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GB2080149A - Concrete products for use in building - Google Patents

Concrete products for use in building Download PDF

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Publication number
GB2080149A
GB2080149A GB8120699A GB8120699A GB2080149A GB 2080149 A GB2080149 A GB 2080149A GB 8120699 A GB8120699 A GB 8120699A GB 8120699 A GB8120699 A GB 8120699A GB 2080149 A GB2080149 A GB 2080149A
Authority
GB
United Kingdom
Prior art keywords
concrete
article
coating
coating material
concrete article
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB8120699A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Anchor Building Products Ltd
Original Assignee
Anchor Building Products Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Anchor Building Products Ltd filed Critical Anchor Building Products Ltd
Priority to GB8120699A priority Critical patent/GB2080149A/en
Publication of GB2080149A publication Critical patent/GB2080149A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44FSPECIAL DESIGNS OR PICTURES
    • B44F1/00Designs or pictures characterised by special or unusual light effects
    • B44F1/08Designs or pictures characterised by special or unusual light effects characterised by colour effects
    • B44F1/10Changing, amusing, or secret pictures
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4505Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/61Coating or impregnation

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Paints Or Removers (AREA)

Abstract

The invention relates to a method of coating a concrete article, such as a roofing tile, and to a coated concrete article. A coating material such as a water based pigmented synthetic resin dispersion, is applied to at least the visible surface area of the article when laid, so as to provide this surface area with a colour appearance which is non-uniform when viewed close at hand but which when the article is laid with other similarly coated articles provides the laid articles with a substantially uniform colour appearance. The non-uniform coating may, for example, be formed of spots or flecks.

Description

SPECIFICATION Concrete products for use in building This invention relates to concrete products and more particularly to concrete articles used in building, for example tiles. The invention is particularly concerned with providing roofing tiles which when laid together to form the roof of a building give the roof a uniform colour appearance.
Hitherto, several methods have been used to provide a uniform colour to roofing tiles but such methods do not always give a uniform colour appearance to the roofing tiles when laid.
In the production of tiles used for roof and decorative vertical panels, for example, there are many factors which contribute to give the laid tiles or panels a non-uniform colour appearance. In the case of machine or hand made roofing tiles, it is very difficult to produce tiles which are of the same colour appearance without treating the tile subsequently to its manufacture, due to the variations in basic raw materials and methods of manufacture. Thus, the colour appearance of tiles even in the same batch cannot be guaranteed and before the tiles are laid variations in colour appearance occur resulting in a nonuniform colour appearance which gives a patched look to the roof even although the quality of the tile itself is unimpaired.The basic materials from which tiles are made include sand, cement and, usually, natural or synthetic colouring agents such as iron oxide pigment (the colouring material normally used) to give the roofing tiles a body colour.
Variations in the composition of sand, particularly as regards its silt and silica content, and particle size effect the final colour of the tiles.
Also, variations in the composition, particle size and production of cement given cement of different colours which similarly affect the tiles.
The addition of pigment to the sand and cement mix even by very small quantities also changes the colour appearance of one batch of tiles compared with another batch of tiles.
Various optional additives such as water proofing compounds, plasticizing compounds etc., also give rise to variations in colour appearance of the finished tile.
Even the mineral content of water used for the mix can have an effect on the colour appearance as will be discussed hereinafter, particularly as regards the content of lime.
Also, variations in the ratio of the mixed basic materials will produce colour appearance variations.
The factors influencing the colour appearance of roofing tiles occurring during actual manufacture include the manner in which the sand, cement and iron oxide or other pigment and any other additives, if any are mixed, these factors influencing the manufacturing pressure exerted by various types of tile making machinery, for example the pressure exerted by the extrusion die in extrusion machines. Such changes in pressure result in variations in the surface texture of the tiles so that although the actual colour of the tiles may be similar, the amount of light reflected from a rougher surface as compared with a smoother surface will give rise to variations in the colour appearance of the laid tiles.
Colour variations also occur during the curing cycle due to differences in the environmental conditions. Moreover, since the tiles are usually stored in the open, here again, environmental conditions may also have an effect on the colour appearance of the tiles.
Finally, there is the serious problem of efflorescence caused by the "leaching" out of lime in the tile onto the surface of the tile causing an unsightly white deposit thereon; this phenomenon often occurs after the tiles have been laid.
Thus it will be appreciated from the foregoing that at each step in the process of manufacture and after laying of roofing tiles variations in their colour appearance can occur.
One known method for producing a uniform colour appearance on a tile consists in providing the tile with a sand or granule facing on its visible surface. Such a method involves the application of a cement slurry to the wet tiles, the burning and coating of sand with pigment and silica particles in a furnace, the application of the coated burnt sand to the cement slurry by sprinkling, brushing excess sand particles from the surface of the tiles and then immersing the tiles in a ferric chloride or hydrochloric acid bath. This method is not only expensive as regards time, personnel employed and in materials but has the disadvantages arising from the use of corrosive materials. Moreover, the sand or granule facing may become dislodged from the slurry over a period of time giving a patchy appearance to the roof and blocking gutters and drains.
A more recent method of providing roofing tiles with a uniform colour appearance consists in spraying onto roofing tiles a uniform coating of a suitable paint or other suitable material. However, a disadvantage of such a method is its expense, particularly where it is necessary to provide a relatively thick coating of material and, moreover, the texture of the tile surface can given rise to apparent colour differencies due to changes in reflected light.
This may given rise to variations in the colour appearance of the tiles of different batches when laid on a roof.
Accordingly, it is an object of the invention to provide a method for use in the manufacture of a concrete article, particularly a concrete tile for use in building, which provides the article with a colour appearance which is uniform when the article is laid, which uniform colour appearance does not degrade during normal use.
To this end, and from one aspect, the invention provides a method for use in the production of a concrete article, particularly a concrete tile such as a roofing tile, which method consists in applying at least to the visible surface area of the article, a coating material, which is preferably not a material from which the concrete article is made, in such manner as to provide the surface area with a colour appearance which is non-uniform when viewed close at hand but which when the article is laid with other similarly coated articles provides the laid articles with a substantially uniform colour appearance.
From another aspect the invention consists in a concrete article, particularly a concrete tile such as a roofing tile, in which at least the visible surface area of the article has a coating of a material which is preferably other than that from which the concrete article is made, said coating being applied in such manner that surface area of the article is provided with a colour appearance which is non-uniform when viewed close at hand but which when the article is laid with other similarly coated articles provides the laid articles with a substantially uniform colour appearance.
The expression "visible surface area" means that area of the article which is visible when laid. For example, in the case of a roofing tile the visible surface area is that area which when the tile is laid on a roof is not over-lapped and the bottom end of the tile, which areas can be seen by a person standing on the ground. For convenience, in manufacture, the entire upper surface of the tile may be coated as well as the side and upper end edge areas.
In contrast to the continuous coating applied by the known method mentioned previously, the method of the invention applies the coating material as a dis-continuous coating on the visible surface area of the concrete article. The dis-continuous coating may be of any convenient pattern, shape, or form consistent with laid articles having such coatings thereon presenting a uniform colour appearance. The coating may be formed of a multiplicity of spots, particulate areas, fine spots giving a net curtain effect, coarser spots of larger size, flecks or an irregularly shaped pattern of which some or all of the areas of applied coating are linked together leaving areas of the concrete article showing therebetween.In each case, the concrete article is incompletely coated so that the colour of the article before the coating is applied, i.e. the body colour of the article or where no body colour has been added the grey colour of the concrete from which the article is made, is visible when the article is viewed close at hand.
The applied coating may be of any convenient colour, compatible with the overall colour appearance required when the articles are laid. For example, in the case of a roofing tile having a reddish-brown body colour due to the addition of synthetic iron oxide pigment, the visible surface-area of the tile may be spotted with black spots which may be very large or very small or a mixture of large and small spots to provide a uniform colour appearance.
Alternatively, the visible surface-areas of the articles may be provided with a continuous coating of material and then provided with a non-uniform coating in any of the manner referred to above. With such a method and in the case where no body colour is added to the articles, there results a considerable saving since there is no need to add body colour pigments to the articles. This is particularly the case with roofing tiles where natural or synthetic iron oxide is the pigment most commonly used.
The coating material is conveniently a pigmented synthetic resin dispersion. The synthetic resin dispersions used are generally aqueous dispersions having a particle size between 0.02 and 4 microns. Examples of synthetic resins that can be used in aqueous dispersion are homopolymers or copolymers of acrylates or methacrylates; styrene acrylate copolymers; homopolymers of vinvyl acetate and copolymers and terpolymers of vinyl acetate; homopolymers and copolymers of vinyl propionate; vinyl chloride-ethylene copolymers; and butadiene copolymers.
The pigments used in the pigmented synthetic resin dispersion may be present in any amount under the critical pigment volume concentration but the pigments are more usually present in an amount between 1 5 and 50% of volume of the pigmented dispersion.
Examples of pigments which may be used are iron oxide, titanium dioxide, quartz powder, mica, talc, barium sulphate, slate powder or mixtures thereof.
The coating material may be applied before and/or after the curing stage. By way of example, the coating material may be applied directly to a cured concrete article or, alternatively, the cured concrete article may first be provided with a continuous coating of pig mented synthetic resin dispersion and then the coating material is applied according to the invention. The application of the coating material may be made either before or after the first continuous coating has dried and film formed but preferably before. By way of further example, the coating material may be applied to a wet, uncured concrete article which may then be cured directly or, prefera bly, prior to curing, be further treated with a non pigmented synthetic resin dispersion which may be the same synthetic resin disper sion as used in the coating material.If de sired, the cured concrete article may then have applied thereto a further amount of coating material according to the invention. In this manner more than one colour may be applied to the same article.
In the case of extruded concrete roofing tiles, the coating material could be applied to the extruded ribbon and the synthetic resin dispersion to the ribbon or the discrete tiles.
Any suitable means may be used to apply the coating material. For example, a spray gun may be used to spray the discontinuous coating on the articles or alternatively, the coating may be applied by a roller or other suitable means shaped to provide the non-uniform colour appearance. The invention is primarily concerned with concrete roofing tiles, which may be extruded, pressed or hand made but other concrete articles could be similarly provided with the non-uniform colour appearance.
The invention provides a concrete article having a sandfaced surface appearance but which yet has the characteristics of a smooth face article.
The invention has the advantage of avoiding the time consuming sandfacing method, the necessity for applying continuous coatings with precision, a reduction in expense due to materials, particularly, reduction in the amount of iron-oxide pigment needed which is not only expensive but difficulty can be experienced in supply.
The invention will now be described, by way of example, with reference to the accompanying drawing which is a perspective view of a concrete roofing tile. In carrying out the method of the invention the upper surface 1 and lower edge 2 which is visible in the drawing have applied thereto a discontinuous coating of, for example, a pigmented styrene acrylic copolymer dispersion such that the coating (not shown) gives to the tile a nonuniform appearance when viewed close at hand but when laid on the roof with other similarly coated tiles the laid tiles present a uniform colour appearance.
If the tile illustrated has a body colour imparted by synthetic iron oxide giving a reddish-brown colour to the tile and is spotted or splashed with black coating material, giving a mottled black and red appearance, when such a tile is laid on a roof with other similar tiles an overall reddish-brown colour appearance may obtain.
Various modifications may be made without departing from the scope of the invention. For example, instead of spraying the coating material the coating material may be splashed onto the visible surface area of the tile. Moreover, the splashing, spraying or application in any other convenient way may cover a portion of the visible surface area of the tile only.
The choices of tile body colour, coating material colour and combinations thereof are in effect infinite and are dependent upon the colour appearance desired for a roof made up of such tiles.

Claims (32)

1. A method of coating a concrete article comprising applying a coating material to at least the visible surface area of the article in such manner as to provide said surface area with a colour appearance which is non-uniform when viewed close at hand but which when the article is laid with other similarly coated articles provides the laid articles with a substantially uniform colour appearance.
2. A method as claimed in claim 1, wherein the coating material is free from material from which the concrete article is made.
3. A method as claimed in claim 1 or 2, wherein the coating material is a water based pigmented synthetic resin dispersion.
4. A method as claimed in claim 3, wherein the synthetic resin dispersion comprises homopolymers or copolymers of acrylates or methacrylates; styrene acrylate copolymers; homopolymers of vinyl acetate and copolymers and terpolymers of vinyl acetate; homopolymers and copolymers of vinyl propionate; vinyl chloride-ethylene copolymers; or butadiene copolymers.
5. A method as claimed in claim 3 or 4, wherein the pigment in the synthetic resin dispersion comprises iron oxide, titanium dioxide, quartz powder, mica, talc, barium sulphate, slate powder or mixtures thereof.
6. A method as claimed in any one of claims 1 to 5, which comprises previously coating the concrete article with a continuous coating of material.
7. A method as claimed in claim 6, which comprises applying the continuous coating to a concrete article which is free of added body colour pigments.
8. A method as claimed in any one of the preceding claims, which comprises applying the coating material after the concrete article has been cured.
9. A method as claimed in claim 8, as dependent on claim 6 or 7, which comprises applying the coating material before the continuous coating has dried.
10. A method as claimed in claim 8, as dependent on claim 6 or 7, which comprises applying the coating material after the continuous coating has dried.
11. A method as claimed in any one of claims 1 to 7, which comprises applying the coating material prior to the concrete article being cured.
1 2. A method as claimed in claim 11, which comprises applying the coating material when the concrete is wet.
1 3. A method as claimed in claim 11 or 12, which comprises applying the coating material to an extruded ribbon of concrete prior to the ribbon being cut to form concrete tiles.
14. A method as claimed in any one of claim 1 to 12, which comprises applying the coating material to a concrete tile.
15. A method as claimed in claim 11, 12, 1 3 or claim 14 as dependent on claim 11, which comprises applying a non-pigmented synthetic resin dispersion to the concrete article, extruded ribbon or concrete tile after the coating material has been applied but prior to curing.
1 6. A method as claimed in any one of the preceding claims, which comprises applying further said coating material to the concrete article, extruded ribbon or concrete tile, after curing.
1 7. A method as claimed in any one of the preceding claims, which comprises applying the coating material by means of a spray gun or a roller.
18. A method of coating a concrete article substantially as hereinbefore described with reference to the accompanying drawing.
1 9. A concrete article whenever produced by the method claimed in any one of the preceding claims.
20. A concrete article in which at least the visible surface area of the article has a coating of material which has been applied in such manner that said surface area of the article is provided with a colour appearance which is non-uniform when viewed close at hand but which when the article is laid with other similarly coated articles provides the laid articles with a substantially uniform colour appearance.
21. A concrete articis as claimed in claim 20, wherein said coating material is free from material from which the concrete article is made.
22. A concrete article as claimed in claim 20 or 21, wherein the coating is formed of a multiplicity of spots, particulate areas, or flecks.
23. A concrete article as claimed in claim 20 or 21, wherein the coating comprises an irregularly shaped pattern of which some or all of the areas of applied coating are linked together leaving areas of the concrete article showing therebetween.
24. A concrete article as claimed in any one of claims 20 to 23, wherein the coating material is a water based pigmented synthetic resin dispersion.
25. A concrete article as claimed in claim 24, wherein the synthetic resin dispersion comprises homopolymers or copolymers of acrylates or methacrylates; styrene acrylate copolymers; homopolymers of vinyl acetate and copolymers and terpolymers of vinyl acetate; homopolymers and copolymers of vinyl propionate; vinyl chloride-ethylene copolym ers; or butadiene copolymers.
26. A concrete article as claimed in claim 24 or 25, wherein the pigment in the synthetic resin dispersion comprises iron oxide, titanium dioxide, quartz powder, mica, talc, barium sulphate, slate powder or mixtures thereof.
27. A concrete article as claimed in any one of claims.20 to 26, wherein said coating material has been applied to a concrete article having a continuous coating of material.
28. A concrete article as claimed in claim 27, wherein the concrete article is free of added body colour pigment.
29. A concrete article as claimed in any one of claims 20 to 28, wherein the article is a concrete tile.
30. A concrete article as claimed in claim 29, wherein the entire upper surface of the tile is coated with the coating material.
31. A concrete tile as claimed in claim 29 or 30, wherein the side and lower edges of the tile are coated with the coating material.
32. A concrete tile substantially as hereinbefore described with reference to the accompanying drawing.
GB8120699A 1980-07-03 1981-07-03 Concrete products for use in building Withdrawn GB2080149A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB8120699A GB2080149A (en) 1980-07-03 1981-07-03 Concrete products for use in building

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8021909 1980-07-03
GB8120699A GB2080149A (en) 1980-07-03 1981-07-03 Concrete products for use in building

Publications (1)

Publication Number Publication Date
GB2080149A true GB2080149A (en) 1982-02-03

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
GB8120699A Withdrawn GB2080149A (en) 1980-07-03 1981-07-03 Concrete products for use in building

Country Status (1)

Country Link
GB (1) GB2080149A (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2184369A (en) * 1985-12-23 1987-06-24 Anchor Building Products Ltd Improvements in or relating to roofing and cladding tiles
AU745221B2 (en) * 1997-12-05 2002-03-14 Evonik Rohm Gmbh Methods for manufacture of films which are highly glossy on both sides
US7033427B2 (en) 2002-10-22 2006-04-25 Silica Pacific Pty. Limited Composition and method for coloring the surface of a porous substrate
GB2420347A (en) * 2004-11-18 2006-05-24 Tecenergy Entpr Ltd Polymer and slate composite material and method of making such
WO2013165650A1 (en) * 2012-04-30 2013-11-07 3M Innovative Properties Company High solar-reflectivity roofing granules utilizing low absorption components
US10100521B2 (en) 2012-09-11 2018-10-16 3M Innovative Properties Company Porous glass roofing granules
EP3798198A1 (en) * 2019-07-26 2021-03-31 Empresa das Lousas de Valongo, SA Composite material, method for obtaining the same and articles thereof

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2184369A (en) * 1985-12-23 1987-06-24 Anchor Building Products Ltd Improvements in or relating to roofing and cladding tiles
AU745221B2 (en) * 1997-12-05 2002-03-14 Evonik Rohm Gmbh Methods for manufacture of films which are highly glossy on both sides
US7033427B2 (en) 2002-10-22 2006-04-25 Silica Pacific Pty. Limited Composition and method for coloring the surface of a porous substrate
GB2420347A (en) * 2004-11-18 2006-05-24 Tecenergy Entpr Ltd Polymer and slate composite material and method of making such
WO2013165650A1 (en) * 2012-04-30 2013-11-07 3M Innovative Properties Company High solar-reflectivity roofing granules utilizing low absorption components
US11371244B2 (en) 2012-04-30 2022-06-28 3M Innovative Properties Company High solar-reflectivity roofing granules utilizing low absorption components
US10100521B2 (en) 2012-09-11 2018-10-16 3M Innovative Properties Company Porous glass roofing granules
EP3798198A1 (en) * 2019-07-26 2021-03-31 Empresa das Lousas de Valongo, SA Composite material, method for obtaining the same and articles thereof

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