Method of fabricating decorative concrete articles

FIELD: process engineering.

SUBSTANCE: invention relates to production of decorative concrete articles. Proposed method comprises preparing mix of intermediate layer of the mix of crushed glass cullet, liquid glass and water, laying concrete mix and intermediate layer mix, maturing and thermomoist processing, plasma fusion of article face surface at plasmatron power of 9 kW and plasma burner feed rate of 0.1 m/s.

EFFECT: higher quality, accelerated glasing, power savings.

3 tbl, 2 ex

 

The invention relates to the manufacture of decorative concrete products and can be used in the building materials industry.

Currently, there are several ways of making decorative concrete products using as an energy source screen furnaces, flame torch, plasma torch, laser beam.

A known method of manufacturing a decorative concrete products by melting the front surface of the plasma torch with subsequent heat-moisture treatment and curing for 28 days [1].

[A.C. 1705090. A method of manufacturing a decorative concrete products. / Immortal B.C., Khodykin A.P., Burlakov NM, Travkin V.M., Krokhin, V.P. Stated 03.05.89. Publ. 15.01.92. Bull. No. 2. - Priority of 03.05.89]

However, despite the good quality of the end product, the method has the following disadvantages: the duration and intensity of the process, a significant amount of scrap in the form of spalls and delaminations glaze layer.

The closest technical solution is a method of manufacturing decorative concrete products, consisting in the preparation of the mixture of the intermediate layer, the concrete mixture and the mixture of the intermediate layer, shutter speed, and heat and moisture treatment products, plasma melting front surface when the power p is osmotron 20,34-25,30 kW.

The disadvantage of this method is the high energy intensity of the process, the low flow plasma torch on the front surface of the product equal to 0.05 m/s, and the relatively low quality of the glaze layer [2]. [Gromov J.E., Liapunov VP, Ye CENTURY Industrial facades of the buildings. - M.: stroiizdat, 1980, - p.61-64]

The advantage of the proposed method is to improve the quality of the final product, accelerating melting of the top surface, reducing the intensity of production and, as a consequence, obtaining high-quality competitive products.

This objective is achieved in that the intermediate layer is prepared from a mixture of broken glass, water glass and water, and plasma melting front surface of the products is carried out when the power of the plasma torch 9 kW and the speed of passage of the plasma torch at the front surface of 0.1 m/s

A distinctive feature of the proposed method is the elimination processes of dehydration of the surface layer and the effects of thermal shock due to the use of an intermediate layer on the basis of breakage of glass with liquid glass and water. This allows you to increase the speed of passage of the plasma torch on the front surface of the products and reduce energy consumption.

In the known method the intermediate layer is made from lightweight concrete with what ispolniteljami of clay and perlite. The intermediate layer is applied on the concrete surface and exposed to a plasma melting. In the process of plasma melting the necessary high power operation of the plasma torch and the low flow plasma torch over the surface of the products to obtain a homogeneous melt of digidrirovanny products of the intermediate layer and the filler. In the surface melted layer of concrete products under high temperature processes of dehydration, which ezuprechnaya intermediate layer. This significantly reduces the adhesive strength of the melted layer basis.

It is the value of the strength of adhesion of the melted layer with a basis determines the durability and quality of concrete products.

In the proposed method, with the purpose of eliminating the effects of heat stroke and dehydration of the cement stone the last intermediate layer is made from a mixture of broken glass, water glass and water. The intermediate layer under the action of high temperature plasma torch melted with the formation of high quality front surface and prevents the concrete from dehydration and destruction, and also protects against thermal shock, the product of concrete.

Inventive step of the proposed method is confirmed by the fact that the elimination of the consequences of heat stroke and dehydration of the cement to the mnya by applying an intermediate layer of a mixture of glass with liquid glass and water can not only get high quality product with high strength, but to speed up the process and reduce energy consumption.

The analysis of the known methods for the production of decorative concrete products allows to make a conclusion on the compliance of the claimed invention, the criterion of "novelty".

Comparative analysis of the technological operations of the proposed and known methods is presented in table 1. As can be seen from table 1, in the conventional method is time-consuming and expensive operation is applied on the panel surface of an aqueous solution of metal oxides or glaze slip. The most important operations are the preparation of the intermediate layer and the melt front surface of the plasma torch. The technological operation of the melting front surface is crucial in the method of manufacturing a decorative concrete products.

td align="justify"> 1. Preparation of a mixture of the intermediate layer of expanded clay or perlite sand, cement and water
Table 1
Comparative analysis of the technological operations of the proposed and known methods [2], pp.61-62
The proposed methodThe known method
12
1. Preparation of the intermediate layer of ground glass breakage, water glass, water
2. Laying in the form of a concrete mix and embedded parts; laying face layer of heavy concrete thickness of 3 cm (level 2 cm from the top edge)2. Laying in the form of a concrete mix and embedded parts; laying face layer of heavy concrete thickness of 3 cm (level 2 cm from the top edge)
3. Laying a mixture of the intermediate layer stacked on the concrete with a thickness of 3.0-3.5 cm in loose condition3. Laying a mixture of the intermediate layer stacked on the concrete with a thickness of 3.0-3.5 cm in loose condition
4. Compaction of the mixture of the intermediate layer level with the edge of the form.4. Compaction of the mixture of the intermediate layer level with the edge of the form.
5. The heat and humidity exposure and processing panels5. Exposure and heat and humidity of obrabativala
6. Melt the front surface of the plasma torch with a speed of 0.1 m/s6. Coating the surface of the molten panel of an aqueous solution of metal oxides or glaze slurry to give a specified color
7. Melt the front surface of the electric-arc torch (plasma torch)* with a speed of 0.05 m/s
* - note authors

The optimal conditions of the melting front surface of concrete products, experimentally obtained, is the power of the plasma torch 9 kW at a speed of passage of the plasma torch 0.1 m/s (table 2).

Table 2
The optimal parameters of the plasma melting front surface of concrete products.
№ p/pThe power of the plasmatron, kWThe plasma gas flow, l/minThe rate of passage of a plasma torch, m/s The adhesive strength of the melted layer basis, MPa
1.7200,0251,96
0,0502,18
0,0752,49
0,1002,81
0,1252,71
2.8200,0252,07
0,0502,37
0,0752,61
0,1002,96
0,1252,65
3.9*20*0,0252,68
0,0502,84
0,0753,02
0,100*3,24*
0,1253,06
4.10200,0252,13
0,0502,53
0,0752,79
0,1003,01
0,1252,83
* is the optimal mode

Comparative data quality indicators and technological parameters of the proposed and known methods are presented in table 3.

Table 3
Indicators of quality and technological parameters of the proposed and known methods.
№ p/pIndicatorsEd. dimensionThe proposed methodThe known method [2]
12245
1Energy (MoE is the ability of plasma torch operation) kW920,3-to 25.3
113×180=20300 W=20,3 kW
110×230=25300 W=25,3 kW
2The rate of passage of a plasma torchm/s0,1000,05
3The adhesive strength of the melted layer with a basisMPa3,24-
4The quality of the fused layerWith smooth spillStreaks melt roughness [2, pp.62]
5Plasma gasArgonArgon
6The average thickness of the melted layermm0,3-0,50,3-0,8

Example. Manufacturer of decorative concrete products.

In the form for the production of panels of standard size was 2.76×,18 laid heavy concrete.

Was previously prepared mixture for the intermediate layer. Ground combat sheet glass were mixed in a mortar with liquid glass and water in the ratio: glass : water glass : water = 10:2:3

Laid-in form on the surface of the heavy concrete mixture of the intermediate layer thickness 3.0 cm in loose condition.

To summarize the platen mixture of the intermediate layer level with the edge of the form.

The form was kept for 2 hours and conducted heat and humidity treatment on standard factory settings.

Free product of the form and perform the melt front surface of the plasma torch MT-5P arc plasmatron UPA-8m with a speed of 0.1 m/s

Full melt front surface of the panel produced thirty passages plasma torch MT-5P. Plasma gas was argon, the flow rate was 20 l/min After plasma melting on the front surface of the panel formed of high-quality glaze layer thickness of 0.3-0.5 mm.

After plasma melting front surface of the panel was determined by the strength of adhesion of the coating to the base.

An example implementation of quality control.

To determine the strength of adhesion of the melted layer was prepared 5 samples of size 60×60×60 mm according to the technology specified in the example.

To the melted surface of five samples go active is ivali epoxy resin five metal rods with a length of 150 mm and an area of 1 see After polymerization of the epoxy resin within 24 hours was begun to determine the strength of adhesion of the melted layer based on a tensile testing machine To 0.5 in. The metal rods are secured in a special clamps bursting machine. After uniform loading was separation of the melted layer. The adhesive strength of the melted layer was defined as the arithmetic average of the five measurements:

σp3=(3,25+3,24+3,26+3,22+3,25)/5=3,24 MPa.

A method of manufacturing a decorative concrete products, comprising preparing a mixture of the intermediate layer, the concrete mixture and the mixture of the intermediate layer, compacting the mixture of the intermediate layer, the heat and humidity exposure and processing products, plasma melting their front surface, wherein the intermediate layer is prepared from a mixture of ground glass breakage, water glass and water, and plasma melting is carried out at the power of the plasma torch 9 kW and the speed of passage of the plasma torch at the front surface of 0.1 m/s



 

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