JP7693172B2 - Formwork device for manufacturing column members and method for manufacturing column members - Google Patents

Description

The present invention relates to a formwork device for producing precast concrete column members, and a method for producing column members using the same.

When manufacturing a column member made of precast concrete, a common method is to assemble a sheathing whose inner periphery has the cross-sectional shape of the column member on the ground or on the floor, and then arrange column reinforcement inside the sheathing while restraining it from the outer periphery with shoring, and pour concrete (see Patent Documents 1 and 2). The sheathing is formed in a shape in which a closed cylindrical hollow member is divided into several pieces in the circumferential direction so that it can be used repeatedly.

In either case, when manufacturing the column members in an upright position, the sheathing and shoring will be erected on the ground or on the floor, so it will be necessary to assemble scaffolding above the ground to a height that allows workers to perform reinforcing bar work and concrete pouring work at the top of the sheathing, or at the top sheathing.

Japanese Utility Model Application Publication No. 3-9467 (specification, page 6, line 5 to page 9, line 8, Figures 1 to 3) JP-A-3-212562 (page 2, lower left column, line 14 to page 3, lower right column, line 5, Figures 1 to 5)

Working at the top of the sheathing involves working at a height, which means there is a risk of falling, so it is essential to use safety harnesses or other equipment to avoid danger.

In light of the above background, the present invention proposes a formwork device for producing precast concrete column members and a method for producing column members that allows for the production of precast concrete column members without working at height.

The formwork device for producing a column member according to claim 1 is installed on the bottom surface of a pit having a bottom surface below the ground surface or floor surface, and comprises a bottom plate for forming the bottom surface of a column member made of precast concrete, and a side plate for forming the side surface of the column member;
The ground surface or the floor surface is located around the pit ,
The side dam is composed of a plurality of side dam members which are separably joined to each other,
The constituent element is that at least two of the multiple side sheathing board materials that are positioned in a perpendicular direction on a plane support a joint sheathing board for forming a joint portion in which a precast concrete beam portion connected to the upper part of the column member is integrated.

The floor surface refers to the top surface of a concrete base or slab that is constructed or has been constructed on the ground surface, or a temporary steel floor slab or the like. A pit is a space "with a bottom surface that is relatively lower than the ground surface or floor surface," on which bottom and side sheathing can be installed, and has a planar area large enough at least to allow the side sheathing to be removed within the pit so that the column members can be detached from the side sheathing after the concrete hardens. However, the bottom surface of the pit does not have to be a basement; for example, if the floor surface is laid on scaffolding or supports (shoring) installed on a certain floor surface, the floor surface that is relatively lower becomes the bottom surface of the pit.

The depth of the pit, i.e. the depth from the ground or floor to the bottom of the pit, does not necessarily have to be close to the full length of one of the pillar members, as long as it is deep enough that work on the ground or floor around the pit, or on the top of the side sheathing, does not amount to work at a height. Since there is technical significance in "installing the bottom and side sheathing on a bottom surface that is relatively lower than the ground or floor," the depth of the pit, in terms of the pillar member to be produced, should be in the range of about the full length of the pillar member to be produced to a fraction of that length.

The bottom of the pit is located below the ground level or floor level, and is deep enough that work on the ground level or floor level or on the side sheathing does not require working at height. This means that tasks such as arranging the reinforcing bars that make up the column components and pouring concrete do not require working at height, which avoids the risk of falling during work and also eliminates the need for safety harnesses, etc.

The bottom and side sheathings can be of any shape as long as they have the ability to be removed from the concrete after the concrete poured in the area surrounded by them has hardened. The side sheathings 3 can be formed as a single member in a cylindrical shape, for example, if a release agent is applied to the inner peripheral surface of the side sheathings 3 so that they can be removed from the concrete surface when the column members are lifted after the concrete has hardened. However, it is appropriate that the side sheathings 31 are made up of a number of side sheathings 31 that are joined together so as to be separable from each other in terms of the work of removing the form, as shown in Figures 2 to 4 (Claim 1 ).

"The ground surface or floor surface is located around the pit" means that the ground surface or floor surface 14 (hereinafter referred to as floor surface 14, etc.) is located somewhere around the pit 12 and faces (overlooks) the pit 12. The floor surface 14, etc. may also serve as a work floor for fabricating pillar members while checking the situation inside the pit 12. "Serving as a work floor" basically means that the floor surface 14, etc. is used as a work floor for fabricating pillar members, but it also includes the floor surface 14, etc. being placed continuously with the work floor 8 integrated into the upper part of the side sheathing 3 as shown in Figures 1 to 4, or the floor surface 14, etc. being used to supplement work on the work floor 8 by supporting it, or the work floor being installed directly or indirectly on the floor surface 14, etc.

"(Work floor) for producing pillar components" refers mainly to the work of pouring concrete that will make up the pillar components on the work floor in the area on the bottom dam 2 surrounded by the side dam 3, but may also include work such as placing column reinforcing bars in the area surrounded by the side dam 3. Reinforcing bar placement work is also carried out on the bottom surface 13 of the pit 12. In addition, a reinforcing bar cage assembled in advance from the main column reinforcement bars 15 and shear reinforcement bars may be lowered onto the bottom dam 2, and work for this or auxiliary work may be carried out on the bottom surface 13 of the pit 12, or on the floor surface 14, etc.

As shown in Fig. 3, a plurality of side sheathing materials 31 that can be separated from one another are combined and joined together to form a side sheathing 3 that has a closed cylindrical shape in plan as shown in Figs. 1 and 4, but the shape of each side sheathing material 31 and the number of side sheathing materials 31 are optional. In this case , two side sheathing materials 31, 31 adjacent in the circumferential direction of the side sheathing 3 are detachably joined together by connecting devices such as bolts 31b, pins, and clamps.

The side sheathing 3 is divided into at least two side sheathing materials 31, but in order to simplify the demolding and assembly work, it is reasonable to have at least any two of the side sheathing materials 31 facing each other and to make at least one of them relatively movable in the facing direction (Claim 2 ). In this case, the side sheathing 3 is composed of, for example, two (two) orthogonal plate-shaped (plate-shaped) side sheathing materials 31 and at least one planar L-shaped side sheathing material, or four (four) plate-shaped side sheathing materials 31. When the side sheathing 3 is, for example, cylindrical, the side sheathing material 31 is formed into a curved plate shape.

When at least any two of the side sheathings 31, 31 face each other and are movable (claim 2 ), the movable side sheathings 31 become movable, for example, by wheels (rollers) 6 connected (axially supported) to their lower ends, etc., rolling on the bottom surface 13 of the pit 12, or by the lower ends (sliding members 4) of the side sheathings 31 sliding on the wheels 6 axially supported on rails 5 laid on the bottom surface 13 of the pit 12, as shown in Figures 3 and 4. When the wheels 6 are used, the frictional force generated by the lower ends (sliding members 4) of the side sheathings 31 is reduced, making the movement of the side sheathings 31 smoother, improving the work efficiency of demolding and subsequent reassembly.

Including the case where at least any two of the side sheathing materials 31, 31 face each other and are movable (claim 2), at least any two of the side sheathing materials 31 positioned in a perpendicular direction on a plane out of the plurality of side sheathing materials 31 support a joint sheathing 9 for forming a joint portion in which a precast concrete beam portion connected to the upper portion of the column member is integrated (claim 1 ). "At least any two side sheathing materials" refers to two perpendicular side sheathing materials 31 if the column member is a corner column, three side sheathing materials 31 if it is a side column, and four side sheathing materials 31 if it is a center column.

The joint dam 9 supports the ends of the beam reinforcing bars that make up the beam member connected to the top of the column member, defines the area for pouring concrete that makes up the beam section (joint section), which is part of the beam member, and serves as a dam that forms the beam section.

When using the formwork device for manufacturing column members described in claim 1 or claim 2 , the column member is manufactured through a process of arranging column bars that constitute a precast concrete column member in the area surrounded by a bottom plate 2 and a side plate 3 installed on the bottom surface 13 of a pit 12 having a bottom surface 13 below the ground surface or floor surface 14, and a process of pouring concrete that constitutes the column member in the area surrounded by the side plate 3 on the bottom plate 2 from above the ground surface or floor surface 14 around the pit 12 (claim 3 ).

The side sheathing 3 is composed of a plurality of side sheathing materials 31 joined to each other so as to be freely separated. At least two of the side sheathing materials 31, 31 positioned in a direction perpendicular to each other on a plane are supported by a joint sheathing 9 for forming a joint portion in which a precast concrete beam portion connected to the upper portion of the column member is integrated , and a column member with a joint portion is manufactured through a process of placing a beam reinforcing bar constituting the joint portion in an area surrounded by the joint sheathing 9 and a process of pouring concrete in the area surrounded by the joint sheathing 9 (claim 3 ). Concrete is poured simultaneously in the side sheathing 3 on the bottom sheathing 2 and in the sheathing 9 placed thereon, and the beam reinforcing bar in the sheathing 9 is buried in the concrete.

The formwork device for producing column members is installed on the bottom of a pit whose bottom is below the ground or floor, and is equipped with a bottom plate for forming the bottom of the column member made of precast concrete, and side plate for forming the side of the column member. Because the bottom of the pit is located below the ground or floor, it is possible to perform tasks such as arranging the column rebar that makes up the column member and pouring concrete without working at a height. As a result, the risk of falling during work is avoided, and the use of safety harnesses, etc. is also unnecessary.

(a) is a plan view showing the appearance of a formwork device having a side plate made up of multiple side plate materials installed on the bottom of a pit, with column reinforcing bars arranged inside the side plate and beam reinforcing bars arranged on the top of the formwork device, and (b) is a vertical cross-sectional view. 1-(a) is a plan view showing the state in which the side sheathing shown in FIG. 1-(a) has been separated, and FIG. 3A is a plan view showing the state in which the side sheathing shown in FIG. 2 has been separated, and FIG. 3B is a cross-sectional view taken along line xx of FIG. 1-(a) is a plan view showing the details of the side sheathing shown in FIG. 1-(a), (b) is an elevational view of (a), (c) is a side view of (a) in a direction perpendicular to (b), and (d) is a plan view showing the bottom sheathing. This is an elevational view showing the situation where concrete is poured from above the joint board. 13A to 13C are perspective views showing an example of an assembly procedure for a joint board. FIG. 2 is a perspective view showing an example of the configuration of a thin-walled sheathing for pouring concrete into a joint section from the surface of the pillar member. 7A to 7F are perspective views showing an example of a procedure for placing beam reinforcing bars using the joint plate shown in FIG. 6.

Figures 1-(a) and (b) show a formwork device 1 for producing column members, which is installed on the bottom surface 13 of a pit 12 having a bottom surface 13 below the ground surface or floor surface 14, and which is equipped with a bottom plate 2 for forming the bottom surface of the precast concrete column member and a side plate 3 for forming the side surface of the column member, installed on the bottom surface 13 of the pit 12. The ground surface or floor surface (hereinafter referred to as floor surface 14, etc.) is located around the pit 12 and faces the pit 12.

The side sheathing 3 may be formed of a single member, such as a cylindrical shape, but in Figs. 1 and 2, an example is shown in which the side sheathing 3 is made up of multiple side sheathing materials 31 that are joined together in a circumferential direction so that they can be separated from one another, in order to ensure a reliable demolding operation and to improve the efficiency of the demolding process. In Fig. 1, in particular, in order to improve the efficiency of the demolding of each side sheathing material 31 and the subsequent reassembly, at least two of the multiple side sheathing materials 31 are arranged to face each other in the horizontal direction, and at least one of them is movable relative to the other in the opposing direction.

In Figures 1 and 2, the side dam 3 is divided into four (four) plate-shaped side dam materials 31, and each side dam material 31 is installed on the bottom surface 13 of the pit 12 so that it can move back and forth on the bottom surface. Specifically, as shown in Figures 3 and 4, a rail 5 is fixed directly on the bottom surface 13, or on a bottom plate (hereinafter, on the bottom surface 13, etc.) installed on the bottom surface 13 to ensure stability, in the direction of the reciprocating movement of each side dam 31, and a slide member 4 that can move back and forth along the rail 5 in the axial direction of the rail 5 is supported on the rail 5, allowing each side dam material 31 to move back and forth in one direction.

The rails 5 are fixed to the bottom surface 13 below the bottom dam 2 so that each side dam material 31 can be removed from the hardened concrete as shown in Figures 3(b) and 2(b). Figure 3 shows the state in which the four divided side dam materials 31 have been separated from each other and removed from the mold, while Figure 4 shows the state in which the side dam materials 31 have been joined together to form the side dam 3.

In the example shown in Figure 3, where the side sheathing 3 is divided into four, the rails 5, 5 are fixed on the bottom surface 13, etc., facing in two perpendicular directions on a plane. The perpendicular rails 5, 5 intersect under the bottom sheathing 2 as shown in Figure 3-(a), so they are laid on the bottom surface 13, etc. with a step between the top and bottom as shown in Figure 3-(b). The lower rail 5 is fixed on the bottom surface 13, etc., and the upper rail 5 is fixed to the lower rail 5. In the drawing, in order to stabilize both ends of the upper rail 5 in the axial direction, support members 7 of the same height as the lower rail 5 are placed under both ends of the upper rail 5, and the upper rail 5 is fixed and supported by the support members 7 as well. The rails 5, 5 in each direction are placed parallel to each other at a distance from each other in order to stably support the side sheathing material 31.

The method of supporting the sliding material 4 on the rail 5 so that it can move back and forth is arbitrary, but in the example shown in Figures 3 and 4, wheels (rollers) 6, 6 are journaled at at least two points spaced apart in the axial direction of the rail 5, and the sliding material 4 is supported on these two wheels 6, 6, so that the sliding material 4 is supported on the rail 5 so that it can move back and forth in its axial direction. In addition, the wheels 6 shown in the figure can be made smaller and placed in pairs above and below inside the rail 5 at the position of each wheel 6 shown in the figure.

Two wheels 6, 6 are supported on both sides of the section where the slide member 4 reciprocates along the rail 5, with their axles facing horizontally, for example. When viewed from above, the wheels 6, 6 are positioned at both axial ends of the rail 5 and at a position overlapping the bottom plate 2, as shown in Figure 3-(a). The wheels 6 may also be supported with their axles facing vertically.

The axial direction of the rail 5, or the direction of the line connecting the axes of at least two wheels 6, 6, may be horizontal, but in the example shown in Figures 3 and 4, it is inclined upward from the outer periphery of the bottom plate 2 to the center, making it easier to remove the side plate material 31. In this case, it is possible to move the side plate material 31 by simply applying a small force to the outer periphery of the bottom plate material 31 when removing the plate. Conversely, if the axial direction of the rail 5, etc. is inclined downward from the outer periphery of the bottom plate 2 to the center, it is possible to make it easier to reassemble the plate from the removed state.

Two slide members 4 are fixed (joined) in parallel to the lower part of each side sheathing material 31, spaced apart horizontally in accordance with the arrangement of the rails 5, 5. Each slide member 4 is arranged on one side in the width direction of the rail 5 that supports it, as shown in Figures 3-(a), 4-(b), and (c). Each slide member 4 reciprocates between the separated state shown in Figure 3-(a) and the joined state shown in Figure 4-(a) while being supported by at least two wheels 6, 6 of each rail 5.

In the drawings, in order to ensure the bending and torsional rigidity of the rail 5, a steel material (square steel pipe) with a closed cross-sectional shape with both axial ends closed is used for the rail 5, and the wheels 6 are supported on the outside of the rail 5, but the cross-sectional shape of the rail 5 and the support position of the wheels 6 are not important. Since the wheels 6 are held in place by the sliding material 4 sandwiching them from above and below, the sliding material 4 is made of a steel material with an open cross-sectional shape with both axial ends closed (H-shaped steel), but the cross-sectional shape of the sliding material 4 is also not important.

As shown in Figures 3-(a) and (b), each side sheathing 31 is placed on two parallel slide members 4, 4 and is joined to both slide members 4, 4 to form an integrated unit. The four-part side sheathing 31 forms a closed side sheathing 3 in plan view when it transitions from the separated state shown in Figure 3-(a) to the joined state shown in Figure 4-(a). At this time, two adjacent (orthogonal) side sheathing members 31, 31 are joined to each other so that they can be separated, for example, by the flanges 31a, 31a integrated on both sides of the width of the side sheathing 31 overlapping each other, and nuts being fastened to the bolts 31b that pass through the flanges 31a, 31a.

In the illustrated example, one of the overlapping flanges 31a, 31a is, for example, a portion that protrudes from the main body of the side sheathing material 31 on both sides in the width direction, and the other is a portion that is bent vertically from both sides in the width direction of the main body of the side sheathing material 31. In the drawings, as shown in FIG. 3, one flange 31a protruding from the main body portion has a pin 31c that fits into a hole in the other bent flange 31a, and the pin 31c is inserted into a hole in the adjacent side sheathing material 31, so that the two orthogonal side sheathing materials 31, 31 are positioned.

The drawings also show that the work floor 8, which protrudes toward the floor surface 14, etc., is integrally joined to the top of each side sheathing 31. When the side sheathing 31 is formed as shown in Figures 4-(a) and 1-(a), the work floors 8 integrated with the four side sheathing 31 butt against each other or overlap in the circumferential direction while leaving the top of the side sheathing 3 open, and can be used as a floor for work such as arranging reinforcing bars for columns and pouring concrete to manufacture column members. The floor surfaces 14, etc. located around the pit 12 are used to assist work on the work floor 8, or to perform work that is continuous with the work on the work floor 8.

The work of placing the main column reinforcement bars 15 and the shear reinforcement bars (hoops) 16 that make up the column members, shown in Figures 1-(a) and 2-(a), can also be carried out on the bottom surface 13 of the pit 12, but in order to increase the efficiency of the work, it is more rational to lower a reinforcing bar cage that has been assembled in advance from the main column reinforcement bars 15 and the shear reinforcement bars 16 in a different location from the sky onto the bottom sheathing 2 while adjusting its position on the work floor 8 or floor surface 14, etc. Pouring concrete into the side sheathing 3 on the bottom sheathing 2 is also carried out on the work floor 8 or floor surface 14, etc., as shown in Figure 5, by adjusting the pouring position and applying vibration.

Figure 5 shows the situation when concrete is poured into the formwork device 1A in which a joint plate 9 is placed on top of the formwork device 1 consisting of the bottom plate 2 and side plate 3 shown in Figures 3 and 4 to integrally form a joint section (joint section) with the beam member connected to the column member, and the bottom plate 2 and side plate 3 are joined to the joint plate 9. When the formwork device 1 is composed of the bottom plate 2 and side plate 3, concrete is poured from above the side plate 3.

Figure 6-(c) shows an example of the configuration of a joint dam 9. The joint dam 9 can be placed on top of and connected to the formwork device 1, which is made up of the bottom dam 2 and side dam 3, and can have any shape (configuration) as long as the structure allows for the arrangement of column reinforcing bars and beam reinforcing bars at the joint, but in Figure 6, the configuration takes into account the arrangement of beam main bars 17 that pass through the joint, as shown in Figure 8.

Specifically, as shown in Figure 6-(b), four divided corner sheathing materials 91 that make up the joint sheathing board 9 are placed at the four corners on a plane, and as shown in (c), a lower sheathing material 92 with a support material 93 that supports the beam main reinforcement bars 17 is placed between adjacent corner sheathing materials 91, 91. As shown in Figure 8-(d), an upper sheathing material 94 that pairs with the lower sheathing material 92 is placed on top of the support material 93 on the upper level. In Figure 6, in order to assemble the multiple divided components of the joint sheathing board 9 in an orderly and efficient manner, each component is placed on a bed 95 that acts as a ruler installed on the bottom surface 13, etc.

The joint dam 9 is placed on top of the formwork device 1, which consists of the bottom dam 2 and the side dam 3, and concrete is poured into the side dam 3 and the joint dam 9 as shown in Figure 5. The joint section to which the beam connects is integrated into the top of the completed column member, but the length and width of the beam connected to the joint section may differ for each column member depending on the position of the column member, such as whether the column member is a side column or a center column.

In this regard, in Figures 6 and 8, a shank board 10 as shown in Figure 7 is placed inside the corner board material 91 as shown in Figures 6-(c) and 8-(d) to make the surface side of the pillar member relatively recessed from the joint so that the concrete in the joint can be poured thicker (protruding) than the surface of the pillar member. After pouring concrete with the shank board 10 in place, the surface of the joint of the pillar member will be finished in a state that protrudes toward the beam side more than the surface of the part other than the joint.

Figure 6-(c) shows the corner 10a of the Nusumi sheathing 10 shown in Figure 7 and the lower part 10b that spans between the lower parts of the adjacent corners 10a, 10a, placed inside the corner sheathing material 91. The remaining part of the Nusumi sheathing 10, the upper part 10c that spans between the upper parts of the adjacent corners 10a, 10a, is placed after the beam reinforcing bars are placed, as shown in Figure 8-(d).

Figures 8-(a) to (f) show the procedure for placing beam reinforcement using the joint dam 9 shown in Figure 6-(c). Figure 8-(a) shows the state in which the upper end beam reinforcement 17 and shear reinforcement (stirrup) 18, and the shear reinforcement (hoop) 16 around the column reinforcement 15 of the joint are placed on the joint dam 9 in one direction, (b) shows the state in which the lower end beam reinforcement 17 is placed, and (c) shows the state in which the upper and lower ends of the beam in the perpendicular direction are placed with the beam reinforcement 17 and shear reinforcement 18. The column reinforcement 15 and shear reinforcement 16 are not shown in Figure 8-(a), but as shown in Figures 1-(a) and 2-(a), the column reinforcement 15 and shear reinforcement 16 are placed in the state shown in Figure 8-(a).

Figure 8-(d) shows the arrangement of the upper sheathing material 94 of the joint sheathing 9 and the upper part 10c of the embossed sheathing 10, while (e) shows the installation of protective material 11 with a cap on the upper sheathing material 94 to protect the main reinforcement bars 15 of the column members arranged inside the side sheathing 3 from the concrete that will be poured later, completing the assembly and reinforcement of the joint sheathing 9. (f) shows (e) viewed from a different angle.

Figure 5 shows the pouring of concrete when the joint dam 9 is placed on top of the formwork device 1, which consists of the bottom dam 2 and side dam 3 as described above. When the joint dam 9 is placed on top of the formwork device 1 after the beam reinforcing bars have been placed as shown in Figure 8-(f), the bed 95 shown in Figures 6 and 8 is removed, and the space inside the formwork device 1 and the space inside the joint dam 9 are connected.

1 ... (for manufacturing column components) formwork device, 1A ... formwork device (with joint board 9),
2... Bottom plate,
3: side dam, 31: side dam material, 31a: flange, 31b: bolt, 31c: pin,
4...Slide material,
5... rail, 6... wheel (roller), 7... support material,
8...Work floor,
9: Joint sheathing, 91: Corner sheathing, 92: Lower sheathing, 93: Support, 94: Upper sheathing, 95: Bed,
10: Nusumi sheath, 10a: Corner, 10b: Lower part, 10c: Upper part,
11...protective material,
12...pit, 13...bottom,
14...Floor surface,
15...main column reinforcement, 16...shear reinforcement (hoop), 17...main beam reinforcement, 18...shear reinforcement (stirrup).

Claims (3)

The pit is installed on the bottom surface of the pit, which has a bottom surface below the ground surface or floor surface, and is provided with a bottom plate for forming the bottom surface of a precast concrete column member, and a side plate for forming the side surface of the column member;
The ground surface or the floor surface is located around the pit,
The side dam is composed of a plurality of side dam members which are separably joined to each other,
A formwork device for manufacturing column members, characterized in that a joint plate for forming a joint portion in which a precast concrete beam portion connected to the upper portion of the column member is integrated is supported on at least any two of the multiple side plate members that are located in a perpendicular direction on a plane among the multiple side plate members. The formwork device for manufacturing column members according to claim 1, characterized in that at least two of the side sheathing materials face each other, and at least one of the side sheathing materials is movable relative to the other in the facing direction. A process of arranging column reinforcing bars constituting precast concrete column members in an area surrounded by a bottom plate and a side plate installed on the bottom surface of a pit having a bottom surface below the ground surface or floor surface;
pouring concrete constituting the pillar member from above the ground surface or floor surface around the pit into an area on the bottom plate surrounded by the side plate ,
The side dam is composed of a plurality of side dam members which are separably joined to each other,
Among the plurality of side sheathing boards, at least two of the side sheathing boards positioned in a direction perpendicular to each other on a plane are supported with a joint sheathing board for forming a joint portion in which a precast concrete beam portion connected to an upper portion of the column member is integrated,
A step of placing a beam reinforcing bar constituting the joint portion in an area surrounded by the joint sheathing;
pouring concrete into the area enclosed by the joint board;
A method for manufacturing a pillar member, comprising the steps of: manufacturing a pillar member having the above-mentioned joint portion .

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