JP2852013B2 - Ultralight members such as gate posts and fences, and methods of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for constructing a wall or a wall of a house or the like using an ultralight block (core material) or a pack for a block.

[0002]

2. Description of the Related Art In a conventional method, when a general pack of decorative materials such as tiles and natural stones is pre-attached to a concrete plate, a plurality of decorative materials are arranged on a bottom plate of a horizontally placed formwork. At present, concrete is poured over the concrete, and after the concrete hardens, the concrete plate is removed from the formwork, and the concrete plates are combined to form a fence, a wall of a building, or the like.

[0003]

In the conventional manufacturing method as described above, since a general pack is used, the concrete paste adheres to the surface decorative material at the time of placing the concrete, which takes a lot of time and effort to wash the surface. It was difficult to produce a violent or rough surface. In addition, there is a problem in that the product itself is heavy in the weight of concrete itself, transportation cost is high, and a large heavy machine is required for construction.

[0004] The object of the present invention is to solve the above-mentioned conventional problems, to produce a beautifully finished product which is inexpensive and requires no washer, and to provide an ultra-light-weight pillar which can be easily carried to a construction site. An object of the present invention is to provide a method for manufacturing a fence and a method for constructing the fence.

It is another object of the present invention to bring a pack material to the site, set it, and place fresh concrete on the site, and to provide an ideal site pre-installation method for eliminating tile peeling accidents and the like.

[0006]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a plurality of recesses for fitting a decorative material on one surface of a support, and a hole communicating with each of the recesses from the other surface. A block pack in which a cosmetic material is fitted and fixed in each of the recesses of the support, and an object which is liquefied by heating and solidified at room temperature is poured in a liquid form from each of the holes to the back surface of each cosmetic material to be solidified. After fixing the block pack on the surface of a core material made of an ultralight material such as a separate foamed resin with a gap between the decorative material and the core material side, and injecting mortar into the gap. And a method of manufacturing an ultralight member to obtain a gate post, a fence, and the like by removing the support by curing the mortar.

According to the above-mentioned method, for example, in a factory, for example, a gate post, a fence, and the like can be integrally formed and precast, and can be carried to a construction site and joined to a foundation as it is for construction.

Further, it is possible to manufacture a small block for constructing a fence or the like by the above-mentioned manufacturing method.

In this case, a cavity is provided in a core material such as a gate post, a fence, or a block, and a reinforcing bar connected to a foundation at a construction site is inserted into the cavity. By connecting with the core material, the ultra-light member such as the gate post, the fence and the like can be made independent at the construction site.

In addition to precasting, a block pack used in the above-mentioned manufacturing method and a core material made of a separate ultra-light material such as a foamed resin are carried to a construction site, and the core material is transferred to the construction site. After installing, the block pack is fixed on the surface of the core material with the gap between the decorative material and the core material side, and after the mortar is injected into the gap, the mortar is cured and the support is removed. By doing so, a gate post, a fence, and the like may be formed at the construction site.

The core material itself does not need to be integral,
An ultra-light member such as a fence may be constructed by connecting a plurality of core members in a lateral direction with a connecting member and fixing the block pack to both or one surface of these core members with mortar.

In the above-described method for manufacturing an ultralight member, a release agent is applied to the surface of the core material in advance, and a block pack is placed on the surface of the release agent layer with the decorative material facing the core material. After the mortar is injected into the gap, the mortar is cured and the core material and the support are removed to produce a flower bed or the like having a hollow inside.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION A side or side and bottom surface of a core material made of an ultralight material in the shape of a gate post or a wall is surrounded by a block pack, mortar is poured into the gap, and after the mortar is hardened, the block pack is removed. If the support is removed, a precast product of the gate post and fence with the mortar with the decorative material around the core material is completed, and the precast product such as this post and fence is ultra-lightweight, It can be easily transported to the construction site.

[0014] It is also possible to carry the block pack and the core material to the construction site and directly construct a gate post or a fence at the site. In this case, the support of the block pack is also made of an ultra-light material such as foamed resin. If it is made of a material and lightened, it can be easily transported to the construction site together with the core material.

[0015] In any of the above methods, a cavity is provided in the core material, a reinforcing bar connected to the foundation of the construction site is inserted into the cavity, and then the mortar or concrete is injected into the cavity. The ultra-light member such as a gate post, a fence or the like can be connected to stand alone at the construction site, but this cavity can be provided not only for inserting a reinforcing bar, but also for pouring mortar or for releasing air at that time.

These core materials can be left as they are inside the gate post or fence, but if a release agent is applied to the surface in advance, it can be extracted after the mortar is hardened, and a hollow ultra-light member, for example, A flower bed (flower pot) can also be created.

[0017]

【Example】

(Embodiment 1) FIGS. 1 and 2 show an embodiment of a block pack used in the present invention, wherein 1 is an ultra-light support made of styrofoam, styrofoam, or the like. Are provided, and holes 3 communicating with the respective recesses 2 from the other surface are provided.

The recess 2 of the support 1 is shown in FIGS.
FIG. 1 (B), FIG.
Some have no steps as in (B).

Next, as shown in FIG. 3, a hard decorative material 4 in which tiles, natural stones and the like are formed in an appropriate size and shape is fitted into the respective recesses 2 of the support 1 as shown in FIG. A water-soluble adhesive is applied and fixed between the inner surface of 2 and the outer periphery of the decorative material 4.

When the decorative material 4 is fitted into the recess 2 as described above, the concave and convex surface 5 for joining the decorative material 4 to concrete is outside, and the side which becomes the surface when the concrete wall surface is completed is inside. .

When the surface is flat like a tile, it can be fitted in the stepped recess 2 as shown in FIG. 3A, so that the uneven surface 5 of each decorative material 4 can be aligned on the same plane.

FIG. 3 shows a case in which natural stone is formed into a square shape so that the natural stone surface is exposed when the wall is completed.
As shown in (B), a deep stepless one is used as the recess 2.
Carefully fix so that the uneven surface 5 is aligned on the same plane.

When the decorative material 4 is fixed to the recess 2 as described above, the dimensions of the recess 2 and the decorative material 4 do not completely match, and as shown in FIGS. Cosmetic material 4 and recess 2
A gap is created in

The support 1 on which the hard decorative material 4 is fixed is shown in FIG.
(A) and (B), the decorative material 4 is placed in a mold 8 having a bottom plate 6 and a peripheral wall 7 with the decorative material 4 facing down.
Pour in.

Next, an object which is lighter in weight than water and becomes liquid by heating and solidifies at room temperature, for example, a material obtained by heating paraffin 10 to be in a liquid state, as shown in FIGS. From the back of each hard cosmetic material 4.

At this time, an air vent hole 11 for discharging air from each of the recesses 2 is provided in an appropriate place of the support 1 in advance.
No air remains in each recess 2 when the paraffin 10 is injected.

Liquid paraffin 1 poured from hole 3
6 is filled in the recess 2 as shown in FIGS. 6A and 6B and further penetrates the gap between the recess 2 and the decorative material 4 to fill the gap. Because of its low specific gravity, it does not penetrate below the water surface.

After the poured paraffin 10 is cooled and solidified as described above, the support 1 is taken out of the mold 8 to complete the block pack A shown in FIGS. 7A and 7B.

The pack A for a block obtained by the above-described manufacturing method is used for the support 1 due to a dimensional error of the decorative material 4 or the like.
Even if there is a gap between the recess 2 and the decorative material 4, the paraffin 10 closes the gap and is integrated, so that concrete or mortar does not leak to the surface of the decorative material during wall construction, After the water 9 is poured into the lower portion of the mold 8, the paraffin 10 having a lower specific gravity than the water 9 is poured, so that the paraffin 10 adheres to the uneven surface 5 of the decorative material 4 which was in contact with the water at this time. In addition, the decorative material does not fall off due to the paraffin peeling effect after construction.

8 (A) and 8 (B), B is an ultra-light core made of foamed styrofoam or the like. It has the shape of a fence.

The uneven surface 5 of the decorative material 4 of the block pack A is fixed at intervals with a spacer or the like toward the surface of the wall surface 12 of the core material B, and then the mortar 13 is poured from above to block. Fixing pack A.

After the mortar 13 has hardened, the paraffin 10 is dissolved using a drier or the like, and each hole 3
When the support 1 is removed by dissolving the water-soluble adhesive bonding the hard decorative materials 4 to the recesses 2 with water at the same time, only the hard decorative materials 4 are removed, as shown in FIGS. 9A and 9B. 2), the surface of the wall surface 12 is decorated with a beautiful decorative material 4, and an accurate joint 14 is formed between the decorative materials 4.

Embodiment 2 FIG. 10 shows a method of constructing a fence at a factory after constructing a fence. B is a square plate-shaped core material having a predetermined thickness made of styrene foam. A plurality of vertical cavities 15 for weight reduction, air bleeding and rebar insertion are formed at regular intervals, and a plurality of air bleed holes are opened from each of the cavities 15 to the outside of the core material B. 16 are provided.

Then, the support 1 side of the block pack A shown in FIG. 7 is adhered to the inner side surface and the bottom surface of the iron form 17 fixed on the processing bed 18 by using bolts 19 and the like. After that, the core material B is fixed in the iron form 17 by using a spacer or the like so as to leave a gap between the core material B and the block pack A.

Thereafter, the mortar 13 is poured into the gap between the block pack A and the core B. At this time, the mortar 13 is not poured into the cavity 15 of the core B.

After the mortar 13 is hardened, the paraffin is dissolved and removed, and the iron form 17 and the support 1 of each block pack A are removed to obtain a precast product of the wall.

Then, as shown in FIG. 11, the completed wall C from which each support 1 has been removed is transported to a target site, and placed on a foundation 20 upside down.

In the foundation 20, a fume pipe 22 is embedded in a target ground 21, concrete 23 is poured into the bottom thereof to fix the lower end of the reinforcing bar 24, and the reinforcing bar 24 is inserted into the cavity 15 of the wall C. When the concrete 25 is poured into the cavity 15, the wall C is completely fixed.

In the case of the gate post, the structure is the same as that of the above-mentioned fence, except that it is only approximately square in the transverse plane.

(Embodiment 3) FIG. 12 shows a case where a fence is assembled at a construction site. B is a square plate-shaped core material having a predetermined thickness made of styrene foam, which is manufactured by bonding a single or a plurality of blocks. In addition, a plurality of vertical cavities 15 are formed at regular intervals for inserting a reinforcing bar or for reducing the weight and bleeding air. Is provided.

At the construction site, a reinforcing bar 24 connected to the foundation is inserted into the cavity 15 of the core material B, and concrete 25 is poured into the cavity 15 and solidified, thereby fixing the core material B to the foundation.

Then, the block pack A shown in FIG. 7 is fixed to the surface of the core material B. In this case, a spacer is used, or the block pack A is adhered to an iron plate, and the iron plate is erected. For example, a gap is formed between the core material B and the block pack A. At this time, the core material B
The corners of the above are formed in close contact with the block pack A by forming a 45 ° slope.

Next, the mortar 13 is poured between the core material B and the block pack A, and after the mortar 13 is hardened, the paraffin 10 is dissolved and removed, and the support 1 of the block pack is removed.

FIG. 13 is a cross-sectional plan view showing an example of the wall after removing the support of the block pack A by the construction method of the present invention. The core material B is made of the same ultra-light material as that of FIG. The blocks are formed by stacking a plurality of blocks in the form of bricks and joining them with an adhesive, and the plurality of cores B are connected to form a wall.

In this case, a dovetail groove 27 in the vertical direction is formed on the opposing surface of the adjacent core material B, and the opposing dovetail groove 27 is formed.
When the mortar or concrete 25 is injected and hardened after the reinforcing bar 24 is inserted in the vertical direction, the concrete 25 becomes a joint and the core materials B on both sides are connected.

FIG. 14 shows a case where an H-section steel is used as the joint fitting 28. In this case, the core material B is used.
The two core materials B, B are connected by forming a T-shaped groove 29 in the vertical direction at the connecting portion, and inserting the T-shaped portions on both sides of the joint fitting 28 with the grooves 29 facing each other. .

FIG. 15 is a cross-sectional view of a wall having yet another configuration, showing a case where a plurality of core members B are connected in the lateral direction by bolts 30. In this case, a plurality of long bolts 30 are connected in the lateral direction. When the core material B is made of a thermoplastic material such as styrene foam, the core material B is inserted while being heated and melted by heating the bolts 30.

At this time, concave portions are formed in portions where the bolts outside the core material B at both ends pass, and an iron plate or F is formed at the bottom of each concave portion.
A hard backing plate 31, 31 such as an RP plate is applied, and a bolt 30 is inserted into a hole of each backing plate 31, 31 to secure a bolt 3
The head 0 and the nut 32 do not bite into the core material B. In this case, irregularities are provided on the opposing surfaces of the adjacent core members B so that the adjacent core members B do not shift back and forth.

(Embodiment 4) FIG. 16A shows an ultra-light block D according to claim 3 manufactured by the method according to claim 1 of the present invention. Has a size of about 300 mm to about 450 mm.

The inside of the block D is made of a core material B made of polystyrene foam and having a cavity 15 penetrating in the vertical direction, and the block pack A of FIG. 7 is attached on the core material B at intervals. The core material B and the exterior material 4 are integrated by pouring a mortar 13.

As shown in FIG. 16 (B), the block D is carried into the site, and a reinforcing bar is inserted into the cavity 15 of the block D and piled up in the same manner as a general block.
Fences and gate posts can be constructed by the method of pouring concrete into 5. At this time, since the core material B is made of styrene foam and is very lightweight, it can be easily transported to the site and installed on the site.

(Embodiment 5) FIGS. 17 and 18 show an embodiment of the seventh and eighth aspects of the present invention, in which a large flower pot is manufactured.

In this case, a cavity 15 and an air vent hole 16 are appropriately provided in a styrofoam core B having a size and a shape corresponding to the intended flower pot, similarly to the case of the fence, and a mold is released on the surface of the core B. Agent 33 is applied.

Then, as shown in FIG. 17, the block pack A shown in FIG. 7 is fixed inside the rebar frame 17 fixed on the processing bed 18 by bolts 19,
In the case of a flower pot, the bottom 34 which does not need to be decorated only needs to be a mortar layer, so that the reinforcing bar frame 17 is exposed here.

Further, the core material B having the surface coated with the release agent 33 is fixed at intervals with the block pack A and the bottom 34 of the reinforcing bar frame 17 using a spacer or the like. At this time, a member 35 made of polystyrene foam for forming a drain hole is fixed to the bottom portion 34.

Further, the mortar 13 is poured into the gap between the core material B and the block pack A, and after the mortar 13 has hardened, the one in which the core material B mortar 13 and the block pack A are integrated is taken out from the iron form 17. After the paraffin is dissolved and removed, the support 1 and the core material B of the block pack A are removed.

FIG. 18 shows a completed flower pot E from which the support 1 and the core material B have been removed. The bottom of the flower pot E has only a mortar structure.
Are formed.

[0058]

As described above, according to the present invention, a light-weight building fence or gate is formed by using a block pack and an ultra-light core material manufactured in advance in a factory as described above, and then installed at a construction site. It can be constructed with extremely simple construction just by fixing it properly, so the construction period is significantly shorter than the conventional on-site construction method, and the core material is made of ultra-light material, so it can be transported. It is easy to handle, easy to construct, and easy to form a large flower pot.

If the support for the block pack is also made of an ultra-light material in advance as in the embodiment, the lightweight core material and the block pack can be easily transported to the construction site. It is possible to directly construct a gate post, a fence, and the like, and it is possible to increase the size by utilizing the light weight, and to improve the work efficiency.

Further, since the decorative material is attached to the gate post, the fence, etc. using the block pack, the intervals between the decorative materials can be accurately maintained, and the joints of the decorative materials can be accurately formed. This has the effect of preventing this.

[Brief description of the drawings]

FIGS. 1A and 1B are partially cutaway longitudinal sectional views showing examples of a support for a block pack.

FIG. 2 is a partially cutaway plan view of the same.

FIG. 3 is a partially cutaway longitudinal sectional view showing each example of a state in which a decorative material is attached.

FIG. 4 is a partially enlarged longitudinal sectional view of the above.

FIG. 5 is a partially cutaway longitudinal sectional view showing each example of a state where the support is mounted on a mold.

FIG. 6 is a partially enlarged longitudinal sectional view of the above.

FIG. 7 is a partially cutaway longitudinal sectional view showing each example of a block pack taken out of a mold.

FIG. 8 is a partially cutaway longitudinal sectional view showing a state where each example of the pack is attached to a wall surface of a core material.

FIG. 9 is a partially cutaway longitudinal sectional view showing each example of a completed state of the wall surface of the core material.

FIG. 10 is a partially cut-away longitudinal side view showing an example of a processing state of a fence.

FIG. 11 is a longitudinal sectional view of a completed fence.

FIG. 12 is a partially cutaway cross-sectional view showing an example of a fence construction method.

FIG. 13 is a partially cutaway cross-sectional view showing an example of a connecting portion of a fence.

FIG. 14 is a partially cutaway cross-sectional view showing an example of a connecting portion of a fence.

FIG. 15 is a partially cutaway cross-sectional view showing an example of a connecting portion of a fence.

FIG. 16A is a perspective view of an ultra-light block. (B) is a perspective view showing the construction state.

FIG. 17 is a longitudinal sectional side view showing an example of a processing state of a flower pot.

FIG. 18 is a vertical sectional side view of a completed flower pot.

[Explanation of symbols]

 Reference Signs List A pack for block B core material C wall D ultra-light block E flower pot 1 support 2 recess 3 hole 4 makeup material 5 uneven surface 6 bottom plate 7 peripheral wall 8 formwork 9 water 10 paraffin 11, 16 air vent hole 12 wall surface 13 mortar 14 joint 15 cavity 17 iron formwork 18 working bed 19 bolt 20 foundation 21 ground 22 fume tube 23,25 concrete 24 reinforcing bar 26,27 dovetail groove 28 joint fitting 29 T-shaped groove 30 bolt 31 backing plate 32 nut 33 release agent 34 Bottom 35 Member 36 Drain hole

──────────────────────────────────────────────────続 き Continued on the front page (58) Fields surveyed (Int. Cl. ⁶ , DB name) E06B 11/02 B28B 19/00 E04C 2/40 E04H 17/14 101 E04F 13/14 101

Claims (8)

(57) [Claims] 1. A plurality of recesses for fitting a cosmetic material on one surface of a support, holes communicating with the recesses from the other surface are provided, and a cosmetic material is fitted and fixed in each of the recesses of the support. An object which is liquefied by heating and solidified at normal temperature is formed into a block pack in which the liquid is poured into the back of each decorative material through the respective holes in a liquid form and solidified, and is made of a super lightweight material such as a separate foamed resin. On the surface of the core material, the block pack is fixed by providing a gap with the decorative material as the core material side, and after injecting mortar into the gap, the mortar is cured and the support is removed by removing the support. A method for producing ultra-light members such as walls and walls. 2. An ultra-light member such as a gate post or a fence formed integrally by the manufacturing method according to claim 1. 3. An ultralight member such as a block for forming a gate post, a fence, or the like, obtained by the manufacturing method according to claim 1. 4. A hollow is provided in the core of the ultra-light member according to claim 2 or 3, and a reinforcing bar connected to a foundation of a construction site is inserted into the hollow, and then mortar or concrete is filled in the hollow. A method of manufacturing ultra-lightweight members for constructing gate pillars, fences, etc. by injecting and connecting the foundation and core material. 5. The method according to claim 1, wherein
After installing a core material made of a super lightweight material such as a separate foamed resin at the construction site, fix the block pack on the surface of this core material with a decorative material to form a gate post or a fence. The method for manufacturing an ultralight member according to claim 1, wherein the method is obtained on site. 6. A plurality of core members made of the ultra-light material are connected laterally by a connecting member, and a block pack is fixed to both sides or one side of these core members by mortar. A method for producing an ultralight member such as the fence according to 1, 4, or 5. 7. A plurality of recesses for fitting a cosmetic material on one surface of a support, holes for communicating with the recesses from the other surface are provided, and a cosmetic material is fitted and fixed in each of the recesses of the support. An object which is liquefied by heating and solidified at normal temperature is formed into a block pack in which the liquid is poured into the back of each decorative material through the respective holes in a liquid form and solidified, and is made of a super lightweight material such as a separate foamed resin. A release agent is applied to the surface of the core material, and the block pack is fixed on the surface of the release agent layer with a gap between the decorative material and the core material side, and mortar is injected into the gap. A method for producing an ultra-light member such as a flower bed, wherein the mortar is cured to remove the core and the support to make the mortar hollow. 8. A flowerbed obtained by the method according to claim 7.