JPS6248028B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing and a formwork for constructing concrete structures.

For more details, see concrete foundations for fixing the legs of steel towers, retaining walls, bridge abutments and piers, for construction, for civil engineering,
This article relates to methods for manufacturing concrete structures used in other construction projects, and formwork for construction.

The conventional manufacturing method for concrete structures is to use unit formwork such as wood panels, iron or synthetic resin as concrete formwork, assemble it into the desired shape, and then pour concrete into the formwork. However, the drawback is that assembling and removing these formworks at the construction site requires a great deal of effort, and especially the creation and assembly of formworks with complex shapes requires skilled workers. There was a problem in that the formwork required transporting a large amount of materials to the construction site to create the formwork, which increased transportation costs.

In particular, construction work such as new construction or renovation of power transmission line towers that transport electricity is more often carried out in mountainous areas than in flat areas, and in particular, construction of high-voltage power transmission line towers is extremely often carried out in remote mountainous areas. Therefore, it is extremely difficult to transport the necessary materials for the construction work, and as it is usually almost impossible to transport them from the ground, the current situation is that material transport relies on aerial transport such as helicopters. In addition, the construction of these steel towers is the same as that of flat land, starting with the transportation of materials, excavation of the ground,
Casting waste concrete, forming frameworks with complex shapes,
A great deal of labor and time is required for pouring concrete, removing formwork, backfilling, caring for recovered formwork, and transporting it to the next construction area.

The inventors of the present invention have carried out various researches to solve the above-mentioned drawbacks, and as a result, they have developed a method for manufacturing concrete structures that is inexpensive, uses lightweight formwork materials, and is extremely easy to construct. Submitted the issue. That is, in the manufacturing method of the product, (a) a cage-like frame is made, then (b) a sheet or film is provided around the outer periphery of the frame to form a formwork, and (c) concrete is poured into the formwork. We proposed a manufacturing method for a completely new structure.

However, it has been found that this patent application has a relatively complicated problem, particularly when providing a sheet or film around the outer periphery of the cage-like frame, and it is desirable to improve the construction.

In this patent application, for example, the diameter of the uppermost member of the cage-like frame is the same as the diameter of the lower member in contact with the ground, and the center axis of the frame is perpendicular to the horizontal ground, and is cylindrical or square. In the case of columns, etc., the connecting members connecting the upper and lower members can be installed in parallel positions.
It is relatively easy to wrap both ends of the sheet or film in the longitudinal direction (width) around the outer periphery of the frame approximately parallel to the plane (substantially horizontal) that constitutes the upper or lower member of the frame. It's easy to do. In other words, if the cage frame is cylindrical or prismatic,
The frame must have mechanical strength that can withstand the lateral pressure caused by concrete placement, and a state that prevents leakage and seepage of poured concrete and moisture, with no gaps between the stacked sheets or films. It is relatively easy to wind multiple sheets or films in such a tight and airtight state. However, if the diameter of the upper member of the cage-like frame is different from the diameter of the lower member, for example, the shape is a truncated cone, or the central axis of the cage-like frame is inclined to the horizontal ground. For example, in the case of a frame in the shape of a rotating body with a trapezoidal cross section, the connecting members that connect the upper member and the lower member cannot be installed in parallel positions with respect to the central axis of the frame. When wrapping both longitudinal ends of a wide sheet or film around the outer periphery of a frame having such a shape, approximately parallel to the plane (approximately horizontal) constituted by the upper or lower member of the frame, the lower member One longitudinal end of the film on the side can be brought into close contact with the outer periphery of the frame, but the other end of the film on the upper member side is shorter than the outer periphery of the frame on the lower member side, so A space is created at a considerable distance from the outer periphery of the frame. This problem is particularly common with wide sheets or films that have poor flexibility. For this reason, in order to continuously overlap one end of the sheet or film on the lower member side that has been previously wound around the outer periphery of the frame, for example,
It has been found that it is a relatively complicated problem to wind the sheet or film multiple times so that one end of the spirally wound sheet or film on the upper member side is in close contact with the other end.

As mentioned above, the present inventors have discovered the comparative problems encountered when providing a sheet or film on the outer periphery of a cage-like frame in the case of a rotating body having a truncated conical shape, a truncated pyramidal shape, a trapezoidal cross section, etc. As a result of intensive research in order to further simplify the complicated problem of They have discovered that the problem can be solved all at once, and have completed the present invention.

That is, the present invention provides the following steps: a. A basket-shaped frame is made; b. An outer frame made of synthetic resin or inorganic fiber-reinforced concrete reinforced with a metal mesh is provided around the outer periphery of the frame to form a form; c. A method for manufacturing a structure, characterized in that: d) the outer frame is combined with the concrete to form at least a part of the outer surface of the structure, by pouring concrete therein and curing it; , a formwork for a structure, in which the outer periphery of the basket-shaped frame is made of: a) an outer frame made of synthetic resin or inorganic fiber-reinforced concrete reinforced by incorporating a metallic net; b) an outer frame made of poured concrete; A formwork for a structure, characterized in that it is provided with an outer frame having a smooth surface that is combined with the concrete upon hardening to constitute at least a part of the outer surface of the structure.

The present invention has the following features: 1. The cage-like frame has a structure that can be easily made from lightweight materials, and is reinforced by incorporating a metal net around the outer periphery of the cage-like frame (hereinafter simply referred to as "metallic mesh"). (sometimes abbreviated as "reinforced with fiberglass net"), it can be made into a formwork extremely easily by simply installing an outer frame made of synthetic resin or inorganic fiber reinforced concrete, and does not require any skilled workers. . 2. If necessary, the formwork can be made at the construction site, or the pre-made formwork can be transported and used, but the materials used for this can be the same as in the case of conventional panel assembly formwork, etc. It is significantly cheaper and smaller in quantity than the conventional method, and is also lightweight, so material costs and transportation costs can be greatly reduced. 3. In the conventional method, it is necessary to remove the formwork and finish the surface of the structure after pouring concrete into the formwork, but with the manufacturing method of the present invention, the surface of the structure has strength, durability, and smoothness. The outer frame is made of synthetic resin or inorganic fiber-reinforced concrete, reinforced with a highly durable metal mesh, so there is no need for surface finishing. The present invention provides a manufacturing method and formwork.

The cage-like frame in the present invention is formed using a frame in which plate-shaped, tubular, linear, etc. frame forming materials are connected or tied together and reinforced as necessary. It has a structure that can maintain the necessary shape as a structure. Also,
The frame can take any shape depending on the shape required for the structure, such as a cylindrical shape, an elliptical cylinder shape, a prismatic shape, a polygonal truncated pyramid shape, a truncated conical shape, a truncated elliptic conical shape, etc. I can give an example.

Materials for forming the cage-like frame include metals,
Synthetic resins, wood, concrete, etc. can be used without difficulty. Moreover, two or more of these materials can also be used in combination. The material is not particularly limited as long as it has the strength to allow the cage-like frame to maintain the desired shape as a structure, but it is subject to processability and workability when manufacturing the frame. For example, iron,
Preferably, metals such as brass, copper, aluminum and stainless steel are used. Further, the shape of the material forming the cage-like frame may be any shape such as plate, rod, wire, or tube, and there is no problem in using two or more of these materials in combination, and there are no particular limitations. It's not something you can do.

In the present invention, the outer frame made of synthetic resin or inorganic fiber-reinforced concrete reinforced with a metal net has any shape necessary for a desired structure and can cover a cage-like frame, for example, Made of synthetic resin reinforced with a hollow metallic mesh such as cylindrical, elliptic cylindrical, prismatic, polygonal truncated pyramid, truncated conical, and truncated elliptic cone, or made of synthetic resin reinforced with a metallic mesh, or An outer frame made of inorganic fiber-reinforced concrete, which has the strength to withstand the lateral pressure generated by the concrete when concrete is poured into the outer frame, and maintain the desired shape of the structure. Once the concrete has hardened, it forms the outer surface of the structure and is the frame to which it comes together.

The synthetic resin in the present invention is not particularly limited as long as it has properties such as strength and cohesion as described above, but examples of thermosetting resins include polyester resin, epoxy resin, and phenol resin. , melamine resins, xylene resins, toluene resins, and mixtures or co-condensed resins thereof, and examples of thermoplastic resins include vinyl chloride resins, vinyl acetate resins, acrylic resins, polyethylene resins, polypropylene resins, Examples include polystyrene resins, and mixed or copolymer resins thereof.

The inorganic fiber-reinforced concrete in the present invention refers to a cured product of a composition comprising inorganic fibers, inorganic cement, water, and, if necessary, aggregate such as sand and/or gravel. self-hardening cements such as cement, aluminum cement, expansive cement, and calcined gypsum; latent hydraulic cements such as lime slag cement, blast furnace cement, high sulfate slag cement, and Keens cement; and lime-silicate mixed cements, etc. There are mixed cements, and as the inorganic fibers, artificial or natural inorganic fibers such as glass fibers, metal fibers, rock fibers, slag fibers, asbestos, etc. are used, but glass fibers are preferable from the viewpoint of reinforcing effect, and the most preferable. Preferably, alkali-resistant glass fibers can be used.

In the present invention, the metal net refers to one knitted with metal wire, punched metal, metal lath boat, etc., and the material having a rope-like structure is iron, brass,
It is made of copper, aluminum, stainless steel, etc. The material of the metal rope and the size of the rope structure are not particularly limited, and the shape, size, and purpose of the outer frame made of synthetic resin or inorganic fiber reinforced concrete reinforced with the metal rope, etc. Considering this, depending on the mechanical strength to be reinforced, wire mesh made of the same material or other types of wire mesh may be selected and used in combination, or one wire mesh or two or more wire meshes may be used. However, in general,
The material is iron, and the wire mesh has a mesh size of 10 to 50 on each side.
For metal lath boards, those with a mesh length of 30 to 150 mm and a width of 10 to 50 mm can be conveniently used. The outer frame made of synthetic resin or inorganic fiber-reinforced concrete reinforced with these metal nets can be made thinner to about 50% or less of the thickness of a conventional outer frame due to the reinforcing action of the metal net. It is extremely lightweight and has the advantage of being easy to transport, and the thickness of the outer frame is especially 10 mm.
The following may be advantageously used:

The synthetic resin outer frame reinforced with a metal mesh according to the present invention can be molded into any desired shape as described above using ordinary molding techniques. for example,
A metal mesh is placed near the inner wall of a mold with a shape suitable for giving the shape of the outer frame, and then a synthetic resin material is added and then molded. A method of forming an outer frame with a plurality of metallic meshes in it using a mold, and then combining or joining the divided outer frame parts to form an outer frame; Examples include a method of cutting a resin plate into a predetermined shape and then gluing or fusing the cut portions to form an outer frame.

The synthetic resin outer frame reinforced with the metal mesh mentioned above may be made of inorganic fibers, especially polyester resin, acrylic resin, vinyl chloride resin, etc. reinforced with glass fiber, as it is lightweight and has excellent strength and durability. It is preferable to use an outer frame made of glass fiber-reinforced synthetic resin reinforced with metal netting, but among these, glass fiber-reinforced polyester reinforced with metal netting (hereinafter referred to as " It is particularly preferable to use an outer frame made of FRP (sometimes abbreviated as "FRP").

The raw materials for this polyester resin are mainly unsaturated dibasic acids, saturated dibasic acids, dihydric alcohols,
Vinyl monomers are generally used, and the properties of the resin, curing characteristics, properties of the cured product, etc. can be adjusted by combining the type and amount of vinyl monomers. Examples of unsaturated dibasic acids include maleic anhydride and fumaric acid; examples of saturated dibasic acids include phthalic anhydride, isophthalic acid, terephthalic acid, tetrahydrophthalic anhydride, adivic acid,
Sebacic acid, 3,6 endomethylenetetrahydrophthalic anhydride, etc., and dihydric alcohols include ethylene glycol, diethylene glycol, 1,
2-propylene glycol, dipropylene glycol, hydrogenated bisphenol A, 2,2-bis(4
-oxyethoxyphenol)propane, 2.2
-bis(4-oxypropioxyphenyl)propane, etc., and as the vinyl monomer, styrene, vinyltoluene, dialphthalate, methyl methacrylate, triallylcyanuric acid, triallylphosphoric acid, etc. are used.

Further, the glass fiber is not particularly limited, and as long as it is generally commercially available for FRP, one type or a combination of two or more of these materials can be used. These materials are generally 3 to 35 micron roving, roving cloth, tip strand pine, tip strand, grass cloth, laminated pine, etc., depending on the molding method and the strength required for the molded product. However, the thinner the fineness, the higher the strength, the better the flexibility and abrasion resistance, and the better the impregnability of the polyester resin, so it is preferable to use a thinner one.

Molding methods for molding the outer frame of the present invention from the above-mentioned polyester resin raw materials, glass fibers, and metal mesh include the Primix method, the matte die method, the hand lay-up method, the spray-up method, the filament winding method, and the resin method. There are various methods such as the injection molding method, but for example, the hand lay-up method is used to form a cylindrical outer frame. After applying a thin layer of mold release agent (manufactured by Koshin Chemical Co., Ltd., trade name Ponlease H), liquid polyester resin (manufactured by Hitachi Chemical Co., Ltd.) is applied.
Methyl ethyl ketone peroxide curing agent (manufactured by Nippon Oil & Fats Co., Ltd., trade name Permeck N) is 1% by solubility in relation to Polyset PS-2182APT-S (trade name: Polyset PS-2182APT-S).
A glass fiber mat (manufactured by Nitto Boseki Co., Ltd., Chip Strand Mat MC450A) having a predetermined size is impregnated with the mixed solution at 450 g/ ^m2 , and then applied to the surface of the mold. A sheet of iron wire mesh with a wire diameter of 1.0 mm and a mesh size of 10 x 10 mm is placed on top, and the glass fiber mat is rolled together with the wire mesh to defoam. After defoaming, a glass fiber mat impregnated with liquid polyester resin and a hardening agent is further layered, and laminated to a thickness of, for example, 3 mm, depending on the desired strength after molding, using a similar rolling operation. After lamination,
Leave it at room temperature for about 2 hours, remove it from the stainless steel mold after hardening, and make a gutter-shaped 2 with a smooth outer surface and a semicircular cross section.
You can create a divided outer frame. This FRP
Two frames can be combined and used as a hollow cylindrical outer frame.

The outer frame made of inorganic fiber-reinforced concrete reinforced with a metal mesh according to the present invention can also be formed into any desired shape as described above using ordinary forming techniques. The spray-up method, hand-lay-up method, primix method, and other methods are used to form the outer frame. A mold release agent for glass fiber reinforced cement (manufactured by Chemiskus Kogyo Co., Ltd.: trade name Chemiskus WS) is placed on the surface of a stainless steel plate mold.
After applying a thin layer of 1.2 mm wire diameter and a hexagonal mesh structure (major axis 15 mm), a piece of iron wire mesh was placed on top of it, and on top of this, 100 parts by weight of cement, about 60 parts by weight of sand, and about 35 parts by weight of water were placed. Mixed cement mortar and alkali-resistant glass fiber (manufactured by Asahi Glass Co., Ltd.: product name)
cem-FIL roving) was cut into 25 to 40 mm pieces, sprayed with 3 to 7% by weight based on the weight of the cement mortar while mixing using two spray guns, rolled, and defoamed. Depending on the desired strength after molding, the same process of spraying cement mortar and glass fibers is repeated to form layers to a thickness of, for example, 3 mm. Once the desired thickness has been reached, leave it at room temperature for about 24 hours to harden, then remove it from the stainless steel mold and form a gutter-shaped 2 piece with a smooth outer surface and a semicircular cross section.
You can create a divided outer frame. The frame made of glass fiber reinforced concrete having a two-part shape thus created can be used as a hollow cylindrical outer frame by combining two pieces.

The shape of the outer frame in the present invention depends on the desired shape of the structure as described above, for example, cylindrical, elliptical cylindrical, prismatic, polygonal truncated pyramid, truncated conical, truncated pyramid, etc. Although it can be easily formed into any shape using the method described above, in order to firmly bond the concrete within the outer frame and prevent separation as much as possible, it is necessary to Preferably, the ribs or joints are provided in the axial direction, ie in the direction from the bottom to the top of the outer frame. By providing the ribs or the joints on the inner wall of the outer frame, the outer frame is mechanically reinforced, which not only reduces the amount of materials used to manufacture the outer frame, but also prevents the ribs or the joints from digging into the concrete. As a result, the outer frame is more firmly bonded to the concrete. For example, in the case of an outer frame made of FRP, small particles of inorganic substances such as sand or alkali-resistant glass fibers may be sprayed or sprinkled on the inner wall of the outer frame before the polyester resin hardens when the outer frame is made. to make the inner wall uneven,
It is also preferable to establish a strong bond with concrete. Furthermore, if the outer frame has a sharp edge, it is likely to be damaged when it receives some external force, so it is better to have an inwardly curved edge at the top of the outer frame. This is preferable as the shape of the outer frame in terms of strength as well.

The outer frame made of synthetic resin or inorganic fiber-reinforced concrete reinforced with a metal mesh according to the present invention is constructed as a part of the surface of the structure as follows.

When constructing a structure, for example, a foundation structure or a structure for fixing the legs of a steel tower, on-site, the ground is first excavated and a borehole is created, then the desired position at the bottom of the borehole is A cage-like frame is made at the location and the frame is fixed by simple installation, and then concrete is poured into the bottom of the excavation hole and a part of the bottom of the cage-like frame to harden it. After the concrete has hardened, the top of the cage-like frame is aligned with the top of an outer frame made of synthetic resin or inorganic fiber-reinforced concrete reinforced with a metal net, and the outer periphery of the cage-like frame is covered with the outer frame. Cover formwork. After that, concrete is poured into the formwork from the top opening of the outer frame, hardened, and the outer periphery is reinforced with a metal net to create an outer frame made of synthetic resin or inorganic fiber reinforced concrete. can do.

Further, the outer frame may be composed of one outer frame made of synthetic resin or inorganic fiber reinforced concrete reinforced with a hollow cylindrical metal mesh, or two or more individual outer frames may be used as necessary. The frame may be used by suitably connecting the frame in the axial direction, circumferential direction, etc. of the frame.

Hereinafter, the present invention will be explained in detail with reference to an embodiment shown in FIG. 1, but the present invention is not limited to this embodiment.

Structure for fixing the legs of high-voltage power transmission line towers (10° inclination, truncated conical shape, upper diameter 0.6 mφ, lower diameter 1.5 m
φ, height 2.5m), first excavate the target ground to a depth of 2.2m and create excavation hole 1. A concrete block 12 is provided at the bottom of the excavation hole, a steel tower support material cat 3 is placed on it, and a steel tower support 2 is placed on top of it at an inclination angle of 10° and fixed with a shoring 4. Next, the frame forming upper member 5 and the frame forming lower member 6 (30 m/mL type steel) are positioned and fixed at a height of 2.5 m above and below the tower support 2 as the center. The frame-forming upper member 5 and the frame-forming lower member 6 are provided with 12 connecting member bonding parts 8 at regular intervals for connecting the connecting members 7 to form a cage-like frame.
(3.2m/mφ steel wire) was tied under tension. Connecting member 7 in the cage-like frame created in this way
Furthermore, in order to have sufficient strength against the lateral pressure during concrete pouring, the frame forming upper member 5 is
Intermediate holding members 9 (6 m/mφ steel rods) are set at three locations in the middle portion of the lower frame forming member 6 to reinforce and retain the shape of the connecting member 7. Next, sacrificial concrete 10 is placed. When the waste concrete hardens, it has a hollow truncated conical shape with a chamfered top, an upper diameter of 0.6 mφ, a lower diameter of 1.5 mφ, and a height of 2.5 m.
The outer frame 11 is made of glass fiber reinforced concrete with a thickness of 2.5 mm, which is reinforced by inserting one iron wire mesh with a wire diameter of 1.2 mm and a hexagonal mesh structure (major diameter of 15 mm) in both the vertical and horizontal directions. It is made by combining a total of four frame parts divided into two parts, and the top part of the outer frame 1 is placed at the same height as the frame forming upper member 5 at the top part of the cage-like frame, so that the whole cage-like frame is assembled. cover.

Next, make sure that the concrete to be poured does not leak from the gap between the bottom of the outer frame and the concrete.
Outer frame 11 made of glass fiber reinforced concrete reinforced by incorporating iron wire mesh after being sealed
Pour concrete into the formwork from the top opening of
The structure was completed by backfilling to the ground level before excavation.

The structure for fixing the steel tower legs constructed as described above uses steel or iron wire mesh as an internal material, compared to the conventional wood panel construction method or the unit form construction method, which uses steel or synthetic resin. It is a material with a simple shape, such as a thin glass fiber-reinforced concrete outer frame reinforced with concrete, and it is extremely easy to transport because it is small and lightweight. .

In addition, the creation of the cage frame, formwork, and shoring work are extremely easy and light work, especially when wrapping the sheet or film around the outer periphery of the cage frame using conventional methods. A considerable amount of time and effort was required to prevent leakage and oozing of cement, etc., which is wrapped around the mold and cast, but the present invention does not require this effort, so the labor and time required to create the formwork are lower than that of the conventional method. In addition, we were able to complete the structure for fixing the legs of a high-voltage power transmission line by burying the legs in the excavated hole below the ground level, which is not necessary with conventional methods. Disassembly and removal of formwork,
The labor and time required for cleaning the collected formwork, transporting it to the next construction area, etc. were completely unnecessary.

Furthermore, compared to structures manufactured using conventional methods, the strength of the structure of the present invention is completely satisfactory, with no inferiority, and in particular, the strength of the structure made of glass fiber reinforced concrete reinforced with metal netting is excellent. As a result of its use, it not only strongly integrated with the poured concrete but also exhibited an excellent appearance.

As described above, compared to conventional construction methods for structures, the present invention does not require skilled workers for construction, and it is possible to easily construct a structure with an arbitrary shape and an aesthetic appearance in a short time. It also has many features in terms of transportation, such as minimal formwork materials and no need to remove the formwork, and is extremely innovative as a manufacturing method for leg structures of power transmission towers, especially in remote mountainous areas. , and its industrial significance is extremely large.

[Brief explanation of the drawing]

FIG. 1 is a schematic sectional view showing an embodiment of the method for manufacturing a structure according to the present invention. 1... Excavation hole, 2... Steel tower support, 3... Steel tower support material cat, 4... Shoring, 5... Frame forming upper member, 6... Frame forming lower member, 7... Connecting member, 8
...Connection member connecting portion, 9...Intermediate holding member, 10
...Discarded concrete, 11...Outer frame made of glass fiber reinforced concrete reinforced with metal mesh, 12...
...Concrete block.

Claims (1)

[Claims] 1. A basket-shaped frame is made, and b. An outer frame made of synthetic resin or inorganic fiber-reinforced concrete reinforced by incorporating a metal net is provided around the outer periphery of the frame to serve as a formwork. , c. By pouring concrete into it and hardening it, d. Integrating the outer frame with the concrete to form at least a part of the outer surface of the structure. . 2. The method for manufacturing a structure according to claim 1, wherein the structure is a basic structure of a building. 3. The method for manufacturing a structure according to claim 1, wherein the structure is a structure for fixing the legs of a high-voltage transmission line tower. 4 Formwork for a structure, which is a basket-shaped frame with a) an outer frame made of synthetic resin or inorganic fiber-reinforced concrete reinforced by incorporating a metal mesh, and b) an outer frame made of poured concrete. 1. A formwork for a structure, comprising: an outer frame having a smooth surface that is combined with the concrete upon hardening to constitute at least a part of the outer surface of the structure.