JPH04371612A - Execution method of foam block for civil engineering - Google Patents

Abstract

PURPOSE:To ensure high accuracy, and to reutilize a synthetic resin molded form, etc., and use resources effectively by employing a foam block for civil engineering having two layer structure, in which the periphery of the core body of a reutilizing article is covered with expanded polystyrene. CONSTITUTION:A core body 26 mainly comprising small pieces obtained by preferably crushing a spent synthetic resin molded form or synthetic resin foam is formed, and a foam block 30 for civil engineering having two layer structure, in which at least one surface of the core body 26 is covered with an anew in-mold molded expanded polystyrene layer 2, is constituted. When a road, etc., are constructed on a poor subsoil and a slope, the foam blocks 30 are arrayed in the horizontal direction through nonwoven fabrics, etc., as banking on the poor subsoil while being stacked in the vertical direction, and covered with asphalt, and concrete boards are laid, and a subbase course is formed on the concrete boards. A surface layer for a road surface is formed onto the subbase course, thus completing the road.

Description

[Detailed description of the invention]

0001

TECHNICAL FIELD OF THE INVENTION The present invention relates to a construction method for civil engineering blocks that can be used as embankment materials and backfilling materials, and reuses used synthetic resin foams such as expanded polystyrene or synthetic resin moldings such as FRP. Regarding.

0002

[Technical background of the invention] Expanded polystyrene (Expan
ded Poly-Styrol (hereinafter referred to as EPS) is produced using an in-mold foaming method in which pre-expanded polystyrene beads are injected into a predetermined mold and heated and cooled to form a foam with a predetermined density, or a high-pressure foaming method is used. This is carried out by the extrusion foaming method, which involves injecting and mixing a foaming agent into molten polystyrene to create a fluid gel, which is then extruded into the atmosphere and rapidly expanded and molded.

[0003] In recent years, large blocks made of expanded polystyrene have been used as embankment materials and backfill materials because they have characteristics such as ultra-lightweight, compression resistance, water resistance, and self-supporting properties when stacked. As a result, its use in civil engineering works such as roads, railways, and land reclamation has become popular (EPS construction method).

[0004] In addition to the above-mentioned foamed polystyrene, synthetic resin foams such as foamed vinyl chloride and foamed polyurethane are used for various purposes. For example, synthetic resins are widely used not only for industrial purposes such as packaging for fragile items, containers, insulation materials for buildings, panels, doors, core materials for tatami mats, and shock absorbing materials, but also for daily necessities. Foams are highly prized.

Furthermore, it is well known that non-foamed synthetic resin molded bodies are used in large quantities, regardless of whether they are thermoplastic or thermosetting resins. By the way, synthetic resin foams and synthetic resin moldings that have been foam-molded into predetermined shapes for various uses are so-called "disposable" materials, and after use, they are disposed of by being incinerated or melted and then incinerated. It has become common to do so.

However, when such synthetic resin foams or synthetic resin moldings are incinerated, toxic gases and bad odors may be generated. There has been a problem in that the work of transporting or disposing of large synthetic resin foams is complicated.

Therefore, rather than disposing of these synthetic resin foams or synthetic resin moldings, the present inventors decided to
We have completed the present invention because we believe that it is more preferable to reuse these synthetic resin foams or synthetic resin moldings, which is in line with the effective use of resources and eliminates the above-mentioned problems.

[0008]

[Object of the Invention] The present invention has been made in view of the above circumstances, and provides a method for constructing foam blocks for civil engineering that can effectively reuse synthetic resin foams or synthetic resin moldings. The purpose is to provide.

[0009]

[Summary of the Invention] In order to achieve the above object, the method for constructing a foam block for civil engineering according to the present invention includes a core body mainly composed of a synthetic resin molded article or small pieces obtained by crushing a synthetic resin foam. Then, civil engineering foam blocks having a two-layer structure in which at least one side of the core body is covered with newly molded expanded polystyrene are arranged horizontally and stacked vertically to perform embankment and backfilling. , or as a backfilling material, and then used to install roads, temporary roads, buildings, soil cover, etc.

[0010] As described above, the civil engineering block according to the present invention has a reused core inside, and at least one surface around the core is formed of new EPS, so that molding accuracy can be improved. It can be secured to the same level as normal EPS, and can be applied to members that require high precision. It is especially suitable for the EPS construction method in which a large number of civil engineering blocks are piled up.

[0011] Furthermore, since most of the core materials among the raw materials are used synthetic resin foams or synthetic resin moldings, it is difficult to reuse these synthetic resin foams or synthetic resin moldings. In turn, it is possible to achieve significant cost reductions and effective use of energy.

0012

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described in detail below based on embodiments shown in the drawings. As shown in FIG. 1, the civil engineering foam block 30 according to the present invention has a core body 26 whose main component is a synthetic resin molded body or small pieces obtained by crushing a synthetic resin foam.
It has a two-layer structure in which at least one surface (the entire surface in FIG. 1) of the core body 26 is covered with a newly molded expanded polystyrene layer 28. In FIG. 1, the entire surface (six sides) of the core body 26 is covered with the foamed polystyrene layer 28, but it is not necessarily necessary to cover the entire surface;
It may cover any one, two, three, four, or five sides of 6.

Furthermore, the size of the civil engineering foam block 30 is not particularly limited, but is determined to have a weight that can be easily carried by two people. It has a rectangular parallelepiped shape with a length of 10 m or less. For example, the outer dimensions of the civil engineering foam block 30 are 50 x 100 x 200 (unit: cm). At this time, the outer dimensions of the core inside the civil engineering foam block 30 are:
As mentioned above, the size of the molded body is 25 x 50 x 100 (unit: cm) to 45 x 90 x 180 (unit: cm), preferably 40 x 80 x 160 (unit: cm). In the future, the external dimensions of the civil engineering foam block 30 will be 100 x 2.
A large one measuring 00 x 600 (unit: cm) is preferable. However, these dimensions are merely examples, and it goes without saying that the civil engineering foam block 30 of the resin molded body according to the present invention is not limited to these dimensions.

The method for manufacturing this foam block for civil engineering will be briefly described. The core body 26 is made by crushing a synthetic resin molded body or a synthetic resin molded body once molded, adding a binder to the crushed pieces, and compacting this by in-mold molding. Examples of the resin foam include foamed polystyrene, foamed urethane, foamed vinyl chloride, foamed polyolefin, etc., and as the synthetic resin molded product, both thermoplastic and thermosetting resins can be used.

When covering such a core body 26 with a foamed polystyrene layer 28, for example, as shown in FIG. A plurality of molds are provided, and the core body 26 is accommodated in, for example, the lower mold 24b in an open state. At this time, the core body 26 is supported from three directions by the support pins 25 according to the shape of the molded body. Next, the upper mold 24a is closed, expanded polystyrene beads are injected from the material injection port 27 (gate), and the support pins 25 are retreated. After that, foam molding of polystyrene resin is performed. Although the civil engineering foam block 30 may be manufactured in this manner, the following three manufacturing methods may also be used.

[0016] ■ Expanded polystyrene beads are heated and foam-molded in a concave mold to form a hollow box-like body with an opening, and the once-molded synthetic resin foam or synthetic resin molded body is crushed into crushed pieces. , adding a binder and filling the crushed pieces into the box-shaped body, heating the crushed pieces to which the binder has been added to bring them into close contact with each other to form a core, and simultaneously or subsequently adding expanded polystyrene beads. A method of manufacturing a foam block for civil engineering in which a core body is covered with a box-shaped body and a lid body, by heating and foam-molding a lid body that closes an opening of the box-shaped body.

[0017] ■ Expanded polystyrene beads are heated and foam-molded in a concave mold to form a hollow box-like body with an opening, and the once-molded synthetic resin foam or synthetic resin molded body is crushed into crushed pieces. A core body formed by adding a binder and molding in a mold is housed in the box-shaped body, and a lid body for sealing the opening of the box-shaped body is heat-foam-molded with expanded polystyrene beads, thereby forming the box-shaped body. A method of manufacturing a foam block for civil engineering in which a core body is covered with a lid body and a lid body.

[0018] ■ A foamed polystyrene plate that has been heated and foam-molded is placed on the bottom of the mold, and a binder is added to the once-molded synthetic resin foam or crushed pieces of the synthetic resin molded body, and then molded in the mold. The core formed by the above is placed on the foamed polystyrene plate at the bottom of the mold, and the space between the mold and the core is filled with foamed polystyrene beads, which are heated and foamed to form a box shape. A method of manufacturing a foam block for civil engineering in which a core body is covered with an expanded polystyrene plate and a box-like body.

Although various manufacturing methods can be considered as described above, the method for manufacturing the civil engineering block according to the present invention may be any method and is not particularly limited to the above method. next,
A construction method using the civil engineering foam block 30 configured as described above will be exemplified below. In other words, such a resin-molded civil engineering foam block 30 is used to reduce loads and earth pressure in embankments on soft ground, embankments on steep slopes, backfilling of structures, upright walls, widening of embankments, etc. It can be applied wherever there is. These will be specifically exemplified below.

FIGS. 3 and 4 are longitudinal sectional views of a road in which the foam blocks for civil engineering according to the present invention are applied to embankments on soft ground and embankments on steep slopes. First, in the embodiment shown in FIG. 3, a non-woven fabric 3a is laid on a soft ground 1, and this non-woven fabric 3a is made of the same material as the non-woven fabric 3b, which will be described later, and is designed to drain water etc. that have passed through the waterproof layer. It has a role and acts to separate the block part from the ground. Furthermore, a civil engineering foam block 30 according to the present invention is laminated on the nonwoven fabric 3a. In addition, Figures 3 and 4
In the embodiment shown in , the civil engineering foam blocks 30 are laminated to have a rectangular cross-section, but the invention is not limited to this, and the cross-section may be laminated to have a trapezoidal shape with a wide base.

After the civil engineering foam blocks 30 are stacked in a predetermined shape in this way, the civil engineering foam blocks 30
A nonwoven fabric 3b is laid around the . The nonwoven fabric 3b is made of, for example, polyester long fibers like the nonwoven fabric 3a described above. After this nonwoven fabric 3b is laid, asphalt is applied to this nonwoven fabric 3b by a coating method such as spraying to form a waterproof layer. Thereafter, the surface of this nonwoven fabric 3b is covered with a protective sheet 5. The protective sheet 5 is for protecting the waterproof layer and is made of polyethylene film, polyester film, or the like.

The road 2 is formed on the civil engineering foam block 30 covered with the waterproof layer and the protective sheet 5 in the following manner, for example. First, a concrete plate 6 is laid on the protective sheet 5. Thereafter, roadbeds 7 and 8 are formed using gravel or the like, and a road surface layer 9 is formed thereon. After that, or simultaneously with the above steps, the road is completed by forming retaining walls 10 on both sides with cover soil or the like. In addition, retaining wall 1
0 can also be replaced with a simple wall protection material without using cover soil.

As described above, when the civil engineering foam block 30 of the present invention is applied to road construction, since a waterproof layer is formed around the laminated civil engineering foam block 30, moisture such as rainwater is absorbed from the civil engineering work. It will not be absorbed into the civil engineering foam block and therefore will not cause an increase in the weight of this civil engineering foam block. Moreover, since the civil engineering foam block itself does not need to be water resistant, it is preferable to use a recycled EPS product like the above-mentioned civil engineering foam block of the present invention.

FIG. 4 shows a specific example in which the foam block for civil engineering of the present invention is used when constructing a road on sloping ground. In this embodiment, civil engineering foam blocks 30 are stacked along the sloped ground 12, and one side is covered with a wall protection material 11. This embodiment also has the same effects as those of the previous embodiment, has almost no adverse effect on the sloped ground, and can suppress the occurrence of road subsidence, slipping, etc.

Next, FIG. 5 shows an example in which the civil engineering foam block 30 according to this embodiment is used as embankment when constructing a pool tank on soft ground. When constructing a pool tank on soft ground, if the pool tank is constructed without improving the soft ground, there is a risk that the pool tank will gradually sink. Therefore, in this embodiment, before constructing the pool tank, the soft ground is removed and the civil engineering foam block 30 according to the present invention is laminated. At this time, if non-woven fabric etc. are required, install them at appropriate locations. Thereafter, a pool tank 42 is constructed using concrete or the like on top of the laminated civil engineering foam blocks 30. In this way, the civil engineering foam block 30 is stacked under the pool tank 42, and since this civil engineering foam block 30 is extremely lightweight, it is possible to prevent the pool tank 42 from sinking, and it is also easy to maintain. Management can be reduced. Note that construction on soft ground is not limited to pool tanks, and the same construction can be applied to roads and buildings on soft ground, and ground subsidence can be effectively prevented.

Next, FIG. 6 shows an example in which the civil engineering foam block 30 according to this embodiment is used for backfilling a structure. After a structure 43 such as a tunnel is installed underground, a civil engineering foam block 30 is laminated on top of this structure 43, and a road 41 etc. is installed on top of it. In this case, since the civil engineering foam block 30 is extremely lightweight, the overload applied to the structure 43 can be reduced, and the cross section of the members that make up the structure 30 can be reduced, and It also becomes possible to install the structure 30 at a greater depth. Furthermore, when backfilling is performed with soil, the water in the backfilled soil may freeze during the winter night and freeze and thaw during the day, but if this is repeated. , gaps may form in the backfilled soil, reducing the bearing capacity of the soil. However, when backfilling is performed with civil engineering foam blocks 30 as in this example,
Since the foam blocks 30 for civil engineering also have excellent heat insulation and heat retention properties, water does not freeze in these blocks 30, and sufficient soil bearing capacity can be obtained.

Next, FIG. 7 shows an example in which the civil engineering foam block 30 according to this embodiment is used as backfill for an abutment or a retaining wall. When the back side of the abutment 45 that supports the bridge girder 44 is on soft ground, earth pressure acts on the back side of the abutment 45, and a force that presses the abutment 45 toward the river side acts. However, in this example, instead of backfilling the back side of the abutment 45 with soil, civil engineering foam blocks 30 are stacked on the back side of the abutment 45, and a road or the like is installed on top of this. Thereby, the pressure acting on the back side of the abutment 45 can be reduced, that is,
It is possible to reduce the pressure on the back side of the abutment, and also to reduce the lateral flow pressure. In addition, when constructing this, the stacked blocks 30 are constructed diagonally on the opposite side of the abutment 45, but this inclination angle is
It is preferable to determine the pressure acting on the abutment 45 from both the stacked blocks 30 and the diagonal embankment 46, and furthermore, there is a possibility that buoyancy will act on the stacked blocks 30, It is preferable to give sufficient consideration to this as well.

FIG. 8 shows an example of constructing a temporary road using the civil engineering foam block 30 according to this embodiment. When constructing this temporary road, a recess is formed at the construction site, a nonwoven fabric 48 is laid in the recess, and a civil engineering foam block 30 is laminated thereon. At this time, the blocks 30 may be stacked in two or more layers, but the blocks 30
It is also possible to arrange only one layer of. Then, a paved road 46 is constructed on the laminated civil engineering foam blocks 30. Conventionally, when constructing a temporary road by embanking with earth, construction and removal are complicated, but in this case, the temporary road can be constructed and removed easily in an extremely short period of time. This will significantly shorten the construction period for temporary roads. In addition, when a temporary road is constructed by embanking earth on soft ground, the earth pressure of the embanked soil may act laterally and affect the area around the temporary road. Since the block 30 is extremely lightweight, there is little risk of such lateral pressure acting on it, and there is no risk of affecting the surroundings of the temporary road.

FIG. 9 shows an example in which the civil engineering foam block 30 according to this embodiment is used as a free-standing wall. Civil engineering foam blocks 30 are stacked between a pair of retaining walls 49,
On top of that, paved roads are being constructed. In this case, since the pressure acting in the horizontal direction is reduced, the structure of the retaining wall 49 can be simplified and the minimum amount of land can be secured. As an example of simplifying the structure of the retaining wall 49, the retaining wall 49 may be constructed of steel sheet piles or skin plates;
Tie the 9 spaces with a tie bar. Further, the retaining wall 49 may be constructed of sprayed concrete. In this way, since the load acting on the retaining wall 49 is reduced, a retaining wall with a simple structure can be used.

FIG. 10 shows an example in which the civil engineering foam block 30 according to this embodiment is used to widen embankments and reclaimed land. A retaining wall 51 is installed, civil engineering foam blocks 30 are laminated inside this retaining wall 51, and a paved road 52 etc. is installed on top of this. This makes it possible to easily widen roads and the like on steep slopes. At this time, even if there is an existing structure 53 near the steep slope, in this example, the retaining wall 5
Since the horizontal pressure acting on the structure 1 is small, lifting of the existing structure 53 can be effectively prevented. Other specific examples to which this example can be applied include parking lot widening work and golf course teeing ground repair work.

FIG. 11 shows an example in which the civil engineering foam block 30 according to this embodiment is used in the head embankment of a landslide site. Foam blocks 30 for civil engineering are laminated on the head of the landslide surface 54 and covered with soil. Also in this example, since the civil engineering foam block 30 is extremely lightweight, the pressure acting on the landslide surface 54 can be significantly reduced, and it is possible to effectively prevent a landslide from occurring again. In other words, the slip safety factor can be improved. Furthermore, it can be constructed extremely quickly compared to earthen embankments.

FIG. 12 shows an example in which the civil engineering foam block 30 according to this embodiment is used as a disaster recovery embankment. Foam blocks 30 for civil engineering are laminated at a location affected by a disaster or landslide, and then covered with earth. Also in this example, since the civil engineering foam block 30 is extremely lightweight, recurrence of landslides and the like can be effectively prevented. Furthermore, since construction is simple, early recovery in the event of a disaster is possible. Furthermore, it can be applied not only to temporary recovery but also to permanent recovery.

FIG. 13 shows an example in which a civil engineering foam block 30 is used to prevent underground pipes and drainage holes from sinking. In this example, before burying the underground pipe etc. 55, a civil engineering foam block 30 is laminated at a position below the underground pipe etc. 55. When stacking, the number of blocks 30 is reduced as the depth increases. Then,
An underground pipe etc. 55 is buried and covered with soil, and then a paved road etc. 56 is constructed. For example, in soft ground,
There is a risk that underground pipes, drain ports 55, etc. may sink due to their own weight, but in this example, civil engineering foam blocks 30 are stacked below the underground pipes, drain ports 55, etc., so these underground pipes may sink. , drainage port 55, etc. can be effectively prevented from sinking. Therefore, the underground pipe 55 and the like can be buried deeper.

FIG. 14 shows an example in which a civil engineering foam block 30 is used to prevent sinking of side gutters. In this example, prior to constructing the side gutter 57, civil engineering foam blocks 30 are stacked and buried, and then the side gutter 57 is laid and covered with soil. In this case as well, in soft ground etc.
Although there is a risk that the side gutter 57 may sink due to its own weight, in this example, the civil engineering foam blocks 30 are laminated below the side gutter 57, so that this sinking of the side gutter 57 can be effectively prevented. Further, the construction can be performed extremely quickly compared to the case where the side ditch 57 is laid by replacing the soil to improve soft ground.

FIG. 15 shows an example in which a civil engineering foam block 30 is used for recovery from landslides and the like. This example is similar to the case shown in Fig. 24, and at the location of the landslide,
After the civil engineering foam blocks 30 are arranged in the horizontal direction, they are covered with soil. Also in this example, the civil engineering foam block 3
0 is extremely lightweight, it can effectively prevent landslides from occurring again. Furthermore, since construction is simple, early recovery in the event of a disaster is possible. Furthermore, it can be applied not only to temporary recovery but also to permanent recovery. Furthermore, in the example of FIG. 15, the civil engineering foam block 30
are not stacked, but only one layer is arranged in the horizontal direction. In the construction method of the present invention, the civil engineering foam blocks 30 do not necessarily need to be stacked in multiple layers as described above, and may be arranged horizontally in only one layer.

It should be noted that the present invention is not limited to the above-mentioned embodiments, and can be modified in various ways within the scope of the present invention. In particular, the use of the foam block for civil engineering according to the present invention is as follows:
Although it is suitable for the EPS construction method, it is of course not limited to this and may be used for other civil engineering applications.

[0037]

[Effects of the Invention] As explained above, in the present invention,
It has a reused core inside, and the periphery of this core is made of new EPS, so the molding accuracy is higher than that of normal EPS.
It can be secured to the same level as PS, and can be applied to members that require high precision. It is particularly suitable for the EPS construction method in which a large number of foam blocks for civil engineering are stacked.

[0038] Furthermore, since most of the cores among the raw materials are used expanded polystyrene synthetic resin foams or synthetic resin moldings, it is difficult to recycle these synthetic resin foams or synthetic resin moldings. It is possible to use energy effectively, and in turn, it is possible to significantly reduce costs and use energy effectively.

[Brief explanation of drawings]

FIG. 1 is a sectional view of a foam block for civil engineering according to the present invention.

FIG. 2 is a longitudinal sectional view of an example of a manufacturing apparatus for manufacturing the above-mentioned foam block for civil engineering.

FIG. 3 is a sectional view of a construction site showing an example of an embankment road using the foam block for civil engineering according to the present invention.

FIG. 4 is a sectional view of a construction site showing an example of a road on a steep slope using the foam block for civil engineering according to the present invention.

FIG. 5 is a cross-sectional view of a construction site showing an example in which the civil engineering foam block according to the same embodiment is used as the ground for a pool.

FIG. 6 is a sectional view of a construction site showing an example of using the civil engineering foam block according to the present invention for backfilling a structure.

FIG. 7 is a cross-sectional view of a construction site showing an example of using the civil engineering foam block according to the present invention as backfilling for a retaining wall.

FIG. 8 is a sectional view of a construction site showing an example of using the foam block for civil engineering according to the present invention as the ground for a temporary road.

FIG. 9 is a cross-sectional view of a construction site showing an example of using the civil engineering foam block according to the present invention as backfilling for a free-standing wall.

FIG. 10 is a cross-sectional view of a construction site showing an example of using the foam block for civil engineering according to the present invention to widen a reclaimed land.

FIG. 11 is a sectional view of a construction site showing an example of using the civil engineering foam block according to the present invention as the head embankment of a landslide site.

FIG. 12 is a sectional view of a construction site showing an example of using the foam block for civil engineering according to the present invention as embankment for disaster recovery.

FIG. 13 is a cross-sectional view of a construction site showing an example of using the foam block for civil engineering according to the present invention to prevent subsidence of underground pipes and discharge ports.

FIG. 14 is a cross-sectional view of a construction site showing an example of using the foam block for civil engineering according to the present invention to prevent sinking of side gutters.

FIG. 15 is a sectional view of a construction site showing an example of using the foam block for civil engineering according to the present invention as embankment for disaster recovery.

[Explanation of symbols]

30 Foam block for civil engineering (resin molding) 26 Core body

Claims (2)

[Claims] [Claim 1] A two-layered product having a core mainly composed of small pieces obtained by crushing a synthetic resin molded article or a synthetic resin foam, and having at least one side of the core covered with expanded polystyrene that is newly molded in a mold. Layered civil engineering foam blocks are arranged horizontally and stacked vertically to form embankments, backfills, or backfills, and are then used for roads,
A method of constructing foam blocks for civil engineering, characterized by the installation of temporary roads, buildings, soil covering, etc. [Claim 2] A two-layered product having a core mainly composed of small pieces of crushed synthetic resin molding or synthetic resin foam, and at least one side of the core being covered with expanded polystyrene that is newly molded in a mold. Foam blocks for civil engineering having a layered structure are arranged only in the horizontal direction to serve as embankment, backfilling, or backfilling material, and then roads, temporary roads, buildings, soil covering, etc. are installed. , Construction method of foam blocks for civil engineering.