JP6504852B2 - Production method of on-site mixing concrete - Google Patents

Description

  The present invention is a concrete that is produced by mixing and mixing concrete materials such as cement, aggregate, and water at a construction site when performing casting work (operation of pouring concrete into a mold) at the construction site In particular, the present invention relates to a method for producing on-site kneaded concrete suitable for repair work or repair work of an existing structure.

  At present, ready-mixed concrete (so-called fresh concrete: fresh concrete) is used in many constructions. Since ready-mixed concrete is manufactured in large quantities based on certain standards at a well-maintained factory, concrete of stable quality is obtained, and its quality is also guaranteed at shipment.

  In the standard, the transport time of ready-mixed concrete is limited within a certain time because ready-mixed concrete changes its quality over time. Therefore, in order to stably obtain high-quality concrete using green concrete, there is a disadvantage that the process from production to transportation and placing must be performed in a limited time.

  In that respect, on-site mixing, in which concrete material and water are mixed at the construction site, has the advantage of not being subject to transportation time limitations.

  For example, in Patent Document 1, concrete materials such as cement, sand, gravel, and water packed in a predetermined amount are transported to a construction site by a truck separately from the mixer vehicle, and each concrete material transported at the construction site is A method of producing concrete by kneading with a mixer truck is disclosed.

  There has also been proposed a truck-integrated measuring device capable of measuring each concrete material and mixing it with a predetermined composition (Patent Document 2).

  The weighing device there is composed of a weighing hopper for cement, a weighing hopper using sand, a weighing hopper for sand, a belt conveyor, etc., and is integrally assembled to the loading platform portion of the truck. Each concrete material is weighed by a weighing hopper and then sequentially transferred by a belt conveyor and stored in a container bag.

  Then, the container bag is transported to a construction site, and concrete is manufactured by injecting each concrete material stored in the container bag together with the measured water into a mixer and kneading it.

JP, 2006-123285, A JP, 2014-151577, A

  In the repair work and repair work of existing structures in the city such as office buildings, there are many places where the working time is often limited at night etc., and there are also sites where the mixer itself can not get in itself. Moreover, there are many places where the use of ready-mixed concrete is difficult, such as indoors and rooftops, and the amount of concrete required is small compared to the new construction work, so on-site mixing is often performed.

  At such sites, workers often manually weigh each concrete material and water, and repeatedly mix and mix it using a small mixer. Therefore, the work load on the workers is large and the quality of the concrete tends to vary.

  Moreover, in the case of repair work etc., unlike in the case of new construction work, it is necessary to adjust the type and amount of water of the concrete material to be used according to the existing structure, so management of manufacturing conditions is complicated and weighing errors etc. There is also a drawback that the risk of occurrence is high.

  Therefore, an object of the present invention is to provide a method for on-site mixing and production of concrete that is suitable for small-scale placing work such as repair work.

  The manufacturing method according to the present invention is a method of manufacturing on-site-mixed concrete which is manufactured by mixing and mixing concrete material and water at a construction site.

This production method is a production method of on-site kneading concrete produced by mixing and mixing concrete material including aggregate and cement and water at a construction site, and the aggregate drying step of drying the aggregate, and drying The aggregate production step is carried out by measuring aggregate and bagging separately by a certain amount to produce a coarse aggregate pack, and the material preparation step of bagging the other concrete material containing the cement by a certain amount, and the coarse Production at the construction site by installing a main hopper for aggregate pack, a sub-hopper for the other concrete material and a plurality of related devices including a mixer having a weighing function integrally incorporated therein A unit setting process, a material transporting process for transporting the bagged concrete material to the construction site, and Manipulating the door, comprises by mixing kneading predetermined time by introducing a certain amount of said concrete material and water to the mixer, and field kneading step for producing the concrete, the.

  That is, according to this manufacturing method, since water is excluded from the concrete material to be used, the variation of the amount of added water can be effectively suppressed by adjusting the amount of supplied water. Therefore, even when producing a small amount of concrete at a construction site, high quality concrete can be stably produced.

  Concrete materials are packed in bags, so they are easy to transport and store, and are suitable for small-scale placement work such as repair work.

  In addition, since the on-site kneading is performed mechanically by using a dedicated manufacturing unit including a mixer having a weighing function, human error can be suppressed and concrete can be easily manufactured.

  Furthermore, each time the on-site kneading step is performed, a manufacturing condition storing step of storing manufacturing conditions including measurement data and date data of the concrete material and water may be provided.

  Since the reliability of the measurement data is secured by removing the moisture of the concrete material, the quality of the manufactured concrete can be guaranteed by storing the manufacturing conditions related to the quality in the so-called manufacturing lot degree.

  Still further, the material preparation step has an identification data application step of giving identification data to each of the packed concrete materials, and in the manufacturing condition storage step, the manufacturing conditions and the identification data are It may be stored in association with each other.

  As a result, the corresponding material data can be identified, and higher quality assurance can be performed.

  Furthermore, a data communication step of transmitting the stored data of the manufacturing conditions from the on-site kneading and manufacturing unit to the external terminal may be included.

  Then, high quality assurance can be easily performed, and an increase in the storage amount on the manufacturing device side can be suppressed, so that the structure of the control device can be simplified.

  According to the on-site kneading and manufacturing method of the present invention, on-site kneading can be mechanically performed with a compact dedicated manufacturing unit using concrete materials of stable quality, so even small-scale construction sites such as repair work Stable production of high quality concrete.

It is a flowchart which shows the main processes of the manufacturing method of on-site kneading concrete. It is a flowchart which shows each process in a material preparation process. (A), (b) is schematic which shows the bagging form of a concrete material. It is a schematic side view showing a field kneading production unit. It is a schematic plan view which shows a field kneading production unit. It is a schematic side view which shows one form of a field kneading manufacturing unit. It is a block diagram showing the main composition of a control device.

  Hereinafter, embodiments of the present invention will be described in detail based on the drawings. However, the following description is merely illustrative in nature, and does not limit the present invention, its application, or its application.

<Method of manufacturing on-site mixing concrete>
The manufacturing method shown in the present embodiment is mainly established for construction sites where work time and work space are limited, such as repair work of existing structures, repair work, reinforcement work, etc. This is a method of producing so-called on-site paste concrete, which is produced by mixing and producing water at a construction site. In this manufacturing method, it is devised to be able to stably produce on-site kneaded concrete (also simply referred to as concrete) while securing high quality, and also to guarantee the quality.

  FIG. 1 shows a flowchart showing the main steps. The present manufacturing method is configured of a material preparation step S1, a manufacturing unit installation step S2, a material conveyance step S3, an on-site kneading step S4, a manufacturing condition storage step S5 and the like.

(Material preparation process)
Material preparation process S1 is a process of a preparation stage. In material preparation process S1, concrete material used for preparation of concrete is bagged in a dry state.

  The detail of material preparation process S1 is shown in FIG. The concrete material referred to here is a solid material other than water used in the production of concrete, and specifically, cement, admixture, sand (fine aggregate), crushed stone (coarse aggregate), and the like. The admixture is, for example, fly ash, silica fume, blast furnace slag powder, or the like. The material itself of concrete material is general in this industry, and can be selected appropriately according to the situation of the construction site.

  In the present manufacturing method, the moisture of the concrete material used is thoroughly eliminated in order to stably ensure the high quality of the concrete and to be able to guarantee the quality.

  The amount of water in cement and admixture generally used is at an error level relative to the amount of water supplied, so cement and admixture can usually be used as they are.

  However, aggregate such as sand and crushed stone is generally in a state in which water is contained inside (surface dry state) even though the surface is dry, and the amount thereof is not small. Therefore, when used as it is, there is a possibility that the quality of the concrete may become unstable due to the variation of the water content. It is particularly susceptible to batch production of small quantities of concrete.

  Therefore, the aggregate used in this manufacturing method is dried to a bone-dried state (a dried state until no water evaporating at a temperature of 100 ° C. or more exists) by using a rotary kiln or the like (aggregate Drying step S6).

  The aggregate dried to dryness is classified to a predetermined particle size, weighed to a certain amount, and then packaged in a moisture-proof packaging material to prevent water absorption.

  The form of the package can be appropriately selected according to the specification. For example, each concrete material may be bagged, or a plurality of concrete materials may be mixed and bagged. All of the concrete materials may be mixed and bagged.

  In particular, mortar packs are prepared by weighing and bagging a mixture of cement, admixture, and sand at a predetermined blending ratio, and together with that, crushed stone is separately weighed and sacked. Preferably, the coarse aggregate pack is made by packing.

  If a plurality of fine particle materials are compounded in advance, the compounding burden at the construction site is reduced, so that the quality can be improved, and as described later, by using the compact manufacturing unit 1, by simple operation. Highly accurate blending can be realized.

  As the form of bagging, as shown in (a) of FIG. 3, general bagging of several tens of kg is preferable, but it may be a container bag of 1000 kg level as shown in (b) of FIG. . In the present embodiment, a mortar pack MP and a coarse aggregate pack KP as shown in FIG. 3A will be described as an example.

  In the manufacturing method of the present embodiment, identification data SD such as a symbol or a bar code is given to each of the mortar pack MP and the coarse aggregate pack KP (identification data giving step S7).

  In the material preparation step S1, data (material data) related to concrete quality, such as date data prepared, lots of concrete material used, and weighing data, are provided in each of the mortar pack MP and the coarse aggregate pack KP. It is acquired.

  A manufacturing condition database is implemented in a predetermined computer system 100 (an example of an external terminal, see FIG. 4), and the acquired material data is stored in the manufacturing condition database in a state associated with the identification data SD. It has become so.

  In the present embodiment, the identification data SD is given by printing or sealing on the outer surface of each of the mortar pack MP and the coarse aggregate pack KP. The mortar pack MP and the coarse aggregate pack KP thus produced are stored in a warehouse or the like until the use opportunity comes.

(Manufacturing unit installation process)
The manufacturing unit installation process S2 is a process of the preparation stage. In the production unit installation step S2, a dedicated on-site kneading production unit is used.

  The on-site kneading and manufacturing unit is easy to transport and can be installed at narrow construction sites, and is designed to stably produce high-quality concrete with simple operation. Next, the details of the on-site kneading and manufacturing unit 1 will be described.

<Field kneading production unit>
4 and 5 show an example of the on-site kneading and production unit (also referred to simply as production unit 1). This production unit 1 is a small batch production apparatus with a volume of concrete production of about 50 to 200 L at a time, and on a single compact unit table 10, a plurality of related apparatuses necessary for on-site kneading are integrated Is built into the

  Specifically, the unit stand 10 is configured of a rectangular floor surface 11, a support frame 12, and the like. The length W of the short side of the floor surface 11 is set to 1.5 m or less, and the length of the long side L is set to 3 m or less. The support frame 12 includes a lower frame installed along the edge of the floor surface 11, a rectangular upper frame disposed opposite to the upper side of the lower frame, and a plurality of bridges installed between the lower frame and the upper frame. It consists of a support frame and the like.

  The related devices are the mixer 20, the main hopper 30, the sub hopper 31, the belt conveyor 40, the screw feeder 50, the water supply device 60, the control device 70 and the like.

  These related devices are collectively installed on the unit stand 10 so as to fit on the floor surface 11 and not to protrude outside the floor surface 11 and the height H from the floor surface 11 does not exceed 2 m. As installed. The total weight of the manufacturing unit 1 is set to 2000 kg or less.

  As a result, the manufacturing unit 1 can be loaded on a small truck bed and can be easily transported, and can easily get on and off.

  The mixer 20 is a so-called pan-type mixer, and includes a kneading unit 21 and a drive unit 22 connected to the lower part thereof. The kneading portion 21 can open and close the shallow bottomed cylindrical kneading container 23, the upper lid 24 covering the upper portion of the kneading container 23, and the stirring blades 25 installed inside the kneading container 23. And an outlet 26. A motor 27 is installed inside the drive unit 22, and a stirring blade 25 is attached to the rotation shaft of the motor 27 that protrudes into the kneading container 23.

  A dust collector 28 is attached to the mixer 20. The dust collector 28 captures dust generated inside the kneading container 23 at the time of kneading, and suppresses the diffusion of dust to the outside.

  The mixer 20 is disposed on one short side of the unit base 10, and is supported by the unit base 10 via a load cell 80. The load cell 80 is a sensor that converts a load into an electrical signal, and the load cell 80 can measure a change in weight of the mixer 20.

  Each of the main hopper 30 and the sub hopper 31 is a box-shaped container having a large inlet 33 for receiving concrete material at the top and a small outlet 34 at the lower, and is lined with the other short side of the unit base 10 It has been installed. In the present embodiment, the main hopper 30 and the sub hopper 31 are formed to have the same shape and dimensions, and both are configured to be divisible by an intermediate portion in the height direction.

  Specifically, each of the main hopper 30 and the sub hopper 31 is configured of a fixed lower portion 35 fixed to the unit base 10 and a removable upper portion 36 detachably mounted on the upper side of the fixed lower portion 35. By attaching / detaching the attaching / detaching upper portion 36, it is possible to change to a container back specification in which a large storage amount is secured, and a pouch specification that can be easily manually inserted as shown in FIG.

  The belt conveyor 40 is disposed between the main hopper 30 and the mixer 20 so as to convey the concrete material received by the main hopper 30 and to feed the concrete material into the mixer 20.

  Specifically, the end on the introduction side of the belt conveyor 40 is installed below the discharge port 34 of the main hopper 30, and the end on the discharge side of the belt conveyor 40 is installed on the top of the mixer 20. The middle portion of the belt conveyor 40 is inclined upward from the end on the introduction side toward the end on the discharge side. The end on the outlet side is inserted into the inside of the introduction duct 43 communicating with the inside of the kneading container 23.

  The screw feeder 50 is disposed between the sub hopper 31 and the mixer 20 so as to convey the concrete material received by the sub hopper 31 and to feed the concrete material into the mixer 20.

  Specifically, the end on the introduction side of the screw feeder 50 is installed below the discharge port 34 of the sub hopper 31, and the end on the discharge side of the screw feeder 50 is installed on the top of the mixer 20. The screw feeder 50 is inclined upward from the end on the introduction side toward the end on the discharge side. The end on the outlet side is connected to an inlet duct 53 in communication with the inside of the kneading vessel 23.

  The water supply device 60 includes a water supply pipe 61, an electromagnetic on-off valve 62, a flow meter 63, a buffer tank 64, and the like. The downstream end of the water supply pipe 61 enters the inside of the kneading vessel 23. Although not illustrated, the upstream end of the water supply pipe 61 is connected to a water supply device 60 including a water storage tank, a pump, or the like, or a water supply source such as a pipe for industrial water.

  In the vicinity of the mixer 20, a temperature sensor 90 is disposed to measure the temperature of the surroundings.

  The control device 70 is configured by a computer, various software installed in the computer, and the like, and executes control to mechanically manufacture concrete. Further, the control device 70 is also provided with a function of storing manufacturing conditions for each batch and a function of performing data communication with the computer system 100 in order to guarantee the quality of the concrete to be manufactured.

  The control device 70 further includes a monitor capable of displaying manufacturing conditions and the like, an input device capable of inputting instruction data and identification data SD, and an output device capable of printing manufacturing conditions and the like.

  The main configuration of the control device 70 is shown in FIG. The control device 70 includes a manufacturing control unit 71, a manufacturing condition storage unit 72, a weighing control unit 73, a data communication unit 74, and the like. The metering control unit 73 of the manufacturing unit 1 is provided with a water supply amount correction unit 75.

  The manufacturing control unit 71 controls the belt conveyor 40, the screw feeder 50, the mixer 20, and the electromagnetic switching valve 62, and executes control related to manufacturing such as the operation timing, the water supply timing, and the operation time of the mixer 20.

  The manufacturing condition storage unit 72 measures, for each manufacturing process, the measured value of the load cell 80 that changes with the operation of the belt conveyor 40, the measured value of the load cell 80 that changes with the operation of the screw feeder 50, and the water supply amount. Remember. In the manufacturing condition storage unit 72 of the manufacturing unit 1, the measurement value and the amount of water supplied to the load cell 80 can be stored in association with the identification data SD.

  The measurement control unit 73 executes control regarding measurement of concrete material and water. Specifically, the input amount and the water supply amount of the concrete material to the mixer 20 are controlled based on the instruction data. The instruction data is data for instructing the control device 70 to produce concrete, including production conditions such as the mixing ratio.

  In this production unit 1, in particular, the input amount and the water supply amount of the concrete material to the mixer 20 can be controlled based on the identification data SD inputted for each production process.

  The data communication unit 74 has a function of transmitting and receiving data to and from the computer system 100. The water supply amount correction unit 75 executes control to correct the water supply amount based on the measurement value of the temperature sensor 90. Details of each control will be described later.

  In the manufacturing unit installation step S2, the manufacturing unit 1 having such a structure is installed at a construction site.

(Material transport process)
The material conveyance step S3 is a step of conveying the bagged concrete material to the construction site. The material conveyance step S3 is not limited to after the manufacturing unit installation step S2, but may be before or at the same time. The point is that the amount of concrete material needed for the construction may be transported to the construction site during the construction period.

(Field kneading process)
The on-site kneading step S4 is a step of mechanically producing concrete by operating the production unit 1. Specifically, a worker operates the manufacturing unit 1 to introduce a certain amount of concrete material and water into the mixer 20 and mix it for a certain period of time to produce concrete. Since there are a plurality of manufacturing patterns, an example is shown below.

  The operator takes out crushed stone from the coarse aggregate pack KP and puts an appropriate amount into the main hopper 30, takes out the mixed material from the mortar pack MP, and puts an appropriate amount into the sub hopper 31. By operating the control device 70, the instruction data is manually input to operate the manufacturing unit 1.

  Then, the manufacturing control unit 71 drives the belt conveyor 40, and the crushed stone is introduced into the mixer 20. The crushed stone is weighed by the weighing control unit 73 based on the measurement value of the load cell 80, and when the crushed stone for one batch is fed, the production control unit 71 stops the belt conveyor 40.

  Subsequently, the manufacturing control unit 71 drives the screw feeder 50, and the mixed material is introduced into the mixer 20. Based on the measurement value of the load cell 80, the weighing control unit 73 weighs the mixed material to be charged, and when one batch of mixed material is charged, the manufacturing control unit 71 stops the screw feeder 50. In addition, the order of charging the crushed stone and the mixed material may be reversed.

  Subsequently, the manufacturing control unit 71 opens the solenoid on-off valve 62 to supply the mixer 20 with water. The metering control unit 73 measures the amount of water supplied based on the flow meter 63, and closes the electromagnetic on-off valve 62 when the amount corresponding to the concrete material input to the mixer 20 is supplied.

  Thereafter, the production control unit 71 operates the mixer 20 to produce concrete. The manufactured concrete is discharged from the outlet 26. The required amount of concrete is manufactured by repeatedly performing such on-site kneading step S4.

  Since the concrete material used contains almost no water, the water management can be easily performed, and concrete with a constant water content can be stably manufactured. Since the fine grained material is collectively measured by the screw feeder 50 with high measuring accuracy separately from the crushed stone having a large grain size, the blending ratio is also stable, and higher quality concrete can be manufactured.

  And since it manufactures mechanically, measuring in the manufacturing unit 1, an artificial mistake is excluded and it can manufacture stably, even if it is a small amount of on-site kneading.

(Manufacturing condition storage process)
In the manufacturing condition storing step S5, manufacturing conditions are stored in batch units. Specifically, every time when the on-site kneading step S4 is performed, the measurement data of the mixed material, crushed stone, and water, date data when batch processing is performed, and manufacturing data such as operation time of the mixer 20 and surrounding temperature The data of the manufacturing conditions are stored in the manufacturing condition storage unit 72.

  Therefore, since the data affecting the quality of the concrete is stored for each batch, the quality of the concrete can be guaranteed.

  At the construction site, the identification data SD of the mortar pack MP and the coarse aggregate pack KP to be input are input to the control device 70 by reading using a reader or the like, and data of manufacturing conditions are stored in association with the identification data SD It is also good. As a result, the corresponding material data can be identified, and higher quality assurance can be performed.

  Furthermore, the stored manufacturing condition data may be transmitted from the manufacturing unit 1 to the computer system 100 (data communication step). Specifically, data of manufacturing conditions are transmitted to the computer system 100 through the data communication unit 74, and the transmitted data of manufacturing conditions is stored together with the corresponding material data in association with the identification data SD.

  Then, advanced quality assurance can be easily performed. It is also advantageous in that the increase in the storage amount of the manufacturing condition storage unit 72 can be suppressed.

  In the case of this production unit 1, it is also possible to produce concrete more easily using the identification data SD.

  That is, the identification data SD and the instruction data corresponding to the concrete material are associated with each other, and the identification data SD is read and input to the control device 70 before the insertion. Then, since the instruction data can be mechanically input, there is no need for manual input, and the control device 70 can be operated simply and reliably.

  Furthermore, this manufacturing method is devised to be able to suppress the influence of temperature on the quality.

  That is, it is known that an appropriate water supply amount changes depending on the ambient temperature at the time of mixing. Therefore, water supply correction data capable of obtaining an optimum water supply amount according to the temperature is created by experiment or the like, and the water supply correction data is stored in advance in the control device 70. The water supply amount correction unit 75 automatically corrects the water supply amount based on the water supply correction data and the measurement value of the temperature sensor 90.

  Therefore, even if the ambient temperature at the time of mixing changes, appropriate water supply can be performed, so high quality concrete can be stably manufactured. Since the corrected measurement data is stored in the manufacturing condition storage unit 72, its quality can also be guaranteed.

  In addition, the on-site kneading and manufacturing method according to the present invention is not limited to the above-described embodiment, and includes various other configurations.

  In the embodiment, the mortar pack MP and the coarse aggregate pack KP have been described as concrete materials by way of example, but the concrete materials may be obtained by individually packaging each of cement, admixture, and sand, or combining all of them. It may be bagged.

DESCRIPTION OF SYMBOLS 1 Field kneading production unit 10 Unit stand 20 Mixer 30 Main hopper 31 Sub hopper 40 Belt conveyor 50 Screw feeder 60 Water supply device 70 Control device 72 Manufacturing control unit 72 Manufacturing condition storage unit 73 Measurement control unit 74 Data communication unit 75 Water supply amount correction unit 80 load cell 100 computer system S1 material preparation process S2 manufacturing unit installation process S3 material conveyance process S4 field kneading process S5 manufacturing condition storage process S6 aggregate drying process S7 identification data application process MP mortar pack KP coarse aggregate pack SD identification data

Claims (4)

A method for producing on-site kneaded concrete, which comprises mixing concrete material containing aggregate and cement and water at a construction site,
An aggregate drying step of drying the aggregate;
A material preparation step of measuring the dried aggregate and bagging separately by a certain amount to make a coarse aggregate pack, and bagging the other concrete material containing the cement by a certain amount ,
A field kneading and manufacturing unit, in which a plurality of related devices including a main hopper for the coarse aggregate pack, another sub hopper for the concrete material, and a mixer having a weighing function are integrated, installed at the construction site Manufacturing unit installation process,
A material conveying step of conveying the bagged concrete material to the construction site;
An on-site kneading step of producing concrete by operating the on-site kneading and manufacturing unit, introducing a certain amount of the concrete material and water into the mixer and mixing and mixing for a certain period of time;
Method of on-site mixing concrete comprising: In the method for producing on-site kneaded concrete according to claim 1,
Furthermore, a manufacturing condition storing step of storing manufacturing conditions including measurement data and date data of the concrete material and water each time the on-site mixing step is performed. In the method of producing on-site kneaded concrete according to claim 2,
The material preparation step includes an identification data giving step of giving identification data to each of the bagged concrete materials,
The manufacturing method of on-site kneading concrete in which the manufacturing conditions and the identification data are stored in association with each other in the manufacturing condition storing step. In the method of producing on-site kneaded concrete according to claim 2 or claim 3,
Furthermore, the manufacturing method of on-site kneading concrete including a data communication step of transmitting the stored data of the manufacturing conditions from the on-site kneading and manufacturing unit to the external terminal.

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