JPH09155835A - Production of curved surface precast plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simply produce a curved surface precast plate high in accuracy to achieve cost reduction. SOLUTION: A powdery and granular material 2 is charged in a casting frame 1 and the upper surface thereof is depressed into a spherical shape or a circular arc shape to mold a powdery and granular material layer and a hydraulic material having a curved surface part depressed into a spherical shape or a circular arc shape concentrically formed thereto is superposed on the surface of the layer 3 to form a composite and a casting mold 5 is shaped by using this composite. A lattice member 7, a reinforcing rod truss 8 and ribbed lath 9 are placed on the curved part within the curved surface part region of the casting mold 5 and three of them are mutually bonded to constitute a reinforcing member 13 and, thereafter, a hydraulic material 11 is cast on the upper surface of the casting mold to embed the lattice member 7, the ribbed lath 9 and the lower half part or whole of the reinforcing rod truss 8 and the hydraulic material 11 is dried and cured to be demolded to produce a curved surface precast plate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention provides an arbitrary free-form surface having a spherical shape, an arc shape, or a composite shape thereof which is suitable for a ceiling of a music hall, a downward sloped wall, etc., where it is necessary to consider sound reflection. The present invention relates to a method for manufacturing a curved precast plate.

[0002]

2. Description of the Related Art Conventionally, a technique described in Japanese Patent Laid-Open No. 63-176108 or Japanese Patent Laid-Open No. 2-186027 has been proposed as a curved plate manufacturing apparatus.

Among these conventional techniques, in the former technique, a large number of straight rods are arranged side by side on front and rear support rods having height adjusting bolts at both ends, and a thin plate is placed on the upper portion of these rods, and these are placed in front and rear directions. By holding the left and right side frames between the front and rear holding frames, and adjusting the screw tightening amount or the returning amount of the nut screwed to the height adjusting bolt, By adjusting and twisting the height adjustment bolt's insertion part with a height difference, the side faces of the adjacent straight rods are slightly shifted, forming a twisted curved surface as a whole, and formed by the straight rods. A smooth curved surface according to the curved surface is formed by the thin plate. Then, on a thin plate formed with a smooth curved surface, after placing truss-shaped reinforcing bars in the space surrounded by the front and rear holding frames and the left and right side frames, concrete is placed and demolded after the concrete hardens. By performing the above, a precast concrete plate having a curved surface that is controlled by the curved surface formed by the thin plate is manufactured.

On the other hand, in the latter technique, a lattice shell is formed by assembling wood, synthetic resin, metal material, etc. into a three-dimensional lattice of free-form curved surfaces, and a water vapor permeable and moisture-proof sheet is laid on the upper surface of the lattice shell. A net formwork is arranged on the top of the net formwork, and concrete or synthetic resin is placed and cured to a predetermined thickness on the net formwork, and the lattice shell is supported by the formwork when the concrete or synthetic resin is cast. It is configured to be used as an internal finishing material after completion, and when forming precast concrete with a predetermined thickness on the net formwork, with the water-permeable and moisture-permeable sheet. The net formwork is placed only at the joints between the precast concrete and the grid shell is used as a support for the precast concrete. A precast synthetic resin material or metal plate of a predetermined thickness is formed on the lattice shell formed by assembling in a three-dimensional lattice of free-form curved surfaces, which is configured to be used as an internal finishing material, and the lattice shell is precast. It is used as a support for a synthetic resin material or a metal plate, and is also used as an internal finishing material after completion.

However, in the former technique, in the former technique, the curved surface of the precast concrete plate is made up of a large number of straight rods as a whole by adjusting the screw tightening amount or the returning amount of the nut screwed to the height adjusting bolt. Since it is formed on the basis of twisting, the degree of freedom of forming a curved surface is limited, and it is impossible to manufacture a curved surface precast plate having an arbitrary free curved surface having a spherical shape, an arc shape, or a composite structure of these.

The latter technique is a method for manufacturing a curved surface cast concrete having an arbitrary free curved surface having a spherical shape, an arc shape, or a composite structure of these in which the restriction on the degree of freedom of forming a curved surface is relaxed. The method can be used to make precast plates. However, the number of parts required for manufacturing is large, and the manufacturing is complicated and difficult, which results in a cost increase.

[0007]

That is, according to the prior art, the degree of freedom of forming a curved surface is restricted, and it is impossible to manufacture a curved surface precast plate having an arbitrary free curved surface having a spherical shape, an arc shape or a composite structure of these. It is impossible, or the constraint on the degree of freedom of curved surface formation is relaxed, and a method for manufacturing curved surface cast-in-place concrete with an arbitrary free curved surface consisting of a spherical shape, an arc shape, or a composite structure of these is used for precast plate manufacturing. Even in such a case, there are drawbacks that the number of parts required for manufacturing is large and the manufacturing is complicated and difficult, which leads to cost increase. Therefore, the invention according to claim 1 provides a method for manufacturing a curved surface precast plate capable of easily and inexpensively manufacturing a curved surface precast plate having an arbitrary free curved surface having a spherical shape, an arc shape, or a composite structure thereof. It is intended for.

[0008]

In order to achieve the above-mentioned object, the invention according to claim 1 forms the upper surface of the powder or granular material put into a casting mold into a substantially curved surface, and a hydraulic material or It is characterized by using a mold having a predetermined curved surface made of synthetic resin or the like.

According to the first aspect of the invention, it is possible to easily form a predetermined curved surface portion on the upper surface of the mold, which is not only spherical or arcuate but also an arbitrary free-form surface having a composite structure such as spherical or arcuate. Therefore, it is easy to form the curved surface of the die-cut curved surface precast plate into an arbitrary free curved surface having a composite structure such as a spherical shape or an arc shape, as well as a spherical shape or an arc shape. Further, the number of parts required for manufacturing is reduced and the number of manufacturing steps is small, so that the manufacturing can be easily performed. Further, since it is possible to manufacture a plurality of precast plates having the same curved surface with one mold, the accuracy and yield of products are improved.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the invention described in claim 1 will be described below in the order of steps with reference to the drawings. As shown in FIG. 1 and FIG. 2, a powder or granular material 2 such as sand or sawdust is put into a flask 1, and the upper surface of the powder or granular material 2 is recessed into a spherical or arc shape to form a powder or granular material layer 3. A hydraulic material 4 such as a mortar layer or a water-soluble gypsum that is formed and has a curved surface 4A concentrically formed in a spherical or arcuate shape on its upper surface.
The mold 5 is formed by a composite body in which the above are overlapped, that is, a composite body of the granular material layer 3 and the hydraulic material 4.

After the hydraulic material 4 is dried and cured, the upper surface of the curved surface portion 4A of the mold 5 and the inner surface of the casting frame 1 are subjected to a peeling treatment to form a peeling layer 6 (see FIG. 3). The peeling layer 6 is formed by a means using a resin sheet, a film or the like, a means for spraying or brushing a peeling agent with a spray, a means for spraying a peeling powder, or the like.

Within the area of the curved surface portion 4A of the mold 5, the curved surface portion 4A
The metal reinforcing member 13 is placed on the upper surface of the peeling layer 6 corresponding to A (see FIGS. 4 to 7). The reinforcing member 13 is composed of a composite body of the lattice body 7, a plurality of reinforcing bar trusses 8 and rib laths 9.

Therefore, first of all, as shown in FIG.
On the upper surface of the peeling layer 6 corresponding to the curved surface portion 4A, a grid body 7 formed of a rod-shaped metal and bent so as to be attached to the curved surface portion 4A is placed.

Next, as shown in FIG. 5 and FIG. 6, a plurality of rebar trusses 8 bent so that they can be attached to the upper surface of the lattice body 7 are provided.
Are arranged on the upper surface of the lattice body 7 at a predetermined interval in the front-back direction of the mold 5 (direction orthogonal to the paper surface of FIG. 5), and a plurality of lower rebars 8A of the reinforcing bar truss 8 and the lattice body 7 are arranged. Connected together with the number line (not shown).

A rib lath 9 is superposed on the upper surface of the lattice 7 while straddling the lower rebar 8A of the reinforcing truss 8 and the rib lath 9 and the lattice 7 are integrally connected by a plurality of number lines (not shown) ( (See FIGS. 7 and 8).

As shown in FIG. 9, the upper reinforcing bar 8 of the reinforcing bar truss 8
A plurality of hooks 10 are attached to B at a predetermined pitch. The reinforcing member 13 and the hook 10 can be simplified or omitted depending on the size of the curved surface precast plate 12 described later.

A hydraulic material 11 made of mortar or water-soluble plaster is cast on the upper surface of the mold 5 to form a grid 7
Then, the rib lath 9 and the lower half portion or the entire reinforcing bar truss 8 are embedded (see FIG. 10).

After drying and hardening the hydraulic material 11 made of mortar or water-soluble gypsum, the hook 10 is locked to a hoisting device (not shown) so that the curved surface precast plate 12 above the mold 5, that is, the curved surface portion projects downward. The predetermined curved surface precast plate 12 is manufactured by die-cutting the curved surface precast plate 12 (see FIG. 11).

According to the first aspect of the present invention, the predetermined curved surface portion 4 is not limited to a spherical shape or an arc shape on the upper surface, but is also an arbitrary free curved surface having a composite structure such as a spherical shape or an arc shape.
Since the mold 5 having A can be easily molded,
It is easy to form the curved surface of the curved precast plate 12 that has been die-cut into an arbitrary free curved surface having a composite structure such as a spherical shape or an arc shape, as well as a spherical shape or an arc shape. When the hydraulic material 11 and the hydraulic material 4 of the mold material have a relative property that makes it difficult to peel from the hydraulic material 4 after the hydraulic material 11 is cured, the peeling action of the peeling layer 6 causes It can be easily die-cut. Otherwise, the formation of the release layer 6 can be omitted. further,
The number of parts required for manufacturing is reduced to the mold 5, the reinforcing member 13, and the peeling layer forming material, and the number of manufacturing processes is small, so that the manufacturing can be easily performed, so that the cost can be reduced. Furthermore,
Precast plate 1 having a plurality of identical curved surfaces with one mold 5
Since 2 can be manufactured, the accuracy and yield of products are improved.

Further, a method for manufacturing the curved surface precast plate 12 with the curved surface portion protruding downward by molding the mold 5 having the curved surface portion 4A recessed in a spherical shape or an arc shape has been described. Alternatively, by molding a mold 5 having a curved surface portion 4A that is convexly provided in an arc shape,
It is also possible to manufacture the curved surface precast plate 12 in which the curved surface portion is recessed upward. It is also possible to manufacture the curved surface precast plate 12 having a curved surface portion.

Further, a method of arranging a plurality of reinforcing bar trusses 8 which are constituent members of the reinforcing member 13 on the upper surface of the lattice body 7 at a predetermined interval in the front-rear direction of the mold 5 (direction orthogonal to the paper surface). As explained, a method of arranging the mold 5 on the upper surface of the lattice body 7 with a predetermined space in the left-right direction, or a plurality of reinforcing bar trusses 8 intersecting in both the front-rear direction and the left-right direction to form a lattice shape. Assemble this reinforcing bar truss 8 to the lattice 7
It may be arranged on the upper surface of the.

On the other hand, it can be carried out not only in the factory but also on the floor of the site. By carrying out on the floor of the site, it is possible to omit the transportation work to carry in the curved surface precast plate 12 manufactured in the factory from the factory to the site, and it is easy by using the lifting device attached to the site. It can be installed in place on the building.

[0023]

As described above, according to the first aspect of the present invention, the upper surface of the mold is not limited to a spherical shape or an arc shape, but is also a predetermined free curved surface having a composite structure such as a spherical shape or an arc shape. Since the curved surface portion can be easily formed, the curved surface of the stamped curved surface precast plate can be formed not only in a spherical shape or an arc shape, but also in an arbitrary free-form surface having a composite structure such as a spherical shape or an arc shape. In addition to being simple, the number of parts required for manufacturing is reduced in the mold and the reinforcing member, and the number of manufacturing steps is small, so that the manufacturing can be easily performed, so that the cost can be reduced. In addition, on-site construction is possible, so transportation costs can be reduced. Further, since it is possible to manufacture a plurality of precast plates having the same curved surface with one mold, the accuracy and yield of products are improved.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a step of forming a sand layer according to the first aspect of the invention.

FIG. 2 is a cross-sectional view showing a molding process of a mold.

FIG. 3 is a cross-sectional view showing a step of forming a release layer.

FIG. 4 is a cross-sectional view showing a placing step of the lattice body.

FIG. 5 is a cross-sectional view showing an arrangement process of a reinforcing bar truss.

FIG. 6 is a partial plan view of FIG. 5;

FIG. 7 is a cross-sectional view showing a rib lath overlapping step.

FIG. 8 is an enlarged sectional view taken along line BB of FIG. 7;

FIG. 9 is a cross-sectional view showing a hook attaching process.

FIG. 10 is a cross-sectional view showing a step of casting a hydraulic material.

FIG. 11 is a cross-sectional view showing a curved precast plate that has been die-cut.

[Explanation of symbols]

 1 Casting frame 2 Powder and granules 4 Hydraulic material 5 Mold

Claims (1)

[Claims] 1. A curved surface precast plate characterized by using a mold in which the upper surface of a powder or granular material placed in a casting mold is formed into a substantially curved surface, and a predetermined curved surface portion is formed thereon by a hydraulic material. Method.