JPH09228380A - Manufacture of panel joining type caisson and panel joining type caisson - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a caisson used in constructing a breakwater and a revetment, and especially to manufacture a caisson in standardized parts and units in a manufacturing process. SOLUTION: According to the manufacturing method, a base 1, an internal skeleton 2 and an exterior wall panel 3 are separately manufactured in the respective factories, the base 1, the internal skeleton 2 and the exterior wall panel 3 are separately carried to a designated assembling position, the internal skeleton 2 is assembled on the base 1 in that position, and then the already formed exterior panel 3 is fitted to the outer wall part of the internal skeleton 2. The base 1 is manufactured as a synthetic base or a reinforced concrete construction base, the internal skeleton 2 is manufactured as a sub-assembly, and the exterior wall panel 3 is manufactured as a synthetic base, or a precast concrete panel such as a PC base, a reinforced concrete construction base and the like.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a caisson used for constructing a breakwater or a seawall, and more particularly to a panel joining type caisson having a manufacturing process prefabricated into a unit and a panel bonding manufactured by the same method. Regarding the expression caisson.

[0002]

2. Description of the Related Art Conventionally, caisons used for constructing structures such as breakwaters and seawalls have various sizes.
In the case of RC caisson, it is customary to have a length of about 15 m and a height of about 9 m. Such a large caisson is conventionally regarded as a reinforced concrete structure. The manufacturing process has been made by repeating work processes such as assembling a reinforcing bar, installing a formwork, placing concrete, and demolding. However, at the construction site where the above-mentioned manufacturing work is carried out, due to the poor working conditions and working environment, the work place of skilled workers, mainly young people, is moving away from other industries. As a result, many problems have arisen due to a labor shortage, such as aging due to lack of successors to skilled workers and a decrease in work efficiency due to lack of skilled workers.

[0003]

[Problems to be Solved by the Invention] In order to recover the labor force as described above, the purpose is to improve the image of the work environment, to ensure safety, to improve working conditions, and to save labor in the field. In recent years, there has been a particularly strong demand for technological development related to the production of large caissons by means of mechanized construction, robotized construction, and development of construction materials using new materials.

SUMMARY OF THE INVENTION It is therefore an object of the present invention to overcome the above mentioned problems and meet the needs. More specifically, by prefabricating the caisson manufacturing and making it into a unit, a large work yard is not required when manufacturing the caisson, and a large labor saving of field work reduces the number of skilled workers and shortens the construction period. It is an object of the present invention to provide a method for manufacturing a panel-joint type caisson capable of achieving a reduction in manufacturing cost by shortening the cost, and a panel-joint type caisson manufactured by the method.

[0005]

[Means for Solving the Problems] As a means for solving the above problems, a method for manufacturing a panel-jointed caisson according to the invention of claim 1 is such that a bottom slab, an internal skeleton and an outer wall panel are separately provided in a factory. Manufacture, the bottom slab, internal skeleton, and outer wall panel are assembled at predetermined positions (locations).
It is characterized in that it comprises a step of transporting to an inner skeleton on the bottom slab at the same position, and then attaching an existing outer wall panel to an outer wall portion of the inner skeleton.

The bottom plate according to the invention of claim 1 is
A composite plate in which concrete is placed on a steel plate material and integrated.
Or as a reinforced concrete platemaking, the internal skeleton is manufactured as a steel frame or steel plate or a steel structure skeleton by a combination of both, and the outer wall panel is a synthetic plate in which steel plate is placed on the inner surface and concrete is integrated with it, or in concrete It is characterized in that it is manufactured as a PC plate reinforced by arranging a PC steel wire on it or a precast concrete panel (prefabricated panel) such as a reinforced concrete plate, and these are assembled at an assembly position (place).

In the invention described in claims 1 and 2,
Synthetic bottom slabs are assembled by pre-manufacturing steel plate material as an integrated body at the factory and then transporting it to the next assembly position, or as block steel plate material at the factory and transporting it to the next assembly position and then assembling each block. After that, the steel sheet material is produced by in-situ concreting, and after completion of the concrete casting, the steel frame members etc. processed in the factory are assembled, or the steel frames are transported in blocks in the factory in advance. The feature is that the internal skeletons are assembled in the order in which the blocks are assembled.

According to the first aspect of the present invention, the joint portion between the outer wall panels attached to the outer wall portion of the internal skeleton is accommodated by connecting the ends of the reinforcing bars protruding from the outer wall panel by abutting them in a sleeve joint. It is characterized in that mortar is injected into the sleeve joint and the joint is filled with a filler to be integrated. In the invention according to claim 1 or 4, the longitudinal joint portions between the outer wall panels attached to the outer wall portion of the internal skeleton are accommodated by abutting the ends of the horizontal reinforcing bars protruding from both outer wall panels in the sleeve joint. It is characterized in that the connection is made, mortar is injected into the sleeve joint, and the vertical joints are filled with concrete to be integrated.

According to the first or fourth aspect of the present invention, the lateral joint portions between the outer wall panels attached to the outer wall portion of the internal skeleton are accommodated by abutting the ends of the vertical reinforcing bars of the upper and lower outer wall panels in the sleeve joint. It is characterized in that they are connected to each other, mortar is injected into the sleeve joint, and the side joints are laid and filled with mortar. Next, in the panel joint type caisson according to the invention as set forth in claim 7, the internal skeleton also manufactured in the factory is assembled on the bottom slab manufactured in the factory, and the existing outer wall panel manufactured in the factory is It is characterized in that it is attached to the outer wall portion of the internal skeleton.

The bottom plate in the invention according to claim 7 is
A composite plate in which concrete is placed on a steel plate material and integrated.
Or it is configured as a reinforced concrete platemaking, the internal skeleton is configured as a steel structural skeleton by a steel frame member or a steel plate or a combination of both, the outer wall panel is a composite plate in which the steel plate is arranged on the inner surface and concrete is integrated into it. Or PC reinforced by arranging PC steel wire in concrete
It is characterized in that it is configured as a plate or a precast concrete panel for reinforced concrete platemaking.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION The basis of the method for manufacturing a panel joint type caisson according to the invention of claim 1 is that the bottom slab, the internal skeleton and the outer wall panel are separately prefabricated or unitized in a manufacturing yard of a factory. Manufacturing, these bottom slab and internal skeleton and outer wall panel are separately transported to a predetermined assembly position (caisson manufacturing yard), and the inner skeleton is assembled on the bottom slab at the same position, after which the existing wall part of the inner skeleton is prefabricated. It is carried out in the step of attaching the outer wall panel.

The bottom slab is manufactured as a composite plate in which concrete is cast into a steel plate material to be integrated, or as a reinforced concrete plate. The internal skeleton is manufactured as a steel structural skeleton by a steel frame member, a steel plate, or a combination of both. The outer wall panel is a synthetic plate in which a steel plate is placed on the inner surface and concrete is integrated into the steel plate, or P is placed in the concrete.
It is manufactured as a PC plate in which C steel wire is arranged and reinforced, or as a precast concrete panel (prefabricated panel) such as a reinforced concrete plate, and these are assembled at an assembly position.

When manufacturing a synthetic bottom slab, a steel plate material is manufactured in advance as an integrated product (semi-finished product) at a factory and is transported to the next assembly position (caisson manufacturing yard), or divided into a plurality of blocks at the factory. The produced steel plate material block is transported to the next assembly position and then manufactured by one of the methods of integrating the blocks, and then the steel plate material is manufactured (completed) by placing a conley on the steel plate material block. However, a method of manufacturing as a ready-made synthetic bottom slab or reinforced concrete bottom slab that is completed in advance at the factory and transporting it to the assembly position is also implemented. In the caisson manufacturing yard, the internal skeleton is assembled after the concrete casting of the bottom slab is completed.

The outer wall panel attached to the outer wall portion of the internal skeleton aims to reduce the number of panels for the purpose of shortening the length of the joint portion which is complicated to construct as much as possible. In addition, it is desirable to use a lightweight and high-strength composite plate from the viewpoint of consideration of the capacity and transportability of the construction machine, and the weight saving of the outer wall panel necessary to secure the handling property on the site. Labor saving, shortening of construction period and improvement of safety are achieved. The joints between the outer wall panels are roughly divided into vertical joints and horizontal joints, but in any case, the ends of the reinforcing bars protruding from the outer wall panels are butted and connected in the sleeve joint, and the sleeve joint Basically, mortar is injected into the inside of the container, and the joints are filled with a filler such as concrete or mortar to be integrated. The vertical joints between the outer wall panels are stored by connecting the ends of the horizontal reinforcing bars protruding from both outer wall panels by butt-joining in the sleeve joint and performing mortar injection into the sleeve joint. Fill the joints with concrete to integrate them. In addition to ordinary concrete, expanded concrete, non-shrinkable concrete, superfluid expansive concrete, etc. are used for this filling concrete to improve workability and control dry cracks. In addition, the horizontal joints between the outer wall panels can be accommodated by connecting the ends of the vertical reinforcing bars of the upper and lower outer wall panels by abutting them in the sleeve joint and performing mortar injection into the sleeve joint. Part is spread and mortar is filled and integrated.

Next, the panel joint type caisson according to a seventh aspect of the present invention is a prefabricated outer wall panel in which the internal skeleton also manufactured in the factory is assembled on the bottom slab manufactured in the factory. Is attached to the outer wall portion of the internal skeleton. In short, the manufacturing process is basically prefabricated and unitized. The bottom slab is configured as a composite slab in which concrete is cast into a steel plate material to be integrated, or a reinforced concrete plate, and the internal skeleton is configured as a steel frame member or a steel plate or a steel structural skeleton formed by a combination of both. The outer wall panel is configured as a composite plate in which steel plates are placed on the inner surface and concrete is integrated into it, or a PC plate in which PC steel wires are placed in the concrete for reinforcement, or as a precast concrete panel (prefabricated panel) for reinforced concrete platemaking. It

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, illustrated embodiments of the present invention will be described.
FIG. 1 shows each constituent element of a panel joint type caisson manufactured by the method of the present invention in an exploded state, and FIG. 2 shows an example of a structural concept at an intermediate stage of assembling the panel joint type caisson. In FIG. 1, on the upper surface of the steel plate material 1 ′ that constitutes the bottom slab, a steel plate frame 1 a that forms a lower fixing part for later assembling an internal skeleton and a concrete that is placed later are strengthened in an integrated connection. It shows a configuration in which rib steel plates 1b, which also serve as a reinforcing member, are arranged and provided in a grid pattern. Moreover, this steel plate material 1'is shown as being manufactured by dividing it into two blocks of appropriate size. The internal steel frame is also manufactured by dividing it into two right and left steel frame blocks 2 and 2 and preparing steel frame members 23 and 24 for connecting the two steel frame blocks. An example of the size of the caisson shown in FIG. 2 is that the bottom plate 1 has a width of 7.5 m, a length of 25 m, and a height of 9.1 m.

As can be seen from FIG. 2, in the method for manufacturing a panel joint type caisson, an inner skeleton 2 is assembled on a concrete bottom slab 1, and an outer wall panel which is already formed on the outer wall portion of the inner skeleton 2. It is carried out in the procedure of attaching 3. The bottom plate steel sheet material 1 ′ is manufactured in a factory in consideration of ensuring overall rigidity, and then transported to a caisson manufacturing yard. In the internal skeleton 2 of the illustrated example, the H-shaped steel columns 20 ... Standing vertically with a predetermined span are firmly connected to each other by a girder 22, a diagonal member 23, a beam 24, etc., which are also manufactured by processing a steel material. It has a steel structure.

In FIG. 3, the bottom plate steel sheet material 1'manufactured in the factory in consideration of the overall rigidity and the like as described above is placed on the pontoon 4 and towed by the towing ship 5 to a predetermined assembly position (the caisson manufacturing yard). ) Shows the state of transporting to. Symbol 1 in the figure
6 is a tug. Internal skeleton 2 also manufactured at the factory
Again, as shown in FIG. 4, it is placed on the pontoon 4, towed, and transported to a predetermined assembly position. The assembling position (caisson manufacturing yard) is selected as a site where the caisson is laid down, or a place near the manufacturing plant or the site where the caisson is laid down. The steel plate material 1'of the bottom plate that has been transported to the assembly position is unloaded by the hoisting tool 6 and the crawler crane 7 that are prepared in advance as shown in Fig. 5, and then transported as it is to the assembly place on the ground as shown in Fig. 6. Be done. When the steel plate material 1 ′ is manufactured in blocks, the blocks are arranged side by side in a predetermined arrangement when they are carried, and the integration work is advanced. After that, as shown in Fig. 7, steel plate material 1 '
The mold 8 is temporarily installed in the lower fixing portion 11 of the internal skeleton 2 assembled on the (bottom plate), the concrete pump 9 is operated, and the concrete 17 supplied by the agitator 10 is placed to complete the bottom plate 1. To do.

On the other hand, as shown in FIG. 4, the internal skeleton 2 transported from the factory by a barge 4 is also landed by using a lifting tool and a crawler crane, as in FIGS. Then, after the concrete 17 has been cast into the steel plate material 1 ′, as shown in FIG. 8, the internal skeleton 2 is placed on the lower fixing portion 11 of the bottom plate 1 by using a crawler crane 7 or the like. The work of assembling is sequentially performed, and the W point is joined by welding.

Subsequently, as shown in FIG. 9, the outer wall panel 3 is attached to the outer wall portion of the internal skeleton 2 by using the crawler crane 7 and the phase suspension method using the main hook 12 and the auxiliary hook 13. . For details of the internal frame 2 and outer wall panel 3 mating structure and joints
This is shown in FIGS. 10 and 11. FIG. 10 shows details of the vertical joint portion. A joint steel plate 25 is attached to the flange portion of the H-shaped steel column 20 forming the internal skeleton 2 by welding so as to be flush with the outer surface of the flange by the gusset 21.
Both ends of the jointed steel plate 25 and the protruding portions of the inner steel plate 30 of the outer wall panel 3 manufactured as a composite plate are butted against each other,
The W point is joined by welding to form a considerably large joint gap. The outer wall panel 3 manufactured as a composite plate is
Concrete 33 with studs 50 standing on the inner steel plate 30
Integral with the concrete, horizontal concrete 31 vertical concrete 3
It is reinforced with 2. Further, the studs 51 embedded in the concrete are projected toward the joint space to be integrated with the filled concrete 40. Similarly, toward the joint space, the flange of the H-shaped steel column 20 and the joint steel plate 2
The stud 52 is also set up in the 5 and the filled concrete 40
Is being integrated with. In FIG. 10, the left outer wall panel 3A is attached in advance, and the right outer wall panel 3A is attached.
When the procedure of attaching B later is performed, the horizontal reinforcing bars 31 protruding from the side edge portions of the outer wall panels 3A, 3B are connected to the horizontal reinforcing bars 31 of the left outer wall panel 3A in advance in order to connect them with the sleeve joint 15. Attach the sleeve joint 15 and move it to the left side as much as possible. Then, after suspending and mounting the outer wall panel 3B on the right side, each sleeve joint 15 is moved toward the corresponding right horizontal reinforcing bar so that both horizontal reinforcing bars 31 are evenly inserted in the right and left positions. To do. In this state, the mortar 18 is injected into the hollow portion of the sleeve joint 15 and fixed. After that, the formwork 19 is assembled in the vertical joints so as to extend over the outer surfaces of both outer wall panels 3A and 3B, and concrete 40 (normal concrete, expansive concrete, non-shrink concrete, superfluid expansive concrete, etc.) is filled. To join together.

Next, FIG. 11 shows details of the lateral joint portion. The work order is such that the lower outer wall panel 3D is attached first, and then the upper outer wall panel 3C is attached in a stacking manner. The upper end of the vertical reinforcing bar 32 protruding from the upper edge of the lower outer wall panel 3D is left as it is, and the end of the vertical reinforcing bar 32 that should protrude to the lower edge of the upper outer wall panel 3C has its lower end positioned at the same position as the panel lower edge. The sleeve joint 15 is embedded in the lower outer wall panel 3C, and is inserted into the hollow portion of the sleeve joint 15 for about half the length. When the upper outer wall panel 3C is suspended by a crawler crane, the mortar 41 is laid on the upper edge of the lower outer wall panel 3D in advance with a considerable thickness. Then, in the hollow portion of the sleeve joint 15, the corresponding vertical reinforcing bar 3 in the lower outer wall panel 3D is provided.
2. Stack so that the upper end of 2 is inserted. Thereafter, the mortar 18 is placed in the hollow portion of the sleeve joint 15.
Is injected and fixed, so that the upper and lower outer wall panels 3C, 3
D is integrally joined.

[0022]

According to the method for manufacturing a panel-jointed caisson according to the present invention, an existing bottom plate 1, an internal skeleton 2, which are separately processed and manufactured in advance in a factory at an assembly position such as a caisson manufacturing yard, Since the outer wall panel 3 and the outer wall panel 3 are sequentially assembled and manufactured like a building construction, the completed caisson has a structure similar to a so-called composite caisson or a hybrid caisson, which is a lightweight and high-strength caisson, which is convenient for use. Moreover, it does not require a large working yard in the assembly position.

Further, as a result of the caisson manufacturing being prefabricated and unitized, the rebar assembly work, concrete placing work, formwork assembly, dismantling work, etc., which were conventionally required at the site, are all omitted and labor is saved. Therefore, it is possible to shorten the construction period, and it is possible to carry out manufacturing in response to the shortage of skilled workers. Further, there is also an effect that the joint portion between the outer wall panels can be efficiently and firmly and easily accommodated by the method using the sleeve joint.

[Brief description of drawings]

1 is an exploded perspective view of structural elements of a caisson manufactured by the method of the present invention.

FIG. 2 is a perspective view showing a stage in the process of assembling a caisson manufactured by the method of the present invention.

FIG. 3 is a front view showing a towed state of a bottom plate (steel plate material).

FIG. 4 is a front view showing a towed state of an internal skeleton.

FIG. 5 is a front view showing a landing state of a towed bottom plate (steel plate material).

FIG. 6 is a front view showing an installed state of a bottom plate (steel plate material) that has been landed.

FIG. 7 is a front view showing a state of placing concrete on a steel plate material.

FIG. 8 is a front view showing an assembled state of the internal skeleton.

FIG. 9 is a front view showing an attached state of an outer wall panel.

FIG. 10 is a horizontal cross-sectional view showing a structure for accommodating a vertical joint portion of an outer wall panel.

FIG. 11 is a vertical cross-sectional view showing a storage structure of a lateral joint portion of an outer wall panel.

[Explanation of symbols]

 1 Bottom plate 2 Internal skeleton 3 Exterior wall panel 31 Horizontal rebar 32 Vertical rebar 15 Sleeve joint 18 Mortar 40 Filled concrete 41 Floor mortar

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yutaka Kameyama 5-57 Kita Nakatsu Dori, Naka-ku, Yokohama City Ministry of Transport Second Port Construction Bureau (72) Inventor Ryo Kiyomiya 3-1-1 Nagase, Yokosuka City, Kanagawa Prefecture Port Research Institute of Ministry of Transport

Claims (8)

[Claims] 1. A bottom slab, an internal skeleton, and an outer wall panel are separately manufactured in a factory, respectively, and the bottom slab, the inner skeleton, and an outer wall panel are transported to a predetermined assembly position, and the inner skeleton is assembled on the bottom slab at the same position. A method for manufacturing a panel-jointed caisson, which comprises the step of attaching an existing outer wall panel to the outer wall portion of the inner skeleton. 2. The bottom slab is manufactured as a composite slab in which concrete is cast into a steel plate material and integrated, or as a reinforced concrete plate, and the internal skeleton is manufactured as a steel frame member or a steel plate or a steel structure skeleton by a combination of both. The outer wall panel is pre-manufactured in the factory as a precast concrete panel of a composite plate in which a steel plate is arranged on the inner surface and concrete is integrated with it, or a PC plate in which PC steel wire is arranged in the concrete for reinforcement, or a reinforced concrete plate. The method for manufacturing a panel-bonded caisson as set forth in claim 1, wherein these are carried to an assembly position and assembled. 3. The synthetic bottom slab is manufactured by integrally manufacturing a steel plate material in advance at a factory and then transporting it to the next assembling position, or transporting a steel plate material block produced by making a block at the factory to the assembling position, and then removing each block. After assembling them into one piece, the steel sheet material is then cast into concrete to manufacture it, and after the concrete casting is finished, the steel frame members etc. processed in the factory are assembled, or the blocks are pre-blocked and transported in the factory. The method for manufacturing a panel joint type caisson according to claim 1 or 2, wherein the internal skeleton is assembled by a method of assembling the steel block. 4. The joint portion between the outer wall panels attached to the outer wall portion of the internal skeleton is accommodated by connecting the ends of the reinforcing bars projecting from the outer wall panel by abutting and connecting them in the sleeve joint. The method for producing a panel-bonded caisson according to claim 1, wherein mortar injection is performed, and the joint portion is filled with a filler to be integrated. 5. The vertical joint portion between the outer wall panels attached to the outer wall portion of the internal skeleton is accommodated by connecting the ends of the horizontal reinforcing bars protruding from both outer wall panels by abutting and connecting them in a sleeve joint. The method for producing a panel joint type caisson according to claim 1 or 4, wherein mortar is injected into the joint, and the joint portion is filled with concrete to be integrated. 6. The storage of the lateral joints between the outer wall panels attached to the outer wall portion of the internal skeleton is performed by connecting the ends of the vertical reinforcing bars of the upper and lower outer wall panels in a sleeve joint, and connecting them. The method for manufacturing a panel-bonded caisson according to claim 1 or 4, characterized in that mortar is injected into the lacquer and the lateral joints are filled with spread mortar for integration. 7. A construction in which an internal skeleton also produced in the factory is assembled on a bottom slab produced in the factory, and an existing outer wall panel produced in the factory is attached to an outer wall portion of the internal skeleton. A panel-jointed caisson characterized by that. 8. The bottom slab is configured as a composite slab in which concrete is poured into a steel plate material and integrated, or a reinforced concrete plate, and the internal skeleton is configured as a steel frame member or a steel plate or a steel structural skeleton made of a combination of both. The outer wall panel is configured as a precast concrete panel for a reinforced concrete plate, or a composite plate in which a steel plate is placed on the inner surface and concrete is integrated with it, or a PC plate in which PC steel wire is placed in the concrete for reinforcement. The panel-bonding type caisson according to claim 7, wherein