JP7538073B2 - Floor construction method and floor inspection device - Google Patents

Description

Application of Article 30, Paragraph 2 of the Patent Act (Publication 1) ▲1▼ Publication name Kumagai Gumi Technical Research Report No. 79/2020 ▲2▼ Publication date February 26, 2021 ▲3▼ Publisher Kumagai Gumi Co., Ltd., 2-1 Ote 3-chome, Fukui City, Fukui Prefecture ▲4▼ Disclosed by Kumagai Gumi Co., Ltd. ▲5▼ Disclosed content "Floor construction method and floor inspection device" (Publication 2) ▲1▼ Date held November 13, 2020 ▲2▼ Meeting name and location Kumagai Gumi 84th National Construction Technology Presentation Inside Kumagai Gumi Co., Ltd. Headquarters 2-1 Tsukudo-cho, Shinjuku-ku, Tokyo ▲3▼ Disclosed by Abe Takahiro ▲4▼ Disclosed content "Floor construction method and floor inspection device"

The present invention relates to a floor construction method, etc., and particularly to a floor construction method, etc. that is suitable for construction of floor surfaces that require high surface accuracy.

Conventionally, for example, in the case of a floor slab in an RC structure, concrete is poured after reinforcing bars are arranged, and the surface is leveled using a tool such as a drawstring to ensure a certain degree of surface precision.
On the other hand, as shown in the patent documents, depending on the use of the floor of the structure, extremely high precision may be required for the floor surface. In such cases, it is known to use the above-mentioned slab as a base (substrate) and pour a highly fluid slurry, also known as a self-leveling floor material, onto the surface, thereby obtaining a highly precise floor surface due to its self-smoothness.

Japanese Unexamined Patent Publication No. 63-219754

However, the construction method described in the above patent document requires the removal of the partition material after pouring the slurry into the area defined by the partition material placed on the base, which may cause the slurry to flow slightly when removed, resulting in a concern that the surface accuracy of the entire floor may decrease. In particular, for floors that require extremely high surface accuracy in the order of ±1 mm, the above construction method, which involves the subsequent flow of the slurry, is difficult to adopt.

The present invention was made to solve the above problems, and aims to provide a floor construction method that can achieve extremely high surface accuracy.

One aspect of the present invention for solving the above problems is a method for constructing the floor surface of a concrete structure, which includes an inspection step in which an inspection device equipped with a shaped member extending parallel to the surface of the floor material and a light source extending along the shaped member and irradiating light onto the surface of the floor material is grounded along the surface of the floor material after it has been poured, while scanning in one direction, and unevenness in the surface of the floor material is detected based on the presence or absence of light exposure between the ground surface of the shaped member and the surface of the floor material.
According to this embodiment, unevenness can be detected based on the presence or absence of exposure between the contact surface of the shaped material and the surface of the flooring material, making it possible to recognize the occurrence of unevenness as a surface having a certain width, and making it easy to improve the surface accuracy through subsequent repair work.
In another embodiment, the flooring material may be a SL material poured on an existing foundation slab, and the pouring of the SL material may include a flooring pouring process in which partition materials are placed on the foundation slab to divide the surface of the foundation slab into multiple areas, and the SL material is poured into each of the formed partitions, so that each partition material is buried and immobilized in the hardened SL material.
According to this embodiment, each partition material is embedded in the hardened SL material, so there is no subsequent flow of the SL material, and surface precision can be improved.
As another configuration, there is provided an unevenness inspection device for the floor surface of a concrete structure, which is configured to include a shaped member of a predetermined length that extends parallel to the floor surface and has a contact surface that can contact the floor surface, and a light source that extends along the shaped member and can irradiate light toward the surface of the floor material.
According to this configuration, unevenness can be detected based on the presence or absence of exposure between the contact surface of the shaped material and the floor surface.

FIG. 1 is a flow chart showing the overall flow of a construction method. 1 is a schematic cross-sectional view and a plan view of a floor surface. FIG. 1 is a perspective view showing an overview of an inspection device.

Below, the entire process up to the construction of the floor surface of a concrete structure will be explained with reference to Figures 1 and 2. As shown in S1 of Figure 1, after the construction of the concrete structure's framework, such as steel beams and steel frames, is completed, reinforcing bars 3 that will become the foundation slab 1 are placed. As shown in S2, after the reinforcing bars 3 are placed, concrete C1 that will become the foundation slab 1 is poured.

As shown in S3, when pouring concrete C1, the concrete surface is tapped using a vibrating tapping tool, for example, about 3 m long, to remove air from within the concrete C1, so as to include the entire area after pouring. This smoothes the foundation slab itself and improves surface accuracy. Note that, assuming the pouring of a self-leveling material (hereinafter also referred to as SL material) in a subsequent process, it may be considered that there is no need to improve the surface accuracy of the foundation slab 1 itself. However, in order to meet the required accuracy of ±1 mm, it is desirable to set the surface accuracy of the foundation slab 1 itself high at the time of pouring, since the unevenness of the foundation slab 1 itself inhibits the fluidity of the SL material and affects the surface accuracy after the SL material hardens.

As shown in S4 of FIG. 1 and FIG. 2(b), after the concrete C1 hardens, the surface is marked out in a grid pattern of, for example, 1 m width, and the level of the concrete C1 surface is measured using, for example, a laser measuring device. In this level measurement, the intersection points P of the grid (hereinafter sometimes referred to as a grid) formed by marking out are set as multiple measurement points, and the relative level of each measurement point is measured using the laser measuring device. At this time, the allowable level difference on the surface of the concrete C1 is about ±8 mm, and if the level difference is within this range, the self-smoothness of the SL material makes it possible to fully absorb the level difference. Note that, when performing more precise level measurement, the level difference can be reduced by increasing the number of observation points and measurement points. Also, if there is a level difference that is greater than the allowable level difference, repair work is performed within that range.

As shown in S5, after the foundation slab 1 is formed, aluminum rulers D, for example 5 mm square, are placed on the foundation slab 1 at a specified interval (2 m in this example). Each ruler D has a length of, for example, 3 m, and as shown in Figure 2, multiple rulers D are placed on the foundation slab 1 so that they are parallel to each other via mortar. The height of the surface D1 of the ruler D is determined taking into account the set thickness of the floor surface.

As shown in FIG. 2, in this example, the set thickness from the surface of the foundation slab 1 is 10 mm, so mortar is poured on the surface of the foundation slab 1 to a thickness of 5 mm, and the ruler D is placed on the mortar to set the surface D1 of the ruler D at a position 10 mm from the surface of the foundation slab 1. When setting the height of the ruler D, it is desirable to measure the heights of multiple rulers D arranged in parallel with each other using a laser measuring device or the like, and precisely adjust the heights of each ruler D by adding mortar or cutting. As shown in FIG. 2(b), multiple rulers D arranged in parallel with each other on the foundation slab 1 form multiple sections R along the length of the ruler D on the surface of the foundation slab 1, and SL material is poured into each section R.

As shown in S6, after the formation of the section R, a flow test of the SL material is carried out. The SL material is, for example, a gypsum-based or cement-based SL material, and the required flow value is set taking into account the time required for pouring into the section (potable time), the type of material, composition, water ratio, temperature, and other conditions.

As shown in S7, after the flow test is completed, the SL material is poured for each of the above sections R. Specifically, an amount of SL material roughly corresponding to the volume of section 1 is poured onto the foundation slab 1, and the surface of the SL material is smoothed at a position flush with the surface D1 of the ruler D using a leveling tool (dragonfly) T that is slightly longer than at least the interval of the ruler D (2 m in this example). As shown in FIG. 2(a), in the above leveling work, both ends of the dragonfly T are spanned between the rulers D, and the surface height of the SL material is smoothed to be flush with D1 using the surface D1 of the ruler D as a guide. Thereafter, the SL material is poured in the same way for all sections, completing the pouring of the SL material in the entire area on the foundation slab 1. At this time, the ruler D that separates the adjacent sections R is not removed, but is buried and killed as the SL material hardens. In this way, in this example, the ruler D is filled in without being removed, which prevents the SL material from flowing into the gap left after removal, improving surface accuracy.

As shown in S8, after the SL material has been poured and hardened for all sections R, an inspection of the surface accuracy is carried out. Prior to this inspection, it is advisable to again mark out the grid.

Figure 3 is a diagram showing an overview of an inspection device 10 suitable for the inspection work. As shown in the figure, the inspection device 10 includes a ruler 12 having a fixed shape (a plastering ruler in this example), an angle 14 attached along the side of the ruler 12, and a light source 16 arranged on the bottom surface of the angle 14. The ruler 12 is set to a length of, for example, 3 m, but this can be changed as appropriate depending on the dimensions of the floor surface to be inspected. The angle 14 is L-shaped with an attachment surface 14a parallel to the side of the ruler 12 and a bottom surface 14b perpendicular to the attachment surface 14a, and extends to correspond to the length of the ruler 12 or to a predetermined length. The light source 16 is a fluorescent tube type light and is set to a dimension that roughly corresponds to the length of the ruler 12. Note that multiple light sources 16 may be connected in the length direction. The light source 16 has, for example, an LED built in, and is preferably a rechargeable type in consideration of workability and portability.

As shown in FIG. 3, the inspection operation by the inspection device 10 is performed by pointing the light source 16 of the inspection device 10 toward the floor surface 20 formed by pouring the SL material, and sliding the ruler 12 so as to scan in one direction while the bottom surface 12c, which serves as the grounding surface, is in contact with the floor surface 20. In this way, when the inspection device 10 is grounded on the floor surface 20, the light from the light source 16 is blocked by the floor surface 20 and the ruler 12 within the range where the surface accuracy of the floor surface 20 is guaranteed, so that when the inspection device 10 is viewed from the operation direction side, the light irradiated from the light source 16 cannot be seen.

On the other hand, in areas where the surface accuracy of the floor surface 20 is poor and so-called unevenness occurs, the light from the light source 16 is exposed between the floor surface 20 and the bottom surface 12c of the ruler 12, so when viewed from the inspection device 10 side, the light irradiated from the light source 16 can be recognized as a band-like light having a certain length across the uneven area.

As shown in FIG. 2B, by scanning the floor surface 20 in the X and Y directions using the inspection device 10, it is possible to precisely grasp unevenness over the entire range of the floor surface 20.
That is, in an inspection process using a conventional laser measuring instrument, in order to meet the required accuracy of ±1 mm, it is necessary to set up a huge number of measurement points and to conduct observations from multiple observation points. Furthermore, since the level difference obtained is relative, the processing work can become an excessive burden.
On the other hand, the inspection device 10 can recognize very slight unevenness occurring continuously or locally as a continuous band of light or light points by scanning in one direction, so that the unevenness can be easily corrected by simply recording the grid corresponding to the location exposed to the light. In other words, the inspection device 10 can grasp the occurrence of unevenness not as a point but as a surface having a certain width, so that the inspection work can be performed extremely efficiently.
If any unevenness is found as a result of the inspection work, the grid of that point is recorded as coordinates or the like, and repair work can be carried out later to form a floor surface 20 with extremely high surface accuracy and no exposure to light. After the floor surface 20 is formed, floor tiles or the like are laid as a finishing material.

As described above, the floor construction method in this example consists of the steps of forming a foundation slab (S1-S4), pouring SL material onto the foundation slab 1 to form the floor surface 20 (S5-S7), and an inspection step (S8) to ensure the surface precision of the floor surface 20. By burying the ruler D without removing it and further inspecting by exposure using the inspection device 10, it is possible to obtain a floor surface 20 with extremely high surface precision.

In the above example, the foundation slab 1 is formed by pouring the foundation concrete C1, and then the SL material is poured as a slurry on the foundation slab 1 to obtain a floor surface 20 with high surface accuracy. However, the surface accuracy of the foundation concrete C1 itself may be improved without pouring the SL material. Specifically, when arranging the reinforcing bars 3 of the foundation slab 1, a ruler D may be arranged using a jig such as an L-shaped angle, and the concrete C1 may be poured until it is flush with the surface D1 of the ruler D to form the floor surface. In this case, the concrete C1 itself becomes the floor material, and the surface of the concrete C1 is inspected by the inspection device 10, and any unevenness detected is repaired, making it possible to obtain a floor surface with extremely high surface accuracy without using a separate SL material.

Although the present invention has been described above through the embodiments, the technical scope of the present invention is not limited to the above embodiments. It is clear to those skilled in the art that various modifications and improvements can be made to the above embodiments, and it is clear from the claims that forms incorporating such modifications or improvements can also be included within the technical scope of the present invention.

1 foundation slab, 1C concrete, 3 reinforcing bar, 10 inspection device, 16 light source,
20 Floor surface, D Ruler, D1 Surface, R Section

Claims (3)

A method for constructing a floor surface of a concrete structure, comprising the steps of:
An inspection device having a shaped bar extending parallel to the surface of the flooring material and a light source extending along the shaped bar and irradiating light onto the surface of the flooring material is grounded along the surface of the flooring material after it has been poured and scanned in one direction;
A floor construction method comprising an inspection step of determining unevenness in the surface of the flooring material based on the presence or absence of exposure between the contact surface of the shaped material and the surface of the flooring material. The floor material is a SL material to be poured on an existing foundation slab,
A floor construction method as described in claim 1, characterized in that when pouring the SL material, a floor material pouring process is included, in which partition materials are placed on the foundation slab to divide the surface of the foundation slab into multiple areas, and the SL material is poured into each of the formed partitions, so that each partition material is buried and killed in the hardened SL material. An inspection device for a floor surface of a concrete structure, comprising:
A shaped member of a predetermined length extending parallel to the floor surface and having a contact surface that can contact the floor surface;
A light source that extends along the shaped material and can irradiate light toward a surface of the floor material;
An inspection device comprising:

Images