. 8 is a view on arrow C of the embodiment of FIG.

FIG. 9 is a perspective view showing an embodiment of a socket fitting.

FIG. 10 is a perspective view showing an example of a pin fitting.

FIG. 11 is an explanatory view showing a forming process of a molding die for a surface concrete plate.

FIG. 12 is an explanatory view showing a forming process of a molding die for a surface concrete plate.

FIG. 13 is an explanatory view showing a process of forming a surface concrete plate.

FIG. 14 is an explanatory diagram showing a step of compacting a surface concrete plate.

FIG. 15 is an explanatory view showing a demolded surface concrete plate.

FIG. 16 is an explanatory view showing another step of forming a mold for a surface concrete plate.

FIG. 17 is an explanatory view showing another step of forming a molding die for a surface concrete plate.

FIG. 18 is an explanatory view showing a step of forming a surface concrete plate.

FIG. 19 is a side sectional view showing a construction example using the surface concrete plate of the present invention.

20 is a view on arrow D of the embodiment of FIG.

21 is a sectional view taken along line EE of the embodiment of FIG.

FIG. 22 is a side sectional view showing another construction example of the present invention.

FIG. 23 is a perspective view illustrating a construction method of the present invention.

FIG. 24 is a perspective view illustrating a construction method of the present invention.

FIG. 25 is a perspective view illustrating a construction method of the present invention.

FIG. 26 is a cross-sectional view illustrating the construction method of the present invention.

FIG. 27 is a perspective view illustrating a construction method of the present invention.

FIG. 28 is a perspective view illustrating a construction method of the present invention.

FIG. 29 is a cross-sectional view illustrating the construction method of the present invention.

FIG. 30 is a cross-sectional view illustrating details of a construction example of the present invention.

FIG. 31 is a side sectional view showing another construction example of the present invention.

32 is a view on arrow X of the embodiment of FIG. 31. FIG.

[Explanation of symbols]

 10 Surface Concrete Plate 12 Concrete Forming Part 13 Paint 14 Lath Net 15 Rib with Groove 16 Surface Part 17 Granular Material 18 Wire Mesh 20 Insert Screw 30 Leveling Concrete 32 Foundation 34 Filled Concrete 36 Vertical Frame 68 Original Form 70 Silicone Rubber Mold 72 FRP Type 74 Formwork 76 Stone powder 80 Replica original form 82 Silicone type 84 Urethane type

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display location E02D 29/02 309 E04B 2/86 FE

Claims (8)

[Claims] 1. Molded into a plate by concrete,
In a surface concrete plate that acts as a concrete formwork and is fixed to fresh concrete or mortar that is placed on the back side to form the surface of the building, the concrete surface side is like a surface where stones are arranged by a molding die. Is formed in an uneven shape on the concrete surface, granular material made of hard durable material such as stone powder or crystal fragments,
A surface concrete plate, characterized in that it is transferred and fixed together with the paint from the mold surface of the molding die adhered by the paint, and the paint adheres to the surface of the granular material. 2. The surface concrete board according to claim 1, wherein the paint is a transparent paint. 3. The surface concrete board according to claim 1, wherein the paint is an acrylic paint. 4. A lath net is exposed and adhered to the back surface so as to be surely adhered to poured concrete or mortar, and the lath net is provided in a predetermined direction so as to serve as a passage for discharging air and water. The surface concrete board according to claim 1, 2 or 3, wherein a plurality of ribs with a groove extending are provided. 5. A silicone rubber layer obtained by applying silicone rubber to a rough original surface formed by arranging stones and the like and curing the silicone rubber to obtain a mold, and a silicone so as to maintain the shape of the silicone rubber layer. A mold for a surface concrete plate, comprising a reinforcing layer formed by applying a liquid resin material on a rubber layer and curing the resin material. 6. The mold for a surface concrete plate according to claim 5, wherein the reinforcing layer is made of reinforced plastic or urethane. 7. A step of applying silicone rubber to a rough original surface formed by arranging stones and the like and curing the silicone rubber to form a silicone rubber layer, and a liquid resin material overlaid on the silicone rubber layer. A method for producing a molding die for a surface concrete plate, comprising: a step of applying and curing to form a reinforcing layer; and a step of separating the reinforcing layer and the silicone rubber layer from the original surface. 8. A mold having a silicone rubber layer obtained by applying silicone rubber to a rough original surface formed by arranging stones and the like and acting as an adhesive on the mold surface of the silicone rubber layer. And a step of adhering a granular material made of a hard and durable substance such as stone powder or crystal fragments to the mold surface coated with the adhesive material, and the concrete for the mold for the surface concrete plate Characterized in that it comprises a step of casting and curing, and transferring the particles with the attached paint to the surface to fix them, and a step of disassembling the mold for the surface concrete plate and taking out the surface concrete plate. Method for forming surface concrete plate.