JP2024076037A - Method for constructing structural member and equipment for constructing structural member - Google Patents

Abstract

To improve work efficiency when installing a structural member provided with reinforcing materials, thereby reducing the amount of work and steps involved.SOLUTION: Provided is a method for constructing a structural member 2 including the steps of: forming a layered object 21 by stacking a hydraulic mixture extruded from a first nozzle using a first additive manufacturing device that extrudes the hydraulic mixture from the first nozzle; forming a sprayed object 22 by spraying a fluid material from a second nozzle using a second additive manufacturing device that sprays the fluid material from the second nozzle; and providing reinforcing material 23. The layered object 21 and the sprayed object 22 are formed in a state of being in close contact with each other, and the reinforcing material 23 is fixed to at least one of the layered object 21 and the sprayed object 22.SELECTED DRAWING: Figure 2

Description

The present invention relates to a method for constructing structural members and equipment for constructing structural members.

Conventionally, a method for manufacturing structural components made of concrete, such as pillars, beams, walls, floors, and roofs, has been known in which concrete is ejected from a nozzle using an additive manufacturing device (see, for example, Patent Document 1).

Patent No. 4527107

A conventional additive manufacturing device is a 3D printer that sprays concrete materials. In the case of such a 3D printer, the operation of a nozzle is controlled to automatically construct a structural member made of concrete.
However, in the case of concrete structural members, it is common for reinforcing materials such as steel bars to be embedded, and the reinforcing materials become an obstacle to the movement of the nozzle of the 3D printer, making it difficult to control the nozzle to ensure that the back side of the reinforcing materials is filled while maintaining a specified thickness. The presence of reinforcing materials makes it difficult to manage the spray thickness when using a nozzle, and automation is difficult, so spraying work has had to be done manually as in the past. For these reasons, there is a demand for work that is less time-consuming and requires less effort, and there is room for improvement in this regard.

The present invention was made in consideration of the above-mentioned problems, and aims to provide a method and equipment for constructing structural members that can improve work efficiency and reduce the labor and steps involved in construction of structural members that are constructed from hydraulic mixtures and equipped with reinforcing materials.

In order to achieve the above object, the method for constructing a structural member according to the present invention is a method for constructing a structural member having a reinforcing material constructed from a hydraulic mixture, and includes the steps of forming a first shaped body by stacking the hydraulic mixture extruded from the first nozzle using a first additive manufacturing device that extrudes a hydraulic mixture from a first nozzle, forming a second shaped body by spraying a fluid material from a second nozzle using a second additive manufacturing device that sprays a fluid material from the second nozzle, and providing the reinforcing material, characterized in that the first shaped body and the second shaped body are formed in a state of close contact with each other, and the reinforcing material is fixed to at least one of the first shaped body and the second shaped body.

The construction equipment for structural members according to the present invention is a construction equipment for structural members having a reinforcing material constructed from a hydraulic mixture, and includes a first additive manufacturing device having a first nozzle and operating to form a first shaped body by extruding and stacking a hydraulic mixture from the first nozzle, a second additive manufacturing device having a second nozzle and operating to form a second shaped body by spraying a fluid material from the second nozzle, and a reinforcing material assembly device that installs the reinforcing material so as to be fixed to at least one of the first shaped body and the second shaped body, and the first additive manufacturing device and the second additive manufacturing device form a shaped body in a state of close contact with the previously formed shaped body of the first shaped body and the second shaped body.

In the present invention, two concrete construction methods, a method of forming a first shaped body by extruding a hydraulic mixture from a first nozzle and a method of forming a second shaped body by spraying a fluid material from a second nozzle, are applied, so that even when a structural member is provided with a reinforcing material, efficient construction can be achieved by applying the two concrete construction methods. For example, a first shaped body is formed by extruding a portion where no reinforcing material is provided with a first additive manufacturing device, and a second shaped body is formed by arranging a reinforcing material on the first shaped body and then spraying the reinforcing material on the first shaped body with a second additive manufacturing device, thereby constructing a structural member in which the first shaped body and the second shaped body are integrally provided with the reinforcing material.
In this way, in the present invention, a structural component is constructed using a first shaped body formed so as not to interfere with the reinforcing material, and a second shaped body formed by spraying it against the first shaped body. As a result, compared to constructing a structural component by spraying the reinforcing material directly, the reinforcing material is less likely to interfere with the operations of the first and second nozzles, making it easier to control the first additive manufacturing device and the second additive manufacturing device, and enabling the automatic construction of structural components of any shape, including the reinforcing material.

In addition, in the present invention, the reinforcing material can be fixed by embedding it into at least one of the first and second bodies formed in advance, so the reinforcing bar can be held in the first and second bodies. Therefore, for example, there is no need to assemble the reinforcing bar into a shape such as a rebar cage and make it self-supporting, and work can be carried out efficiently.

The method for constructing a structural member according to the present invention preferably includes the steps of forming the first shaped body by stacking the hydraulic mixture, embedding and fixing at least a portion of the reinforcing material in the first shaped body before the hydraulic mixture in the first shaped body solidifies, and forming the second shaped body by spraying the fluid material so as to cover from the outside the reinforcing material fixed to the first shaped body.

In this case, reinforcing material is embedded and fixed in the hydraulic mixture of the first body formed before it solidifies, and then a fluid material is sprayed onto the outside of the first body to form a second body, thereby efficiently constructing a structural member in which reinforcing material is embedded in a predetermined position within a body consisting of the first body and the second body. Note that only a portion of the reinforcing material may be embedded in the first body, so long as it can maintain its position.

In addition, the method for constructing a structural member according to the present invention preferably includes the steps of embedding and adhering at least a portion of another reinforcing material into the second body before the fluid material of the second body solidifies, and forming a third body by spraying the fluid material so as to cover from the outside the other reinforcing material that has been adhered to the second body.

In this case, multiple shaped parts can be formed by spraying the fluid material, and another reinforcing material can be placed between the second and third shaped bodies. In other words, when multiple reinforcing materials are placed on a structural member, for example in the thickness direction, the process of installing the reinforcing materials and the process of spraying the fluid material to cover the reinforcing materials can be performed alternately, improving work efficiency.

The method for constructing a structural member according to the present invention preferably includes the steps of forming the first shaped body by stacking the hydraulic mixture, forming the second shaped body by spraying the fluid material so as to cover the first shaped body from the outside, and embedding and fixing at least a portion of the reinforcing material in the second shaped body before the fluid material of the second shaped body solidifies.

By configuring in this way, a second shaped body is formed by spraying a fluid material onto the hydraulic mixture of the first shaped body before it solidifies, and then reinforcing material is embedded and fixed into the fluid material of the second shaped body before it solidifies, making it possible to efficiently construct a structural member in which reinforcing material is embedded at a predetermined position on the outer surface of a shaped body consisting of the first shaped body and the second shaped body.

The method for constructing a structural member according to the present invention preferably also includes a step of forming a third structure by spraying the fluid material onto the reinforcing material attached to the second structure from the outside so as to cover the reinforcing material.

In this case, multiple shaped parts can be formed by spraying the fluid material, and the reinforcing material provided on the outer surface of the second shaped body can be covered with the third shaped body, so that the reinforcing material is embedded between the second shaped body and the third shaped body.

In addition, in the method for constructing a structural member according to the present invention, it is preferable that the first body is formed to have a hollow shape, a reinforcing bar cage is inserted into the hollow portion of the first body, and concrete is filled inside the first body.

By using this type of configuration, structural members consisting of columns and walls with reinforcing bar cages as the main reinforcement can be efficiently constructed.
Furthermore, the first shaped body formed in advance can function as a form for the concrete to be filled into the hollow portion, eliminating the need for a form.

In addition, the method for constructing a structural member according to the present invention preferably includes placing a reinforcing bar cage in a predetermined position, then covering the reinforcing bar cage to form the hollow first structure, and filling the inside of the first structure with concrete.

The method for constructing a structural member according to the present invention may also involve forming a reinforcing body consisting of the first and second structures provided with the reinforcing material on the outer periphery of an existing steel frame or structure.

The method for constructing a structural member according to the present invention may also include forming the first structure including an existing steel frame or structure, embedding the reinforcing material on the outside of the first structure, and then spraying the fluid material onto the outside of the reinforcing material to cover it.

The injection nozzle for the additive manufacturing device of the present invention can improve work efficiency when working on structural members equipped with reinforcing materials, reducing the amount of work and steps involved.

1A to 1C are perspective views illustrating a method of constructing a structural member according to a first embodiment of the present invention; FIG. 2 is a horizontal cross-sectional view of the structural member shown in FIG. FIG. 11 is a perspective view showing a formed layered object. FIG. 2 is a plan view of the layered object as viewed from above. FIG. 11 is a perspective view showing a state in which a mesh material is fixed to the layered product. FIG. 13 is a perspective view showing a state in which reinforcing bars are fixed to a mesh material. FIG. 7 is a plan view of the layered object to which the reinforcing material shown in FIG. 6 is fixed, as viewed from above. FIG. 11 is a perspective view showing a state in which a spray-formed object is formed. FIG. 9 is a plan view of the layered object and the spray-formed object shown in FIG. 8 as viewed from above. FIG. 11 is a longitudinal sectional view showing a structural member according to a second embodiment. FIG. 11 is a longitudinal cross-sectional view showing the construction state of the structural member of FIG. 10, illustrating the state in which a layered object and a reinforcing material are formed. 12 is a cross-sectional view taken along line AA in FIG. 11. FIG. 11 is a vertical cross-sectional view showing a construction state following that of FIG. 10, showing a state in which a spray-applied shaped object is formed. 14 is a cross-sectional view taken along line BB in FIG. 13. FIG. 14 is a vertical cross-sectional view showing the construction state following that of FIG. 13, in which a reinforcing bar cage is placed in the hollow portion of the layered molded body. FIG. 11 is a vertical cross-sectional view showing a structural member according to a modified example. 17 is a cross-sectional view taken along line CC shown in FIG. 16.

The following describes a method for constructing a structural member and a construction facility for a structural member according to an embodiment of the present invention, with reference to the drawings.

As shown in Figures 1 and 2, the construction equipment 1 used in the method for constructing a structural member of this embodiment is equipment for constructing a structural member 2 that is a shaped body of any shape, such as a wall or a column, that is constructed from a hydraulic mixture and includes reinforcing material 23 (see Figure 6). The structural member 2 may be applied to one that is constructed directly on-site, or may be applied to one that is manufactured as a precast structural member in a factory, etc.

As shown in Figures 1 to 3, the construction facility 1 includes a first additive manufacturing device 11, a second additive manufacturing device 12, and a reinforcement assembly device 13 (see Figure 6). Here, in the drawings, the construction facility including the first additive manufacturing device 11 is indicated by the reference symbol 1A, the construction facility including the second additive manufacturing device 12 is indicated by the reference symbol 1B, and the construction facility including the reinforcement assembly device 13 is indicated by the reference symbol 1C.

The first additive manufacturing device 11 is equipped with an extrusion nozzle 11A (first nozzle) and is configured to operate to form an additively shaped body 21 (first shaped body) by extruding and stacking the first hydraulic mixture C1 from the extrusion nozzle 11A.
The second additive manufacturing device 12 includes a spray nozzle 12A (second nozzle) and is configured to operate to form a sprayed object 22 (second object) by spraying a second hydraulic mixture C2 (fluid material) from the spray nozzle 12A. The reinforcing material assembling device 13 shown in Fig. 6 is configured to operate to fix and install a reinforcing material 23 to at least one of the layered object 21 and the sprayed object 22 (both in this embodiment).

In this embodiment, the first hydraulic mixture C1 extruded from the first additive manufacturing device 11 and the second hydraulic mixture C2 sprayed from the second additive manufacturing device 12 may be made of different materials. This material collectively refers to various cement-based materials (e.g., cement paste, mortar, concrete, etc.) that are hydraulic mixtures, geopolymer compositions, and fiber-reinforced composite materials in which these are reinforced with short fibers. The short fibers used in fiber-reinforced composite materials include synthetic fibers made of chemically synthesized polymers, and fibers made of inorganic substances. Examples of the former include polypropylene fibers, polyvinyl alcohol fibers, polyethylene fibers, polyester fibers, and aramid fibers. Examples of the latter include glass fibers, steel fibers, carbon fibers, rock fibers (e.g., basalt), ceramic fibers, and silica fibers.

As shown in Figures 1 to 9, the structural member 2 constructed by the construction equipment 1 is a wall curved in a wave shape. The structural member 2 has a wall-shaped layered body 21 formed by a first hydraulic mixture C1, a sprayed body 22 formed by adhering a second hydraulic mixture C2 to a predetermined thickness so as to cover both sides of the layered body 21, and a reinforcing material 23 embedded in the boundary between the layered body 21 and the sprayed body 22.

The reinforcing material 23 has a net-like mesh material 23A arranged along the outer surface of the layered product 21, and linear reinforcing bars 23B with their length oriented in the vertical direction on the outside of the mesh material 23A. The reinforcing bars 23B are arranged in a multiple number at intervals in the horizontal direction.

As shown in FIG. 2, the first additive manufacturing device 11 is controlled so that an extrusion nozzle 11A with an extrusion port 11a is in any extrusion position, and extrudes a first hydraulic mixture C1 from the extrusion port 11a. The first additive manufacturing device 11 is equipped with a robot arm 14 having a configuration similar to that of the second additive manufacturing device 12 shown in FIG. 1. Note that the robot arm 14 is omitted in FIG. 3. The extrusion nozzle 11A is attached to the tip of the robot arm 14.

The extrusion port 11a of the extrusion nozzle 11A is formed in a substantially rectangular shape when viewed from the nozzle axial direction. As shown in FIG. 2, the first hydraulic mixture C1 extruded from the extrusion port 11a has a rectangular cross section that is substantially the same shape as the extrusion port 11a. Therefore, by sequentially stacking on the first hydraulic mixture C1 extruded earlier, a layered product 21 having a wall thickness equivalent to the width dimension of the extrusion port 11a can be formed. The wall thickness of the layered product 21 can be adjusted by changing the shape and dimensions of the extrusion port 11a of the extrusion nozzle 11A or by forming multiple rows in the wall thickness direction in accordance with the shape and size of the structural member 2.

The extrusion nozzle 11A is connected to a hose (not shown), and the first hydraulic mixture C1 flowing through the hose is extruded from the extrusion port 11a. The hose may be disposed along the outside of the robot arm 14, or may pass through the inside of the robot arm 14. The hose is connected to a material pressure pump (not shown) that supplies the first hydraulic mixture C1 in an unhardened (unset) state to the extrusion nozzle 11A.

As shown in FIG. 1, the robot arm 14 is, for example, a six-axis robot, and is controlled with high precision operation based on pre-programmed operation information by a control unit (not shown). That is, the robot arm 14 has multiple arm sections connected via rotatable connectors. The robot arm 14 may be mounted on a self-propelled unit (not shown). The self-propelled unit is capable of ascending and descending (or moving up and down) and is provided to move the robot arm 14 by self-propelling to a predetermined location along the ground surface. The robot arm 14 may be driven by remote control.

As shown in FIG. 3, the second additive manufacturing device 12 forms a spray-molded body 22 in a state of close contact with the layered molded body 21. As shown in FIG. 8 and FIG. 9, the second additive manufacturing device 12 controls a spray nozzle 12A equipped with a spray port 12a to assume an arbitrary spraying posture, and sprays a second hydraulic mixture C2 from the spray port 12a. The second additive manufacturing device 12 is equipped with a robot arm 14 shown in FIG. 1.

The spray nozzle 12A has a spray port 12a formed in a substantially circular shape when viewed from the nozzle axial direction. The second additive manufacturing device 12 controls the operation of the spray nozzle 12A so that the second hydraulic mixture C2 extruded from the spray port 12a adheres to the target surface (the outer surface 21a of the layered product 21) with a constant thickness. The amount of the second hydraulic mixture C2 sprayed from the spray nozzle 12A and the wall thickness of the layered product 21 can be adjusted by changing the shape and dimensions of the spray port 12a of the spray nozzle 12A or by changing the pump pressure of the sprayed second hydraulic mixture C2 in accordance with the shape and size of the structural member 2.

The spray nozzle 12A is connected to a hose (not shown), and the second hydraulic mixture C2 flowing inside the hose is pushed out from the spray nozzle 12a. The hose may be disposed along the outside of the robot arm 14, or may be disposed passing through the inside of the robot arm 14. The hose is connected to a material pressure feed pump (not shown) that supplies the second hydraulic mixture C2 in an unhardened (unset) state to the spray nozzle 12A.
It should be noted that the configuration of the robot arm 14 shown in FIG. 1 is similar to the configuration of the robot arm 14 of the first additive manufacturing device 11 described above, and therefore a detailed description thereof will be omitted here.

The spray nozzle 12A may also be provided integrally with a surface finishing functional part 15 (see FIG. 1), such as a trowel, spatula, or brush, so that the surface of the second hydraulic mixture C2 sprayed from the spray nozzle 12A can be finished at the same time as the spraying.

As shown in FIG. 6, the reinforcing material assembly device 13 is used to grasp mesh material 23A and reinforcing bars 23B and position and place them in a predetermined location within the structural member 2 during construction. The reinforcing material assembly device 13 includes a grasping unit 131 and a robot arm unit 132. The grasping unit 131 is not particularly limited, and an appropriate structure can be adopted according to the type and shape of the reinforcing material 23 to be grasped. The robot arm unit 132 has the same configuration as the robot arm 14 of the first additive manufacturing device 11 and the second additive manufacturing device 12 described above, so a detailed description will be omitted here.

Next, a method for constructing the structural member 2 using the above-mentioned construction facility 1 will be described in detail with reference to the drawings.
3 and 4, first, a first additive manufacturing device 11 is used to extrude a first hydraulic mixture C1 from an extrusion nozzle 11A, and the first hydraulic mixture C1 extruded from the extrusion nozzle 11A is layered to form a layered object 21. At this time, by layering the first hydraulic mixture C1 extruded in advance on the upper side in order, the wall height is increased, and a layered object 21 having a wall thickness equivalent to the width dimension of the extrusion port 11a can be formed.

Specifically, the extrusion nozzle 11A is moved in one direction at a preset speed in a substantially horizontal direction to form a concrete section of the first hydraulic mixture C1 of a certain height, and then the extrusion nozzle 11A is moved in a substantially horizontal direction on top of the concrete section formed immediately adjacent to it to layer the next concrete section. The first hydraulic mixture C1 is then allowed to harden after passing through the extrusion nozzle 11A. In this manner, the movement of the extrusion nozzle 11A and the extrusion operation are repeated to form a layered object 21 of the desired shape.

Next, as shown in Figures 5 to 7, before the first hydraulic mixture C1 of the layered body 21 solidifies, at least a portion of the reinforcing material 23 is embedded and fixed in the layered body 21 using a reinforcing material assembly device 13.
Here, before setting in the hydraulic mixture C, the penetration resistance value measured using a penetration resistance tester in JIS A1147:2019 (method of testing the setting time of concrete) is 10 N/ ^mm2 or less.

Specifically, as shown in FIG. 5, mesh material 23A is fixed along the outer surface 21a on both sides of the layered product 21. The mesh material 23A is arranged over the entire outer surface 21a. At this time, the mesh material 23A is fixed to the first hydraulic mixture C1, for example, while being pressed against the outer surface 21a of the layered product 21. It is preferable that the mesh material 23A fixed to the outer surface 21a of the layered product 21 is exposed to the outer surface 21a in order to fix the reinforcing bars 23B. Next, as shown in FIG. 6 and FIG. 7, multiple reinforcing bars 23B are fixed to the exposed mesh material 23A at appropriate intervals. The reinforcing bars 23B can be fixed to the mesh material 23A by, for example, welding or a reinforcing bar tie wire.

8 and 9, a second additive manufacturing device 12 is used to spray the second hydraulic mixture C2 from a spray nozzle 12A, and the second hydraulic mixture C2 is sprayed from the spray nozzle 12A so as to cover from the outside the entire outer surface 21a of the layered model 21 to which the reinforcing material 23 has been fixed, forming a sprayed model 22. As a result, the layered model 21 and the sprayed model 22 come into close contact with each other, and the structural member 2 is constructed by hardening and curing the respective hydraulic mixtures C1 and C2.

Next, the construction method of the structural member 2 and the operation of the construction equipment 1 for the structural member 2 will be described in detail with reference to the drawings.

As shown in Figures 1 to 5, in the method for constructing a structural member 2 and the construction equipment 1 for the structural member 2 according to this embodiment, the structural member 2 is constructed with a hydraulic mixture and is provided with a reinforcing material 23. In this embodiment, the process includes a step of forming a layered object 21 by stacking the first hydraulic mixture C1 extruded from the extrusion nozzle 11A using a first additive manufacturing device 11 that extrudes a first hydraulic mixture C1 from an extrusion nozzle 11A, a step of forming a sprayed object 22 by spraying the second hydraulic mixture C2 from the spray nozzle 12A using a second additive manufacturing device 12 that sprays a second hydraulic mixture C2 from a spray nozzle 12A, and a step of providing the reinforcing material, where the first object and the sprayed object are formed in close contact with each other, and the reinforcing material is fixed to at least one of the first object and the sprayed object.

In this way, in this embodiment, two concrete construction methods are applied: a method of forming an additively molded body 21 by extruding the first hydraulic mixture C1 from the extrusion nozzle 11A, and a method of forming a sprayed body 22 by spraying the second hydraulic mixture C2 from the spray nozzle 12A.Therefore, even if a reinforcing material 23 is provided on the structural member 2, efficient construction can be achieved by applying the two concrete construction methods.
In this way, in this embodiment, the reinforcing material 23 is prevented from interfering with the operations of the extrusion nozzle 11A and the spray nozzle 12A, making it easier to control the first additive manufacturing device 11 and the second additive manufacturing device 12, and enabling the automatic construction of a structural member 2 of any shape, including the reinforcing material 23.

In addition, in this embodiment, the reinforcing material 23 can be fixed by embedding it in at least one of the previously formed layered body 21 and the sprayed body 22, so the reinforcing material 23 can be held in the layered body 21 and the sprayed body 22. Therefore, for example, there is no need to assemble the reinforcing material 23 into a shape such as a reinforcing bar cage to make it self-supporting, and work can be performed efficiently.

In addition, this embodiment includes a process of forming a layered object 21 by layering the first hydraulic mixture C1, a process of embedding and fixing at least a portion of the reinforcing material 23 in the layered object 21 before the first hydraulic mixture C1 of the layered object 21 solidifies, and a process of forming a sprayed object 22 by spraying the second hydraulic mixture C2 so as to cover from the outside the reinforcing material 23 fixed to the layered object 21.

Therefore, by embedding and fixing the reinforcing material 23 in the hydraulic mixture of the previously formed layered body 21 before it solidifies, and then spraying the second hydraulic mixture C2 onto the outside of the layered body 21 to form the sprayed body 22, a structural member 2 can be efficiently constructed in which the reinforcing material 23 is embedded at a predetermined position within the body consisting of the layered body 21 and the sprayed body 22.

As described above, the method for constructing a structural member 2 and the construction equipment 1 for a structural member 2 according to this embodiment can improve the work efficiency of construction of a structural member 2 equipped with a reinforcing material 23, and can reduce the labor and steps involved in the work.

Next, other embodiments and variations of the method for constructing a structural member according to the embodiment and the equipment for constructing a structural member will be described. Note that components having the same functions as those in the first embodiment described above are given the same reference numerals, and detailed descriptions of these components will be omitted to avoid duplication.

Second Embodiment
As shown in FIG. 10, the method for constructing a structural member according to the second embodiment is for constructing a structural member 2A that is a columnar structure.
The layered product 21A (first product) of the second embodiment is formed in a hollow cylindrical shape. In the structural member 2A, a cylindrical assembled reinforcing bar cage 24 is inserted into the hollow portion 21b of the layered product 21A, and the third hydraulic mixture C3 is filled so as to embed the reinforcing bar cage 24 inside the layered product 21A. The reinforcing bar cage 24 becomes the main reinforcement and rebar of the columnar structural member 2A to be constructed. The reinforcing material 23 (mesh material 23A and reinforcing bar 23B) and the sprayed product 22A (second product) are provided so as to cover only the outer peripheral surface 21c of the layered product 21A, and are arranged along the outer peripheral surface 21c.

The method for constructing the structural member 2A according to the second embodiment first involves extruding a first hydraulic mixture C1 from an extrusion nozzle 11A using a first additive manufacturing device 11, and then stacking the first hydraulic mixture C1 to form a cylindrical layered object 21A, as shown in Figures 11 and 12.

Next, before the first hydraulic mixture C1 of the layered product 21A solidifies, at least a portion of the reinforcing material 23 is embedded and fixed to the layered product 21A using a reinforcing material assembly device 13 (see FIG. 6). Here, a mesh material 23A is embedded in the first hydraulic mixture C1 on the outer circumferential surface 21c of the layered product 21, and multiple reinforcing bars 23B are fixed to the mesh material 23A. As a result, multiple reinforcing bars 23B are arranged in the circumferential direction on the outer circumferential surface 21c of the layered product 21.

Next, as shown in Figures 13 and 14, a second additive manufacturing device 12 is used to spray the second hydraulic mixture C2 from a spray nozzle 12A, and the second hydraulic mixture C2 is sprayed from the spray nozzle 12A so as to cover from the outside the entire outer surface 21a of the layered model 21 to which the reinforcing material 23 has been fixed, forming a sprayed model 22A. As a result, the layered model 21A and the sprayed model 22A come into close contact with each other, and the respective hydraulic mixtures C1 and C2 are hardened and cured.

Next, as shown in Fig. 15, a reinforcing bar cage 24 is inserted from above into the hollow portion 21b of the layered product 21A. Thereafter, as shown in Fig. 10, a third hydraulic mixture C3 is filled inside the layered product 21A to construct a structural member 2A.
In this way, the cylindrical layered molded body 21A and the spray-applied molded body 22A constructed in advance are part of the structural member 2A, and also function as a formwork when the third hydraulic mixture C3 is filled and hardened.

In the second embodiment, a structural member 2A consisting of columns and walls with the reinforcing bar cage 24 as the main reinforcement can be efficiently constructed.
Furthermore, the layered product 21A formed in advance can function as a formwork for the third hydraulic mixture C3 to be filled into the hollow portion 21b, eliminating the need for a formwork.

In another embodiment, a construction method can be adopted in which the reinforcing bar cage 24 is placed in a predetermined position, the reinforcing bar cage 24 is then covered to form a hollow laminated body 21A, and the inside of the laminated body 21A is then filled with a third hydraulic mixture C3.

(Modification)
16 and 17 show a modified structural member 2B in the above-described second embodiment, where a steel column 25 is placed in a hollow portion 21b of a cylindrical layered product 21A (first product) instead of the reinforcing bar cage 24, and the hollow portion 21b is filled with a third hydraulic mixture C3. The reinforcing bars 23C of the reinforcing material 23 of the layered product 21A are arranged horizontally along the circumferential direction. The steel column 25 is made of steel material with a quadrangular (approximately square) cross section.
The structural member 2B of this modified example is formed by inserting a steel column 25 from above into the hollow portion 21b of the layered structure 21A and filling it with a third hydraulic mixture C3, thereby forming a root-wrapped column base with the leg of the steel column 25 fixed thereto.

In addition, in this modified example, the reinforcing bars 23C of the reinforcing material 23 are arranged horizontally, so a shear reinforcement effect can also be added. Also, vertical bars can be added to the outside of the reinforcing bars 23C (horizontal bars) to increase bending strength. Furthermore, a construction method in which the lower part of an existing steel column is reinforced with root wrapping can also be used. In this way, it can also be used as seismic reinforcement to increase the cross-sectional performance of existing structures (steel frame construction or reinforced concrete construction).

The above describes the embodiment of the method for constructing structural members and the equipment for constructing structural members according to the present invention, but the present invention is not limited to the above embodiment and can be modified as appropriate without departing from the spirit of the invention.

For example, in the above-described embodiment, the reinforcing material 23 such as the mesh material 23A and the reinforcing bar 23B is installed using the reinforcing material installation device 13, but it is also possible to omit the reinforcing material installation device 13, for example, when installing the reinforcing material manually without using the reinforcing material installation device 13.

The reinforcing material 23 is not limited to the above-mentioned embodiment, and the shape, material, position, quantity, etc. can be changed as appropriate. For example, it may be a reinforcing material in which reinforcing bars in two different directions, such as vertical main bars and horizontal hoop bars, are arranged, or a spiral-shaped reinforcing material. Furthermore, the material of the reinforcing material may be various metal materials, continuous fibers, FRP (fiber reinforced plastic), etc. The shape of the reinforcing material is not limited to mesh or wire, and may be panel-shaped or sheet-shaped. In other words, when constructing structural members 2, 2A, and 2B with curved shapes as in the above-mentioned embodiment, it is difficult to arrange straight reinforcing materials, so it is preferable to use mesh-shaped or sheet-shaped reinforcing materials that are easy to bend (easily change shape), such as wire mesh or FRP mesh.

In this embodiment, the fluid material sprayed by the spray nozzle 12A (second nozzle) is a general term for various cement-based materials (e.g., cement paste, mortar, concrete, etc.) that are hydraulic mixtures, geopolymer compositions, and fiber-reinforced composite materials in which these are reinforced with short fibers. The short fibers used in fiber-reinforced composite materials include synthetic fibers made of chemically synthesized polymers, and fibers made of inorganic substances. Examples of the former include polypropylene fibers, polyvinyl alcohol fibers, polyethylene fibers, polyester fibers, and aramid fibers. Examples of the latter include glass fibers, steel fibers, carbon fibers, rock fibers (such as basalt), ceramic fibers, and silica fibers. The fluid material is not limited to being a hydraulic mixture, and may be, for example, a resin.

Furthermore, in the method for constructing a structural member according to the first embodiment described above, at least a portion of another reinforcing material may be embedded and fixed into the sprayed sculpted body 22 (second sculpted body) before the second hydraulic mixture C2 (fluid material) of the sprayed sculpted body 22 solidifies, and the second hydraulic mixture C2 (fluid material) may be sprayed to cover the other reinforcing material fixed to the sprayed sculpted body 22 from the outside, thereby forming a sprayed sculpted body (third sculpted body).
In this case, a plurality of shaped portions can be formed by spraying the second hydraulic mixture C2, and another reinforcing material can be disposed between the second shaped body and the third shaped body. In other words, when a plurality of reinforcing materials are disposed in the structural member, for example, in the thickness direction, the step of installing the reinforcing materials and the step of spraying the fluid material so as to cover the reinforcing materials can be performed alternately, thereby improving the work efficiency.

Furthermore, as a method for constructing another structural member, it is also possible to use a construction method that includes the steps of forming a layered body 21 (first body) by stacking a hydraulic mixture, forming a sprayed body 22 (second body) by spraying a fluid material so as to cover the layered body 21 from the outside, and embedding and fixing at least a portion of a reinforcing material in the sprayed body 22 before the fluid material of the sprayed body 22 solidifies.
In this case, a sprayed body 22 is formed by spraying a fluid material onto the pre-solidifying hydraulic mixture of the previously formed layered body 21, and then a reinforcing material is embedded and fixed into the pre-solidifying fluid material of the sprayed body 22, thereby efficiently constructing a structural member in which a reinforcing material is embedded at a predetermined position on the outer surface of the body consisting of the layered body 21 and the sprayed body 22.
Furthermore, even in this case, the third shaped body may be formed by spraying the fluid material so as to cover from the outside the reinforcing material fixed to the second shaped body, which is the spray-applied shaped body 22. In this case, it is possible to provide a plurality of shaped parts formed by spraying the fluid material, and by covering the reinforcing material provided on the outer surface of the second shaped body with the third shaped body, the reinforcing material can be disposed in a state of being embedded between the second shaped body and the third shaped body.

In addition, the components in the above-described embodiments may be replaced with well-known components as appropriate without departing from the spirit of the present invention.

1, 1A, 1B, 1C Construction equipment 2, 2A, 2B Structural member 11 First additive manufacturing device 11A Extrusion nozzle (first nozzle)
11a Extrusion port 12 Second additive manufacturing device 12A Spray nozzle (second nozzle)
13 Reinforcement material assembly device 14 Robot arm 21, 21A Layered object (first object)
21a Outer surface 21b Hollow portion 21c Outer circumferential surface 22, 22A Spray-formed body (second formed body)
23 Reinforcement material 23A Mesh material 23B, 23C Steel bar 24 Steel bar cage 25 Steel column C1 First hydraulic mixture C2 Second hydraulic mixture (fluid material)
C3 Third hydraulic mixture (fluid material)

Claims (10)

A method for constructing a structural member constructed of a hydraulic mixture having a reinforcement material, comprising the steps of:
A step of forming a first shaped body by stacking the hydraulic mixture extruded from a first nozzle using a first additive manufacturing device that extrudes a hydraulic mixture from the first nozzle;
using a second additive manufacturing device that sprays a flowable material from a second nozzle, spraying the flowable material from the second nozzle to form a second shaped object;
providing the reinforcing material;
having
the first body and the second body are formed in a state of being in close contact with each other,
A method for constructing a structural member, characterized in that the reinforcing material is fixed to at least one of the first body and the second body. forming the first shaped body by layering the hydraulic mixture;
embedding and fixing at least a portion of the reinforcing material in the first shaped body before the hydraulic mixture in the first shaped body sets;
forming the second body by spraying the fluid material onto the reinforcing material fixed to the first body from the outside so as to cover the reinforcing material;
2. The method for constructing a structural member according to claim 1, further comprising: embedding and fixing at least a portion of another reinforcing material in the second shaped body before the fluid material of the second shaped body solidifies;
forming a third body by spraying the fluid material onto the other reinforcing material fixed to the second body from the outside so as to cover the other reinforcing material;
3. The method for constructing a structural member according to claim 2, further comprising: forming the first shaped body by layering the hydraulic mixture;
forming the second body by spraying the fluid material onto the first body so as to cover the first body from the outside;
embedding and fixing at least a portion of the reinforcing material in the second body before the fluid material of the second body solidifies;
2. The method for constructing a structural member according to claim 1, further comprising: forming a third body by spraying the fluid material onto the reinforcing material fixed to the second body from the outside so as to cover the reinforcing material;
5. The method for constructing a structural member according to claim 4, further comprising the steps of: The first body is formed into a hollow shape,
Inserting a reinforcing bar cage into the hollow portion of the first shaped body;
6. The method for constructing a structural member according to claim 1, further comprising filling an inside of the first structure with concrete. After placing the reinforcing bar cage in a predetermined position, the first shaped body is formed by covering the reinforcing bar cage and having a hollow shape;
6. The method for constructing a structural member according to claim 1, further comprising filling an inside of the first structure with concrete. The method for constructing a structural member according to any one of claims 1 to 5, characterized in that a reinforcing body consisting of the first body and the second body provided with the reinforcing material is formed on the outer periphery of an existing steel frame or structure. forming the first structure including an existing steel frame or structure;
6. The method for constructing a structural member according to claim 1, further comprising the steps of: embedding the reinforcing material on the outside of the first shaped body; and then spraying the fluid material onto the outside of the reinforcing material to cover it. A construction facility for a structural member constructed of a hydraulic mixture having a reinforcing material,
a first additive manufacturing device comprising a first nozzle and operable to extrude and layer a hydraulic mixture through the first nozzle to form a first shaped object;
a second additive manufacturing device comprising a second nozzle and operable to form a second object by spraying flowable material from the second nozzle;
a reinforcing material assembling device that installs the reinforcing material so as to be fixed to at least one of the first body and the second body;
Equipped with
A structural component construction facility characterized in that the first additive manufacturing apparatus and the second additive manufacturing apparatus form a structure in close contact with the first structure or the second structure which is formed earlier.

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