Gate manufacturing method

Abstract

To provide a gate manufacturing method capable of manufacturing a gate having a solid and heavy appearance and high earthquake resistance in such a way of reducing the labor burden at a construction site and shortening a construction period.SOLUTION: In a factory, the following steps are performed: a steel structure construction step in which steel members are vertically and horizontally assembled by welding to form a gate-shaped steel structure 1; a plywood covering step in which a structural plywood 40 is directly fastened to the steel members to cover the steel structure 1 from the outside with the structural plywood 40 to form a plywood covered structure 2; and a waterproofing step in which the entire area of the outer surface of the structural plywood 40 in the plywood covered structure 2 is coated with a waterproofing layer including a waterproof material layer. A semi-finished product that has undergone the waterproofing step is transported to a construction site and fixed on a concrete foundation, and then the outer surface of the semi-finished product is decorated with a finishing material.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a gate. [Background technology]

[0002] At the boundary between the site of a building such as a house and the road, a gate (a gate-shaped structure) is sometimes installed to allow vehicles and people to enter and exit. Traditionally, concrete gates have been widely used. Concrete gates are popular with customers who want a solid feel.

[0003] However, concrete gates are manufactured by constructing formwork at the construction site, pouring concrete into the formwork, curing the concrete, and then removing the formwork. This poses problems in that the work at the construction site is multi-staged, labor-intensive, and takes a long time to complete. In particular, curing the concrete takes a long time, about four months. There is also the problem that outdoor work over a long period of time is affected by the weather. In addition, when construction work for a gate at the boundary with a road is carried out over a long period of time, the ingress and egress of construction vehicles and people causes problems for road traffic and is a nuisance to nearby residents.

[0004] In addition, concrete gates are heavy, so there is a risk of extensive damage if they were to collapse. Therefore, in order to increase earthquake resistance, it is necessary to place rebars vertically and horizontally inside the concrete, which is a time-consuming and labor-intensive process. Summary of the Invention [Problem to be solved by the invention]

[0005] In view of the above-mentioned circumstances, the present invention has an object to provide a method for manufacturing a gate that can produce a gate that has a heavy feel and is highly earthquake-resistant, while reducing the labor burden at the construction site and shortening the construction period. [Means for solving the problem]

[0006] In order to solve the above problems, the method for manufacturing a gate according to the present invention comprises the steps of: "The steel structure construction process involves assembling steel materials vertically and horizontally by welding to create a gate-shaped steel structure. A plywood covering process in which the structural plywood is directly fastened to the steel frame material to cover the steel frame structure from the outside with the structural plywood to form a plywood-covered structure; A waterproofing process is carried out in a factory to coat the entire area of ​​the outer surface of the structural plywood in the plywood-covered structure with a waterproofing layer including a layer of waterproofing material; The semi-finished product that has undergone the waterproofing process is transported by vehicle to the construction site, fixed onto a concrete foundation, and the outer surface of the semi-finished product is decorated with a finishing material.

[0007] This manufacturing method reduces the workload at the gate construction site because the steel frame construction process, plywood covering process, and waterproofing process are all carried out in the factory. In addition, while conventional methods for manufacturing concrete gates require several months just for curing the concrete, this manufacturing method, which carries out many processes in the factory, can significantly shorten the construction period at the construction site.

[0008] Thus, it is only possible to carry out most of the manufacturing process in a factory by using a steel frame structure constructed by welding steel materials as the base (the basic structure) of the gate. If the base of the gate were a structure constructed by assembling aluminum bars with bolts and screws, the holes that receive the bolts and screws would widen due to vibrations during transportation, causing the assembly to loosen and become wobbly, making it impossible to transport. In contrast, the steel frame structure that serves as the base of the gate in this configuration is a structure assembled vertically and horizontally by welding steel materials, and is a sturdy, rigid body. Therefore, the vibrations that occur when transporting the semi-finished gate by vehicle will not cause the steel frame structure to loosen or become wobbly.

[0009] In addition, because the steel structure is covered with structural plywood from the outside, the inside of the steel structure is hollow, making it significantly lighter than a concrete gate of the same size. This makes it easier to transport than a precast concrete gate that is made in a factory and then transported to the construction site by vehicle.

[0010] Furthermore, since a steel frame structure constructed by welding steel materials is a sturdy rigid body, a gate based on a steel frame structure has extremely high earthquake resistance.

[0011] In addition, the steel structure is covered from the outside with structural plywood, and while structural plywood, which is made of wood, is prone to corrosion when used outdoors, the entire outer surface of the structural plywood is coated with a waterproofing layer that includes a layer of waterproofing material, so that corrosion of the structural plywood is effectively prevented. Also, because the entire outer surface of the structural plywood is coated with a waterproofing layer, corrosion (rust) of the steel material that constitutes the steel structure covered with the structural plywood is similarly effectively prevented.

[0012] Although the inside of the steel frame structure is actually hollow, this is not evident from the outside, making it possible to manufacture a gate that gives off a sense of solidity.

[0013] In addition to the above configuration, the gate manufacturing method according to the present invention further comprises: "The plywood covering structure may be formed with a downwardly open box-shaped space for accommodating the rolled-up shutter."

[0014] With this configuration, the gate used as a shutter gate can be made to have a solid feel and high earthquake resistance, and can be manufactured with reduced labor burden at the construction site and shorter construction time. Effect of the Invention

[0015] As described above, according to the present invention, a gate manufacturing method can be provided that can produce a gate that has a heavy feel and is highly earthquake-resistant, while reducing the labor burden at the construction site and shortening the construction period. [Brief description of the drawings]

[0016] [Figure 1] FIG. 2 is a perspective view of a steel structure that has undergone a steel structure construction process. [Diagram 2] FIG. 2 is an explanatory diagram of a plywood-covered structure that has undergone a plywood covering process. [Diagram 3] FIG. 2 is an explanatory diagram of a waterproofed structure that has undergone a waterproofing process. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] Hereinafter, a gate manufacturing method according to a specific embodiment of the present invention and a gate manufactured by this manufacturing method will be described with reference to the drawings.

[0018] The gate manufacturing method of this embodiment includes a steel frame structure construction process, a plywood covering process, a waterproofing process, an accessory embedding process, a foundation pouring process, an installation and fixing process, and a finishing process. Among these processes, the steel frame structure construction process, the plywood covering process, the waterproofing process, and the accessory embedding process are carried out in the manufacturer's factory.

[0019] In the steel structure construction process, steel materials such as structural rolled steel materials or iron materials are assembled lengthwise and crosswise to construct a gate-shaped steel structure 1. The gate-shaped structure is a structure in which the upper ends of a pair of columnar structural members 20 standing on a base frame 10 are connected by a beam-shaped horizontal structural member 30.

[0020] More specifically, the base frame 10 is the part to be installed on the ground, and is a rectangular frame body in which both ends of a pair of long base horizontal members 11 are connected by short base horizontal members 12. Depending on the length of the long base horizontal members 11, the middle parts of the pair of long base horizontal members 11 may be connected by short base horizontal members 12. All of the connection points between the long base horizontal members 11 and the short base horizontal members 12 are joined by welding. Hereinafter, the direction in which the long base horizontal members 11 extend is referred to as the "horizontal direction", and the direction perpendicular thereto, i.e., the direction in which the short base horizontal members 12 extend, is referred to as the "front-rear direction".

[0021] The pair of columnar structural parts 20 is composed of a plurality of long column vertical members 21 extending in the up-down direction and a plurality of short column horizontal members 22 extending in the front-rear direction. The lower ends of the plurality of long column vertical members 21 are all welded to the base frame 10 and stand vertically from the base frame 10. The long column vertical members 21 include a pair of columns spaced apart in the front-rear direction at one of both ends in the lateral direction of the base frame 10, and a pair of columns spaced apart in the front-rear direction at the other end of the lateral direction of the base frame 10. The long column vertical members 21 that form pairs spaced apart in the front-rear direction at the same position in the lateral direction are connected by a plurality of short column horizontal members 22. The connection points between the long column vertical members 21 and the short column horizontal members 22 are all joined by welding.

[0022] Here, a pair of long column vertical members 21 connected by a plurality of short column horizontal members 22 is illustrated as being reinforced by a reinforcing vertical member 26. The reinforcing vertical members 26 are vertically erected from the base frame 10 by welding their respective lower ends to the base frame 10, and are adjacent to the long column vertical member 21. The reinforcing vertical member 26 is welded to the adjacent long column vertical member 21 at multiple points in the axial direction.

[0023] The cross-frame structure 30 is composed of a plurality of long beam horizontal members 31a, 31b extending in the horizontal direction, a plurality of short beam horizontal members 32 extending in the front-rear direction, and a plurality of short beam vertical members 33 extending in the up-down direction. The long beam horizontal members 31a, 31b include a long upper beam horizontal member 31a and a long lower beam horizontal member 31b. The long upper beam horizontal member 31a includes a member that connects the upper ends of two long column vertical members 21 that are separated in the horizontal direction at the front side in the front-rear direction, and a member that connects the upper ends of two long column vertical members 21 that are separated in the horizontal direction at the rear side in the front-rear direction. The long horizontal member for the lower beam 31b includes a member connecting two long vertical members for the columns 21 at a position spaced downward from the front long horizontal member for the upper beam 31a in the fore-and-aft direction, and a member connecting two long vertical members for the columns 21 at a position spaced downward from the rear long horizontal member for the upper beam 31a in the fore-and-aft direction, and each is joined to the upper end of the reinforcing vertical member 26.

[0024] The two long upper beam horizontal members 31a are connected by a plurality of short beam horizontal members 32, and the long upper beam horizontal member 31a and the long lower beam horizontal member 31b, which are spaced apart from each other at the front and rear sides in the front-to-rear direction, are connected by a plurality of short beam vertical members 33. The connection points between the long upper beam horizontal member 31a and the short beam horizontal member 32, the connection points between the long upper beam horizontal member 31a, the long lower beam horizontal member 31b and the short beam vertical member 33, and the joint points between the long lower beam horizontal member 31b and the reinforcing vertical member 26 are all joined by welding.

[0025] The long horizontal member for the base 11, the short horizontal member for the base 12, the long vertical member for the column 21, the short horizontal member for the column 22, the reinforcing vertical member 26, the long horizontal member for the upper beam 31a, the long horizontal member for the lower beam 31b, the short horizontal member for the beam 32, and the short vertical member for the beam 33 are all the above-mentioned steel materials.

[0026] Through this steel structure construction process, the steel members extending vertically and horizontally are welded together to construct a gate-shaped steel structure 1 (see Figure 1). This steel structure 1 is a very strong and rigid body, as the joints (intersections) of the steel members extending vertically and horizontally are welded together.

[0027] In the plywood covering process, the steel frame structure 1 is covered from the outside with the structural plywood 40. Specifically, the structural plywood 40 is attached from the outside so as to span the long upper beam horizontal members 31a separated from each other in the front-rear direction, the front long upper beam horizontal member 31a and the front long lower beam horizontal member 31b in the front-rear direction, and the rear long upper beam horizontal member 31a and the rear lower beam horizontal member 31b in the front-rear direction, thereby covering the cross-frame structure 30 from above, from the front, and from the rear. In addition, the pair of columnar structure members 20 are covered from four sides with the structural plywood 40. In other words, the structural plywood 40 is attached to the columnar structure members 20 from the front, from the rear, from the outside in the lateral direction, and from the inside in the lateral direction.

[0028] Through this plywood covering process, the steel frame structure 1 is covered from the outside with structural plywood 40, and a plywood-covered structure 2 having a hollow space inside is formed. Here, the front lower beam long horizontal member 31b and the rear lower beam long horizontal member 31b are not connected by steel materials. Therefore, the cross-frame structure part 30 covered with the structural plywood 40 becomes a box-shaped space that is open downward. When the gate is used as a shutter gate, this space becomes the space to accommodate the rolled-up shutter.

[0029] On the other hand, if the gate is not a shutter gate, in the steel structure construction process, the front long horizontal member 31b for the lower beam and the rear long horizontal member 31b for the lower beam are connected with a short horizontal member 32 for the beam, and this part is also covered with structural plywood 40 in the plywood covering process.

[0030] In the plywood covering process, the structural plywood 40 is attached "directly" to the steel structure 1. This is done by fastening fastening members 47, such as screws or nails, to the steel members that make up the steel structure 1 while the structural plywood 40 is in contact with them. The fastening members 47 are fastened at multiple points to all of the steel members that are in contact with the structural plywood 40. In other words, each piece of structural plywood 40 is fastened to the steel structure 1 at an extremely large number of points.

[0031] In this way, in order to attach the structural plywood 40 "directly" to the steel structure 1, the steel structure 1 needs to be constructed extremely precisely so that the surface extending from the outer surface of the adjacent steel frame material forms an accurate plane. This is actually very difficult for the steel structure 1 constructed by welding steel frame materials. For this reason, the structural plywood 40 has not been attached directly to the steel structure 1 in the past. In contrast, in this embodiment, the steel structure construction process is performed in a factory, so it is easier to prepare an environment in which the worker can take a posture that is easy to work in, compared to when welding work is performed at a construction site, and it is also easy to accurately position jigs and the like that position the steel frame material to be welded. Therefore, the steel structure 1 can be constructed extremely precisely, and the structural plywood 40 can be attached "directly" to the steel structure 1.

[0032] In addition, softwood plywood made from softwood such as cypress, cedar, larch, and Yezo spruce can be used as the structural plywood 40. In addition, the structural plywood 40 to be used has a moisture content of 8% or less.

[0033] Through the plywood covering process, a plywood-covered structure 2 is formed in which the steel frame structure 1 is covered from the outside with structural plywood 40 (see FIG. 2).

[0034] In the waterproofing process, waterproofing is performed on the entire area of ​​the outer surface of the structural plywood 40 that covers the steel structure 1 in the plywood-covered structure 2. This waterproofing process can be further divided into three steps: a pre-treatment process, a main treatment process, and a protective treatment process. The pre-treatment process is a process in which a primer is coated on the outer surface of the structural plywood 40 to improve the adhesion of the waterproofing material, which will be coated in the subsequent main treatment process, to the structural plywood 40. As the primer, a coating material that is compatible with wood and has a high affinity with the waterproofing material is used. In this process, a primer layer is laminated on the outer surface of the structural plywood 40.

[0035] This treatment process is a process of coating the outer surface of the structural plywood 40 with a waterproofing material from above the primer layer. Wood such as the structural plywood 40 decays due to the presence of moisture, oxygen, fungi, and nutrients for fungi. By subjecting the structural plywood 40 to a sterilization treatment in advance, fungi and nutrients for fungi are removed as much as possible, and then coating the structural plywood 40 with a waterproofing material prevents water from penetrating the structural plywood 40 and prevents oxygen gas from accessing the structural plywood 40, thereby effectively preventing corrosion of the structural plywood 40.

[0036] In addition, by preventing water from penetrating into the structural plywood 40 and blocking access of oxygen gas, corrosion (rust) of the steel material that constitutes the steel structure 1 covered with the structural plywood 40 can be effectively prevented.

[0037] The waterproofing material is preferably one that can follow the expansion and contraction of the structural plywood 40 caused by temperature changes, and an acrylic resin emulsion type waterproofing material can be preferably used. The waterproofing material is applied multiple times to the outer surface of the structural plywood 40 over the primer layer, so that the entire area of ​​the outer surface of the structural plywood 40 is thoroughly coated. This results in a waterproofing layer being laminated over the primer layer.

[0038] The protective treatment process is a process of coating the outer surface of the structural plywood 40 with a protective waterproof material from above the waterproof material layer in order to cover the waterproof material layer and prevent cracks and peeling in the waterproof material layer. In this process, a protective waterproof layer is further laminated on the waterproof material layer laminated on the primer layer. As the protective waterproof material, a coating material is used that has good stretchability, can cover the entire waterproof material layer, and forms a film with high mechanical strength. If a coating material with adhesive properties is used as the protective waterproof material, the adhesion of the finishing material that is further applied on top of the protective waterproof layer in the subsequent finishing process can be improved.

[0039] Through the waterproofing process, which includes the above-mentioned pretreatment process, main treatment process, and protective treatment process, a waterproofing layer 50, which is a laminated structure of a primer layer, a waterproofing material layer, and a protective waterproofing layer, is coated over the entire area of ​​the outer surface of the structural plywood 40, forming a waterproofed structure 3 (see FIG. 3). Note that FIG. 3 illustrates an example in which a roof panel 60 is installed on the top of the waterproofed structure 3. The roof panel 60 can be, for example, a steel plate plated with an alloy of aluminum or zinc.

[0040] When the primer is coated in the above-mentioned pretreatment step, a mesh cloth can be attached to the surface of the structural plywood 40 by utilizing the adhesiveness of the primer. Such a mesh cloth enhances the effect of retaining the waterproof material to be coated in the subsequent main treatment step, and can effectively reduce the risk of cracking or peeling of the waterproof material layer over time. When the mesh cloth is attached in the pretreatment step, the entire outer surface of the structural plywood 40 is coated with the waterproof treatment layer 50, which is a laminated structure of the primer layer containing the mesh cloth, the waterproof material layer, and the protective waterproof layer, through the waterproof treatment step consisting of the pretreatment step, the main treatment step, and the protective treatment step.

[0041] The accessory embedding process is a process in which accessories such as a mailbox, a delivery box, an intercom, lighting, a switch for operating the shutter, and electric wires for supplying power to those accessories that require power are embedded in the waterproofed structure 3. The installation of the accessories on the outer surface of the structural plywood 40 coated with the waterproofing layer 50 can be carried out after the waterproofing process, but the work of making holes in the structural plywood 40 to pass the electric wires through and the work of placing the electric wires in the internal space covered by the structural plywood 40 are carried out in parallel with the plywood covering process.

[0042] Semi-finished gates are manufactured through the above-mentioned steel frame construction process, plywood covering process, waterproofing process, and accessory embedding process, which are all carried out in the factory. Unlike outdoor work, work in a factory is not affected by the weather, so semi-finished gates can be supplied steadily with a reliable construction schedule.

[0043] The semi-finished product is transported from the factory to the construction site by a truck (unic vehicle) equipped with a crane. The transported object is subjected to large vibrations during transport by the vehicle. Therefore, if the transported object is a product assembled from multiple components, there is a risk that the assembly of the components will loosen due to vibrations during transport, causing rattling. In contrast, in this embodiment, the semi-finished product being transported is based on the steel frame structure 1, which is a solid, rigid body constructed by welding steel materials, so there is no risk of the assembly of the steel materials loosening due to vibrations during transport.

[0044] Furthermore, if the base structure were made of a soft metal such as aluminum, the holes receiving the attached screws or nails would widen due to vibrations during transport, which could cause the screws or nails to become loose. In contrast, in this embodiment, the base structure of the semi-finished product being transported is the steel frame structure 1, which has the advantage that there is no risk of the holes receiving the screws or nails that fasten the structural plywood 40 widening due to vibrations during transport.

[0045] In this way, the semi-finished gate can be transported safely to the construction site without any problems caused by vibrations during transport.

[0046] At the construction site, a foundation pouring process is carried out prior to the arrival of the semi-finished product. In the foundation pouring process, the ground at the construction site where the gate will be installed is excavated to a predetermined depth, crushed stone is laid, and a concrete foundation is poured. Reinforcing bars (anchor reinforcing bars) for welding are erected from this concrete foundation. The gate of this embodiment is lighter than a concrete gate of the same size because the inside of the steel frame structure 1 is hollow. Therefore, there is an advantage that the concrete foundation does not need to be as thick as the concrete foundation for a concrete gate.

[0047] In the installation and fixing process, the semi-finished product that has arrived at the construction site is hung by a crane and lowered onto the concrete foundation. Then, after horizontal and vertical adjustments, the base frame 10 of the steel structure 1 is welded to the anchor rebars erected from the concrete foundation. This fixes the semi-finished gate product to the concrete foundation via the base frame 10. The installation and fixing process takes only a few hours to half a day after the semi-finished product arrives at the construction site.

[0048] In the finishing process, the outer surface of the semi-finished product fixed to the concrete foundation is decorated with a finishing material. That is, the outer surface of the structural plywood 40 in the semi-finished product is decorated with a finishing material over the waterproofing layer 50. By using paint that gives an appearance similar to concrete as the finishing material, it is possible to make a gate that is difficult to distinguish from a concrete gate in appearance. In addition, tiles (decorative thin plates) made of bricks, ceramics, natural stone, resin, etc. can be used as the finishing material. Since there are many types of materials that can be used as finishing materials, gates with a variety of finished designs can be manufactured.

[0049] As the final step, concrete is poured onto the installation surface up to the height at which the base frame 10 will be embedded. As a result, the lower ends of the columnar structural parts 20, which have been decorated with finishing materials, are also embedded in the concrete up to a specified height, completing the gate.

[0050] As described above, according to the gate manufacturing method of this embodiment, the steel frame structure construction process, plywood covering process, waterproofing process, and accessory embedding process are all performed in the factory, which reduces the workload at the gate construction site and shortens the construction period. In this way, performing many of the manufacturing processes in the factory is only possible because the semi-finished gate is configured to withstand the vibrations that occur when it is transported by vehicle. In other words, it is precisely because the steel frame structure 1 constructed by welding steel materials is used as the base that loosening or rattling does not occur due to vibrations that occur when it is transported by vehicle, and it is possible to perform many of the manufacturing processes in the factory.

[0051] In addition, since the steel structure 1 is covered from the outside with the structural plywood 40, the inside of the steel structure 1 is hollow, so even if it is covered with the structural plywood 40 and coated with the waterproofing layer 50, it is considerably lighter than a concrete gate of the same size. Therefore, it is easy to transport the semi-finished product to the construction site.

[0052] Furthermore, since the gate is based on the steel frame structure 1, which is a sturdy, rigid body constructed by welding steel materials, it has the advantage of being extremely earthquake-resistant.

[0053] Although the inside of the steel structure 1 is actually hollow, this is not evident from the outside, making it possible to manufacture a gate that gives off a sense of solidity equal to or greater than that of conventional concrete gates.

[0054] The present invention has been described above with reference to preferred embodiments, but the present invention is not limited to the above embodiments, and various improvements and design changes are possible without departing from the spirit of the present invention, as described below.

[0055] For example, in the above, a case where one gate is manufactured from one semi-finished product having one steel frame structure 1 as a base is exemplified. However, the present invention is not limited to this, and a large gate having multiple entrances and exits can be manufactured from multiple semi-finished products each having one steel frame structure 1 as a base. In this case, a semi-finished product of a size that can be transported by one unic truck is used as a unit, and each is transported to the construction site by the unic truck, and then multiple semi-finished products are arranged side by side at the construction site and combined to form a large gate. Since the finishing process is performed at the construction site, the outer surface of the boundary part generated by arranging multiple semi-finished products side by side is subjected to a base treatment and then decorated with a finishing material, so that a large gate that is not visible from the outside as being composed of multiple units can be easily manufactured.

[0056] In the above, the finishing process is only a process of decorating the outer surface of the semi-finished product with a finishing material. In addition to this process, the finishing process can include a process of installing a roof such as a gable roof or a hipped roof on the top of the semi-finished product. Roof materials such as Japanese tiles or Western tiles can be laid on the roof surface. [Explanation of symbols]

[0057] 1 Steel structure 2 Plywood covered structure 3. Waterproofed structure 11 Long horizontal member for base (steel frame) 12 Short horizontal members for base (steel members) 21 Long vertical members for columns (steel members) 22 Short horizontal members for columns (steel members) 31a Long horizontal members for upper beams (long horizontal members for beams, steel members) 31b Long horizontal members for lower beams (long horizontal members for beams, steel frame members) 32 Short beams (steel) 33 Short vertical beams (steel members) 40 Structural plywood 50 Waterproofing Layer

Claims

1. a steel frame construction process in which steel materials are assembled lengthwise and crosswise by welding to form a gate-shaped steel frame structure; A plywood covering process in which the structural plywood is directly fastened to the steel frame material to cover the steel frame structure from the outside with the structural plywood to form a plywood-covered structure; A waterproofing process is carried out in a factory to coat the entire area of ​​the outer surface of the structural plywood in the plywood-covered structure with a waterproofing layer including a layer of waterproofing material; The semi-finished product that has been subjected to the waterproofing process is transported by vehicle to the construction site, fixed on a concrete foundation, and the outer surface of the semi-finished product is decorated with a finishing material. A method for manufacturing a gate comprising the steps of:

2. The plywood covering structure has a downwardly open box-shaped space for accommodating the rolled-up shutter.

2. The method for manufacturing a gate according to claim 1.

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