JP7714293B2 - Floor structure and construction method - Google Patents

Description

The present invention relates to a floor structure in which concrete or the like is poured into a floor formwork and pipes or the like are installed with the pipes or the like passing through the floor formwork vertically, and to a construction method for the floor structure.

Conventionally, a known floor structure involves placing reinforcement on a specified floor formwork (e.g., a deck plate, typically made of relatively thin steel plates, such as Flat Deck or Fellow Deck (registered trademark)), then pouring flooring materials such as concrete or mortar, with piping and other components running vertically through the formwork. Furthermore, floors in which reinforcement is placed and concrete is poured on top of a specified floor formwork are designated as fire-resistant if they meet the certification requirements. However, if they do not, they will be certified as fire-resistant structures using sprayed fire-resistant materials. In this way, covering materials such as fire-resistant coatings are sometimes applied to the surface of a structure, such as the underside of the floor formwork. Furthermore, not only for the purpose of imparting fire resistance, but also to improve the insulation performance of rooms above or below the floor, covering materials such as insulating urethane materials are sometimes applied to the surface of a structure, such as the underside of the floor formwork (see, for example, Patent Document 1).

Conventionally, floor structures with covering materials and piping such as those described above are constructed, for example, as follows. First, as shown in Figure 20, (1) a tubular member 101 (commonly referred to as a "sleeve") is placed on the floor formwork 100. Then, reinforcing bars (not shown) are placed around the tubular member 101 on the floor formwork 100, and floor material 102 is poured. Next, as shown in Figure 21, (2) the floor formwork 100 inside the tubular member 101 is cut and removed, and frame holes 100a are formed through the floor formwork 100 to insert the piping.

Next, as shown in Figure 22, (3) a covering material 103 such as heat insulating material or fire-resistant covering material is sprayed onto the underside of the floor formwork 100. Then, as shown in Figure 23, (4) any excess covering material 103 that is located near the frame holes 100a or that gets in the way of piping placement is removed.

Next, as shown in Figure 24, (5) the pipe 104 is inserted into the tubular member 101 and into the frame hole 100a so as to pass through the covering material 103. After that, as shown in Figure 25, (6) a sheet-like sealing member 105 is attached from the outer surface of the pipe 104 to the surface of the covering material 103, thereby sealing the gap between the pipe 104 and the covering material 103. Finally, (7) a specified filler material 106 (e.g., mortar) is filled between the tubular member 101 and the pipe 104, thereby completing the construction of the floor structure.

In cases where the floor formwork is a Fellow Deck (registered trademark), which is a deck plate with pre-arranged reinforcement, instead of using tubular members and instead of steps (1) and (2) above, floor materials can be poured onto the floor formwork and then cored out to form through-holes that penetrate the floor formwork and floor materials. Even in this case, once the through-holes are formed, steps (3) to (7) above are carried out to complete the construction of the floor structure.

Patent No. 6987200

Floor structure construction is typically carried out by both the construction and equipment construction teams, with the construction team spraying the covering material after the equipment construction team drills through the frame holes, and the equipment construction team removing any excess covering material from the frame holes. However, if the covering material peels off or chips excessively when the equipment construction team removes the excess covering material from the frame holes, this could result in the construction team having to repair the covering material. This can result in conflicts between the construction and equipment construction teams, which could lead to delays in the construction schedule.

In addition, work to remove or repair covering materials may result in a deterioration in the appearance of the floor due to the presence of removed or repaired areas. Furthermore, removal or repair of covering materials may result in gaps that create insufficient covering thickness, which may prevent the covering material from fully performing its intended functions (such as fire resistance and heat retention), potentially resulting in a deterioration in the quality of the floor structure.

The present invention was made in light of the above circumstances, and its purpose is to provide a floor structure and construction method that can more reliably prevent the occurrence of the above-mentioned problems related to covering materials.

Below, each means suitable for achieving the above objective will be explained item by item. Where necessary, the specific effects of the corresponding means will also be noted.

Means 1. A floor base having a tubular member installed on a floor form corresponding to a frame hole formed in the floor form, and a floor material poured outside the tubular member on the floor form;
A floor structure comprising a covering material sprayed onto the underside of the floor formwork,
The frame hole is formed by cutting the floor formwork on which the tubular member is installed endlessly inside the tubular member, and has a diameter smaller than the inner diameter of the tubular member,
The extension sleeve is cylindrical, has an outwardly protruding locking portion formed at the top, and is provided in series with the cylindrical member by being locked to a portion of the floor formwork that forms the frame hole, and has a length that allows at least the lower portion to protrude downward beyond the covering material,
A floor structure characterized in that the covering material is sprayed onto the outside of the extension sleeve on the underside of the floor formwork.

According to the above-mentioned method 1, in a floor structure in which a tubular member is installed at the floor base, an extension sleeve is installed in series with the tubular member, with the extension sleeve having a length that allows at least the lower portion to protrude below the covering material. By providing such an extension sleeve, it is possible to more reliably prevent excess covering material from adhering when spraying the covering material, which can interfere with the insertion of piping, and therefore eliminate the need to cut and remove excess covering material. This prevents excessive peeling or chipping of the covering material when it is removed, eliminating the need for repair work on the construction side. As a result, construction work and equipment installation work can be done more efficiently, shortening the construction period.

In addition, it is possible to more reliably prevent deterioration in appearance due to the presence of removed or repaired areas of the covering material, resulting in a high level of appearance quality. Furthermore, by eliminating the need to remove or repair the covering material, it is possible to more reliably achieve the intended function of the covering material, thereby improving the quality of the floor structure.

Means 2. A floor base formed by constructing a vertical form using combustible tubular members temporarily installed on a predetermined floor form corresponding to frame holes formed in the floor form, and then pouring a predetermined floor material onto the outside of the tubular members on the floor form;
A floor structure comprising a covering material sprayed onto the underside of the floor formwork,
The cylindrical member is removed after the floor material is poured,
The frame hole is formed by cutting the floor formwork endlessly inside a portion of the floor base corresponding to the removed portion of the tubular member, and has a diameter smaller than the inner diameter of the tubular member,
The extension sleeve is cylindrical, has an outwardly protruding locking portion formed at the top, and is provided in series with a portion of the floor base corresponding to the removal location of the tubular member by being locked to a portion of the floor formwork that forms the frame hole, and has a length that allows at least the lower portion to protrude downward beyond the covering material,
A floor structure characterized in that the covering material is sprayed onto the outside of the extension sleeve on the underside of the floor formwork.

Note that the phrase "the portion of the bed base corresponding to the location where the tubular member was removed" can be rephrased as the portion of the bed base that forms the space remaining after the tubular member is removed (the portion that faces that space).

According to the above-mentioned method 2, in a floor structure in which a tubular member is temporarily installed on the floor base and then floor material is poured, and a frame hole is formed inside the space remaining after the tubular member is removed, an extension sleeve having a length that allows at least the lower portion to protrude below the covering material is installed in series with the portion of the floor base corresponding to the location where the tubular member was removed. In this floor structure, the tubular member that serves as the vertical formwork is a paper void or a flammable void board box, etc., and it is assumed that the tubular member will be removed after the floor material is poured. By installing such an extension sleeve, the same effects as method 1 can be achieved.

Means 3. A pipe that passes through the frame hole and penetrates the floor base and the covering material in the vertical direction;
a filler material filled between at least a portion of the floor base corresponding to the tubular member and the piping;
a sealing member attached to at least the outer peripheral surface of the pipe to prevent the filler from leaking downward,
The floor structure described in means 1 or 2, characterized in that the sealing member is attached from the outer surface of the portion of the piping that passes through the extension sleeve and protrudes downward beyond the extension sleeve to the outer surface of the portion of the extension sleeve that protrudes downward beyond the covering material.

Note that "the portion of the bed base corresponding to the tubular member" refers to the "tubular member" in the above-mentioned Measure 1 (when subordinate to the above-mentioned Measure 1), and refers to the "portion of the bed base corresponding to the removed portion of the tubular member" in the above-mentioned Measure 2 (when subordinate to the above-mentioned Measure 2).

Conventionally, a sealing member to prevent the filler material from leaking downward is attached from the outer surface of the pipe to the surface of the covering material. However, the surface of the covering material has many small irregularities. This makes the sealing member prone to peeling and can also lead to a deterioration in the appearance of the sealing member when attached.

In response to this, it is possible to consider a configuration in which a sealing member is attached to the underside of the floor formwork, but in this case, the portion of the floor formwork to which the sealing member will be attached must not be covered with a covering material. However, if this is done, there is a risk that the intended functions (such as fire resistance) of the covering material will not be fully realized.

In this regard, according to the third method, the sealing member is attached not to the surface of the covering material, but to the outer peripheral surface of the extension sleeve at a portion that protrudes below the covering material. This makes the sealing member less likely to peel off compared to when the sealing member is attached to the surface of the covering material, and also improves the appearance of the attached sealing member.

Furthermore, in order to attach the sealing member (to ensure a surface to which the sealing member can be attached), it is not necessary to leave part of the floor formwork uncovered with covering material. This allows the intended function of the covering material to be more reliably achieved.

Means 4. A floor base formed by pouring a predetermined floor material onto a predetermined floor form, and having a through hole penetrating the floor form and the floor material;
A floor structure comprising a covering material sprayed onto the underside of the floor formwork,
The extension sleeve is cylindrical, has a plurality of slits formed in the upper part thereof extending in the axial direction or in a direction oblique to the axis, and has a plurality of support parts formed in the upper part by bending outward the portions located between the slits, and is provided in series with the through hole forming part by pressing the plurality of support parts against the through hole forming part, which is the part in the floor base where the through hole is formed, and is fixed to the through hole forming part with a predetermined caulking material, and has a length such that at least the lower part can protrude below the covering material,
A floor structure characterized in that the covering material is sprayed onto the outside of the extension sleeve on the underside of the floor formwork.

Method 4 described above achieves the same effects as method 1 described above in floor structures in which through-holes are formed in the floor base by core drilling or the like.

Furthermore, according to the above-mentioned method 4, the extension sleeve has multiple support parts formed using relatively simple techniques such as forming slits and bending them outward, and these multiple support parts are used to arrange the extension sleeve in series with the through-hole forming part of the floor base. Therefore, it is possible to effectively suppress the increase in labor and costs associated with manufacturing the extension sleeve.

Means 5. A pipe that passes through the through hole and penetrates the floor base and the covering material in the vertical direction;
a filler material filled at least between the through-hole forming portion and the piping;
a sealing member attached to at least the outer peripheral surface of the pipe to prevent the filler from leaking downward,
The floor structure described in means 4 is characterized in that the sealing member is attached from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward below the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward below the covering material.

Method 5 above achieves the same effects as method 3 above.

Means 6. A floor base having a tubular member installed on the floor form corresponding to a frame hole formed in the floor form, and a predetermined floor material cast outside the tubular member on the floor form;
A covering material sprayed onto the underside of the floor formwork;
A pipe is provided in a state where it passes through the cylindrical member and the frame hole and penetrates the floor base and the covering material in the vertical direction;
a filler material filled at least between the cylindrical member and the pipe;
A construction method for a floor structure comprising a sealing member attached to at least the outer peripheral surface of the piping to prevent the filler material from leaking downward,
a frame hole forming process in which the floor formwork is cut endlessly inside the cylindrical member to form the frame hole having a diameter smaller than the inner diameter of the cylindrical member;
an extension sleeve installation process in which an extension sleeve having a cylindrical shape, an outwardly protruding locking portion formed at the top, and a length that allows at least the lower portion to protrude below the covering material is inserted into the frame hole from above, and the locking portion is locked to the portion of the floor formwork that forms the frame hole, thereby arranging the extension sleeve and the tubular member in series;
a coating material spraying process for spraying the coating material onto the outside of the extension sleeve on the underside of the floor formwork after the extension sleeve installation process;
a piping insertion step of inserting the piping into the cylindrical member and the extension sleeve;
After the piping insertion step, a pasting step of pasting the sealing member from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward from the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward from the covering material;
A floor structure construction method characterized by including, after the attaching step, a filling step of filling the filler material between the piping and the tubular member and the extension sleeve.

Measure 6 above provides the same effects as those provided by measures 1 and 3 above.

Means 7. A floor base formed by constructing a vertical form using combustible tubular members temporarily installed on a predetermined floor form in accordance with frame holes formed in the floor form, and then pouring a predetermined floor material onto the outside of the tubular members on the floor form;
A covering material sprayed onto the underside of the floor formwork;
a pipe that passes through a portion of the floor base corresponding to the removed portion of the tubular member and the frame hole, and that is provided in a state of vertically penetrating the floor base and the covering material;
a filler material filled between at least a portion of the floor base corresponding to the removed portion of the cylindrical member and the piping;
A construction method for a floor structure comprising a sealing member attached to at least the outer peripheral surface of the piping to prevent the filler material from leaking downward,
a cylindrical member removing step of removing the cylindrical member after the floor material is poured;
a frame hole forming process in which the floor formwork is cut endlessly inside a portion of the floor base corresponding to the removed portion of the tubular member to form the frame hole having a diameter smaller than the inner diameter of the tubular member;
an extension sleeve installation process in which a cylindrical extension sleeve having an outwardly protruding locking portion formed at the top and a length that allows at least the lower portion to protrude below the covering material is inserted into the frame hole from above, and the locking portion is locked to the portion of the floor formwork that forms the frame hole, thereby arranging the extension sleeve in series with the portion of the floor base that corresponds to the removed portion of the tubular member;
a coating material spraying process for spraying the coating material onto the outside of the extension sleeve on the underside of the floor formwork after the extension sleeve installation process;
a piping insertion step of inserting the piping into a portion of the bed base corresponding to the removed portion of the tubular member and into the extension sleeve;
After the piping insertion step, a pasting step of pasting the sealing member from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward from the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward from the covering material;
A floor structure construction method characterized by including, after the attaching process, a filling process of filling the filler material between the piping and the area of the floor base corresponding to the removed location of the tubular member and the extension sleeve.

Method 7 above provides the same effects as those provided by methods 2 and 3 above.

Means 8. A floor base formed by pouring a predetermined floor material onto a predetermined floor form, and a through hole penetrating the floor form and the floor material is opened after the floor material is poured;
A covering material sprayed onto the underside of the floor formwork;
A pipe that passes through the through hole and penetrates the floor base and the covering material in the vertical direction;
A filler material is filled between at least a through-hole forming portion, which is a portion of the floor base where the through-hole is formed, and the piping;
A construction method for a floor structure comprising a sealing member attached to at least the outer peripheral surface of the piping to prevent the filler material from leaking downward,
an extension sleeve installation process in which an extension sleeve having a cylindrical shape, a plurality of slits formed in the upper part extending in the axial direction or in a direction oblique to the axis, and a plurality of support parts formed in the upper part by bending outward the portions located between the slits, and a length that allows at least a lower part to protrude below the covering material, is inserted into the through hole from above, and while pressing the plurality of support parts against the through hole forming part, the extension sleeve is fixed to the through hole forming part with a predetermined caulking material, thereby arranging the extension sleeve and the through hole forming part in series;
a coating material spraying process for spraying the coating material onto the outside of the extension sleeve on the underside of the floor formwork after the extension sleeve installation process;
a piping insertion step of inserting the piping into the through hole and the extension sleeve;
After the piping insertion step, a pasting step of pasting the sealing member from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward from the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward from the covering material;
A floor structure construction method characterized by including, after the attaching step, a filling step of filling the filler material between the piping and the through hole forming portion and the extension sleeve.

Measure 8 above provides the same effects as those provided by measures 4 and 5 above.

FIG. 2 is a partially cutaway front view of the floor structure according to the first embodiment. FIG. 2 is a partially enlarged perspective schematic view of a sealing member attached to a pipe or the like. FIG. 2 is a partially enlarged perspective schematic view showing a gap formed between a pipe and an extension sleeve. FIG. 2 is a schematic perspective view showing a sealing member before use. 4 is a flowchart showing the construction process of the floor structure in the first embodiment. FIG. 3 is a partially cutaway schematic front view showing a state in which a locking portion is locked to a frame hole forming portion in the first embodiment. FIG. 2 is a partially cutaway schematic front view showing the state in which a covering material has been sprayed onto the underside of the floor formwork in the first embodiment. FIG. 2 is a partially cutaway schematic front view showing a state in which piping is inserted into a cylindrical member and an extension sleeve in the first embodiment. FIG. 2 is a partially cutaway schematic front view showing a state in which a sealing member is attached from the extension sleeve to the piping in the first embodiment. FIG. 10 is a partially cutaway front view of a floor structure according to a second embodiment. FIG. 10 is a schematic perspective view showing a slit formed in an extension sleeve in the second embodiment. FIG. 10 is a schematic perspective view showing an extension sleeve according to a second embodiment. 10 is a flowchart showing the construction process of the floor structure in the second embodiment. FIG. 11 is a partially cutaway perspective schematic view showing insertion of an extension sleeve into a through hole in the second embodiment. FIG. 11 is a partially cutaway schematic front view showing an extension sleeve inserted into a through hole in the second embodiment. FIG. 10 is a partially cutaway schematic front view showing the state in which the extension sleeve is fixed to the through-hole forming portion by caulking material in the second embodiment. FIG. 10 is a partially cutaway schematic front view showing the state in which a covering material has been sprayed onto the underside of the floor formwork in the second embodiment. FIG. 11 is a partially cutaway schematic front view showing a state in which a pipe is inserted into a through hole and an extension sleeve in the second embodiment. FIG. 11 is a partially cutaway schematic front view showing a state in which a sealing member is attached from the extension sleeve to the piping in the second embodiment. FIG. 1 is a partially cutaway perspective schematic diagram showing a state in which floor material has been poured into a floor formwork in the prior art. FIG. 1 is a schematic cross-sectional view showing a state in which a frame hole is formed in a floor formwork in the prior art. FIG. 1 is a schematic cross-sectional view showing a state in which a covering material is sprayed onto the underside of a floor formwork in the prior art. FIG. 1 is a schematic cross-sectional view showing a state in which excess coating material has been removed in the prior art. FIG. 1 is a schematic front view, partially cut away, showing a state in which a pipe is inserted into a cylindrical member or the like in the prior art. FIG. 1 is a partially cutaway front view showing a state in which a sealing member is attached from a pipe to a covering material in the prior art. FIG. 2 is a partially cutaway schematic front view of a floor structure from which a tubular member is finally removed in the first embodiment.

Hereinafter, embodiments will be described with reference to the drawings.
First Embodiment
The floor structure 11 is a structure corresponding to the floor of a building, and as shown in FIG. 1, includes a floor base 12, a covering material 13, piping 14, an extension sleeve 15, a sealing member 16, and a filler material 17.

The floor base 12 is a composite floor formed by pouring a predetermined floor material 122 (e.g., concrete, mortar, etc.) onto a floor formwork 121 made of thin steel plates. In this embodiment, the floor formwork 121 is a so-called flat deck, and is formed by bending it so that protruding ridges 121a protrude downward to ensure rigidity, while the upper surface is configured to be flat. Note that the upper surface of the floor formwork 121 may also have some irregularities.

The floor base 12 also includes a tubular member 123 for preventing the floor material 122 from being poured into the area of the floor formwork 121 where the frame hole 121b (described below) is to be formed. The tubular member 123 is cylindrical and formed from a specified thin-walled metal plate. Note that the tubular member 123 may be, for example, a non-cylindrical shape (such as a rectangular tubular member), or may have a grid or the like formed on the inner periphery to prevent falling. As another example, the tubular member 123 may be cylindrical or rectangular, but may also constitute a vertical formwork made from a flammable material such as specified paper or corrugated resin board, and may be removed after the floor material 122 is poured.

In this embodiment, tubular members 123 are installed on the floor formwork 121 in correspondence with the planned locations of frame holes 121b (described later), and flooring 122 is then poured outside the tubular members 123 on the floor formwork 121, thereby preventing the flooring 122 from being poured into the planned locations of frame holes 121b. Before pouring the flooring 122, mesh reinforcement, prefabricated rebar trusses, and standard reinforcement are arranged on the floor formwork 121, and the flooring 122 is poured so that the mesh reinforcement is embedded. A cover (not shown) may be installed to cover the upper opening of the tubular members 123, or a member may be placed between the top surface of the floor formwork 121 and the lower end of the tubular members 123 to seal the gap between them, before pouring the flooring 122. Depending on the size of the tubular members 123, reinforcing bars may be placed around the tubular members 123 to reinforce the floor base 12.

Furthermore, a frame hole 121b that penetrates the floor formwork 121 is formed at a position in the floor base 12 that overlaps with the inside of the tubular member 123. The frame hole 121b is used to pass the piping 14 and is formed after the floor material 122 is poured. More specifically, after the floor material 122 is poured, the inner space of the tubular member 123 basically forms a space for the insertion of the piping 14, but since only the floor formwork 121 exists in a way that prevents this insertion, the floor formwork 121, which is a thin steel plate, is cut and removed endlessly inside the tubular member 123, thereby forming a frame hole 121b with a diameter smaller than the inner diameter of the tubular member 123. Furthermore, when using a tubular member 123 made of a combustible material, this tubular member 123 is removed after the bedding material 122 is poured. However, after that, the only difference is that the tubular member 123 is not present, but the internal space at the portion of the floor base 12 corresponding to the removal of the tubular member 123 forms a space for the insertion of the piping 14, and only the floor formwork 121 exists to prevent the insertion. Therefore, in this case, too, the floor formwork 121, which is made of thin steel plate, is endlessly cut and removed within the tubular member 123 or within the portion of the floor base 12 corresponding to the removal of the tubular member 123 (the cylindrical space formed after the bedding material 122 solidifies due to the presence of the tubular member 123), thereby forming a frame hole 121b with a diameter smaller than the inner diameter of the tubular member 123.

Furthermore, as described above, the inner diameter of frame hole 121b is smaller than the inner diameter of tubular member 123. As a result, frame hole forming portion 121c, which is the portion that forms frame hole 121b in floor formwork 121, has an inner flange shape that protrudes inward from the inner circumferential surface of tubular member 123 (or the portion where tubular member 123 was located). The shape of frame hole 121b is not particularly limited as long as frame hole forming portion 121c has a shape that protrudes inward from the inner circumferential surface of tubular member 123 (or the portion where tubular member 123 was located), and may be, for example, rectangular or polygonal in plan view.

The covering material 13 is applied by spraying it onto the outside of the extension sleeve 15 on the underside of the floor formwork 121 after the frame hole 121b is formed, covering the entire underside of the floor formwork 121. Examples of covering material 13 include heat insulating material and fire-resistant covering material. The surface of the covering material 13 has many small irregularities.

The piping 14 is formed from a specified metal plate and has a cylindrical shape. The piping 14 passes through the tubular member 123 (or the area of the bed base 12 corresponding to the removed portion of the tubular member 123) and the frame hole 121b, penetrating the bed base 12 and the covering material 13 from top to bottom. The outer surface of the piping 14 is smooth and even.

The extension sleeve 15 is a cylindrical member whose function, when spraying the coating material 13, is to prevent the coating material 13 from spilling into the space where the piping 14 is placed (the space where it is intended to be placed). The extension sleeve 15 is made of a thin (e.g., 0.5 mm) metal plate (e.g., iron plate) and has an outer diameter slightly smaller than the inner diameter of the frame hole 121b (e.g., an outer diameter 5 mm smaller than the inner diameter of the frame hole 121b).

Furthermore, a flange-shaped engaging portion 15a is formed on the upper portion of the extension sleeve 15 by, for example, flange processing (flaring), and protrudes outward. The engaging portion 15a engages with the frame hole forming portion 121c, so that the extension sleeve 15 is arranged in series with the tubular member 123 (or the portion of the bed base 12 corresponding to the removed portion of the tubular member 123). The engaging portion 15a may also have a tapered shape, with the outer diameter gradually increasing toward the upper end of the extension sleeve 15.

The extension sleeve 15 has a length that allows at least the lower portion to protrude downward from the covering material 13. In this embodiment, the length of the extension sleeve 15 is set to a length that allows it to protrude downward from the covering material 13 by, for example, approximately 100 mm. Furthermore, the outer peripheral surface of at least the portion of the extension sleeve 15 that protrudes downward from the covering material 13 is smoother than the surface of the covering material 13.

The sealing member 16 is a sheet-like member made of a thin metal sheet, such as aluminum, with an adhesive layer applied to the backside. The sealing member 16 is attached from the outer peripheral surface of the portion of the piping 14 that passes through the extension sleeve 15 and protrudes downward beyond the extension sleeve 15 to the outer peripheral surface of the portion of the extension sleeve 15 that protrudes downward beyond the covering material 13 (see Figure 2). This seals the gap S (see Figure 3) located between the lower end of the extension sleeve 15 and the piping 14, thereby preventing downward leakage of the filler material 17. Before use, the sealing member 16 is a flat sheet with a rectangular shape in a plan view. The sealing member 16 is used with its central circular portion 16a bent outward (see Figure 4). Figure 1 and other figures show a simplified view of the portion of the sealing member 16 that is attached to the extension sleeve 15.

The filler material 17 is filled between the outer surface of the pipe 14 and the inner surfaces of the tubular member 123 (or the portion of the bed base 12 corresponding to the removed portion of the tubular member 123) and the extension sleeve 15. Examples of the filler material 17 include mortar and rock wool.

Next, the construction method (construction process) for the above-mentioned floor structure 11 will be described. As shown in Figure 5, the construction process for the floor structure 11 includes a pouring process, a frame hole forming process, an extension sleeve installation process, a coating material spraying process, a piping insertion process, an adhering process, and a filling process. Here, the construction of the floor structure 11 is carried out by both the construction work side and the equipment work side, with at least the extension sleeve installation process, the piping insertion process, and the adhering process being carried out by the equipment work side, and at least the coating material spraying process being carried out by the construction work side.

First, in the casting process of step S1, a tubular member 123 is placed on the floor formwork 121 corresponding to the intended location of the frame hole 121b, and then reinforcement (not shown) is applied. After that, floor material 122 is cast outside the tubular member 123 on the floor formwork 121.

Next, in the frame hole forming process of step S2, a predetermined cutting tool (e.g., a saber saw) is used to cut the floor form 121 endlessly inside the tubular member 123, thereby forming a frame hole 121b in the floor form 121. With the formation of the frame hole 121b, an inner flange-shaped frame hole forming portion 121c that protrudes inward from the inner surface of the tubular member 123 is formed in the floor form 121. When using a tubular member 123 made of a flammable material, a "tubular member removal process" is performed to remove the tubular member 123. For example, when the tubular member 123 is made of a paper void, a release agent is typically applied to the outer surface of the paper void. Therefore, the tubular member 123 can be peeled off and removed by deforming the paper void so that it is recessed toward the interior of the space. Furthermore, when using a tubular member 123 made of a flammable material, the frame hole 121b can be formed by cutting the floor formwork 121 inside the area of the floor base 12 corresponding to the area where the tubular member 123 will be removed.

Next, in the extension sleeve installation process of step S3, the extension sleeve 15 is inserted into the frame hole 121b from above, and the locking portion 15a is locked into the frame hole forming portion 121c, resulting in a state in which the extension sleeve 15 and the tubular member 123 (or the portion of the floor base 12 corresponding to the removed portion of the tubular member 123) are arranged in series (see Figure 6; Figures 6-9 are diagrams showing the case in which the tubular member 123 is ultimately left). Note that when the tubular member removal process is performed, the extension sleeve 15 and the portion of the floor base 12 corresponding to the removed portion of the tubular member 123 (in this embodiment, the floor material 122 located just outside the tubular member 123 in Figure 6) are arranged in series. The extension sleeve installation process is performed by the facility construction company. Note that a member to seal the gap between the locking portion 15a and the frame hole forming portion 121c may be placed between them. This member may be pre-fixed to the locking portion 15a before inserting the extension sleeve 15 into the frame hole 121b.

In the subsequent coating material spraying process of step S4, the coating material 13 is sprayed onto the outside of the extension sleeve 15 on the underside of the floor formwork 121 (see Figure 7). The coating material spraying process is performed by the construction work side, not the equipment construction side. Due to the presence of the extension sleeve 15, the construction work side will usually not spray the coating material 13 onto the tubular member 123 side (inside the extension sleeve 15), but will only spray the coating material 13 onto the outside of the extension sleeve 15.

Next, in the pipe insertion process of step S5, the pipe 14 is inserted into the tubular member 123 (or into the portion of the floor base 12 corresponding to the location where the tubular member 123 was removed) and into the extension sleeve 15 (see Figure 8). The pipe insertion process is performed by the equipment installation team. Here, when the pipe 14 is inserted, there is no coating material 13 in a position that would hinder the insertion and installation of the pipe 14, so the pipe 14 is inserted without removing any excess coating material 13. Note that the pipe insertion process may be performed before the coating material spraying process.

Next, in the attachment process of step S6, the sealing member 16 is attached from the outer peripheral surface of the portion of the piping 14 that protrudes downwardly beyond the extension sleeve 15 to the outer peripheral surface of the portion of the extension sleeve 15 that protrudes downwardly beyond the covering material 13 (see Figure 9).

Then, in the filling process of step S7, filler material 17 is filled between the piping 14 and the tubular member 123 (or the portion of the floor base 12 corresponding to the location where the tubular member 123 was removed), and the extension sleeve 15, thereby completing the construction of the floor structure 11. The floor structure 11 from which the tubular member 123 is finally removed will have the configuration shown in Figure 26.

As described above, according to this embodiment, the provision of the extension sleeve 15 more reliably prevents excess coating material 13 from adhering and interfering with the insertion of the pipe 14 when spraying the coating material 13, thereby eliminating the need to cut and remove the excess coating material 13. As a result, the coating material 13 does not peel off or chip excessively when removed, eliminating the need for repair work on the construction side to repair the coating material 13. As a result, construction work and facility construction work can be done more efficiently, and the construction period can be shortened.

In addition, it is possible to more reliably prevent deterioration in appearance due to the presence of removed or repaired portions of the covering material 13, resulting in a high level of appearance quality. Furthermore, by eliminating the need to remove or repair the covering material 13, it is possible to more reliably achieve the intended functions (such as thermal insulation and fire resistance) of the covering material 13, thereby improving the quality of the floor structure 11.

In addition, the sealing member 16 is attached not to the surface of the covering material 13, but to the outer peripheral surface of the extension sleeve 15 at a portion that protrudes downward from the covering material 13. This makes the sealing member 16 less likely to peel off compared to when it is attached to the surface of the covering material 13, and also improves the appearance of the sealing member 16 when attached.

Furthermore, in order to attach the sealing member 16 (to ensure a surface to which the sealing member 16 is attached), it is not necessary to leave part of the floor formwork 121 uncovered by the covering material 13. This makes it possible to more reliably achieve the intended function of providing the covering material 13.
Second Embodiment
Next, the second embodiment will be described, focusing on the differences from the first embodiment. In the first embodiment, the floor base 12 of the floor structure 11 is formed by installing a tubular member 123 on the floor formwork 121 in correspondence with the frame hole 121b of the floor formwork 121, and then pouring a floor material 122 outside the tubular member 123 on the floor formwork 121. In contrast, in the second embodiment, as shown in Figure 10, the floor base 22 of the floor structure 21 is formed by pouring a floor material 222 on the floor formwork 221, and then forming a through hole 22a that penetrates the floor formwork 221 and the floor material 222 by a core drilling method or the like. Therefore, in this second embodiment, the floor base 22 has a through hole 22a for passing the piping 24 formed without using a cylindrical member 123, and the through hole 22a has a constant inner diameter in the vertical direction, and the portion of the floor formwork 221 that forms the frame hole 221b (frame hole forming portion 221c) does not protrude inward.

The floor formwork 221 in this second embodiment is a so-called Fellow Deck (registered trademark), and has reinforcing bars (not shown) such as reinforcing bar trusses pre-installed on its upper surface. The reinforcing bars become embedded in the floor material 222 when the floor material 222 is poured into the floor formwork 221. The through-holes 22a are formed after the floor material 222 is poured.

In addition, in this second embodiment, the extension sleeve 25 is configured to have multiple support portions 25a on its upper portion, in response to the frame hole forming portion 221c not protruding inward as described above. Here, the multiple support portions 25a are formed by forming multiple slits 25b extending in the axial direction (the central axial direction of the extension sleeve 25) on the upper portion of the extension sleeve 25, and bending the portions of the extension sleeve 25 located between the slits 25b outward (see Figures 11 and 12). Note that the slits 25b may also extend obliquely relative to the axis of the extension sleeve 25.

The extension sleeve 25 is arranged in series with the through-hole forming portion 22b, which forms the through-hole 22a in the floor base 22, by pressing multiple support portions 25a against the through-hole forming portion 22b, and fixing the support portions 25a to the through-hole forming portion 22b with a specified caulking material 28. The caulking material 28 is, for example, a silicone-based caulking material (sealing material) that hardens over time. The presence of the caulking material 28 prevents communication between the space within the through-hole forming portion 22b and the space outside the extension sleeve 25 through gaps between the support portions 25a.

The covering material 23, piping 24, sealing member 26, and filler material 27 in this second embodiment are similar to the covering material 13, piping 14, sealing member 16, and filler material 17 in the first embodiment. However, in this second embodiment, the piping 24 passes through the through-hole 22a and penetrates the bed base 22 and covering material 23 vertically. Furthermore, the filler material 27 is filled between the outer surface of the piping 24 and the inner surfaces of the through-hole forming portion 22b and the extension sleeve 25.

Next, the construction method (construction process) for the floor structure 21 in this second embodiment will be described. As shown in Figure 13, the construction process for the floor structure 21 includes a pouring process, a through-hole forming process, an extension sleeve installation process, a coating material spraying process, a piping insertion process, an attachment process, and a filling process. Here, at least the extension sleeve installation process, the piping insertion process, and the attachment process are performed on the equipment construction side, and at least the coating material spraying process is performed on the building construction side.

First, in the casting process of step S11, floor material 222 is cast onto floor formwork 221, on which reinforcing bars have already been placed. Next, in the through-hole forming process of step S12, a core cutting tool such as a diamond core drill (diamond core cutter) is used to cut out the floor material 222 and floor formwork 221, forming through-holes 22a in the floor base 22.

Next, in the extension sleeve installation process of step S13, the extension sleeve 25 is inserted into the through hole 22a from above, and multiple support portions 25a are pressed against the lower part of the through hole forming portion 22b (see Figures 14 and 15). Furthermore, by injecting caulking material 28 onto the outer periphery of the support portions 25a, the extension sleeve 25 is fixed to the through hole forming portion 22b with the caulking material 28, and the extension sleeve 25 and the through hole forming portion 22b are arranged in series (see Figure 16). The extension sleeve installation process is performed by the facility construction team.

In the subsequent coating material spraying process of step S14, the coating material 23 is sprayed onto the outside of the extension sleeve 25 on the underside of the floor formwork 221 (see Figure 17). The coating material spraying process is carried out by the construction site.

Next, in the pipe insertion process of step S15, the pipe 24 is inserted into the through-hole 22a and extension sleeve 25 (see Figure 18). The pipe insertion process is performed by the facility construction company. Note that the pipe insertion process may be performed before the coating material spraying process.

Next, in the attachment process of step S16, similar to the first embodiment described above, the sealing member 26 is attached from the outer peripheral surface of the portion of the piping 24 that protrudes downwardly beyond the extension sleeve 25 to the outer peripheral surface of the portion of the extension sleeve 25 that protrudes downwardly beyond the covering material 23 (see Figure 19).

Then, in the filling process of step S17, the filler material 27 is filled between the piping 24 and the through-hole forming portion 22b and the extension sleeve 25, thereby completing the construction of the floor structure 21.

As described above, this second embodiment basically achieves the same effects as the first embodiment.

In addition, in this second embodiment, the extension sleeve 25 has multiple support portions 25a formed using relatively simple techniques such as forming slits 25b and bending them outward, and these multiple support portions 25a are used to provide a series connection with the through-hole forming portion 22b. This effectively reduces the effort and cost involved in manufacturing the extension sleeve 25.

The technical features of the first embodiment and the second embodiment may be combined as appropriate. For example, the extension sleeve 15 in the first embodiment may be provided with a locking portion 15a having a structure similar to the support portion 25a in the second embodiment.

Note that the present invention is not limited to the above-described embodiment, and may be implemented, for example, as follows. Of course, other applications and modifications not exemplified below are also possible.

(a) In the above embodiment, the extension sleeves 15, 25 are cylindrical, but the extension sleeves may be cylindrical in shape and are not limited to cylindrical. Therefore, for example, the extension sleeves may be rectangular, elliptical, or polygonal (hexagonal, etc.) in shape.

(b) In the above embodiment, the sealing members 16, 26 are sheet-like members, but tape (e.g., aluminum tape) may also be used as the sealing members. Of course, both sheet-like members and tape may also be used as the sealing members.

(c) In the above embodiment, flat decks and Fellow Decks (registered trademarks) are used as the floor formwork 121, 221, but deck plates other than these may also be used as the floor formwork.

(d) In the above embodiment, the tubular member 123 and the through-hole 22a are configured to have the pipes 14 and 24 inserted therethrough. However, the tubular member 123 and the through-hole 22a may also be configured to have something other than a pipe, such as a wiring cable, inserted therethrough.

11, 12...Floor structure, 12, 22...Floor base, 13, 23...Covering material, 14, 24...Piping, 15, 25...Extension sleeve, 15a...Latching portion, 16, 26...Sealing member, 17, 27...Filling material, 22a...Through hole, 22b...Through hole forming portion, 25a...Support portion, 25b...Slit, 28...Caulking material, 121, 221...Floor formwork, 121b, 221b...Frame hole, 122, 222...Floor material, 123...Cylindrical member.

Claims (8)

A floor base portion having a tubular member installed on the floor form corresponding to a frame hole formed in the floor form, and a predetermined floor material cast outside the tubular member on the floor form;
A floor structure comprising a covering material sprayed onto the underside of the floor formwork,
The frame hole is formed by cutting the floor formwork on which the tubular member is installed endlessly inside the tubular member, and has a diameter smaller than the inner diameter of the tubular member,
The extension sleeve is cylindrical, has an outwardly protruding locking portion formed at the top, and is provided in series with the cylindrical member by being locked to a portion of the floor formwork that forms the frame hole, and has a length that allows at least the lower portion to protrude downward beyond the covering material,
A floor structure characterized in that the covering material is sprayed onto the outside of the extension sleeve on the underside of the floor formwork. A floor base is formed by constructing a vertical form using combustible tubular members temporarily installed on a predetermined floor form corresponding to a frame hole formed in the floor form, and then pouring a predetermined floor material outside the tubular members on the floor form;
A floor structure comprising a covering material sprayed onto the underside of the floor formwork,
The cylindrical member is removed after the floor material is poured,
The frame hole is formed by cutting the floor formwork endlessly inside a portion of the floor base corresponding to the removed portion of the tubular member, and has a diameter smaller than the inner diameter of the tubular member,
The extension sleeve is cylindrical, has an outwardly protruding locking portion formed at the top, and is provided in series with a portion of the floor base corresponding to the removal location of the tubular member by being locked to a portion of the floor formwork that forms the frame hole, and has a length that allows at least the lower portion to protrude downward beyond the covering material,
A floor structure characterized in that the covering material is sprayed onto the outside of the extension sleeve on the underside of the floor formwork. A pipe that passes through the frame hole and penetrates the floor base and the covering material in the vertical direction;
a filler material filled between at least a portion of the floor base corresponding to the tubular member and the piping;
a sealing member attached to at least the outer peripheral surface of the pipe to prevent the filler from leaking downward,
The floor structure described in claim 1 or 2, characterized in that the sealing member is attached from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward below the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward below the covering material. A floor base formed by pouring a predetermined floor material onto a predetermined floor form, and having a through hole penetrating the floor form and the floor material;
A floor structure comprising a covering material sprayed onto the underside of the floor formwork,
The extension sleeve is cylindrical, has a plurality of slits formed in the upper part thereof extending in the axial direction or in a direction oblique to the axis, and has a plurality of support parts formed in the upper part by bending outward the portions located between the slits, and is provided in series with the through hole forming part by pressing the plurality of support parts against the through hole forming part, which is the part in the floor base where the through hole is formed, and is fixed to the through hole forming part with a predetermined caulking material, and has a length such that at least the lower part can protrude below the covering material,
A floor structure characterized in that the covering material is sprayed onto the outside of the extension sleeve on the underside of the floor formwork. A pipe that passes through the through hole and penetrates the floor base and the covering material in the vertical direction;
a filler material filled at least between the through-hole forming portion and the piping;
a sealing member attached to at least the outer peripheral surface of the pipe to prevent the filler from leaking downward,
The floor structure described in claim 4, characterized in that the sealing member is attached from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward beyond the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward beyond the covering material. A floor base portion having a tubular member installed on the floor form corresponding to a frame hole formed in the floor form, and a predetermined floor material cast outside the tubular member on the floor form;
A covering material sprayed onto the underside of the floor formwork;
A pipe is provided in a state where it passes through the cylindrical member and the frame hole and penetrates the floor base and the covering material in the vertical direction;
a filler material filled at least between the cylindrical member and the pipe;
A construction method for a floor structure comprising a sealing member attached to at least the outer peripheral surface of the piping to prevent the filler material from leaking downward,
a frame hole forming process in which the floor formwork is cut endlessly inside the cylindrical member to form the frame hole having a diameter smaller than the inner diameter of the cylindrical member;
an extension sleeve installation process in which an extension sleeve having a cylindrical shape, an outwardly protruding locking portion formed at the top, and a length that allows at least the lower portion to protrude below the covering material is inserted into the frame hole from above, and the locking portion is locked to the portion of the floor formwork that forms the frame hole, thereby arranging the extension sleeve and the tubular member in series;
a coating material spraying process for spraying the coating material onto the outside of the extension sleeve on the underside of the floor formwork after the extension sleeve installation process;
a piping insertion step of inserting the piping into the cylindrical member and the extension sleeve;
After the piping insertion step, a pasting step of pasting the sealing member from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward from the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward from the covering material;
A floor structure construction method characterized by including, after the attaching step, a filling step of filling the filler material between the piping and the tubular member and the extension sleeve. A floor base is formed by constructing a vertical form using combustible tubular members temporarily installed on a predetermined floor form corresponding to a frame hole formed in the floor form, and then pouring a predetermined floor material outside the tubular members on the floor form;
A covering material sprayed onto the underside of the floor formwork;
a pipe that passes through a portion of the floor base corresponding to the removed portion of the tubular member and the frame hole, and that is provided in a state of vertically penetrating the floor base and the covering material;
a filler material filled between at least a portion of the floor base corresponding to the removed portion of the cylindrical member and the piping;
A construction method for a floor structure comprising a sealing member attached to at least the outer peripheral surface of the piping to prevent the filler material from leaking downward,
a cylindrical member removing step of removing the cylindrical member after the floor material is poured;
a frame hole forming process in which the floor formwork is cut endlessly inside a portion of the floor base corresponding to the removed portion of the tubular member to form the frame hole having a diameter smaller than the inner diameter of the tubular member;
an extension sleeve installation process in which a cylindrical extension sleeve having an outwardly protruding locking portion formed at the top and a length that allows at least the lower portion to protrude below the covering material is inserted into the frame hole from above, and the locking portion is locked to the portion of the floor formwork that forms the frame hole, thereby arranging the extension sleeve in series with the portion of the floor base that corresponds to the removed portion of the tubular member;
a coating material spraying process for spraying the coating material onto the outside of the extension sleeve on the underside of the floor formwork after the extension sleeve installation process;
a piping insertion step of inserting the piping into a portion of the bed base corresponding to the removed portion of the tubular member and into the extension sleeve;
After the piping insertion step, a pasting step of pasting the sealing member from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward from the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward from the covering material;
A floor structure construction method characterized by including, after the attaching process, a filling process of filling the filler material between the piping and the area of the floor base corresponding to the removed location of the tubular member and the extension sleeve. A floor base formed by pouring a predetermined floor material onto a predetermined floor form, and a through hole penetrating the floor form and the floor material is opened after the floor material is poured;
A covering material sprayed onto the underside of the floor formwork;
A pipe that passes through the through hole and penetrates the floor base and the covering material in the vertical direction;
A filler material is filled between at least a through-hole forming portion, which is a portion of the floor base where the through-hole is formed, and the piping;
A construction method for a floor structure comprising a sealing member attached to at least the outer peripheral surface of the piping to prevent the filler material from leaking downward,
an extension sleeve installation process in which an extension sleeve having a cylindrical shape, a plurality of slits formed in the upper part extending in the axial direction or in a direction oblique to the axis, and a plurality of support parts formed in the upper part by bending outward the portions located between the slits, and a length that allows at least a lower part to protrude below the covering material, is inserted into the through hole from above, and while pressing the plurality of support parts against the through hole forming part, the extension sleeve is fixed to the through hole forming part with a predetermined caulking material, thereby arranging the extension sleeve and the through hole forming part in series;
a coating material spraying process for spraying the coating material onto the outside of the extension sleeve on the underside of the floor formwork after the extension sleeve installation process;
a piping insertion step of inserting the piping into the through hole and the extension sleeve;
After the piping insertion step, a pasting step of pasting the sealing member from the outer peripheral surface of the portion of the piping that passes through the extension sleeve and protrudes downward from the extension sleeve to the outer peripheral surface of the portion of the extension sleeve that protrudes downward from the covering material;
A floor structure construction method characterized by including, after the attaching step, a filling step of filling the filler material between the piping and the through hole forming portion and the extension sleeve.