JP7492266B2 - Washout panel and its manufacturing method - Google Patents

Description

The present invention relates to a washout panel and a method for manufacturing the same.

One way to add decoration to inorganic concrete surfaces to improve their appearance is with a wash-out finish in plastering work.

This method delays the hardening of the cement paste on the finishing surface after the concrete is poured, and then washes it away to expose decorative materials such as aggregate on the concrete surface.

Similar surface finishing methods include polishing and blasting, but the advantage of washout finishing is that it is low cost and easy to apply since no equipment is required.

Washing finishes can be achieved by using a set retarder to slow down the setting and hardening of cement, by washing unhardened concrete with water, or by pickling after the concrete has hardened.

Patent Document 1 discloses a surface decoration method in which a certain thickness of mortar made by adding water and silica sand to a binder made of alumina cement with added setting retarders and hardening accelerators is applied, a net is laid on the surface of the mortar, decorative stones are scattered on the net, the decorative stones are spread evenly and aligned close to each other, the decorative stones are pressed into the mortar, any mortar that has come up from the joints is leveled to cover the decorative stones, and when the mortar has hardened to the extent that the decorative stones do not move, the surface mortar is wiped off to expose the decorative stones.

Japanese Patent No. 4268676

Generally, when washing unhardened concrete with water to create a washout finish, the surrounding area becomes flooded with water, making it difficult to perform the washout finish indoors.

In addition, when using a wash-out finish, it was necessary to wait for the concrete to become semi-dry, which resulted in a long construction time.

The object of the present invention is to provide a washout panel that can be used indoors.

Another object of the present invention is to shorten the construction time for wash-out finishing.

A panel according to a first aspect of the present invention that can be attached to a wall surface or laid on a floor, comprising:
A mesh-like fiber disposed on the lower surface side;
a first cement layer including aggregate disposed above the fibers;
a second cement layer including aggregate disposed on the first cement layer;
a core material disposed between the first cement layer and the second cement layer;
This is a washout panel in which part of the aggregate is exposed on the surface of the second cement layer.

Examples of aggregates include round stones such as Nachi stone (white Nachi stone, black Nachi stone), Oiso gravel, white jade stone, rust stone, green fossil stone, and Hongoshiki stone.

This type of washout panel can also be used indoors.

In addition, this can shorten the construction time that would normally be required for the washout finish.

The panel according to the second aspect of the present invention is the washout panel according to the first aspect, in which the core material is reinforcing bars and the washout panel is latticed.

The core material is reinforcing bars, and the lattice-shaped core material makes the washout panel sturdy. The reinforcing bars may be deformed bars or round bars.

The panel according to the third aspect of the present invention is the washout panel according to the first or second aspect, in which the fibers are made of plastic and have a lattice pattern.

Because the fibers are made of plastic, they are less likely to deteriorate, and because they are latticed, they are breathable, and the panels are easier to wash out and peel off from the wooden or metal mold.

A method for producing a panel according to a fourth aspect of the present invention is a method for producing a panel that can be attached to a wall surface or laid on a floor, comprising the steps of:
a fiber placement step of placing a mesh-like fiber on a wooden or metal mold;
A first cement layer process in which cement containing aggregate is rubbed on the upper side of the fiber using a trowel to create a first cement layer;
a core material placement step of placing a core material on the first cement layer containing aggregate;
A second cement layer process of rubbing cement containing aggregate onto the core material placed on the first cement layer to create a second cement layer;
and a washing step of washing out the surface of the second cement layer before the surface of the second cement layer hardens to expose a part of the aggregate on the surface.

By using washout panels manufactured using this manufacturing method, walls and floors can be finished with a washout finish even indoors without using water.

In addition, compared to the usual case of using a wash-out finish, the wash-out panels can be manufactured in advance, shortening the construction period.

The panel manufacturing method according to the fifth aspect of the present invention is the panel manufacturing method according to the fourth aspect, which is a washout panel manufacturing method including a hardening retarder spraying step of spraying or applying a hardening retarder onto the second cement layer after the second cement layer step and before the washout step.

By spraying or applying a hardening retarder to the second cement layer, it becomes less likely that the timing for washing out will be missed.

FIG. 2 is an exploded perspective view of a washout panel inserted into a wooden mold according to an embodiment of the present invention. FIG. 2 is a cross-sectional side view of the washout panel inserted into the wooden mold according to the embodiment; FIG. FIG. 4 is a flowchart showing a method for manufacturing the wash-out panel according to the embodiment.

The following describes an embodiment of the present invention with reference to the drawings.

First, we will give a general explanation of examples of "washed-out finishes" on walls. "Washed-out finishes" are also called "washed-out finishes" and are a type of wall and floor finish in which seed stones and cement are mixed and applied to the mortar base, and then the surface is washed with water using a sprayer or similar device just before hardening to expose the seed stones.

The method for a washout finish involves first soaking the base, such as a mortar wall, with water or applying an absorption adjuster to prevent drying out.

Next, a trowel or similar tool is used to "scrub" the surface, and then the first coat of seed stone is applied. Then the second coat of seed stone is applied.

When working on a floor, if the seed stones are large, workers may place them by hand.

Next, the "flake" on the surface is removed and the first laying is performed. "Flake" is a type of cement that looks like a masonry.

If it's taking too long to dry, use newspaper to apply some flour to absorb the moisture and remove the humidity.

Next, remove the surface lining, check how the stones are packed, and lay them down for the second time.

Next, before the surface hardens, the surface is "washed out" with a brush dipped in water to complete the process. Washing out can also be done with a sponge dipped in water.

<Method of manufacturing the washout panel 100>
A washout panel 100 according to an embodiment of the present invention will be described with reference to the drawings. In this embodiment, a wooden mold is used, but a metal mold may also be used.

First, the worker places the mesh-like fiber 300 on the wooden mold 200 for producing the washout panel 100 (step S11, fiber placement process).

The fiber 300 is preferably made of plastic fibers such as vinylon, glass fiber, or polyethylene, which are resistant to deterioration.

In addition, the fiber 300 in this embodiment is lattice-shaped, but it may also be mesh-shaped or punched.

By placing the fiber 300 on the bottom side (negative z-axis side, xy plane), it becomes easier to separate from the wooden mold 200 and moisture can escape more easily.

In addition, by placing the fiber 300 on the back surface (negative z-axis side) of the washout panel 100, there is an advantage in that it is less likely to crack.

The fiber 300 may or may not be visible when viewed from the back side (negative z-axis side) of the washout panel 100.

Next, the worker uses a trowel to rub cement (cement mortar) containing aggregate 400 onto the upper side (positive z-axis direction) of the fiber 300 to create a first cement layer 410 (step S12, first cement layer process).

In this embodiment, a mortar adhesion enhancer is mixed into the cement mortar.

In this embodiment, round stones are used as aggregate 400, examples of which include Nachi stone (white Nachi stone, black Nachi stone), Oiso gravel, white jade stone, rust stone, green stone, and five-color stone.

In addition, in this embodiment, the cement mixed with the aggregate 400 is rubbed on, but if the seed stones that make up the aggregate 400 are large, the workers may arrange them by hand.

In addition, instead of round stones, glass, shells, recycled aggregate, crushed stone for artificial stone, etc. may be used as aggregate 400.

In this embodiment, Portland cement or the like is used as the cement mortar.

If the washing out process needs to be completed in a short time, a mortar made by mixing alumina cement with a setting retarder and hardening accelerator, water and silica sand may be used.

Set retarders that can be added to alumina cement include starch ether, casein, cellulose, polyvinyl alcohol (Poval), as well as citric acid, sodium citrate, sodium gluconate, tartaric acid, boric acid, lignin sulfonate, oxycarboxylate, sugar, and sugar derivatives.

Also, materials whose main components are silicofluorides or oxycarboxylates can be used in the same way.

Retarder agents are generally thought to delay the initial hydration reaction by temporarily blocking contact between the cement and water by adsorbing themselves or their reactants onto the surface of cement particles, and the amount of retarder to be added is determined taking into account factors such as working time.

Next, the worker places the core material 500 on top of the first cement layer 410 containing the aggregate 400 (step S13, core material placement process).

In this embodiment, the core material 500 is a lattice-shaped reinforcing bar, but it may also be round steel or deformed reinforcing bar.

It is preferable that the size of the lattice of the core material 500 be larger than the squares of the aggregate material 400.

This allows aggregate 400 such as round stones to fit into the lattice squares of the core material 500, making the washout panel 100 less likely to crack.

By inserting the core material 500 inside the washout panel 100, the washout panel becomes less likely to crack.

Next, the worker rubs the cement containing aggregate 400 again onto the core material 500 placed on the first cement layer 410 to create the second cement layer 420 (step S14, second cement layer process).

If the area is large, you can flatten it with a register or ruler, or you can tap it.

Next, the worker uses a trowel to lay the second cement layer 420 down from above (step S15).

Next, the worker sprays or applies a set retarder onto the second cement layer 420 (step S16, set retarder spraying process).

In this embodiment, the hardening retarder used is "Lugasol C" manufactured by Sika Chemicals Japan Co., Ltd.

By spraying a hardening retarder onto the second cement layer 420, the mortar on the surface does not harden, making it easier to wash off.

Next, the worker performs washing before the surface 421 of the second cement layer 420 hardens, exposing part of the aggregate 400 on the surface 421 (step S17, washing process).

If the area of the second cement layer 420 is large, the cement on the surface 421 is washed away with water to expose part of the aggregate 400 on the surface 421.

For small areas where water cannot be drained, wash out the surface 421 by scrubbing it with a wet brush or wet sponge, exposing part of the aggregate 400 on the surface 421.

<Washing Panel 100>
The washout panel 100 will be described with reference to the drawings. Note that the same contents as those described in the manufacturing method of the washout panel 100 will be omitted or briefly described.

The washout panel 100 according to this embodiment is
A mesh-like fiber 300 disposed on the lower surface side;
a first cement layer 410 including aggregate disposed on top of the fibers 300;
a second cement layer 420 including aggregate disposed on the first cement layer 410;
and a core material 500 disposed between the first cement layer 410 and the second cement layer 420 .

As described above, the fiber 300 is a plastic fiber, and in this embodiment, it is lattice-shaped.

In this embodiment, the first cement layer 410 contains aggregate 400 such as round stones, and also contains a mortar adhesion enhancer.

In this embodiment, the core material 500 is placed on the first cement layer 410, is reinforcing steel, and has a lattice shape.

The second cement layer 420 has the same or similar components as the first cement layer 410 and also contains aggregate 400.

The aggregate 400 in the second cement layer 420 is smaller than the squares of the lattice-shaped core material 500 and fits into the squares of the core material 500.

The surface 421 of the second cement layer 420 exposes a portion of the aggregate 400, such as round stones, due to washing.

If the washout panel 100 is manufactured in advance before construction begins, on-site work can be shortened.

In addition, because the washout panel 100 is manufactured in advance, there is no need to perform washout by spraying water on-site, and the washout panel 100 can be used indoors by sticking it to a wall or laying it on the floor like tiles.

The washout panel 100 may be manufactured large and then cut into small tile-sized pieces.

The present invention can be implemented in various forms with various improvements, modifications, or variations without departing from the spirit of the invention.

100 Washout panel 200 Wooden mold 300 Fiber 400 Aggregate 410 First cement layer 420 Second cement layer 421 Surface 500 Core material

Claims (4)

A panel that can be attached to a wall or laid on a floor,
It is possible to remove moisture from the underside, and mesh-like fibers are placed on the underside to make it less likely to crack,
a first cement layer including aggregate disposed above the fibers;
a second cement layer including aggregate disposed on the first cement layer;
A lattice-shaped core material is disposed between the first cement layer and the second cement layer to prevent cracking ,
By washing out the surface of the second cement layer, a part of the aggregate is exposed on the surface of the second cement layer , and the washed-out panel is used by cutting it into tiles . 2. The washout panel according to claim 1, wherein the core material is a reinforcing bar and the fibers are made of plastic . A method for manufacturing a panel that can be attached to a wall or laid on a floor, comprising the steps of:
A fiber arrangement process of arranging a mesh-like fiber on a wooden or metal mold having a bottom and a side surface so that the mold can be easily released from the wooden or metal mold, moisture can be removed from the bottom surface side, and the mold is less likely to crack;
A first cement layer process in which cement containing aggregate is applied to the upper side of the fibers arranged on a wooden or mold having a bottom and sides using a trowel to create a first cement layer;
A core material arranging step of arranging a lattice-shaped core material on the first cement layer containing aggregate to make it difficult to crack ;
A second cement layer process of rubbing cement containing aggregate onto the core material placed on the first cement layer to create a second cement layer;
a washing step of washing out the second cement layer before the surface of the second cement layer hardens to expose a part of the aggregate on the surface;
A cutting step of cutting the panel into tiles . 4. The method for manufacturing a washout panel according to claim 3 , further comprising a set retarder spraying step of spraying or applying a set retarder on said second cement layer after said second cement layer step and before said washout step.

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