JP7548511B2 - How to make concrete blocks - Google Patents

Description

The present invention relates to a method for manufacturing concrete blocks. More specifically, the present invention relates to a method for manufacturing concrete blocks that can be easily transported by hanging them.

A conventional method for manufacturing concrete blocks is disclosed in Patent Document 1.
This conventional manufacturing method uses a formwork that has recesses for forming concrete blocks and is open at the top, and sequentially carries out the following steps: i) a concrete pouring step, in which the formwork is turned upside down and fresh concrete is poured into the recesses; ii) a molding step, in which a template is used to apply pressure to the top surface of the fresh concrete poured into the formwork to mold it; iii) an inversion step, in which a protective plate is fixed to the top of the formwork after the template is removed, and the formwork is turned upside down with the protective plate still fixed; iv) a demolding step, in which a receiving stand is placed below the formwork, the unhardened concrete product with the protective plate laid on it is transferred to the receiving stand and the receiving stand is lowered to remove the unhardened concrete product downward from the formwork; and v) a curing and hardening step, in which the unhardened concrete product on the protective plate is moved and then cured and hardened.

A lifting device is used for the concrete blocks obtained by the above manufacturing method in order to suspend and move them during transportation or at the construction site. The lifting device consists of an insert that is embedded in the concrete block and a hanging ring that is attached to the insert so that it can be inserted and removed freely. Once the hanging ring is inserted and engaged with the insert, a wire rope or the like is passed through the hanging ring, and the concrete block can be transported by being suspended by a mobile crane or the like.

The insert is to be embedded in the concrete block, and is therefore attached to the formwork at the beginning of the above manufacturing process. Specifically, in the concrete pouring step i, the formwork is used with its top open, and the recess in the formwork surrounded by the bottom plate and the surrounding side plates. When the fresh concrete poured into the formwork hardens, a concrete block is obtained, and the surface corresponding to the top surface of the bottom plate of the formwork becomes the back surface of the concrete block. Then, the insert is inserted into a metal fitting such as a pin fixed to the formwork in advance, with the insert facing downward, into the cavity for inserting the hanging ring, and the tip of the insert is attached toward the inner wall surface of the formwork. When the fresh concrete is poured into the formwork, the fresh concrete fills the area around the insert.
Thereafter, a pressing step ii, an inversion step iii, a demolding step iv, and a curing and hardening step v are carried out to obtain a concrete block with an insert.

However, when a portal-shaped concrete block was manufactured using the above-mentioned conventional technique, the insert was inserted downward into a pin or the like installed on the bottom plate of the formwork, so that the tip of the insert was attached to the back surface of the block body facing downward.
In this case, when suspending and moving the concrete block, it is necessary to wrap a wire rope 7 or the like around the top and side of the concrete block CB, as shown in Figure 12, and then guide it to the back side of the block body b1 and pass it through a suspension ring 2 attached to the insert 1.
Therefore, when moving the structure under suspension, it is necessary to first hang the wire rope 7 on the side and then wrap it around the back side, which requires extra work, and reduces efficiency at the construction site.

JP 2008-74033 A

In view of the above circumstances, the present invention aims to provide a method for manufacturing concrete blocks that can be easily transported by hanging them.

The method for manufacturing a concrete block of the first invention is a method which sequentially carries out the steps of: an insert fixing step of attaching an insert to a formwork surrounded by a bottom plate and surrounding side plates and having an open top; a raw material feeding step of feeding raw material for a block into the formwork; a molding step of using a mold to apply pressure to mold the raw material for the block; a mold plate removing step of removing the mold plate from the formwork; an inversion step of placing the formwork on a pallet and inverting it; and a demolding step of lowering the pallet from the formwork to remove a molded concrete product. In the insert fixing step, an insert fixing jig which is a cylindrical member with a bottom is fixed to the bottom plate of the formwork which is set with its open side facing upward, and the lower part of the insert is inserted into the internal cavity of the insert fixing jig with the insert facing upward, so that the tip of the insert faces upward and is positioned flush with the top surface of the molded concrete product. In the demolding step, the molded concrete product is removed from the formwork together with the insert embedded therein, with the insert fixing jig still attached to the bottom plate of the formwork .
The second invention is a method for manufacturing a concrete block according to the first invention , characterized in that the block raw material is ready-mixed concrete, and the concrete block is a portal-shaped block having a block body and legs formed on both sides of the block body.
The third invention is a method for manufacturing a concrete block according to the first invention , characterized in that the block raw materials consist of a base material using ready mixed concrete and a surface material for the block surface, and the concrete block is a surface-layered block having a block body molded using the base material and a surface layer made of the surface material laminated on the upper surface of the block body.

According to the first aspect of the present invention, the following effects are achieved.
a) When the manufacturing of the portal concrete block is completed, the insert is embedded in the block body facing upwards, and the tip of the insert is located flush with the top surface of the cast concrete product . Therefore, the concrete block can be hung without wrapping a wire rope around the side of the concrete block, which increases the work efficiency of the hanging and transportation.
b) The insert fixing jig is removed from the intermediate concrete product together with the formwork during the demolding process, eliminating the need for manual removal.
According to the second invention, even in the case of a gate-shaped concrete block, it is possible to suspend the block without wrapping a wire rope or the like around the side of the concrete block, thereby improving work efficiency.
According to the third invention, even in the case of a surface-layered block consisting of a block body and a surface layer laminated on the upper surface of the block body, the insert is attached facing upwards in the formwork, so that the insert is embedded in the block body facing upwards even when the concrete block is in a completed state. This means that the concrete block can be hung without having to wrap a wire rope around the side of the concrete block, improving the efficiency of the work of hanging and transporting it.

FIG. 1A is a cross-sectional view of a concrete block CB according to a first embodiment of the present invention obtained by a manufacturing method thereof, and FIG. FIG. 1(I) is an explanatory diagram of the insert fixing process, and FIG. 1(II) is an explanatory diagram of the raw material input process. FIG. 3(III) is an explanatory diagram of the molding process, and FIG. 3(IV) is an explanatory diagram of the mold plate removal process. Figure (V) is an explanatory diagram of the inversion process, and Figure (VI) is an explanatory diagram of the demolding process. A cross-sectional view of a second form of portal concrete block CB obtained by the manufacturing method of the first embodiment of the present invention. FIG. 1A is a cross-sectional view of a concrete block CB according to a third embodiment obtained by a manufacturing method according to a second embodiment of the present invention, and FIG. FIG. 1(I) is an explanatory diagram of the insert fixing process, and FIG. 1(II) is an explanatory diagram of the raw material input process. FIG. 3(III) is an explanatory diagram of the molding process, and FIG. 3(IV) is an explanatory diagram of the mold plate removal process. Figure (V) is an explanatory diagram of the inversion process, and Figure (VI) is an explanatory diagram of the demolding process. FIG. 1A is a cross-sectional view of an insert 1 and a hanging ring 2, and FIG. 1B is a cross-sectional view taken at a right angle to FIG. 1A is a plan view of the insert 1, FIG. 1B is a side view, and FIG. 1 is an explanatory diagram of the problems with a portal-shaped concrete block CB obtained by a conventional manufacturing method.

Next, an embodiment of the present invention will be described with reference to the drawings.
In the following description, the invention of the manufacturing method will be described separately as a first embodiment and a second embodiment. The concrete block obtained by the manufacturing method of the first embodiment will be described separately as a first form and a second form, and the concrete block obtained by the manufacturing method of the second embodiment will be described as a third form.

The manufacturing method for the concrete block CB according to the first embodiment of the present invention will be explained with reference to Figs. 1 to 4, but before that, the hanging hardware used to hang the concrete block will be explained with reference to Figs. 10 and 11. The hanging hardware consists of an insert 1 and a hanging ring 2.

10A and 10B show a cross section of a portion of a concrete block CB. Reference numeral 1 denotes an insert that is embedded inside the concrete block CB. The insert 1 has a roughly cylindrical body 11 with triangular anti-rotation blades 12 on the outside, and the inside of the cylinder 11 is a cavity 13. A stepped locking portion 14 is formed at the bottom end of the cavity 13.
Reference numeral 2 denotes a hanging ring, which comprises a ring 21 and a shaft body 22, and a locking piece 23 is provided at the lower end of the shaft body 22.

As shown in Figure 10 (A), the shaft 22 of the hanging ring 2 is inserted into the cavity 13 of the insert 1 and rotated approximately 90 degrees, so that the locking piece 23 of the hanging ring 2 supports the underside of the locking part 14 of the insert 1, as shown in Figure 10 (B). In this state, if a wire rope or the like is passed through the hanging ring 2, the concrete block CB can be suspended and transported.

The insert 1 suitable for the manufacturing method of the present invention will be described in detail with reference to FIG.
As shown in the plan view (a) and the side view (b), the cylindrical body 11 is made up of an upper cylinder 11a and a lower cylinder 11b which are integrally formed.
The upper cylinder 11a has four anti-rotation vanes 12 on the outside, while the lower cylinder 11b is finished in a cylindrical shape. The cavity 13 consists of an upper medium diameter section 13a, an intermediate small diameter section 13b, and a lower large diameter section 13c. The shoulder between the small diameter section 13b and the large diameter section 13c forms the locking section 14 that supports the locking piece 23 of the hanging ring 2.

11(c) shows the insert fixing jig 3. The insert fixing jig 3 is a metal fitting for attaching the insert 1 to a formwork 4 when manufacturing a concrete block CB.
The insert fixing jig 3 has a structure in which an internal cavity 32 is formed in a cylindrical mounting base 31, and the internal cavity 32 is capable of receiving and holding the lower tube 11b of the insert 1. The mounting base 31 may be short (as shown in FIG. 11) or long (as shown in FIG. 7) in length depending on the size of the formwork 4. The insert fixing jig 3 can be attached to the formwork by any means, such as by screwing or welding.

(First embodiment of manufacturing method)
A first embodiment of a method for manufacturing a concrete block will be described with reference to FIGS.
The manufacturing method according to the first embodiment is directed to a portal-shaped concrete block having legs on both sides of the block body.
Further, the insert 1 and the insert fixing jig 3 described with reference to FIG. 11 are used for this concrete block.

I. Insert Fixing Step As shown in Fig. 2 (I), the formwork 4 is installed with its open surface facing upward. The formwork 4 is composed of a bottom plate 41, side walls 42 surrounding the four periphery, and a base part 43 provided in the center of the bottom plate 41. In this specification, the base part 43 may be referred to as the bottom plate 41.
The insert fixing jig 3 is fixed to the upper surface of the base portion 43 by screws or the like. As shown in Fig. 11(c) , the insert fixing jig 3 is a cylindrical member with a bottom, and the lower end portion of the insert 1 can be accommodated in the internal cavity 32. When the lower portion of the insert 1 is inserted into the internal cavity 32 of the insert fixing jig 3, the insert 1 is restrained in this state to such an extent that it does not move on its own and is held facing upward.

II. Concrete Pouring Step As shown in Fig. 2 (II), fresh concrete c is poured into the formwork 4. This fresh concrete is the block raw material referred to in the claims. There are recesses a1 and a2 on both the left and right sides of the base 43 of the formwork 4, and when the fresh concrete c poured therein hardens, it becomes the legs b2 and b2 (see Fig. 1) of the concrete block CB.
A template 5 descends from above the mold 4. A through hole 51 is formed in the template 5. The position where the through hole 51 is formed corresponds to the position where the insert 1 is to be installed.

III. Molding process As shown in Fig. 3 (III), the mold plate 5 pressurizes the ready-mixed concrete c while vibrating the entire formwork 4. The ready-mixed concrete c is molded by this pressurization and vibration. During this molding process, excess ready-mixed concrete c escapes through the through holes 51, so sufficient pressurization can be achieved. In addition, the excess ready-mixed concrete c does not push down the insert 1, and the installation position can be maintained as it is.

IV. Mold Plate Removal Step Once sufficient pressure has been applied, the mold plate 5 is raised as shown in FIG.

V: Reversal step When the template 5 is withdrawn upward, the pallet 6 is placed on it as shown in Fig. 4 (V). In this state, the formwork 4 and the pallet 6 are reversed (rotated 180°).

VI Demolding process As shown in Figure 4 (VI), after inversion, the pallet 6 supports the bottom of the intermediate concrete product (concrete that has been cast but not yet fully hardened), and the pallet 6 lowers to remove the intermediate concrete product from the formwork 4. At this time, the insert fixing jig 3 remains attached to the formwork 4 and is removed from the intermediate concrete product.
In this state, the insert 1 is embedded in the concrete intermediate product, with its tip pointing downward.

The intermediate concrete product on the pallet 6 is transported from the manufacturing machine to a curing section by a conveyor or the like, where it is cured and hardened.
After being cured for the required period of time, the intermediate concrete product is completed as a concrete block CB.

(First form of concrete block)
According to the above manufacturing method, the portal-shaped concrete block CB shown in FIG. 1 is obtained.
FIG. 1A shows a cross section of a concrete block CB, and FIG. 1B shows the block as seen obliquely from above.
As shown in Fig. 1(A), the first type of portal concrete block CB has legs b2, b2 provided on the lower sides of both ends of a block body b1. The outer surfaces of the pair of left and right legs b2, b2 are flush with the outer surface of the block body b1.
The completed concrete block CB has an insert 1 embedded therein, as shown in FIG. 1A, with the tip of the insert 1 facing upward and positioned flush with the upper surface of the block body b1.

(Second form of concrete block)
According to the above manufacturing method, the portal-shaped concrete block CB shown in FIG. 5 can also be obtained.
The second form of portal concrete block CB shown in Figure 5 is the same as that shown in Figure 1 (A) in that a pair of legs b2, b2 are provided on the underside of both ends of the block body b1, but the outer surfaces of the pair of legs b2, b2 are recessed inward from the outer surface of the block body b1.

As shown in FIG. 1B, in the first and second forms of the portal concrete block CB, the tip of the insert 1 faces the top surface of the block body b1, so when lifting with a wire rope 7 or the like, the worker can easily insert the suspension ring 2 into the insert 1 by working downward, and the wire rope 7 can also be easily threaded through the suspension ring 2. In other words, there is no need to wrap the wire rope 7 around from the side to the bottom of the concrete block CB. Furthermore, the concrete block CB can be lifted with the top surface facing up and the legs b2, b2 facing downward, improving workability during construction.

(Second embodiment of manufacturing method)
Next, a method for manufacturing a concrete block according to a second embodiment of the present invention will be described with reference to FIGS.
The manufacturing method of the second embodiment is directed to a surface-coated concrete block having a surface layer with a decorative effect on the upper surface of the block body.
The insert 1 and the insert fixing jig 3 described with reference to FIG. 11 are also used for this concrete block.

I. Insert Fixing Step As shown in Fig. 7(I), the formwork 4 is installed with its open surface facing upward. The formwork 4 is composed of a bottom plate 41 and side walls 42 surrounding the four periphery.
The insert fixing jig 3 is fixed to the upper surface of the bottom plate 41 by screws or the like. The insert fixing jig 3 is a cylindrical member with a bottom, and the lower end of the insert 1 can be accommodated in the internal cavity 32. When the lower part of the insert 1 is inserted into the internal cavity 32 of the insert fixing jig 3, the insert 1 is restrained in this state to such an extent that it does not move on its own and is held facing upward.

II. Concrete pouring process As shown in (II) of Fig. 7, fresh concrete c is poured into the formwork 4 as the base material, and the surface layer material d that constitutes the surface layer is poured on top of it. This surface layer material is the block raw material referred to in the claims. There is no particular restriction on the surface layer material d, but porous concrete and the like are used. Porous concrete has the advantage that the shadows caused by the unevenness on the surface reduce the brightness, blend in with the scenery around the construction site, and the gaps can provide a habitat for plants and creatures.
A template 5 descends from above the mold 4. A through hole 51 is formed in the template 5. The position where the through hole 51 is formed corresponds to the position where the insert 1 is to be installed.

III. Molding process As shown in Fig. 8 (III), the surface layer material d and the ready-mixed concrete c are pressed by the mold plate 5 while vibration is applied to the entire formwork 4. The surface layer material d and the ready-mixed concrete c are molded by this pressurization and vibration. During this molding process, excess surface layer material d or ready-mixed concrete c escapes through the through holes 51, so sufficient pressurization can be performed. In addition, the excess surface layer material d or ready-mixed concrete c does not push down the insert 1, and the installed position can be maintained as it is.

IV. Mold Plate Removal Step Once sufficient pressure has been applied, the mold plate 5 is raised as shown in FIG. 8(IV) to remove it from the mold form 4.

V: Reversal step When the template 5 is withdrawn upward, the pallet 6 is placed on it as shown in Fig. 9 (V). In this state, the formwork 4 and the pallet 6 are reversed (rotated 180°).

VI Demolding process As shown in Figure 9 (VI), after inversion, the pallet 6 supports the bottom of the intermediate concrete product (which is made of surface layer material d and ready mixed concrete c that have been molded but not yet fully hardened), and the pallet 6 lowers to remove the intermediate concrete product from the formwork 4. At this time, the insert fixing jig 3 remains attached to the formwork 4 and is removed from the intermediate concrete product.
In this state, the insert 1 is embedded in the concrete intermediate product, with its tip pointing downward.

The intermediate concrete product on the pallet 6 is transported from the manufacturing machine to a curing section by a conveyor or the like, where it is cured and hardened.
After curing for the required period of time, the intermediate concrete product is completed as a concrete block CB with a surface layer.

(Third form of concrete block)
According to the above manufacturing method, a surface layer concrete block CB shown in FIG. 6 is obtained.
FIG. 6A shows a cross section of a surface-coated concrete block CB, and FIG. 6B shows the block as viewed obliquely from above.

(Concrete block with surface layer)
The concrete block CB according to the third embodiment shown in Fig. 6(A) is a concrete block with a surface layer b3 attached to the top surface (surface) of the block body b1. An insert 1 is embedded in the block body b1, and the tip of the insert 1 faces upward and is located flush with the top surface of the block body b1.

As shown in FIG. 1B, in the third form of surface-coated concrete block CB, the tip of insert 1 faces the top surface of block body b1, so when lifting with wire rope 7 or the like, the worker can easily insert suspension ring 2 into insert 1 by working downward, and the wire rope 7 can also be easily threaded through suspension ring 2. In other words, there is no need to wrap wire rope 7 around from the side to the bottom of surface-coated concrete block CB. Furthermore, the surface-coated concrete block CB can be lifted with the top surface facing up and legs b2, b2 facing downward, improving workability during construction.

Reference Signs List 1 Insert 2 Suspension ring 3 Insert fixing jig 4 Formwork 5 Template 51 Through hole CB Concrete block b1 Block body b2 Leg b3 Surface layer

Claims (3)

an insert fixing process in which the insert is attached to a formwork surrounded by a bottom plate and surrounding side plates and has an open top;
A raw material input process of inputting block raw materials into the formwork;
A molding process in which the raw material is pressed using a mold plate to form a block.
a mold plate removing step of removing the mold plate from the mold frame;
an inversion step of placing the formwork on a pallet and inverting it;
A demolding process in which the pallet is lowered from the formwork to remove the cast concrete product,
In the insert fixing step, a cylindrical member with a bottom is fixed to the bottom plate of a formwork installed with the open surface facing upward, and the lower part of the insert is inserted into the internal cavity of the insert fixing jig with the insert facing upward , so that the tip of the insert faces upward and is positioned flush with the upper surface of the cast concrete product;
In the demolding step, the molded concrete product is detached from the formwork together with the insert embedded therein while the insert fixing jig remains attached to the bottom plate of the formwork.
A method for manufacturing a concrete block comprising the steps of : The block raw material is ready-mixed concrete,
2. The method for manufacturing a concrete block according to claim 1 , wherein the concrete block is a portal-shaped block having a block body and legs formed on both sides of the block body. The block raw materials are composed of a base material using ready-mix concrete and a surface material for the block surface,
2. The method for manufacturing a concrete block according to claim 1, wherein the concrete block is a surface-layered block having a block body molded using the base layer material and a surface layer made of the surface layer material laminated on the upper surface of the block body.