JP4007756B2 - Concrete panel and concrete panel manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a concrete panel used for construction of a building floor, a roof, a building wall, a wall plate of an outer wall, a reinforced concrete floor and the like in a concrete structure.
[0002]
[Prior art]
Conventionally, when constructing concrete structure frame floors, frame walls, etc., a construction method has been adopted in which a specific formwork is assembled at the construction site, the necessary reinforcing bars are placed, and then concrete is placed in the formwork. It had been.
[0003]
However, such a construction method requires a lot of time and labor for formwork assembly, concrete placement, concrete solidification and curing, etc., and is an impediment to shortening the construction period. The increase is easy to cause, and there are also problems such as an increase in the weight of the structure.
[0004]
Therefore, in recent years, the workability has been improved and the construction period has been shortened by adopting a method in which so-called precast concrete panels manufactured in advance in the factory are brought into the construction site and attached to the structure. Yes.
[0005]
In such a construction method, it is necessary to reduce the weight of the concrete panel in order to improve the transportability to the construction site and the handling property on the construction site. Has been developed and disclosed in Japanese Patent Laid-Open No. 7-90972.
[0006]
In addition, the present applicant has improved a concrete panel disclosed in Japanese Patent Laid-Open No. 7-90972 and developed a concrete panel having improved strength, heat insulation and sound insulation, and disclosed in Japanese Patent Laid-Open No. 10-25854. is doing. As shown in FIG. 7, this concrete panel forms a pair of concrete layers 71, 72 spaced from each other so as to bury a reinforcing bar net 75 arranged above and below the corrugated plate 73. And a foamed resin 74 in a hollow portion formed by the concrete layers 71 and 72.
[0007]
In the concrete panel 70, the crest 73m and the trough 73v of the corrugated plate 73 are buried in the concrete layers 71 and 72, respectively, thereby improving the compressive strength of the corrugated plate 73 in the wave pitch direction X and the corrugated plate 73. By forming a substantial truss structure based on the cross-sectional shape, the overall rigidity is also improved.
[0008]
[Problems to be solved by the invention]
In the concrete panel 70 shown in FIG. 7, the convex surface side of the corrugated plate 73 m and the trough portion 73 v is firmly fixed to the concrete layers 71 and 72, but the concave surface side is corrugated plate 73 and foamed resin. Since it is only in contact with 74, the balance in strength is poor, and the design strength may not be sufficiently exhibited.
[0009]
Further, after a long period of time has elapsed after the construction, the corrugated plate 73 may be oxidized and corroded by the air remaining in the gaps 76 between the mountain-shaped portion 73m and the valley-shaped portion 73v and the foamed resin 74.
[0010]
The problem to be solved by the present invention is to provide a concrete panel that is relatively light and high in strength, excellent in heat insulation and sound insulation, and excellent in durability.
[0011]
[Means for Solving the Problems]
The concrete panel of the present invention has a corrugated plate having a cross-sectional shape in which angle portions and valley shapes are alternately arranged, and a plurality of through holes formed on the top surface of the angle portion and the bottom surface of the valley shape, A corrugated plate and a concrete layer placed so as to bury the corrugated plate and the reinforcing member, the corrugated plate top surface of the corrugated plate Further, a reinforcing bar material developed in the concrete layer is integrally joined to at least one of the bottom of the valley shape .
[0012]
By adopting such a configuration, a part of the concrete layer flows into the concave portion of the mountain-shaped portion and the valley-shaped portion through the through holes formed in the top surface of the mountain-shaped portion and the bottom surface of the valley-shaped portion of the corrugated plate. The structure between the corrugated plate and the corrugated plate is completely filled, and no air remains between the corrugated plate and the corrugated plate, causing oxidation and corrosion of the corrugated plate. And durability is improved. In addition, by disposing a reinforcing member having a smaller bulk specific gravity than concrete on the concave portions of the corrugated plate and the valley-shaped portion, it is relatively light and high in strength, and has excellent heat insulation and sound insulation properties.
[0013]
Further, at least one of the angled portion top surface and a valley portion bottom surface of said corrugated sheet, by which is integrally joined a reinforcing bar to expand the concrete layer, the rigidity of the corrugated plate is increased, the entire concrete panel stiffness , The strength is improved. Note that the mountain portion top and valley bottom face of the corrugated plate Ri by that the through holes are formed, the residual stress generated in the corrugated plate when welded the reinforcing bar is dispersed, the waveform It is possible to prevent deformation of the plate and partial strength reduction.
[0014]
Furthermore, since the substantial truss structure is formed in the cross section by making the cross-sectional shape of the chevron part and the valley part of the corrugated plate substantially trapezoidal, the rigidity of the concrete panel can be further increased.
[0015]
A synthetic resin material such as a dense synthetic resin material, a foamed synthetic resin material, or a porous synthetic resin material can be used as the reinforcing member disposed on the concave portion of the corrugated plate and the valley-shaped portion. If a synthetic resin material is used, the bulk specific gravity of these members is significantly smaller than that of concrete and the corrosion resistance is excellent, so that the weight and durability of the concrete panel can be improved.
[0016]
The above concrete panel is composed of a step of injecting fluid concrete into a mold having a capacity capable of accommodating the corrugated plate in an embedded state, and a corrugated plate in which reinforcing members are disposed on the concave portions of the mountain-shaped portion and the valley-shaped portion before solidification. Can be manufactured by a manufacturing method including a step of immersing in the fluid concrete and a step of injecting the fluid concrete into the mold until the corrugated plate and the reinforcing member are buried.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view showing a concrete panel according to an embodiment of the present invention, FIG. 2 is a plan view showing a joined body of a corrugated plate and a reinforcing bar network constituting the concrete panel of FIG. 1, and FIG. 2 is a front view of the joined body shown in FIG. 2, and FIG. 2B is a side view of the joined body shown in FIG.
[0018]
As shown in FIG. 1, the concrete panel 4 of the present embodiment is arranged in a corrugated plate 3 having a cross-sectional shape in which mountain-shaped portions 3 m and valley-shaped portions 3 v are alternately arranged, and arranged above and below the corrugated plate 3. The reinforcing members 5 and 6, the reinforcing member 7 made of expanded polystyrene disposed in the concave surface portion 3h of the mountain-shaped portion 3m and the valley-shaped portion 3v, the corrugated plate 3, the reinforcing member 7, and the reinforcing bars 5 and 6 are buried. It is formed by the concrete layers 1 and 2 that are placed.
[0019]
As shown in FIGS. 2 and 3, in the corrugated plate 3, a plurality of through holes 9 are formed at regular intervals on the top surface of the mountain-shaped portion 3 m and the bottom surface of the valley-shaped portion 3 v. Spot welding is performed at the intersections between the reinforcing bars 5 and 6 arranged in a grid and the top surface of the mountain-shaped portion 3m and the bottom surface of the valley-shaped portion 9v, and the intersections between the reinforcing bars 5 and 6 are spot-welded respectively. By doing so, the joined body 8 of the corrugated plate 3 and the reinforcing bars 5 and 6 is formed.
[0020]
The cross section of the mountain-shaped part 3m and the valley-shaped part 3v of the corrugated plate 3 has a substantially trapezoidal shape, and the reinforcing member 7 disposed on these concave surface parts 3h is a columnar member whose cross section has a substantially trapezoidal shape. Specific gravity is smaller than the concrete which comprises the concrete layers 1 and 2.
[0021]
In the concrete panel 4, as can be seen from the concrete panel manufacturing method described later, the concrete layer 1 passes through the plurality of through holes 9 formed in the top surface of the mountain-shaped portion 3 m and the bottom surface of the valley-shaped portion 3 v of the corrugated plate 3. , 2 flows into the concave surface portion 3h of the mountain-shaped portion 3m and the valley-shaped portion 3v, and the space between the reinforcing member 7 disposed on the concave surface portion 3h and the corrugated plate 3 is completely filled. .
[0022]
For this reason, air does not remain between the corrugated plate 3 and the reinforcing member 7, and the corrugated plate 3 does not oxidize or corrode and has excellent durability. In addition, since the reinforcing member 7 made of expanded polystyrene having a smaller bulk specific gravity than concrete is disposed on the concave portions 3h of the corrugated plate 3 and the concave portion 3h of the valley-shaped portion 3v, the concrete panel 4 is relatively light and strong. High heat insulation and sound insulation.
[0023]
Further, the reinforcing members 5 and 6 developed in the concrete layers 1 and 2 are integrally joined to both the top surface of the mountain-shaped portion 3m and the bottom surface of the valley-shaped portion 3v of the corrugated plate 3, whereby the rigidity of the corrugated plate 3 is obtained. To increase the rigidity and strength of the concrete panel 4 as a whole. Since the plurality of through holes 9 are formed in the corrugated plate 3, residual stress generated in the corrugated plate 3 when the reinforcing bars 5 and 6 are welded to the corrugated plate 3 is dispersed. It is possible to prevent deformation of the corrugated plate 3 and a partial decrease in strength.
[0024]
Furthermore, since the substantial truss structure is formed in the cross section because the cross-sectional shapes of the mountain-shaped portion 3m and the valley-shaped portion 3v of the corrugated plate 3 are substantially trapezoidal, the rigidity of the concrete panel 4 is further increased.
[0025]
In the present embodiment, the reinforcing member 7 disposed on the chevron 3m of the corrugated plate 3 and the concave surface 3h of the valley 3v is foamed polystyrene which is one of the foamed synthetic resins, and its bulk specific gravity is much higher than that of concrete. Since it is small and has excellent corrosion resistance, the concrete panel 4 can be reduced in weight and improved in durability.
[0026]
Next, with reference to FIGS. 4-6, the manufacturing method of the concrete panel 4 is demonstrated. FIG. 4 is a perspective view showing a process of incorporating the reinforcing member 7 into the joined body 8 of the corrugated plate 3 and the reinforcing bars 5 and 6 manufactured in advance prior to the production of the concrete panel 4, and FIGS. FIG.
[0027]
As described above, the members incorporated in the concrete panel 4 of the present embodiment are the corrugated plate 3, the reinforcing bars 5 and 6 arranged in a lattice shape, and the reinforcing member disposed on the concave surface portion 3 h of the corrugated plate 3. 7.
[0028]
The corrugated plate 3 has a shape in which a mountain-shaped portion 3m and a valley-shaped portion 3v having a substantially trapezoidal cross section are alternately arranged, and the thickness and size of the corrugated plate 3 are changed depending on the use and required strength of the concrete panel 4. For example, if the concrete panel 4 to be finally produced has a thickness of 120 to 240 mm, it is desirable that the wall thickness is about 0.8 to 1.6 mm and the height dimension is about 70 to 150 mm.
[0029]
Reinforcing bars 5 and 6 are all round bars with a diameter of about 6 to 10 mm. These are arranged vertically and horizontally at regular intervals to form a grid, and the intersections of reinforcing bars 5 and 6 are spot welded respectively. These lattice-shaped reinforcing bars 5 and 6 are arranged on the upper surface side and the lower surface side of the corrugated plate 3, and the top surface of the mountain-shaped portion 3m and the bottom surface of the valley-shaped portion 3v of the corrugated plate 3 are formed. And the joined body 8 is formed by carrying out spot welding of the intersection part with the reinforcing bars 5 and 6. FIG.
[0030]
The joined body 8 has a structure in which a lattice-shaped reinforcing material 6, a corrugated plate 3, and a lattice-shaped reinforcing steel net 5 are sequentially overlapped from the lower side, and the reinforcing member 7 is arranged on the concave surface portion 3 h of the corrugated plate 3. Yes. As shown in FIG. 4, the reinforcing member 7 is disposed at a predetermined position by being inserted from any end surface opening portion of the concave surface portion 3 h.
[0031]
As shown in FIG. 5 (a), fluid concrete R is poured from a concrete injection pipe 17 into a mold 10 having a capacity capable of accommodating the corrugated plate 3 in a buried state. Before solidification, as shown in FIG. 5B, the joined body 8 on which the reinforcing member 7 is arranged is lowered into the mold 10 in the step of FIG. At this time, the mold liner 11 in which the notches 11 a into which the reinforcing bars 5 can be fitted is formed at regular intervals is mounted on both side edges of the upper surface of the joined body 8.
[0032]
As shown in FIG. 5 (c), after the lower half of the joined body 8 is immersed in the fluid concrete R in the mold 10, the fluidity is again returned from the concrete injection pipe 17 as shown in FIG. 6 (a). Concrete R is poured into the mold 10 and the joined body 8 is completely buried. At this time, as shown in FIG. 6B, the fluid concrete R in the mold 10 passes through the through-hole 9 formed in the corrugated plate 3 and flows between the reinforcing member 7 and the corrugated plate 3. Therefore, no air remains in the gap between the reinforcing member 7 and the corrugated plate 3.
[0033]
When the predetermined curing period has elapsed after the fluid concrete R injected into the mold 10 has solidified, the mold 10 is removed and the mold liner 11 is removed, as shown in FIG. A concrete panel 4 having a simple structure is completed.
[0034]
By taking the steps as described above, as described above, the concrete panel 4 can be manufactured that is relatively light and high in strength, excellent in heat insulation and sound insulation, and excellent in durability.
[0035]
【The invention's effect】
The present invention has the following effects.
[0036]
(1) A corrugated plate having a cross-sectional shape in which a chevron portion and a trough portion are alternately arranged, and a plurality of through holes are formed on the top surface of the chevron portion and the bottom surface of the trough portion, and the chevron portion and the trough shape By providing a reinforcing member having a smaller bulk specific gravity than the concrete arranged in the concave portion of the part, and a concrete layer placed so as to bury the corrugated plate and the reinforcing member, it is relatively light weight, high in strength, and heat insulating It becomes a concrete panel with excellent durability and sound insulation, and good durability.
[0037]
(2) The rigidity of the corrugated plate is enhanced by integrally joining the reinforcing bar material developed in the concrete layer to at least one of the top surface of the corrugated plate and the bottom surface of the trough portion. , The strength is improved. Further, since the residual stress when the reinforcing bar material is welded is dispersed in the through holes in the top surface and the bottom surface of the valley portion of the corrugated plate, the corrugated plate can be prevented from being deformed or partially reduced in strength.
[0038]
(3) Since the substantial truss structure is formed in the cross section by making the cross-sectional shape of the mountain-shaped portion and the valley-shaped portion of the corrugated plate substantially trapezoidal, the rigidity of the concrete panel can be further increased.
[0039]
(4) By using a synthetic resin material as the reinforcing member disposed on the concave portions of the corrugated plate and the valley-shaped portion, it is possible to reduce the weight and improve the durability of the concrete panel.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a concrete panel according to an embodiment.
FIG. 2 is a plan view showing a joined body of a corrugated plate and a reinforcing bar net constituting the concrete panel of FIG.
3A is a front view of the joined body shown in FIG. 2, and FIG. 3B is a side view of the joined body shown in FIG. 2;
4 is a perspective view showing a step of arranging a reinforcing member on the concave surface portion of the corrugated plate to which the reinforcing bar material shown in FIG. 1 is joined. FIG.
FIG. 5 is a manufacturing process diagram of the concrete panel shown in FIG. 1;
FIG. 6 is a manufacturing process diagram of the concrete panel continued from FIG. 5;
FIG. 7 is a perspective view showing a conventional concrete panel.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1, 2 Concrete layer 3 Corrugated board 3m Mountain-shaped part 3v Valley-shaped part 3h Concave-surface part 4 Concrete panel 5, 6 Reinforcement material 7 Reinforcement member 8 Joined body 10 Formwork 11 Formwork liner 11a Notch 17 Concrete injection pipe R Fluid concrete

Claims (4)

A corrugated plate having a cross-sectional shape in which chevron portions and trough portions are alternately arranged and having a plurality of through holes formed on the top surface of the chevron portion and the bottom surface of the trough portion, the chevron portion and the trough A reinforcing member having a smaller bulk specific gravity than the concrete disposed in the concave surface portion of the shape portion, and the corrugated plate and a concrete layer placed so as to bury the reinforcing member, the top surface of the corrugated portion of the corrugated plate, A concrete panel in which a reinforcing bar material developed in the concrete layer is integrally joined to at least one of the bottom surfaces of the valley . Chevrons and concrete panel of claim 1, wherein the cross-sectional shape of the valley portion is substantially trapezoidal in the corrugated sheet.   The concrete panel according to claim 1, wherein the reinforcing member is a synthetic resin article. A method of manufacturing a concrete panel according to any one of claims 1 to 3 of the mountain-shaped portions having a cross-sectional shape and the angled portion and the valley portion are arranged alternately top and the valley portion A step of injecting fluid concrete into a form having a capacity capable of accommodating a corrugated plate having a plurality of through-holes formed in a bottom surface, and a reinforcing member is disposed on the concave portion of the chevron and the valley A step of immersing the corrugated plate in the fluid concrete before solidification, and a step of injecting the fluid concrete into the form until the corrugated plate and the reinforcing member are buried. Panel manufacturing method.

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