JP7262193B2 - lightweight self-supporting wall - Google Patents

Description

Article 30, Paragraph 2 of the Patent Act applies December 25, 2017 Published on the website of Matsuoka Industry Co., Ltd.

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight self-supporting wall employing a lightweight foam material and a construction method for the lightweight self-supporting wall. Furthermore, it is possible to easily construct curved self-supporting walls, which were previously difficult to construct due to reasons such as the time required for construction. The present invention relates to a method for constructing a self-supporting wall and a lightweight self-supporting wall.

Concrete walls (self-supporting walls including concrete block walls) are generally known, but there have been reports of personal injury such as collapse of these walls when an earthquake occurs. As one direction for eliminating such damage, there is a movement to adopt self-supporting walls made of lightweight foam materials such as polystyrene foam instead of concrete fences. In addition to being easy to process, lightweight foamed materials are characterized by being extremely lightweight. It is equipped with safety such as being able to minimize the damage caused by

In Patent Document 1, the subject is "to provide a fence and a construction method of a fence having sufficient strength of the surface of the fence composed of expanded polystyrene panels and sufficient connection strength between the expanded polystyrene panels and the foundation" ( Patent Document 1: Abstract), a sheet made of a mesh material having many meshes is covered up to the panel and the foundation, an adhesive is applied between the panel and the foundation, and in this state the sheet is adhered and fixed to the panel and the foundation. Further, the adhesive is applied from the outer surface side of the sheet and the base so that the adhesive penetrates into the mesh of the sheet, and the sheet is fixed to the panel and the base in this state. By doing so, the panel, the foundation, and the sheet are fixed to each other and integrated (Excerpt from Patent Document 1: Summary: Solution) Fence, fence construction method (Patent Document 1: Title of the invention)” is disclosed. ing.

Japanese Unexamined Patent Application Publication No. 2012-021328

In the invention according to Patent Document 1, a through-hole is formed in the expanded polystyrene panel itself. By installing the panel while inserting the anchor bolts erected on the foundation into the through holes, in short, by fixing the styrofoam panel to the concrete foundation using the anchor bolts, the panel and the foundation It has a structure that can ensure the strength of connection with (Prior art: see FIGS. 1 and 2). Therefore, in comparison with the lightweight self-supporting wall according to the present invention, the extra step of drilling through holes in the styrene foam panel is extra labor and is not preferable in terms of manufacturing cost, and the styrene foam panel If a through hole (even if it is not penetrated by the length of the anchor bolt) is drilled in the panel, the strength of the panel itself will decrease, so it can be said that it is not preferable in terms of quality.

The object of the present invention is that the material itself can be easily bent, and the material itself can be easily processed to the extent that it can be cut with a cutter or the like. To provide a lightweight self-supporting wall which hardly causes human damage due to collapse or the like in the event of an earthquake and which is excellent in terms of manufacturing cost, and a construction method for the lightweight self-supporting wall.

In order to solve the above problem, the invention described in claim 1 is formed by forming a foundation of concrete or concrete blocks, and then arranging a plurality of lightweight panels made of a lightweight foam material using the foundation as a base. a lightweight self-supporting wall comprising: a plurality of lightweight panels installed on a concrete or concrete block foundation as a foundation; an adhesive for fixing said lightweight panels to said foundation; a deformed reinforcing bar provided, a mortar block body placed in a gap between the lightweight panel and the position where the deformed reinforcing bar resides, and surfaces and upper surfaces of both the outer surface side and the inner surface side of the lightweight panel. and a base coat layer applied to the foundation, the surfaces of both the exterior side and the interior side of the lightweight panel, and the mesh sheet layer attached to the foundation, and both the exterior side and the interior side of the lightweight panel. and a finish layer formed on the base , wherein the base coat layer, the mesh sheet layer and the finish layer integrate the base and the lightweight panel, and the adhesive is styrofoam and It is characterized by being mixed with cement.

The invention recited in claim 2 is characterized in that, in the invention recited in claim 1 , the lightweight panel is a lightweight self-supporting wall having a small window.

The invention recited in claim 3 is characterized in that, in the invention recited in claim 1 or 2, the lightweight panel is a lightweight self-supporting wall having a curved shape when viewed from directly above.

The invention recited in claim 4 is the invention recited in any one of claims 1 to 3 , wherein the finishing layer comprises any one of plastered walls, stones, bricks, and tiles on the surface of the base coat layer. It is characterized by being a lightweight self-supporting wall that is a layer formed by construction.

Another technical concept of the present invention is a lightweight self-supporting wall formed by forming a concrete or concrete block foundation, and then arranging a plurality of lightweight panels made of a lightweight foam material on the basis of the foundation. A step of vertically installing deformed reinforcing bars on a foundation at predetermined intervals, a step of installing between the deformed reinforcing bars by joining a plurality of the lightweight panels using the foundation as a base with an adhesive material, and the lightweight panel. and a step of filling and hardening mortar so as to bury the deformed reinforcing bars in the gaps between the lightweight panels; a step of applying a base coat to the entire surface of the lightweight panel and the foundation; A lightweight self-supporting structure characterized by comprising a step of installing a mesh sheet on the entire surface except the base and the foundation, a step of applying a base coat to the entire surface of the lightweight panel and the foundation from above, and a finishing step. It is characterized by being a construction method for a wall.

According to the lightweight self-supporting wall and the construction method of the lightweight self-supporting wall according to the present invention, the lightweight foam material used for the lightweight panel can be easily bent, so that it can stand on its own without much effort. The wall can be constructed in a curved shape and can be easily cut with a cutter, etc., so it is possible to flexibly respond to construction, such as adjusting the height with the boundary and installing a small window. It became possible to design a free-standing wall based on ideas.

The lightweight foam material used in the lightweight panel has excellent elasticity, and can prevent cracks and peeling of the finish layer (painted wall layer, etc.) due to earthquakes, etc., and it is a lightweight material. In addition, the risk of collapse in the event of an earthquake can be reduced. Conventional concrete self-supporting walls can only be constructed with a height of about 1.2 m (for safety reasons), but the lightweight self-supporting wall according to the present invention can only be constructed with a height of 3 m. It became possible to construct self-supporting walls up to about 5m.

Furthermore, when constructing a self-supporting wall using concrete or concrete blocks, it is necessary to process and assemble reinforcing bars, forms, etc., and because of its weight, construction costs are high. If it is a wall, there is no need to process and assemble reinforcing bars, formwork, etc., and it can be constructed at a low cost. Furthermore, since it is possible to construct the concrete wall as it is without dismantling the concrete wall, which was impossible in the past, it has become possible to construct the self-supporting wall without incurring unnecessary costs. .

1 is an overall front view of a lightweight self-supporting wall according to the present invention; FIG. It is an overall top view of the lightweight self-supporting wall. FIG. 4 is a top cross-sectional view of a lightweight self-supporting wall and a partially enlarged view; FIG. 4 is a diagram for explaining the performance of a lightweight self-supporting wall constructed in an extremely curved shape;

<Structure of lightweight self-supporting wall>
A lightweight self-supporting wall 10 according to the present invention will be described in detail below with reference to FIGS. 1 to 4. FIG. FIG. 1 is an overall front view of a lightweight self-supporting wall 10 according to the present invention. FIG. 2 is an overall top view of the lightweight self-supporting wall 10. FIG. FIG. 3 is a top cross-sectional view and a partially enlarged view of the lightweight self-supporting wall. FIG. 4 is a diagram for explaining the performance of a lightweight self-supporting wall constructed in an extremely curvilinear shape.

The lightweight self-supporting wall 10 according to the present invention is formed by forming a foundation of concrete or concrete block or the like, and then using the foundation as a base and arranging and installing a plurality of lightweight panels 20 made of polystyrene foam or the like. wall 10; As shown in FIG. 1, a plurality of lightweight panels 20 installed as foundations (existing concrete walls may be used) made of concrete or concrete blocks, and suspended between lightweight panels 20 and 20 A mortar block that is hardened after filling mortar so as to bury the deformed reinforcing bars 30 in the gap between the deformed reinforcing bars 30 and the lightweight panels 20 and the lightweight panels 20 (the deformed reinforcing bars 30 are included in the mortar block body 40). It has a body 40 .

The lightweight panel 20, which is the main member of the lightweight self-supporting wall 10, is made of foamed polystyrene or the like, and can be easily processed. The small window portion 80 of any size can be easily arranged simply by cutting it with a cutter or the like (see FIG. 1), and the construction in a curved line as shown in FIG. It is extremely easy in comparison with the law.

Furthermore, as shown in FIG. 3, the surface of the lightweight panel 20 has a base coat layer 50 (thickness of 2 mm to 3 mm), a mesh sheet layer 60 (thickness of 1.5 mm to 2 mm), and a finishing layer 70 (thickness of 3 mm). ~4 mm) (see Figure 3). In FIG. 3, only the upper part of the lightweight panel 20 cross section of the lightweight self-supporting wall 10 (constructed lightweight panel 20) is shown, and the base coat layer 50 is not shown, although the lower part of the lightweight panel 20 cross section and the foundation are not shown. (thickness 2 mm to 3 mm) is applied to the entire surface of the lightweight panel 20 and the foundation (which may be an existing concrete block fence), and the mesh sheet layer 60 (thickness 1.5 mm to 2 mm) is It is attached to the entire surface of the lightweight panel 20 except for the upper surface and the foundation (see the enlarged view of FIG. 3), and the finishing layer 70 (thickness 3 mm to 4 mm) is installed on the entire surface of the lightweight panel 20 and the foundation. there is

The base coat layer 50 is a base material for improving workability of the finishing layer 70 (in short, improving adhesion to the surface of the lightweight panel 20) before applying the finishing layer 70 to the surface of the lightweight panel 20. The mesh sheet layer 60 is a mesh material (mesh size The thickness can be selected according to the conditions during construction). Therefore, the mesh sheet layer 60 is installed in a state of being embedded inside the base coat layer 50 .

Expanded polystyrene (EPS) is mainly used as the material for the lightweight panel 20. A method for manufacturing expanded polystyrene will be briefly described here. The raw material of Styrofoam is polystyrene grains (beads) with a diameter of about 1 mm containing a foaming agent. These raw material beads are heated with steam to pre-expand (50 times the expansion ratio of normal Styrofoam). Pre-expanded beads are called expanded beads, each of which is separated by small air chambers (closed cells). Furthermore, the foamed beads are put into a mold or the like (in the present invention, it is necessary to have a space portion of the same shape as the lightweight panel 20) so that it has the shape of the product (the lightweight panel 20 in the present invention), and the mold is pressed again. By applying steam, the inflated foamed beads are fixed to each other by heat and formed into a styrene foam product (the lightweight panel 20 in the present invention). As the material for the lightweight panel 20 according to the present invention, a special polystyrene foam (expansion ratio of about 30), which is particularly flexible among polystyrene foams, can be used.

The material of the lightweight panel 20, even if it is not polystyrene foam, may be urethane foam, polystyrene foam which is more overload-resistant than polystyrene foam (formal name is polystyrene foam), or polyethylene foam which is more flexible and bendable than polystyrene foam. Foamed polypropylene or the like having impact resistance may also be used. The lightweight panel 20 has a thickness of 120 mm to 150 mm, a height of 1000 mm to 3500 mm, and a width of 1200 mm to 1600 mm.

FIG. 4 is a diagram for explaining the performance of the lightweight self-supporting wall 10 constructed in an extremely curved shape. The material adopted for the lightweight panel 20 according to the present invention is special polystyrene foam (expansion ratio of about 30 times), which is a particularly flexible material, and can be bent even in an extreme bending manner as shown in FIG. can. If an attempt is made to bend the lightweight panel 20 to the degree shown in FIG. 4 with ordinary polystyrene foam (expansion ratio of about 50), the lightweight panel 20 itself will break and break.

The most important point of the lightweight panel 20 is that the material itself used for the lightweight panel 20 can be greatly curved (see FIG. 4), and the material itself used for the lightweight panel 20 requires special tools. It can be easily processed to the extent that it can be cut with a cutter or the like. This feature enables free-thinking designs that cannot be imagined from conventional free-standing walls. In other words, with the conventional technology, if an attempt is made to construct a free-standing wall in a curved shape, there is no choice but to arrange concrete blocks with a width of about 30 cm so as to form a curved shape as a whole, which is extremely troublesome during construction. However, with the lightweight self-supporting wall 10 according to the present invention, it has become possible to easily construct a curved self-supporting wall, which was difficult due to reasons such as the construction being time-consuming.

<Construction method for lightweight self-supporting walls>
A construction method of the lightweight self-supporting wall 10 according to the present invention will be described. When constructing the lightweight self-supporting wall 10 according to the present invention, the existing concrete block foundation (the concrete block may be installed underground or may be a concrete block fence) or the existing foundation concrete (underground Using a vibrating drill or the like, drill holes of about φ30 mm (depth of about 200 mm) at intervals of 1200 mm to 1600 mm in the concrete (including foundation concrete). Deformed reinforcing bars 30 (φ16 mm to 19 mm) are inserted into the drilled holes one by one, and the gaps between the drilled holes and the deformed reinforcing bars 30 are filled by injecting a leveler to fill the gaps between the drilled holes and the deformed reinforcing bars 30 to form the concrete block foundation. fixed. During this work, it is necessary to cut the deformed reinforcing bars 30 (φ16 mm to 19 mm) to a predetermined length (matching the height of the lightweight panel 20 to be installed) in advance. In addition, a leveler means a non-shrinking mortar. Deformed reinforcing bars are one of the structural materials for buildings, and are bar-shaped steel materials that have uneven protrusions called "ribs" and "nodes" on the surface of rolled steel.

After the deformed reinforcing bars 30 are fixed to the concrete block foundation or foundation concrete, the lightweight panels 20 are shaped according to the intervals of the deformed reinforcing bars 30 (the height is the height of the deformed reinforcing bars 30), and the deformed reinforcing bars 30 and the deformed reinforcing bars 30 are assembled. Temporarily installed by fitting it in between. At this time, an adhesive may be applied (for fixing the lightweight panel 20) to the side of the lightweight panel 20 that contacts the concrete block foundation or foundation concrete. The adhesive used in this step may be obtained by finely pulverizing polystyrene foam to form an aggregate, and mixing the pulverized aggregate with a strong adhesive.

After the lightweight panel 20 is temporarily installed, the gap between the lightweight panels 20 (where the deformed steel frame 30 is erected) is pasted together with packing tape or the like between the edges of the lightweight panel 20 and the edges of the lightweight panel 20. , forming a space (which will later become the mortar block body 40) to be the joint of the lightweight panel 20, so that the mortar can be poured and filled. By pouring mortar into the space, it is filled and waited until it hardens (to form the mortar block 40). After the mortar has hardened, the lightweight panel 20 is subjected to drilling to form a small window portion 80 (see FIG. 1) and rounding (ceiling processing: not shown) using a cutter or the like. Incidentally, before fixing the lightweight panel 20, the small window portion 80 may be formed by drilling (see FIG. 1) or rounded (top end processing: not shown).

In the finishing work, the base coat layer 50 is formed by coating the entire surface of the lightweight panel and the concrete block foundation or the entire surface of the foundation concrete to form the base coat layer 50, and the entire surface except the upper surface of the lightweight panel and the concrete block foundation or foundation concrete. The mesh sheet layer 60 is attached, the base coat layer 50 is applied again to the entire surface of the lightweight panel and the entire surface of the concrete block foundation or foundation concrete, and finally the entire surface of the lightweight panel and the entire surface of the foundation is finished with a finishing layer. 70 is formed (see FIG. 3). As the work for forming the finishing layer 70, plastered wall finishing, stone covering, brick covering, tiling, etc. can be employed.

The advantage of plastered walls is that the finishing method can be freely selected for each site. For example, it is possible to create a self-supporting wall that gives a feeling of material, such as a rugged rough wall, a sand that leaves a rough feeling, or a smooth wall that uses fine aggregates to suppress the rough feeling. In addition, it is possible to create a pattern in which trowel marks are intentionally left on the free-standing wall, a straight horizontal line is drawn with a comb or the like, and a wave is used to continuously create fan-shaped trowel marks. It is possible to create a unique and stylish self-supporting wall such as a square that leaves a square trowel mark. can also be made.

<Effect of lightweight self-supporting wall>
Special Styrofoam, which is the material used for the lightweight panel 20 of the lightweight self-supporting wall 10 according to the present invention, is different from Styrofoam with an expansion ratio of about 50 times, and the material itself bends greatly (see FIG. Then, if it is a normal styrofoam with an expansion ratio of about 50 times, it will break.However, the thickness of the special styrene foam that can be bent to this state is 50 mm or less), so if you try to construct a self-supporting wall in a curved shape, conventional techniques In that case, there is no choice but to line up concrete blocks with a length of about 30 cm one by one in a curved shape as a whole, which requires a great deal of time and effort at the time of construction.

In the lightweight self-supporting wall 10, the lightweight panel 20 itself can be constructed in a curved shape by utilizing the fact that the material itself bends greatly (see FIG. 4). Moreover, the special styrofoam (expansion ratio of about 30), which is the material used for the lightweight panel 20, can be easily cut with a cutter or the like. Since it is now possible to design a free-standing wall based on free ideas, it is possible to construct a satisfactory free-standing wall. That is, since the material of the lightweight panel 20 according to the present invention can be bent at will, the shape of the lightweight panel 20 viewed from above the wall (even if fine blocks are not arranged in a curved line, the lightweight panel 20 It can be installed in a curved line (see FIG. 2), and can be easily arranged by simply cutting a small window portion 80 of an arbitrary size at an arbitrary position of the lightweight panel 20 with a cutter or the like (see FIG. 1). ).

The special polystyrene foam (expansion ratio of about 30 times) used for the lightweight panel 20 has excellent elasticity, and can prevent cracking and peeling of the finish layer 70 and the like due to an earthquake or the like. Constructing a self-supporting wall made of concrete blocks would be dangerous if it collapsed due to an earthquake if it were a heavy object like concrete. However, since the lightweight panel 20 is made of a lightweight material, there is almost no danger of it collapsing in the event of an earthquake, and a tall self-supporting wall can be constructed.

Even if a self-supporting wall is planned to be constructed, but the existing concrete wall cannot be newly constructed without dismantling it, the lightweight self-supporting wall 10 according to the present invention can be used. If there is, it is possible to construct a self-supporting wall on a concrete fence as it is without dismantling the concrete fence, which is impossible with conventional technology, so that a self-supporting wall can be constructed without spending unnecessary costs. became.

Further, the lightweight self-supporting wall 10 is made by applying the base coat layer 50 to the entire surface of the lightweight panel 20 and the entire surface of the concrete block foundation or foundation concrete, attaching the mesh sheet layer 60, and applying the base coat layer 50 again. ing. That is, since the mesh sheet layer 60 is adhered and hardened by the base coat layer 50, the concrete block foundation or foundation concrete and the lightweight panel 20 are integrated, so that the lightweight panel 20 and the concrete block foundation have sufficient bonding strength. can be ensured.

<Example of changing lightweight self-supporting wall>
The lightweight self-supporting wall according to the present invention is not limited to the aspects of the above-described embodiments, and may include a lightweight panel, a deformed reinforcing bar, a mortar block body, a base coat layer, a mesh sheet layer, a finishing layer, a small window portion, and the like. , can be changed as appropriate without departing from the scope of the present invention. When erecting shaped lightweight panels by sandwiching deformed reinforcing bars from both sides, the adhesive used to fix the lightweight panels to the concrete block foundation is a mixture of Styrofoam mixed with adhesive and cement. By using it, it is possible to reduce cracks and the like in the connecting portion.

INDUSTRIAL APPLICABILITY The lightweight self-supporting wall according to the present invention exhibits excellent effects as described above, and can be suitably used in the field of construction such as self-supporting walls employing lightweight foam materials.

DESCRIPTION OF SYMBOLS 10... Lightweight self-supporting wall 20... Lightweight panel 30... Deformed reinforcing bar 40... Mortar block body 50... Base coat layer 60... Mesh sheet layer 70... Finishing layer 80... Small window part

Claims (4)

A lightweight self-supporting wall formed by forming a foundation of concrete or concrete blocks, and then arranging a plurality of lightweight panels made of a lightweight foam material on the foundation as a base,
a plurality of lightweight panels having a concrete or concrete block foundation as a base;
an adhesive for securing the lightweight panel to the foundation;
a deformed reinforcing bar vertically provided between the lightweight panel and the lightweight panel;
a mortar block body installed in a gap between the lightweight panel and the lightweight panel at a position where the deformed reinforcing bar exists;
a base coat layer applied to both outer and inner surfaces and upper surfaces of the lightweight panel and to the foundation;
a mesh sheet layer attached to both the outer and inner surfaces of the lightweight panel and the foundation;
a finish layer formed on both outer and inner surfaces of the lightweight panel and the upper surface and on the foundation;
The base coat layer, the mesh sheet layer and the finishing layer integrate the foundation and the lightweight panel,
A lightweight self-supporting wall, characterized in that said adhesive is a mixture of styrofoam and cement. 2. A lightweight self-supporting wall according to claim 1, wherein said lightweight panel comprises a fenestration. 3. The lightweight self-supporting wall according to claim 1, wherein said lightweight panel has a curved shape when viewed from directly above. 4. The finishing layer according to any one of claims 1 to 3 , wherein the finishing layer is a layer formed by applying any one of plastered walls, stones, bricks and tiles to the surface of the base coat layer. A lightweight self-supporting wall as described in .

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