Natural stone block and production method of natural stone block

Abstract

To provide a natural stone block and a production method of the natural stone block in a simple production process allowing its production at a construction site without discharging waste.SOLUTION: A natural stone block 100 is provided with: a base body 10 having a bottom plate 12 and an erected wall 14 erected from an outer peripheral edge of the bottom plate 12; an adhesive aggregate layer 20 in which an adhesive aggregate material 22 being a mixture of an adhesive agent and adhesive aggregate is coated on an upper surface of the bottom plate 12; and natural stones 30 buried partially in the adhesive aggregate layer 20.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to natural stone blocks and a method for manufacturing natural stone blocks.

Background Art

[0002] Natural stone blocks formed by embedding natural stones in concrete with the natural stones exposed on the surface are known. As such natural stone blocks, for example, a configuration as disclosed in Patent Document 1 (Japanese Patent No. 3890557) is known.

[0003] The natural stone block disclosed in Patent Document 1 is manufactured by laying agar and elastic chips in a mold, embedding a part of the natural stone in the agar and the elastic chips, placing concrete after the agar has gelled, and removing the agar and the elastic chips after the concrete has hardened.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] For the natural stone block disclosed in Patent Document 1, it is necessary to remove the previously laid agar and elastic chips after the concrete placed in the mold has hardened. Therefore, the manufacturing of natural stone blocks is complicated, and it is necessary to discard the removed agar and elastic chips, so there is a problem that manufacturing at the construction site is difficult.

Means for Solving the Problems

[0006] Therefore, the present invention is to solve the above problems, and its object is to provide a natural stone block and a method for manufacturing the same, which have a simple manufacturing process, can be manufactured at a construction site, and do not discharge waste.

[0007] As a result of intensive research by the inventor to solve the above problems, the following configuration was conceived. That is, the present invention is characterized by comprising a base body having a bottom plate and a standing wall standing from the outer peripheral edge of the bottom plate, an adhesive aggregate layer in which an adhesive aggregate, which is a mixture of an adhesive and an aggregate, is laid on the upper surface of the bottom plate, and natural stones partially embedded in the adhesive aggregate layer.

[0008] Thereby, it becomes possible to provide a natural stone block having a simple manufacturing process, which can be manufactured at a construction site and does not discharge waste.

[0009] Further, it is preferable that a concrete layer or a mortar layer is formed in a range from the upper surface of the adhesive aggregate layer to a required height position of the natural stone.

[0010] Thereby, it is possible to more effectively prevent the natural stone from peeling off.

[0011] Further, it is preferable that the upper surface height position of the concrete layer or the mortar layer is the same as the upper surface height position of the standing wall.

[0012] Thereby, the appearance of the natural stone block can be improved, the adhesion strength between the natural stone and the concrete is increased, and the durability of the natural stone block is improved.

[0013] Further, it is preferable that the bottom plate and the standing wall are integrally formed.

[0014] Thereby, the durability of the natural stone block is improved.

[0015] Further, it is preferable that the standing wall has an outer surface standing in a direction orthogonal to the bottom plate, and is formed in a single-taper shape in which the wall thickness gradually decreases as it approaches the upper end side.

[0016] This increases the adhesion area between the base portion and the concrete, improving the durability of the natural stone block.

[0017] There is also an invention of a method for manufacturing a natural stone block, which includes a step of laying a base body having a bottom plate and a standing wall standing from the outer peripheral edge of the bottom plate, a step of laying an adhesive aggregate, which is a mixture of an adhesive and an aggregate, on the upper surface of the bottom plate to form an adhesive aggregate layer, and a step of partially embedding natural stones in the adhesive aggregate layer.

[0018] This enables the provision of a natural stone block with a simple manufacturing process that can be manufactured at the construction site and without waste discharge.

[0019] Further, it is preferable to further include a step of forming a concrete layer or a mortar layer on the adhesive aggregate layer.

[0020] This can provide a natural stone block in which the natural stones are less likely to peel off.

[0021] Further, it is preferable that the step of placing the concrete layer or the mortar layer is performed until the upper surface height position of the standing wall and the upper surface height position of the concrete layer or the mortar layer are at the same height.

[0022] This can improve the appearance of the natural stone block, increase the adhesion strength between the natural stone and the concrete, and improve the durability of the natural stone block.

Effects of the Invention

[0023] By adopting the configuration of the natural stone block and the manufacturing method of the natural stone block in the present invention, it is possible to provide a natural stone block that has a simple manufacturing process, can be manufactured at the construction site, and has no waste discharge.

Brief Description of the Drawings

[0024]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0025] Hereinafter, an embodiment of the natural stone block 100 according to the present invention will be specifically described with reference to the drawings. As shown in FIG. 1, the natural stone block 100 in the present embodiment includes a base body 10, an adhesive aggregate layer 20, a natural stone 30, and a concrete layer 40, and the base body 10 and the natural stone 30 are integrally formed by the adhesive aggregate layer 20 and the concrete layer 40. Note that the natural stone 30 in the present embodiment is a concept that includes not only stones in the state taken from a crushed stone quarry or the like, but also stones obtained by adjusting the stones in the state taken from a crushed stone quarry or the like to a predetermined size.

[0026] The base body 10 is formed in a dish shape having a bottom plate 12 formed in a rectangular shape in plan view and standing walls 14 standing in the plate thickness direction of the bottom plate 12 at the outer peripheral edge position of the bottom plate 12. A guide 16 indicating the height position of the upper end surface of the adhesive aggregate layer 20 corresponding to the dimensions of the natural stone 30 embedded in the base body 10 may be disposed on the inner surface of the standing wall 14. Examples of the guide 16 include a concave groove formed on the inner surface of the standing wall 14, sealing, painting, and the like. Further, as shown in FIG. 1, in the standing wall 14 in the present embodiment, the outer surface 18 stands in a direction orthogonal to the bottom plate 12, and is formed in a so-called single taper shape in which the wall thickness of the standing wall 14 gradually becomes thinner as it approaches the upper end side of the standing wall 14. Furthermore, by roughening the upper surface of the bottom plate 12 and the inner surface of the standing wall 14, the adhesion strength between the adhesive aggregate layer 20 and the concrete layer 40 and the base body 10 can be improved. Such a base body 10 is supplied to a construction site such as a revetment work as a concrete secondary product. Here, the base body 10 in which the bottom plate 12 and the standing wall 14 are integrally formed is illustrated, but a form of the base body 10 in which the bottom plate 12 and the standing wall 14 are separately formed may also be adopted.

[0027] The adhesive aggregate layer 20 is a mixture of an aggregate typified by sand, crushed stone, and waste gravel and an adhesive, and is a mixture of sand and an adhesive with the adhesive coated (adhered) on the outer surface, laid on the upper surface of the bottom plate 12 with a predetermined thickness. Although sand is used as the aggregate here, the aggregate is not limited to sand. Further, as the adhesive, a so-called civil engineering adhesive typified by an epoxy resin-based adhesive or a methacrylic acid-based adhesive is preferably used, but the specific components of the adhesive are not particularly limited. The mixing ratio of the aggregate and the adhesive can be appropriately adjusted according to the mass of the natural stone 30 to be used, the embedding depth of the natural stone 30 in the adhesive aggregate layer 20, the purpose of using the natural stone block 100, and the like. For mixing the aggregate and the adhesive, a concrete mixer or the like can be used to mix the two at the construction site.

[0028] The natural stone 30 is appropriately selected in terms of the stone type and size according to the purpose of use of the natural stone block 100. The natural stone 30 is partially embedded in the adhesive aggregate layer 20 in the height direction with its lower end not in contact with the bottom plate 12, and a natural stone 30 with a height dimension such that the height position of its upper end is the same as the upper surface height position of the standing wall 14 or above the upper surface height position of the standing wall 14 is used.

[0029] The concrete layer 40 is placed from the upper surface of the adhesive aggregate layer 20 to the range of the required height position of the natural stone 30 using concrete with a general mix for reinforced concrete. Here, as shown in FIG. 1, the upper surface height position of the standing wall 14 and the upper surface height position of the concrete layer 40 are at the same height. When the upper surface height position of the concrete layer 40 is made the same as the upper surface height position of the standing wall 14, the upper end of the natural stone 30 protrudes above the upper surface height position of the standing wall 14.

[0030] Next, the manufacturing method of the natural stone block 100 shown in FIG. 1 will be described. FIG. 2 is a flowchart showing the schematic manufacturing method of the natural stone block 100 in the present embodiment. The constructor executes a step (S-1) of laying a concrete base body 10 on the ground surface G at the construction site as shown in FIG. 3. The constructor may perform a step of roughing the upper surface of the bottom plate 12 and the inner surface of the standing wall 14 by blasting or the like on the upper surface of the bottom plate 12 and the inner surface of the standing wall 14 as necessary. Next, the constructor executes a step of laying the adhesive aggregate 22 on the upper surface of the bottom plate 12 to form an adhesive aggregate layer 20 with a preset thickness (S-2). Here, the adhesive aggregate layer 20 is formed up to the height position of the guide 16 formed on the inner surface of the standing wall 14.

[0031] Next, as shown in FIG. 5, the constructor executes a step (S-3) of embedding the required height range on the lower end side of the natural stone 30 in the adhesive aggregate layer 20 (adhesive aggregate 22) before the adhesive aggregate layer 20 hardens. Even when the natural stone 30 is embedded in the adhesive aggregate layer 20, the outward spread of the adhesive aggregate layer 20 is suppressed by the upright wall 14 that stands up from the outer peripheral edge of the bottom plate 12. Further, in the natural stone 30 of the present embodiment, since the lower end portion is partially embedded in the adhesive aggregate layer 20 in a state of being non-contact with the upper surface of the bottom plate 12, the adhesive force between the adhesive aggregate layer 20 and the natural stone 30 can be maximally increased. By embedding the natural stone 30 in the adhesive aggregate layer 20 in this way, the natural stone 30 can be erected on the base body 10 (adhesive aggregate layer 20) in a stable state, and the appearance state of the natural stone 30 at the time of completion of the natural stone block 100 can be determined in advance. As is clear from FIG. 5, the height position of the upper end portion of the natural stone 30 is set to be higher than the upper surface height position of the upright wall 14.

[0032] After the adhesive aggregate layer 20 (adhesive aggregate 22) in which the natural stone 30 is embedded has hardened, the constructor executes a step (S-4) of placing concrete on the adhesive aggregate layer 20 to form a concrete layer 40, as shown in FIG. 6. In the present embodiment, the upper surface height position of the concrete layer 40 is the same as the upper surface height position of the upright wall 14. Since the natural stone 30 erected on the base body 10 via the adhesive aggregate layer 20 is firmly held by the adhesive aggregate layer 20, the natural stone block 100 can be completed without changing the erected state of the natural stone 30 even when concrete is placed. Thus, since there is no waste in the manufacture of the natural stone block 100 in the present embodiment, it is particularly convenient for on-site construction.

[0033] The natural stone block 100 manufactured as described above has the following advantages as compared with a conventional natural stone block (not shown) in which natural stones 30 are simply arranged on a concrete base body 10 and integrated with concrete. First, it is possible to easily manufacture the natural stone block 100 at the construction site. Second, separation (disassembly) between the base body 10 and the portion excluding the base body 10 can be prevented, and the natural stone block 100 in an integrated state can be provided over a long period. Third, the posture of the natural stones 30 erected on the base body 10 is maintained when the concrete layer 40 is placed, and the natural stone block 100 can be manufactured as intended.

[0034] FIG. 7 is a schematic configuration diagram of a revetment 300 using the natural stone block 100 in the present embodiment. A constructor may arrange or construct the foundation block 200 at the toe of the slope of a slope S such as a levee and lay the natural stone blocks 100 along the slope S. Since the base body 10 of the natural stone block 100 is a secondary product manufactured in a factory and has high dimensional accuracy, it is convenient in that it is possible to lay the natural stone blocks 100 as designed even when a plurality of natural stone blocks 100 are laid. Also, adjacent natural stone blocks 100 can be connected using a connector (not shown) if necessary. Thus, by using the natural stone block 100 in the present embodiment, it is possible to inexpensively construct a structure having an appearance similar to that of the natural stone cladding method even without a craftsman of the so-called natural stone cladding method.

[0035] Note that the configuration of the natural stone block 100 according to the present invention is not limited to the embodiment described above. For example, in the above embodiment, the base body 10 having a rectangular shape in plan view is used, but a base body 10 formed in another known planar shape such as a polygonal shape can be used. Thereby, the planar shape of the natural stone block 100 is not limited to the rectangular shape either.

[0036] In the above-described embodiments, the upright wall 14 formed in a single-taper shape is illustrated, but the shape of the upright wall 14 is not limited to this shape. The upright wall 14 can adopt a straight-wall shape in which each of the outer surface 18 and the inner surface stands upright in a direction perpendicular to the bottom plate 12, or a trapezoidal shape in which each of the outer surface 18 and the inner surface gradually approaches as it approaches the upper surface of the upright wall 14.

[0037] In the above-described embodiments, sand and crushed stone are illustrated as the aggregate of the adhesive aggregate 22, but the aggregate of the adhesive aggregate 22 is not limited to these, and granular materials of waste such as waste glass can also be adopted. The aggregate in the adhesive aggregate 22 is not particularly limited as long as the adhesion strength with the adhesive to be used can be ensured and the embedded state of the natural stone 30 can be maintained. And although the natural stone 30 is illustrated in a form embedded in the adhesive aggregate layer 20 in a state of being non-contact with the upper surface of the bottom plate 12, it is not limited to this form. When the adhesion force between the natural stone 30 and the adhesive aggregate 22 is sufficiently ensured, a form in which the natural stone 30 is embedded in the adhesive aggregate layer 20 in a state of being in contact with the upper surface of the bottom plate 12 can be adopted.

[0038] In the above-described embodiments, the height position of the upper surface of the concrete layer 40 is the same as the height position of the upper surface of the upright wall 14, but the height position of the upper surface of the concrete layer 40 may be lower (on the side of the base body 10) than the height position of the upper surface of the upright wall 14. The height position of the upper surface of the concrete layer 40 is not particularly limited as long as the natural stone 30 is reliably held by the adhesive aggregate layer 20. And in the above-described embodiments, a form in which the concrete layer 40 is formed on the adhesive aggregate layer 20 is illustrated, but a form in which a mortar layer (not shown) is formed on the adhesive aggregate layer 20 instead of the concrete layer 40 can also be adopted. And a form of the natural stone block 100 in which the formation of the concrete layer 40 and the mortar layer is omitted can also be adopted.

[0039] Furthermore, it is also possible to adopt a form in which the embodiments described above and the modified examples described in each embodiment are appropriately combined.

Explanation of Reference Numerals

[0040] 10: Base body 12: Bottom plate, 14: Side wall, 16: Guide, 18: Outer surface of side wall 20: Adhesive aggregate layer 22: Adhesive aggregate 30: Natural stone 40: Concrete layer 100: Natural stone block 200: Foundation 300: Revetment G: Ground surface S: Slope

Claims

1. A base body having a bottom plate and a standing wall rising from the outer peripheral edge of the bottom plate, An adhesive aggregate layer in which an adhesive aggregate, which is a mixture of an adhesive and an aggregate, is laid on the upper surface of the bottom plate, Natural stones partially embedded in the adhesive aggregate layer, characterized in that it comprises a natural stone block.

2. The natural stone block according to claim 1, characterized in that a concrete layer or a mortar layer is formed in a range of a required height position of the natural stone from the upper surface of the adhesive aggregate layer.

3. The natural stone block according to claim 2, characterized in that the upper surface height position of the concrete layer or the mortar layer is the same as the upper surface height position of the standing wall.

4. The natural stone block according to any one of claims 1 to 3, characterized in that the bottom plate and the standing wall are integrally formed.

5. The natural stone block according to any one of claims 1 to 3, characterized in that the outer surface of the standing wall stands perpendicular to the bottom plate and is formed in a single-taper shape in which the wall thickness gradually becomes thinner as it approaches the upper end side.

6. A step of laying a base body having a bottom plate and a standing wall rising from the outer peripheral edge of the bottom plate, A step of laying an adhesive aggregate, which is a mixture of an adhesive and an aggregate, on the upper surface of the bottom plate to form an adhesive aggregate layer, A step of partially embedding natural stones in the adhesive aggregate layer, characterized in that it comprises a method for manufacturing a natural stone block.

7. The method for manufacturing a natural stone block according to claim 6, further comprising a step of forming a concrete layer or a mortar layer on the adhesive aggregate layer.

8. The method for manufacturing a natural stone block according to claim 7, wherein the step of placing the concrete layer or the mortar layer is performed until the upper surface height position of the standing wall and the upper surface height position of the concrete layer or the mortar layer become the same height.

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