JP2021031929A - Container house and its manufacturing method - Google Patents

Abstract

To provide a container house which can be installed in various places such as a seaside and a plaza, hardly receiving salt damage, and having excellent durability regardless of an installation place, and to provide a method for manufacturing the same.SOLUTION: A container house 100 comprises: a rectangular parallelepiped steel frame 1 formed by joining a steel ceiling girder 10a, a steel floor girder 20a, a steel floor beam 20b, and a steel column 30a; a steel ceiling plate 40; a floor plate 50; a steel outer wall plate 60; and a zinc-containing layer 2.SELECTED DRAWING: Figure 6

Description

The present invention relates to a container house and a method for manufacturing the same.

Container houses, which are built using containers, are increasingly being used as stores and residences because they are easy to install and move, are robust, and can be installed at low prices. By stacking containers, it can be made into a two-story or three-story building. Buildings using such containers have been devised in various ways, such as improving the appearance of the building, improving the heat insulating property, and making it more livable (for example, Patent Documents 1 and 2). etc).

Moreover, in recent years, buildings using containers have been strictly required to comply with the Building Standards Law. For example, a container house is required to be manufactured of JIS steel in accordance with the Building Standards Law, or must be welded in a JIS-certified factory. Therefore, it is basically impossible to divert a container for transportation as it is, and in most cases, it is designed and manufactured from scratch as a container house.
As a study for conforming to the Building Standards Act, Patent Document 3 discloses a container capable of obtaining a confirmation certificate and an inspection certificate based on the Building Standards Act.

Utility Model Registration No. 3216766 Japanese Unexamined Patent Publication No. 10-238147 Japanese Unexamined Patent Publication No. 2008-180072

As the use of container houses expands, they are increasingly being installed in places that were not often installed in the past. Depending on the installation location of the container house, corrosion such as rusting may easily occur. However, conventionally, the durability of the container house in consideration of the installation location has not been studied. If the walls of the container house are rusted, maintenance is required frequently, and even if the container house can be installed at a low price, the maintenance cost will be high.

The present invention has been made in view of such a situation. An object of the present invention is to provide a container house having excellent durability regardless of the installation location and a method for manufacturing the same.

The container house of the present invention has a rectangular steel frame formed by joining ceiling girders, floor girders, floor girders and columns, a ceiling plate attached to the ceiling portion of the steel frame, and a wall of the steel frame. On the outer wall plate attached to the portion, the floor plate attached to the floor portion of the steel frame, the ceiling girder, the floor girder, the floor girder, the pillar, the ceiling plate, and the outer surface of the outer wall plate. It can be provided with a rectangular unit containing the formed zinc-containing layer.

According to the container house of the present invention, by having a zinc-containing layer on the outer surface of the ceiling girder, the floor girder, the floor girder, the pillar, the ceiling board, and the outer wall board, rust and the like can be prevented regardless of the installation location of the container house. It can be made that corrosion is unlikely to occur. For example, even when it is installed on the beach, it has excellent rust prevention properties, so that corrosion is unlikely to occur. Therefore, the frequency of maintenance for maintaining the container house can be reduced.

Further, in the container house of the present invention, the zinc-containing layer is preferably a zinc-containing coating film. By using a zinc-containing coating film, a zinc-containing layer can be formed on the outer surface of the beams, columns, ceiling boards, and outer wall boards that make up the rectangular parallelepiped unit of the container house without special plating equipment. it can. Further, it is easy to make the zinc-containing layer thicker, and by making the zinc-containing layer thicker, it is possible to make it more resistant to rust.

Further, in the container house of the present invention, the zinc-containing layer preferably contains 90 to 98% by mass of zinc powder and 2 to 10% by mass of epoxy resin.
By having such a zinc-containing layer, even when a general paint is further applied to the surface of the zinc-containing layer, the zinc-containing layer can be made difficult to peel off. Therefore, the color of the outer wall of the container house can be customized and delivered. In addition, even if the owner makes arrangements such as changing the color of the outer wall by himself / herself, the decrease in durability will be small.

The method for manufacturing a container house of the present invention can have the following first and second steps.
First step: A structure in which a ceiling plate is attached to the ceiling portion of a rectangular steel frame formed by joining ceiling girders, floor girders, floor girders and columns, and an outer wall plate is attached to the wall portion of the steel frame. A step of applying a zinc-containing paint to the outer surface of the body and forming a zinc-containing layer on the outer surface of the structure. Second step: A step of attaching a floor plate to the structure on which the zinc-containing layer is formed.

According to the method for manufacturing a container house of the present invention, a structure in which a ceiling plate and an outer wall plate are attached to a rectangular parallelepiped steel frame and a zinc-containing layer is formed on the outer surface, and a floor plate attached to the structure. A container house with a rectangular parallelepiped unit containing is obtained. The obtained container house has excellent rust prevention properties due to the zinc-containing layer. When plating is performed to form a zinc-containing layer, large-scale equipment and facilities are required. By applying a zinc-containing paint to form a zinc-containing layer as in the method for manufacturing a container house of the present invention, it can be manufactured without introducing large-scale equipment and facilities, and can be manufactured at low cost. is there. The zinc-containing layer can be uniformly formed at the joint portion of each member such as the joint portion between the column and the outer wall plate. Further, it is easy to make the zinc-containing layer thicker, and by making the zinc-containing layer thicker, it is possible to make it more resistant to rust.

Further, in the method for producing a container house of the present invention, it is preferable that the zinc-containing paint contains 65 to 80% by mass of zinc powder, 5 to 10% by mass of epoxy resin, and 10 to 30% by mass of solvent. As a result, voids and the like are less likely to remain in the formed zinc-containing layer, and the zinc-containing layer can be made to have excellent physical and chemical properties.

According to the present invention, a container house having excellent durability regardless of the installation location and a method for manufacturing the container house are provided. In particular, since the container house of the present invention has excellent rust prevention properties, it is less susceptible to salt damage, and the maintenance burden can be reduced even if it is installed in a place where rust is likely to occur, such as the beach.

It is a front view which shows the schematic structure of the container house 100 which concerns on this invention. It is a back view which shows the schematic structure of the container house 100 which concerns on this invention. It is a side view which shows the schematic structure of the container house 100 which concerns on this invention. It is a top view which shows the schematic structure of the container house 100 which concerns on this invention. FIG. 5 is a schematic view of a sectional view taken along line AA of FIG. FIG. 5 is a schematic view of a sectional view taken along line BB in FIG.

Hereinafter, embodiments of the present invention will be described in detail, but the description of the constituent elements described below is an example (representative example) of the embodiments of the present invention, and the present invention is described below unless the gist thereof is changed. It is not limited to the contents of.

FIG. 1 is a front view showing a schematic configuration of a container house 100 according to the present invention. FIG. 2 is a rear view showing a schematic configuration of the container house 100. FIG. 3 is a side view showing a schematic configuration of the container house 100. FIG. 4 is a plan view showing a schematic configuration of the container house 100. Further, FIG. 5 is a schematic view of a cross-sectional view taken along the line AA of FIG. FIG. 6 is a schematic view of a cross-sectional view taken along the line BB of FIG.

The container house 100 shown in FIGS. 1 to 6 has a rectangular steel frame 1, a ceiling plate 40, and a floor plate 50 formed by welding and joining a ceiling girder 10a, a floor girder 20a, a floor girder 20b, and a column 30a. It is a rectangular unit containing the outer wall plate 60 and the zinc-containing layer 2. The rectangular parallelepiped unit has a space inside, and this space becomes a living space.

The steel frame 1 has a rectangular shape in a plan view, and four columns 30a are erected at four corners of the rectangle, and the upper ends of the four columns 30a are connected by four ceiling girders 10a, respectively. The lower ends of the columns 30a are connected by four floor girders 20a to form a rectangular parallelepiped shape. Further, the floor beam 20b is bridged and welded between the floor beams 20a on the long side. The number of floor beams 20b is one or more, and is appropriately selected according to the size of the rectangular parallelepiped unit and the like.
The ceiling plate 40 is attached to the ceiling portion of the steel frame frame 1 by being welded to the ceiling girder 10a of the steel frame frame 1 (see FIG. 4). The outer wall plate 60 is attached to the wall portion of the steel frame frame 1 by being welded to the pillar 30a of the steel frame frame 1 (see FIGS. 1 to 3).

The ceiling girder 10a, the floor girder 20a, and the floor girder 20b are steel beams made of JIS steel. The pillar 30a is a steel pillar made of JIS steel. The ceiling girder 10a, the floor girder 20a, the floor girder 20b, and the column 30a can be made of square steel pipe, angle steel, H-shaped steel, or the like, respectively.
Further, the ceiling plate 40 and the outer wall plate 60 can be corrugated steel plates or flat steel plates made of JIS steel, and corrugated steel plates are preferable from the viewpoint of strength.

The zinc-containing layer 2 is a layer formed on the outer surface (outdoor exposed surface) of the ceiling girder 10a, the floor girder 20a, the floor girder 20b, the pillar 30a, the ceiling board 40 and the outer wall board 60 (FIGS. 5 and 6). reference). The zinc-containing layer 2 is not shown in FIGS. 1 to 4. The zinc-containing layer 2 covers the outdoor exposed surfaces of the ceiling and walls of the rectangular parallelepiped unit and the outdoor exposed surfaces of the floor girders 20a and floor beams 20b of the floor of the rectangular parallelepiped unit. Corrosion such as rust due to the structure having the ceiling girder 10a, the floor girder 20a, the floor girder 20b, and the column 30a constituting the steel frame frame 1, the ceiling board 40, and the zinc-containing layer 2 on the outer surface of the outer wall board 60. Is unlikely to occur, and the durability is excellent.

The zinc-containing layer 2 is a layer containing 90 to 98% by mass of zinc powder and 2 to 10% by mass of synthetic resin. Further, the layer may contain 90 to 98% by mass of zinc powder and 2 to 10% by mass of alkyl silicate. The thickness of the zinc-containing layer 2 is 40 to 150 μm (preferably 70 μm to 100 μm). The zinc powder is particles having an average particle size of 1 to 10 μm (preferably 2 to 6 μm). As the zinc powder, powders such as metallic zinc, metallic zinc alloy, and zinc oxide can be used. The zinc powder preferably contains a powder of metallic zinc as a main component, and for example, 90% by mass or more of the zinc powder is preferably metallic zinc powder. The synthetic resin can be an epoxy resin, a urethane resin, an acrylic resin, a styrene resin, or the like, and the epoxy resin is preferable from the viewpoint of the strength of adhesion to the steel plate.
In order to improve the rust resistance and the adhesiveness to the steel sheet, the zinc-containing layer 2 is preferably a layer containing 90 to 98% by mass of zinc powder and 2 to 10% by mass of epoxy resin, and zinc. It is more preferable that the powder is a layer containing 95 to 97% by mass and 3 to 5% by mass of epoxy resin (for example, a coating film).

Further, as shown in FIGS. 5 and 6, the container house 100 has a heat insulating structure. This makes the structure suitable as a living space. The ceiling portion of the container house 100 has a heat insulating structure including a heat insulating layer 3 formed on the inner surface (indoor side surface) of the ceiling plate 40 and a heat insulating board 4 attached to the ceiling girder 10a. Further, the wall portion of the container house 100 is a heat insulating board 4 arranged between a heat insulating layer 3 formed on the inner surface of the outer wall plate 60 and a plurality of pillars 30b erected on the indoor side of the outer wall board 60. It has a heat insulating structure including and.
The heat insulating layer 3 can be formed by spraying these heat insulating materials on the ceiling board 40 and the outer wall board 60 from the inside (indoor side). As the heat insulating material, a fiber-based heat insulating material such as glass wool, rock wool or cellulose fiber, or a foam-based heat insulating material such as urethane foam, phenol foam, polystyrene foam or polyethylene foam can be used. These heat insulating materials may be used together. A foam-based heat insulating material is preferable because it enhances the adhesion to the ceiling board 40 and the outer wall board 60 and easily enhances the heat insulating effect. Further, a plate-like material formed of these heat insulating materials can be used as the heat insulating board 4.
As the pillar 30b, a steel pillar may be used as in the pillar 30a, but a wooden pillar can also be used because it is erected on the indoor side of the outer wall plate 60 and is not easily affected by corrosion due to the installation environment.

The floor portion of the container house 100 includes a floor girder 20a and a floor girder 20b and a floor plate 50 constituting a steel frame. The floor plate 50 can be made of plywood or a veneer plate, and is attached to the floor of the steel frame 1 by being fixed to the floor beam 20b from the indoor side. Further, the floor of the container house 100 also has a heat insulating structure, and the heat insulating material is outside (outdoor room) so as to cover the floor plate 50 fixed to the floor beam 20b and the floor beam 20b having the zinc-containing layer 2. The heat insulating layer 3 is formed by being sprayed from the side).

Further, the container house 100 includes an interior panel 5 such as plywood, wood board, and gypsum board attached to the heat insulating board 4 and the pillar 30b from the indoor side, and a door 6 attached to the door frame formed on the outer wall plate 60. , A window 7 attached to a window frame formed on the outer wall plate 60, and the like are included.

The size of the container house 100 can be a 20-foot container, a 40-foot container, a 45-foot container, and the like.

Further, the steel frame 1 of the container house 100 may have a structure that is installed under the ceiling plate 40 and includes a ceiling beam that is bridged between the ceiling beams 10a on the long side. As the ceiling beam, a steel beam may be used, and a wooden column may be used because it is not easily affected by corrosion due to the installation environment.

Hereinafter, an example of the manufacturing method of the container house 100 will be described.

First, the ceiling plate 40 is attached to the ceiling portion of the rectangular steel frame frame 1 formed by welding the ceiling girder 10a, the floor girder 20a, the floor girder 20b and the column 30a, and the outer wall plate 60 is attached to the wall portion of the steel frame frame 1. Install. As a result, the structure A including the steel frame 1, the ceiling plate 40, and the outer wall plate 60 can be obtained.

Next, a zinc-containing paint is applied to the outer surface of the structure A to form a zinc-containing layer (zinc-containing coating film) 2 (first step). The outer surface of the structure A is the outdoor exposed surface of the ceiling girder 10a, the pillar 30a, the ceiling board 40, and the outer wall board 60 of the structure A, and the floor board 50 of the floor girder 20a and the floor girder 20b is still outdoors. This is the surface that will be exposed. As a result, a structure B including a steel frame frame 1 composed of a ceiling girder 10a, a floor girder 20a, a floor girder 20b, and a column 30a, a ceiling plate 40, an outer wall plate 60, and a zinc-containing layer 2 is obtained. Be done.

As the zinc-containing paint, a paint containing zinc powder, a synthetic resin, and a solvent can be used. Further, those containing pigments and additives may be used.

As the zinc powder, particles having an average particle size of 1 to 10 μm (preferably 2 to 6 μm) can be used. Further, powders of metallic zinc, metallic zinc alloy, zinc oxide and the like can be used as zinc powder. The zinc powder is preferably 65 to 80% by mass (preferably 70 to 75% by mass). If the amount of zinc powder is too small, the rust prevention property tends to decrease. Further, if the amount of zinc powder is too large, various physical and chemical properties of the obtained coating film tend to deteriorate, and the coated surface condition tends to deteriorate.

As the synthetic resin, an epoxy resin, a urethane resin, or an acrylic resin can be used. The synthetic resin is preferably 5 to 10% by mass. Further, if the amount of the synthetic resin is too small, various physical and chemical properties of the coating film are deteriorated. Further, if the amount of the synthetic resin is too large, the amount of zinc powder or the like is relatively small, and the rust preventive property tends to be lowered.

As the solvent, methyl ethyl ketone, acetone, dioxane, ethyl acetate, N-methyl-2-pyrrolidone, butyl acetate, ethanol, cyclohexanone and the like can be used. The solvent is preferably 10 to 30% by mass. If the amount of the solvent is too small, the viscosity of the coating material becomes high, and voids and the like remain inside the coating film, and the durability and rust prevention property tend to decrease. Further, if the amount of the solvent is too large, it is difficult to increase the film thickness, and the durability and rust prevention property are lowered.

For example, a zinc-containing paint is applied to the outer surface of the structure A using a brush, a spray, a roller, or the like so as to have a dry film thickness of 40 to 150 μm, and at room temperature for a predetermined time (for example, 20 to 60 minutes) A zinc-containing layer can be formed by heating and drying.
Specifically, as the zinc-containing paint, "Eporoval (registered trademark)" of Roval Corporation can be used.

Next, the floor plate 50 is attached on the floor beam 20b of the structure B in which the zinc-containing layer 2 is formed on the outer surface (second step). As a result, a rectangular parallelepiped including a structure B in which the ceiling plate 40 and the outer wall plate 60 are attached to the rectangular parallelepiped steel frame 1 and the zinc-containing layer 2 is formed on the outer surface, and the floor plate 50 attached to the structure B. A unit of the shape is obtained.

In addition, a process of attaching insulation and interior panels is performed. In order to impart heat insulating properties, a heat insulating material is sprayed from the outside (outdoor side) to form the heat insulating layer 3 so as to cover the floor plate 50 fixed to the floor beam 20b and the floor beam 20b having the zinc-containing layer 2. To do. After spraying the heat insulating material from the inside of the structure B on the ceiling portion, the interior panel 5 is attached to the ceiling girder 10a from the inside of the structure B via the heat insulating board 4. In the wall portion, after spraying the heat insulating material from the inside (indoor side) of the structure B, the pillar 30b is erected. The heat insulating board 4 is arranged between the pillars 30b, and the interior panel 5 is further attached to the pillars 30b. As a result, the container house 100 is obtained.

For example, a container house manufactured using "Eporoval (registered trademark)" of Roval Corporation as a zinc-containing paint is compared with a conventional container house in which the zinc-containing paint is not applied (first step). As a result, the rust resistance was 5 to 10 times better.

The manufacturing method of the container house 100 is not limited to this. For example, a container house may be manufactured using steel beams, steel columns, and steel plates coated with zinc-containing paint.

Further, the container house of the present invention is not limited to the container house 100. For example, the container house 100 is a one-story building, but two rectangular parallelepiped units can be vertically stacked to form a two-story building. Further, depending on the purpose, a structure may be provided in which shelves, partition walls, etc. are appropriately provided, and the container house may be a structure including stairs, terraces, etc. in addition to the rectangular parallelepiped unit.

The method for manufacturing a container house of the present invention may have other steps in addition to the first step and the second step, depending on the structure of the container house. For example, a step of attaching a heat insulating material or an interior panel, a step of installing a staircase, a terrace, or the like can be provided.

The container house of the present invention can be moved from one installation location to another. The container house of the present invention can be easily installed in various places such as a beach, a plaza, a garden at home, and a mountain, and is excellent in durability and rust prevention regardless of the installation place. Even if the container house of the present invention is installed in, for example, a seaside resort, it is less susceptible to salt damage, the maintenance load of the owner is reduced, and the maintenance cost can be suppressed.

According to the present invention, a container house that can be used as a store or a residence is provided. In the container house of the present invention, even if the container house is installed in various places, the container house is less likely to be corroded and the maintenance frequency and the like can be suppressed.

1 Steel frame 2 Zinc-containing layer 3 Insulation layer 4 Insulation board 5 Interior panel 6 Door 7 Window 10a Ceiling girder 20a Floor girder 20b Floor girder 30a 30b Pillar 40 Ceiling board 50 Floor board 60 Exterior wall board 100 Container house

Claims (5)

A rectangular parallelepiped steel frame formed by joining ceiling beams, floor beams, floor beams and columns,
A ceiling plate attached to the ceiling of the steel frame and
An outer wall plate attached to the wall of the steel frame and
The floor board attached to the floor of the steel frame and
A container house including a rectangular parallelepiped unit including the ceiling girder, the floor girder, the floor girder, the pillar, the ceiling board, and a zinc-containing layer formed on the outer surface of the outer wall board. The container house according to claim 1, wherein the zinc-containing layer is a zinc-containing coating film. The container house according to claim 1 or 2, wherein the zinc-containing layer contains 90 to 98% by mass of zinc powder and 2 to 10% by mass of an epoxy resin. A method for manufacturing a container house having the following first step and second step.
First step: A structure in which a ceiling plate is attached to the ceiling portion of a rectangular steel frame formed by joining ceiling girders, floor girders, floor girders and columns, and an outer wall plate is attached to the wall portion of the steel frame. A step of applying a zinc-containing paint to the outer surface of the body and forming a zinc-containing layer on the outer surface of the structure. Second step: A step of attaching a floor plate to the structure on which the zinc-containing layer is formed. The method for producing a container house according to claim 4, wherein the zinc-containing paint contains 65 to 80% by mass of zinc powder, 5 to 10% by mass of epoxy resin, and 10 to 30% by mass of a solvent.

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