JPH06166012A - Production of lightweight block - Google Patents

Abstract

PURPOSE:To easily produce a lightweight block capable of being surely constructed without sinkage of the lightweight block in weak ground such as the face of slope of a bank. CONSTITUTION:A formwork A opened in the upper part is formed by erecting a cylindrical side frame on a bottom plate 3. Lightweight core material E consisting of foamed styrole 2 or the like is provided in a fixed state in the formwork A by means of a spacer S shared with fixation of the core material. Space (a) for filling concrete is formed between the lightweight core material E and the formwork A. Furthermore a jig 9 for preventing the core material from rising is fitted to the formwork A. Concrete is filled in the space (a) for filling concrete and thereafter cured and hardened.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a lightweight block, and more particularly, to a lightweight block which can be surely laid without sinking on soft ground such as a bank slope. It can be manufactured.

[0002]

2. Description of the Related Art Conventionally, it is very difficult to lay a concrete block on soft ground such as a slope of a bank, and if a normal block is used, the block may sink due to its own weight.

Therefore, in the case of large-scale laying work, the ground is improved and hardened to some extent before laying.

However, since the construction cost is considerably high, a lightweight block that does not require ground improvement has been desired.

As a method of manufacturing a lightweight block, for example, as disclosed in Japanese Patent Application Laid-Open No. 53-5217, a lightweight material such as plane scraps and foam styrene scraps is used as the core material. In addition to spraying mortar or covering it with concrete, etc., it is also used to manufacture lightweight blocks that cast concrete after fixing it in the mold by attaching anchors to the core material, pressing from above, etc. There was a way.

[0006]

However, in the above-described method for manufacturing a lightweight block, there are technical aspects relating to manufacturing,
And, many problems remain in the quality of the manufactured block, and it is very difficult to manufacture a lightweight block that can actually be used by the above method, and it has not been put to practical use. .

For example, when the manufactured lightweight block is used for actual civil engineering work, considerable strength is required. For that purpose, the dimensional accuracy of the concrete around the core material does not vary so that the thickness of the concrete does not vary. Careful attention is required.

[0008] However, when concrete is poured with the core material put in the formwork, a considerable buoyancy force is applied to the light core material, and simply using an anchor or the like cannot withstand the buoyancy force. , If the core material is foamed polystyrene,
Since the styrene foam itself was soft and weak, there was a problem that it was dented or collapsed by the anchor.

Further, when concrete is poured into the mold, the foam polystyrene, which is the core material, tends to be displaced not only in the vertical direction as described above, but also in the left, right, front, and rear. If a vibrator or the like is used for this purpose, the deviation due to such vibration is remarkable.

In this case, it is difficult to secure a desired concrete thickness, and it has been impossible to manufacture a lightweight block which can be actually used.

An object of the present invention is to provide a method for manufacturing a lightweight block which can solve the above problems.

[0012]

According to the present invention, in a form of an upper opening formed by vertically arranging a cylindrical side frame on a bottom plate, a lightweight body made of foamed polystyrene or the like via a core material fixing / spacer. The core material is placed in a fixed state, a concrete filling space is formed between the lightweight core material and the formwork, and further, a core material floating prevention jig is attached to the formwork, and concrete is filled in the concrete filling space. It is an object of the present invention to provide a method for manufacturing a lightweight block, which comprises filling and then curing and hardening.

Further, according to the present invention, a partition plate is provided in a form of an upper opening formed by vertically arranging a cylindrical side frame on a bottom plate to divide the frame, and a spacer for fixing the core material is also provided in the divided space. Through, a lightweight core material made of expanded polystyrene is fixedly placed,
A concrete filling space is formed between the lightweight core and the form or partition plate, and a core material floating prevention jig is attached to the form, concrete is filled in the concrete filling space, and then cured and cured. It is also characterized in that a plurality of lightweight blocks having the same shape can be manufactured at the same time.

Further, a core material fixing / spacer for fixing the lightweight core material is attached to the mold side, and a core material fixing / spacer for fixing the light weight core material is provided.
It is also characterized in that it is attached to a lightweight core material in advance, and that a spacer having a jig function is used in place of the core material floating prevention jig.

[0015]

Embodiments of the present invention will be described in detail with reference to the drawings.

(First Embodiment) FIG. 1 is an explanatory view of a block 1 obtainable by a method for manufacturing a lightweight block according to the present invention, FIG. 2 is a sectional view of the same lightweight block 1, and FIG. 3 is a method for manufacturing the same. FIG. 4 is a perspective view of the form A used, FIG. 4 is a flowchart showing the manufacturing process of the lightweight block 1, and FIG. 5 is a lightweight core material E.
FIG. 6 is a cross-sectional plan view of the form A in a state in which is inserted, and FIG.

As shown in FIG. 1, a block 1 obtainable by the method for manufacturing a lightweight block according to the present invention is formed in a rectangular plate shape having fitting portions 1a, 1a formed on both side surfaces thereof, and is internally formed. Includes a styrene foam 2 having a rectangular plate shape, which is a size smaller than the block 1, as a lightweight core material E.

When the area of the lightweight block 1 to be a product becomes large, the strength as a concrete plate decreases, so that a through hole 2a is provided at an appropriate portion of the foam polystyrene 2, and as shown in FIG. Part of the reinforcing bars 7 and the front and back sides of the block 1 are made of concrete C
It is reinforced by connecting with.

By including the expanded polystyrene 2 as the lightweight core material E, the lightweight block 1 is significantly lighter than the conventional concrete block, and is particularly suitable for laying on soft ground such as the slope of a bank. It has become a thing.

Here, the form A used for manufacturing the above lightweight block 1 will be described.

As shown in FIG. 3, the form A in this embodiment is a cylindrical side frame, and as shown in FIG. 3, a bottom plate 3, front and rear end plates 4, 4 standing upright on the bottom plate 3, and a stepwise shape on the inner side surface, respectively. It is formed of both side plates 5 and 5 having the fitting portion forming surfaces 5b and 5b formed on.

The upper opening is formed in a vertically long shape so that when the concrete C is cast, the concrete C is spread all over the mold. Reference numeral b is a concrete casting port formed in the upper opening.

A partition plate 8 fixed to the bottom plate 3 is disposed between the side plates 5 and 5 in parallel with the front and rear end plates 4 and 4 to divide the interior of the form A into two chambers. The fitting portion forming surfaces 5b, 5b formed continuously on both side plates 5, 5 are each divided into two.

Therefore, one pair of mating portion forming surfaces 5b is provided in each of the two chambers so as to face each other, and the same lightweight block 1 having the mating portions 1a on both sides is formed in one mold. Two can be manufactured at the same time in frame A.

The front and rear end plates 4, 4 are pivotally supported by pivotal support portions 4a provided at the front and rear edges of the bottom plate 3, and have a pivotal support structure that can be opened and closed centering on the pivotal support portions 4a.

Similarly to the end plates 4 and 4, the left and right side plates 5 and 5 are also attached to the pivotal support 5a provided on the bottom plate 3 so as to be openable and closable around the pivotal support 5a.

As a method of attaching the end plate 4 and the side plate 5 to the bottom plate 3, a slide structure may be used in which the end plate 4 and the side plate 5 are slid in a direction orthogonal to a mounting position on the form A, or such a slide structure formula. The above-mentioned pivotal support structure formula may be separately adopted for the end plate 4 and the side plate 5, respectively.

When a pattern is put on the surface of the lightweight block 1 as a product, the end plate 4 is used to reveal the pattern.
It is necessary to form a pattern on the inner surface of the side plate 5 or the side plate 5. At that time, in the pivotal structure type, the pattern pattern formed on the inner surface of the end plate 4 or the side plate 5 interferes with the product when the mold is released. In this case, it is better to use the slide structure type because it may damage the surface or make it impossible to demold.

The steps of actually manufacturing the lightweight block 1 using the form A constructed as described above will be described below with reference to FIGS. The mold A is divided into two chambers as described above, and the blocks can be manufactured simultaneously in both chambers. However, the manufacturing process is performed in one chamber for simplification of description.

First, at the beginning of the mold assembling step 51, the mold A is cleaned in a disassembled state, the mold release material is applied to the inner surface thereof, and then the foam polystyrene 2 as a lightweight core material E to be set in the mold A is set. The core material fixing / spacer S is attached to a predetermined position of.

The spacer S also used for fixing the core material allows the expanded polystyrene 2 to hold a predetermined position in the lightweight block 1 (to hold a desired thickness of the concrete C).
Also, in order to fix the foamed polystyrene 2, it is arranged between each surface of the foamed polystyrene 2 and the form A, and as shown in FIGS. 5 and 6, a rectangular plate-shaped foamed polystyrene 2 is provided.
First spacer S1 attached to the upper surface of the, second spacer S2 attached to the front and rear surfaces, and third spacer S3 attached to both side surfaces
And a fourth spacer S4 attached to the bottom surface, which is generally formed from mortar, resin or the like into a cube or a cylinder.

As a method of attaching the core material fixing / spacer S, for example, as shown in FIG. 7, a protrusion e may be provided on the spacer S and inserted into the foam polystyrene 2.

Next, if necessary, a reinforcing bar 7 is placed in the form A on the partition plate 8 side. At this time, a reinforcing bar spacer S5 is attached to an appropriate portion of the reinforcing bar 7 so that the position in the form A can be maintained.

Next, as described above, the foam polystyrene 2 having the core material fixing / spacer S attached thereto is set on the form A, and if necessary, the end plate 4 side is also reinforced in the same manner as the partition plate 8 side. Arrange the rebar 7 of. Also in this case, the reinforcing bar spacer S5 is attached to an appropriate portion of the reinforcing bar 7 so that the position within the form A can be maintained.

Next, the side plate 5 and the end plate 4 are erected and the form A is assembled. At this time, a concrete-filled space a is formed between the mold A and the polystyrene foam 2.

Then, a core material floating prevention jig 9 is attached between the end plate 4 and the partition plate 8 in a bridging state, and the first spacer is attached.
Press and fix S1.

As shown in FIG. 6, the core material floating prevention jig 9 is formed of an angle material, and both ends thereof are fixed to the end plate 4 and the partition plate 8 with bolts or the like.

As shown in FIG. 8, the jig 9 is seen in plan view from left and right vertical plates 9a fixed to the upper part of the form A by bolts 12 and the like, and a pressing plate 9b pressing the upper surface of the foam polystyrene 2. It may be configured in a substantially H shape.

In this case, the first spacer S1 becomes unnecessary, and if the pressing plate 9b is molded with mortar, when the core material floating prevention jig 9 is later removed, only the left and right vertical plates 9a need to be removed. There is no need to add concrete C.

As described above, since the foam styrene 2 is pressed from above by the core material floating prevention jig 9, when the concrete C is placed in the next step, a considerable buoyancy is applied to the light foam polystyrene 2. Does not levitate.

After completing the mold assembling step 51 by the above-mentioned work,
Next, in the placing step 52, the concrete C is filled into the concrete filling space a from the concrete casting port b.

At this time, the concrete C is in the form A,
It is efficient to apply vibration with a vibrator or the like (not shown) so that the vibrations are evenly distributed.

After concrete C is cast and the foam polystyrene 2 is completely wrapped in the concrete C, the core material floating prevention jig 9 is removed.

When the jig 9 for preventing the floating of the core material is removed, and the jig 9 and the first spacer S1 are trowel-finished so that the mounting surface becomes smooth, the end face of the lightweight block 1 as a product looks good. Can be well.

Next, in the curing step 53, the concrete C is cured for a predetermined time and the concrete C is sufficiently hardened.

Then, in the demolding step 54, the lightweight block 1 can be obtained by demolding using an appropriate suspending tool.

By the way, as the method of attaching the spacer S also used for fixing the core material in the mold assembling step 51, other than the method of previously attaching the spacer S to the foam polystyrene 2, as described above, for example, the first spacer S1 is made of the core material. Levitation prevention jig 9
The fourth spacer S4 may be attached to the bottom plate 3 of the form A before the foam polystyrene 2 is set.

Further, as the shape of the spacer S also used for fixing the core material, as shown in FIG. 9, the spacer S is a plate-like spacer S in which the rod 15 is held so as to maintain a predetermined length on the mold A side. It can be provided in a skewered shape, and the interval between the mold A and the foam polystyrene 2 can be defined on one side, and can be inserted into the foam polystyrene 2 on the other side.

The core material fixing / spacer S may be attached to a predetermined portion of the reinforcing bar 7 instead of being attached to the foam polystyrene 2 in advance.

As a mounting method, for example, as shown in FIGS. 10 (a) and 10 (b), the spacer S for fixing the core material is also used.
The holding groove 28 for holding the reinforcing bar 7 is provided in the
There is a method of holding and holding the reinforcing bar 7 with 28 and fixing it with a binding wire.

In this case, since the second spacer S2 can also serve as the reinforcing bar spacer S5 for holding the position of the reinforcing bar 7, the reinforcing bar spacer S5 becomes unnecessary and the number of parts can be reduced.

(Second Embodiment) FIGS. 11 and 12 show a block which can be manufactured by the method for manufacturing a lightweight block according to the present invention and in which the lightweight core material E is exposed at both ends of the block.
21 is shown, and the process of manufacturing the block 21 will be described below with reference to FIGS. 4 and 13.

In this case, the length of the expanded polystyrene 2 which is the lightweight core material E is different, and the number of mounting points of the spacer S also used for fixing the core material in the mold assembling process is small.
This is almost the same as the embodiment.

That is, first, at the beginning of the mold assembling step 51, the mold A is cleaned in the disassembled state, the mold release material is applied to the inner surface of the mold A, and then the light core E is set in the mold A as a firing. Spacer S for fixing the core material at a predetermined location of the styrene 2.
Install.

At this time, as shown in FIG. 13, only the second spacer S2 attached to the front and rear surfaces of the rectangular plate-shaped foam polystyrene 2 and the third spacer S3 attached to both side surfaces are sufficient.
Since the first and fourth spacers S1 and S4 used in the first embodiment are unnecessary, the labor of the work is reduced.

Also in this embodiment, when the spacer S also used for fixing the core material is used, in the above first embodiment,
The mounting method shown in FIGS. 9 and 10 can also be used.

Next, as in the first embodiment, if necessary,
Reinforcing reinforcing bars 7 are arranged on the side of the partition plate 8 in the form A, and the polystyrene foam 2 having the spacer S also used for fixing the core material is set on the form A, and if necessary, the end plate 4 The rebar 7 is also arranged on the side.

Next, the form A is assembled to form a concrete filling space a, and the core material floating prevention jig 9 is attached between the end plate 4 and the partition plate 8 in a bridging state, and the first spacer S1.
Press and fix. The core material floating prevention jig 9 is formed in a substantially H shape in a plan view, and has substantially the same configuration as the core material floating prevention jig 9 shown in FIG. The pressing plate 9b for pressing the styrene 2 is sandwiched between the left and right vertical plates 9a, and the lower surface of the pressing plate 9b and the left and right vertical plates are the same.
The lower surface of 9a is flush with the lower surface.

After finishing the mold assembling step 51 by the above-mentioned work, concrete C is cast in the concrete filling space a in the placing step 52, and then the core material floating prevention jig 9 is removed.

Then, after a curing step 53 and a demolding step 54,
It is possible to obtain the lightweight block 21 in which the styrene foam 2 is exposed at the end.

By the way, in place of the above-described core material floating prevention jig 9, for example, as shown in FIGS. 14 and 15, a spacer 29 having a jig function can be used.

That is, the first and second spacers 29a and 29b shown in FIGS. 14 (a) and 14 (b) are used as a set of spacers 29, and as shown in FIG. Spacer
An appropriate number of 29a are arranged, and second spacers 29b are provided on both side surfaces.
Are installed.

As shown in FIG. 14, the first spacer 29a
Is attached to the angle member 30 which is fixed to the form A by attaching two long square members 31 and 31 separated by the thickness D of the foam polystyrene 2, and further to the outside of the same square members 31 and 31, a short member respectively. The square members 32, 32 are arranged side by side at a constant interval d.

This is to prevent the foam styrene 2 from shifting in the front-rear direction as a whole.
The rectangular member 31 on the side is made long, and the rectangular member 32 on the end plate 4 side of the mold A is made short so that the concrete C can easily spread in the mold A.

A space d having at least the same diameter as that of the reinforcing bar 7 is provided between the square members 31 and 32 in preparation for disposing the reinforcing bar 7.

Further, it goes without saying that the total thickness (including the interval d) of the above-mentioned square members 31 and 32 arranged in parallel has the same length as the required concrete thickness.

The second spacer 29b is provided on the latch plate 33 which is latched on the side plate 5 of the form A, and the long square member 31 of the first spacer 29a is attached to the latch plate 33.
And a square bar 34 having substantially the same length as the above are attached. It is needless to say that the same square member 34 has the same thickness as the concrete thickness on the side surface side of the lightweight block 31 as a product.

In the method of manufacturing the lightweight block according to the present embodiment described above, the number of the spacers S also used for fixing the core material is small, and if the spacer 29 having the jig function is used,
Since the core material floating prevention jig 9 is not necessary and the installation thereof is not troublesome, efficient manufacturing can be performed and the cost of the product can be reduced.

As described above, the one in which the foam polystyrene 2 as the core material E is exposed at the end of the lightweight block 21 is lighter as the volume of the foam polystyrene 2 increases while maintaining sufficient strength. Can be converted.

In both of the first and second embodiments, the form A has a vertically long rectangular shape composed of front and rear end plates 4 and 4 and left and right side plates 5 and 5 which are erected on the bottom plate 3. The shape is not limited, and the cross-sectional shape may be circular or any other polygonal shape.

[0071]

According to the present invention, a lightweight core material such as styrene foam is fixed in a mold having an upper opening formed by vertically arranging a cylindrical side frame on a bottom plate via a core material fixing / spacer. Placed in a state, form a concrete filling space between the lightweight core material and the form, further, attach a core material floating prevention jig to the form, fill the concrete in the concrete filling space, then, By curing and curing, the following effects are exhibited.

1. Complete the filling of concrete once,
Since the manufacturing time of the block can be shortened, the cost of the product can be reduced.

2. When filling concrete, it is possible to reliably prevent floating of the lightweight core material such as expanded polystyrene without damaging it, and to accurately position the core material in front, back, left and right. Therefore, the dimensional accuracy of the concrete thickness of the product can be improved. Therefore, it is possible to provide a high-quality lightweight block.

3. A partition plate is provided and partitioned in a mold having an upper opening formed by vertically arranging a cylindrical side frame on the bottom plate, and a firing is performed in the partitioned space via a core material fixing / spacer. A lightweight core material made of styrene etc. is arranged in a fixed state, a concrete filling space is formed between the lightweight core material and the form or partition plate, and a core material floating prevention jig is attached to the form, By filling concrete into the concrete filling space and then curing and curing it, it is possible to produce multiple lightweight blocks of the same shape at the same time, so multiple products can be produced simultaneously from one formwork. Manufacturing efficiency can be further improved.

4. Further, since the core material fixing / spacer for fixing the lightweight core material is attached to the core material in advance, it is possible to save the labor of attaching the core material in the formwork and improve the work efficiency. Can be planned.

5. Further, since the spacer having the jig function is used in place of the core material floating prevention jig, the number of parts can be reduced, and the work for mounting the dedicated jig is also eliminated. , Work efficiency is improved.

[Brief description of drawings]

FIG. 1 is an explanatory view of a product obtained by a method for manufacturing a lightweight block according to the present invention.

FIG. 2 is a view taken along line I-I of FIG.

FIG. 3 is a perspective view of a mold used in the manufacturing method.

FIG. 4 is a flowchart showing the manufacturing method.

FIG. 5 is a cross-sectional plan view of the mold with a lightweight core material put therein.

FIG. 6 is a front view of the same section.

FIG. 7 is an explanatory view showing a method for attaching a spacer that also serves as a core fixing member.

FIG. 8 is an explanatory view showing a mounted state of a core material floating prevention jig.

FIG. 9 is an explanatory view showing one form of a method of attaching a spacer that also serves as a core material fixing spacer.

FIG. 10 is an explanatory diagram showing another embodiment of a method of attaching the spacer that also serves as the fixing core material.

FIG. 11 is an explanatory diagram of a product obtained by the method for manufacturing a lightweight block according to another embodiment.

12 is a view taken along line I-I of FIG.

FIG. 13 is a cross-sectional plan view of the mold with a lightweight core material put therein.

FIG. 14 is an explanatory view showing one form of a core material fixing / spacer.

FIG. 15 is an explanatory diagram showing a mounted state of the spacer for fixing and using the core material.

[Explanation of symbols]

 A Formwork C Concrete E Lightweight core material S Spacer for fixing core material a Space for filling concrete 2 Styrofoam 3 Bottom plate 8 Partition plate 9 Core material floating prevention jig

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI Technical display location E02D 29/02 308 9126-2D E04C 1/40 R 7904-2E

Claims (5)

[Claims] 1. A core material fixing and spacer (S) in a mold (A) having an upper opening formed by arranging a cylindrical side frame on a bottom plate (3).
Through, a lightweight core material (E) made of expanded polystyrene (2), etc.
Is fixedly installed, a concrete filling space (a) is formed between the lightweight core material (E) and the formwork (A), and the core material floating prevention jig (9) is attached to the formwork (A). ), The concrete filling space (a) is filled with concrete (C), and then cured and cured, which is a method for manufacturing a lightweight block. 2. A partition plate (8) is provided in a form (A) having an upper opening formed by vertically arranging a cylindrical side frame on a bottom plate (3) to partition the core, and the core is placed in the partitioned space. A lightweight core material (E) made of expanded polystyrene (2) is fixedly placed through the material fixing / combining spacer (S), and the lightweight core material (E) and the formwork (A) or partition plate ( 8) and a concrete filling space (a) is formed between them and the core material floating prevention jig (9) is attached to the formwork (A), and concrete (C) is placed in the concrete filling space (a). A method for manufacturing a lightweight block, which comprises filling and then curing and curing to simultaneously manufacture a plurality of lightweight blocks having the same shape. 3. The lightweight block according to claim 1, wherein a core material fixing / spacer (S) for fixing the lightweight core material (E) is attached to the formwork (A) side. Manufacturing method. 4. The core material fixing and spacer (S) for fixing the lightweight core material (E) is attached to the lightweight core material (E) in advance. Light block manufacturing method. 5. The method for manufacturing a lightweight block according to claim 1, wherein a spacer (29) having a jig function is used in place of the core material floating prevention jig (9).