Steel house foundation construction method and anchor set used therein

Abstract

To provide a foundation construction method capable of accurately positioning an anchor bolt and adjusting a horizontal level for installing a wall panel.SOLUTION: In this foundation construction method, A) an uncurved horizontal template 100 is constructed using angle bars, then B) this horizontal template is installed on a number of height-adjustable anchor posts 200 fixed to a wall core (center line), and its verticality is maintained via diagonal bracing members 250, while C) a top surface of the horizontal template is exposed from the top surface of the foundation concrete, thereby reliably ensuring a horizontal level on the top surface of the foundation and making it easy to position the anchors.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] This relates to a foundation construction method for lightweight steel frame construction (steel house) and an anchor set used therein. [Background technology]

[0002] A lightweight steel structure (hereafter referred to as a steel house) is a building in which the frame material of a wooden 2x4 construction method (frame wall construction method) is replaced with cold-rolled steel shaped galvanized steel sheets with a thickness of about 1.0 mm, and is a platform construction method in which factory-produced structural panels are assembled on-site. That is, like a wooden 2x4 (frame wall construction method), a steel house is a construction method in which walls, floors, etc. are formed from structural panels made of frame materials and surface materials, and factory-produced wall panels are assembled like a box through anchors embedded in the foundation formed on-site. For example, in the NSSF (NS Super Frame) construction method (registered trademark), a structural surface material created according to the shaku dimension (910mm = 1.0P) is used, so the wall arrangement has a basic module with a pitch of 455mm (= 0.5P), and the vertical frame material of the wall and the floor joist material are effectively arranged. Planning that does not follow this basic module would result in the production of panels with special shapes, unnecessary reinforcement arrangements, and complex details, which would affect costs and the process. In particular, in the foundations, since it is necessary to place underground beams under the load-bearing walls and supporting walls, double walls are used in appropriate locations to reduce the load-bearing wall lines in plan and minimize the placement of the foundations, which will improve workability, maintainability, and economy. In the case of lightweight steel construction, technical standards stipulate that wall panels installed on foundations must have foundations in principle, but foundations are not required when wall panels and floor panels are fastened directly to the foundation. However, in order to improve the installation accuracy of anchor bolts in foundation construction, the following three points are listed as control points, since the installation accuracy control of anchor bolts (abbreviated as AB) is particularly important in terms of quality and process control in panel construction work. (1) Avoidance of interference with underground beam reinforcement: The NSSF method is characterized by the fact that many ABs are placed in the underground beam section due to the panel structure, and avoidance of interference in this area is important for improving installation accuracy. The underground beam reinforcement is written on the template anchor frame (hereafter abbreviated as AF) and AB construction drawing, and the presence or absence of mutual interference and the interference between the underground beam main reinforcement joint position and the AF bundle are confirmed in advance to formulate a construction plan, and the position of each component is visualized by marking out on site. (2) Ensuring the fixing strength of AF material: In concrete construction, preventing the movement and deformation of AF during construction is important for controlling the installation accuracy. When fixing AF to the leveled concrete with bolts, the leveled concrete is constructed thicker than planned as a measure to improve the fixing strength, ensuring strength against vibrations and shocks during construction and maintaining accuracy after the AF is installed. (3) AF assembly: AF assembly is performed on the underground beam leveling concrete, and AB is set on the top of the AF upper through angle iron (AF component) after AB positioning and AB through hole (bolt meter +1mm). Furthermore, a U-ring is attached to the AF lower through angle iron (AF component) to fix the AB lower part and prevent accuracy deviation due to factors during construction (shock, etc.). In particular, since the first floor wall panel is installed on the concrete floor of the first floor, the smoothness accuracy of the top level of the concrete floor affects the panel construction accuracy. Therefore, the top level is managed with a finishing accuracy of -5mm at the panel construction position, and furthermore, the unevenness of the same part is adjusted to ±2 to 3mm with mortar or non-shrink mortar material before panel construction. There is a demand for this to ensure the construction quality of the upper floors and smooth process management by improving the construction accuracy of the wall panels on the first floor.

[0003] Therefore, improving the accuracy of anchor bolt (AB) installation and template (AF) horizontal leveling has become a difficult task in foundation construction, and a quick and simple construction method is required. In conventional improvements to foundation construction, not limited to steel houses, a method has been proposed in which anchor bolts are buried vertically in a slab footing, and in order to eliminate the need to adjust the top level of the slab footing after the temporary frame is removed, an anchor plate 3 is installed horizontally between the upper end faces of the temporary frame 2, the heads of anchor bolts 4 are engaged with the anchor plate 3 to suspend the anchor bolts 4, and a level plate 7 is fixed so that its height can be adjusted freely to match the top level of the slab footing 6 (Patent Document 1), as well as a construction method in which a separator 24 is inserted through through holes 22 in a pair of sheathing boards 20, leveling hardware 14 is inserted between the pair of sheathing boards 20, and multiple leveling hardware 14 are arranged horizontally between the pair of sheathing boards 20, and the multiple leveling hardware 14 holds the plate 30 horizontally, as shown in Figure 12(b) (Patent Document 2). However, these methods are insufficient as foundation construction methods for steel houses in the following respects. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Utility Model Application Publication No. 7-38238 [Patent Document 2] JP 2009-275472 A Summary of the Invention [Problem to be solved by the invention]

[0005] That is, in the above-mentioned improvements to the conventional foundation construction method, the installation accuracy of the temporary form 2 and the sheathing 20 placed on the basing concrete is governed by the surface accuracy of the basing concrete, making it difficult to maintain a constant horizontal level of the temporary form 2 and the sheathing 20, and furthermore, since the temporary form 2 and the sheathing 20 are deformed by the external force of the poured concrete, the position of the anchor bolts shifts slightly, making it difficult to maintain the top level of the foundation horizontal, and it is not easy to adjust the installation of the wall panels of a steel house manufactured in a factory on site. Therefore, the objective of the present invention is to provide a foundation construction method that is not affected by poured concrete, i.e., does not use the temporary form or the sheathing as a reference, and that allows accurate positioning of anchor bolts that are suitable for the installation of the wall panels of a steel house, and also allows adjustment of the horizontal level of the wall panel installation. [Means for solving the problem]

[0006] The inventors, in light of the technical standards for installing wall panels on the foundations of steel houses, considered 1) how to ensure the horizontal level of the template without using a temporary frame which is affected by the external force of the poured concrete, and 2) how to use a horizontal template as the top edge of the foundation which will serve as the installation surface for the wall panel, and as a result of extensive research, they discovered that by first A) constructing a horizontal template with no curvature using angle iron, then B) installing this horizontal template on a number of height-adjustable anchor posts which are fixed to the wall core (center line), and maintaining its verticality via diagonal braces, and C) exposing the top surface of the horizontal template from the top surface of the foundation concrete, it is possible to reliably ensure a horizontal level on the top surface of the foundation and to easily position the anchors. The present invention was made based on such findings, and consists of a foundation construction method comprising: A) the step of preparing the corners of the wall core (grid core) on a basing concrete; B) the step of erecting a plurality of anchor posts along the wall core (grid core) with first anchor washers so that their heights can be adjusted, and supporting the anchor posts with diagonal bracing members extending from second anchor washers fixed on a basin away from the first anchor washers; C) the step of fixing a horizontal template extending along the wall core (grid core) to the tips of the anchor posts by adjusting it to the horizontal level; D) installing HD anchors and shear anchors in prescribed positions on the template, and then E) pouring concrete with these anchor sets installed inside, and F) the top surface of the horizontal template serves as the top edge and serves as the wall panel installation surface. Effect of the Invention

[0007] According to the present invention, a plurality of anchor posts are erected in an adjustable height while ensuring their verticality by means of first and second anchor washers fixed to the mortar concrete at a predetermined position of the wall core (passage core), and concrete is poured while the horizontal template is maintained horizontal by the plurality of anchor posts, so that the horizontal template does not fluctuate even when subjected to external forces caused by the solidification of concrete, and the predetermined horizontal level can be easily ensured. In addition, the HD anchors and shear anchors are fixed to the mounting holes provided in advance based on the joining positions with the wall panel on the horizontally adjusted horizontal template, so that they are not affected by the poured concrete and are held in accurate positions. Thus, according to the present invention, the appropriate horizontal level and anchor positions for the installation of the wall panel can be ensured.

[0008] In the present invention, the anchor support preferably comprises a leg made of an angle bar and an anchor washer equipped with a height adjustment bolt, and the upper end is connected to the horizontal template by a connecting means such as a bolt nut, while the lower end is formed with a connecting flange part, and the height of the anchor support is preferably adjusted via a height adjustment bolt formed by a threaded rod fixed by welding or the like to the upright piece of the anchor washer. This is because it eliminates unevenness in the height level of the dummy concrete and gives the horizontal template the necessary horizontal level for the wall panel installation surface. In addition, it is preferable that the anchor support has a second anchor washer fixed on the wall center line (passing center line) away from the anchor washer as necessary, and the upper part of the anchor support and the second anchor washer are fastened by a turnbuckle or the like, and the verticality of the support is ensured by this brace member. This is because the horizontal level of the horizontal template does not change even when subjected to external forces during concrete pouring. The horizontal template is preferably made of a non-curved frame material, such as an angle bar, with a pair of ends of a short angle bar sandwiched between angle joint materials and connected with bolts and nuts, etc. to form a long material extending in the longitudinal direction. In the present invention, the angle bar refers to a structural material whose cross-sectional shape is not curved in the longitudinal direction, such as an L-shape, square, groove-shape, or Z-shape.

[0009] The present invention relates to a foundation construction method for a steel house, but also provides an anchor set for use therein. The anchor set according to the present invention comprises a horizontal template 100 made of an angle bar that forms the installation surface of the wall panel, an anchor support 200 having a support frame 210 made of an angle bar that is fixed to the mortar concrete via a first anchor washer 220 in a height-adjustable manner, an HD anchor 300 attached to the horizontal template 100, a shear anchor 310 also attached to the horizontal template 100, and a brace member 250 that holds the anchor support upright. and a second anchor washer 251 that fixes the diagonal brace member on the basal concrete. The horizontal template 100 is provided with set holes for HD anchors and set holes for shear anchors used for joining to the installation wall panel, as well as holes for venting air and checking concrete filling when pouring concrete, while the anchor support 200 is formed by connecting the support frame 210 and the first anchor washer 220 via a height adjustment screw rod 221, and the diagonal brace member 250 is characterized in that the upper part of the support frame 210 and the second anchor washer are fastened via a turnbuckle.

[0010] By using the above-mentioned anchor set, the present invention makes it possible to erect a number of anchor posts using anchor washers so as to be height adjustable along the corner lines of the wall core (grid core) on basing concrete, without using a temporary frame which is affected by the external force of the poured concrete, and to fix a horizontal template extending along the wall core (grid core) to the tips of the anchor posts by adjusting it to the horizontal level, and after installing HD anchors and shear anchors in their prescribed positions, pour concrete with the anchor set still installed, thereby completing the construction of the foundation of a steel house, with the upper surface of the horizontal template as the top end and the wall panel installation surface. [Brief description of the drawings]

[0011] [Figure 1A](a) is a perspective view of a three-story steel house frame, (b) is a perspective view of a four-story steel house frame, (c) is a perspective view of wall panels WP installed on foundation B for the first floor of a three-story and four-story steel house, (d) is a perspective view of a roof panel RP, (e) is a perspective view of a floor panel FP, (f) is a perspective view of a wall panel using ceramic-based surface materials, and (g) is a perspective view of a wall panel using steel-based surface materials. [Figure 1B] FIG. 1 is a perspective view of a vertical frame (a) standing on the foundation of the first floor of a steel house, and FIG. 2 is a partial enlarged view of the wall panel shown in the perspective view (b) installed. [Figure 1C] FIG. 1 is a plan view showing an example of hold-down anchor bolt installation. [Figure 1D] FIG. 2 is a plan view showing an example of installation of a shear anchor bolt. [Diagram 2] This is a plan view (a) of the first step of the present invention, in which a basing concrete is formed, and a plan view (b) of the wall core (passage core) formed on the basing concrete along the wall panel installation surface with temporary frame grounding wooden frames formed along both sides of the wall core (passage core). [Diagram 3] This is an exploded view showing the state in which the horizontal support frame 100 and the anchor support 200 erected by the first anchor washer are assembled and attached to the throw-away conduit FG. [Figure 4] FIG. 1 is a perspective view of an anchor set consisting of a horizontal template 100 and an anchor post 200 fixed upright by a first anchor washer, directly fixed to a temporary conduit FG by a second anchor washer. [Figure 5A] FIG. 5 is an overall perspective view showing a state in which the anchor post 200 fixed upright on the mortar concrete shown in FIG. 4 is fastened with a diagonal brace member 250. [Figure 5B] FIG. 5A is a detailed view of a main part and is a perspective view showing a state in which the anchor post 200 is fastened by a diagonal brace member 250 that connects a second anchor washer 251 fixed on the wall core (passage core) at a position away from the first anchor washer 220 and an upper part of the frame 210 of the anchor post 200. [Figure 6] FIG. 6 is a perspective view showing a state in which a formwork MF is installed on the anchor set AS in the state of FIG. 5 ; [Figure 7]7 is a perspective view showing a state in which concrete C has been poured into the formwork MF of FIG. 6. FIG. [Figure 8] 8 is a perspective view showing the state in which the foundation B has been formed after removing the formwork MF from the state shown in FIG. 7. FIG. [Figure 9] 9 is a perspective view of the state in which a vertical frame P is installed on the foundation B of FIG. 8. [Figure 10A] FIG. 9 shows a cross section of the anchor set of the present invention when a vertical frame P is fixed onto a foundation B on which concrete has been poured. [Figure 10B] FIG. 13 is an explanatory diagram showing an example of reinforcement state and structure at the cut surface. [Figure 11] FIG. 10 is a perspective view showing a state in which a wall panel WP is attached to the foundation b shown in FIG. 9 via a laid channel steel. [Figure 12] (a) and (b) are construction drawings of the foundation for conventional wall panel installation. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The present invention will now be described in detail with reference to specific examples. Figure 1A shows the current assembly diagram of a steel house. For a three-story building, the roof panel RP, floor panel FP, and wall panel WP are assembled to the frame (a). For a four-story building, the roof panel RP, floor panel FP, and wall panel WP are assembled to the frame (b). For the first floor, the wall panel WP is installed on the foundation B (c). The roof panel RP is constructed by attaching ceramic-based facings and heat-insulating materials to a frame material made of light-gauge steel and lip-channel steel, as shown in the perspective view (d). The floor panel FP is constructed by attaching ceramic-based facings to a frame material made of light-gauge steel and lip-channel steel, as shown in the perspective view (e). There are two types of wall panels. As shown in the perspective view (f), one is constructed by attaching ceramic-based facings, water-resistant reinforced gypsum boards, and heat-insulating materials to a frame material made of light-gauge steel and lip-channel steel. On the other hand, the wall panel using steel-based facings is constructed by attaching steel-based facings, water-resistant reinforced gypsum boards, and heat-insulating materials to a frame material made of light-gauge steel and lip-channel steel, as shown in the perspective view (g).

[0013] As shown in Fig. 1A(b), the first floor of the steel house is constructed by installing wall panels WP on foundation B. As shown in Fig. 1B, the vertical frames P of multiple wall panels (Fig. 1B(a)) are fixed on foundation B with HD hardware, and the wall panels WP are installed (Fig. 1B(b)). Specifically, as shown in Fig. 1B(c), holding hardware 300, HD anchor bolts 230, and shear anchor pins 240 are used, and the panels are fixed on the horizontal template 100 via a rubber sheet. Here, light channel steel and lip channel steel are used for the wall panels WP.

[0014] First, make the following preparations: 1) Check the anchor wall installation diagram in the panel drawing. 2) The installer prepares the anchor floor plan (Figure 1B and Figure 1C) (attaching the hold-down HD anchors and shear anchors to the panel plan). 3) Check the anchor plan to see if the anchor post will interfere with the sleeve, etc. (Indicate where to remove the angle from the sliding sash and window pane). 4) Check that the horizontal angle (horizontal template) of the anchor set will fit into the beam extension section (make sure there is no rebar extension reinforcement, and make sure the horizontal angle will not allow rebar to enter).

[0015] Next, the on-site assembly procedure begins. 1) As shown in Figure 2(a), pour the basin concrete. If the basin concrete is thin, the anchor of the anchor column will not work, so the basin concrete thickness of the column part is set to t100mm. Then, as shown in Figure 2(b), mark out the wall core (passage core) (wall core / HD anchor core), and place wooden frames for temporary frame grounding on both sides of the wall core (passage core).

[0016] 2) Fix the first anchor washer 220 to the throw-away concrete FG with the all anchor 223 in line with the HD anchor core. 3) Next, the standing height adjustment bolts 221 welded to the anchor washers 220 are passed through the lower end flanges 211 of the support frames 210, and a pair of upper and lower nuts 222 are screwed onto the protruding bolts 221 to fix the support frames 210 upright on the wall core (passing core), and the upper parts 212 of the support frames 210 are fixed using fixing bolts 213, and the horizontal template 100 is positioned as shown in Figure 4. The horizontal template 100 uses angle materials, but if it is long, angle joint members are used to connect them. 4) The horizontal template 100 is provided with mounting holes 101 and 102 at the mounting positions of the HD anchors 230 and the shear anchors 240, and is attached using fixing nuts 231 and 241. The top end of the horizontal template 100 is preferably subjected to an anti-rust treatment. 5) Next, as shown in Fig. 5A, the second anchor washer 251 was fixed in a predetermined position. Then, the screw rod 253 welded thereto and the screw rod 252 welded to the upper part of the support frame of the anchor support were tightened with a turnbuckle 254 to firmly fix the anchor support 200 upright. Then, the HD anchor 230 and the shear anchor 240 were attached to the predetermined places of the horizontal template 100 and fixed in place. 6) Finally, check the alignment with a transit and the angle ends of the template, while also checking the pitch and protrusion of the HD anchors and shear anchors. 7) It is recommended that only the top end of the template be painted with an anti-rust paint at the factory, and the threaded parts for fixing the HD anchors and shear anchors should be protected with a resin stopper. 8) Bolts should be attached to the area where the sliding door sash and recessed angle will be removed so that the angle can be removed after the concrete is poured. It is also a good idea to mark the sleeve position on the concrete so that the support pillar does not come into contact with the sleeve position.

[0017] When the anchor setting is completed, as shown in FIG. 6, a form is set along the wooden frame set on both sides of the wall core (passage core) on the basing concrete, and concrete is poured as shown in FIG. 7. Here, it is confirmed that the top end of the foundation concrete is filled until it flows out through the air vent hole 103 of the horizontal template 100. Then, it is confirmed that the poured concrete has solidified through this air vent hole 103. After confirmation, the form is removed to obtain the state shown in FIG. 8. The horizontal template 100 is exposed on the foundation B, and the upper surface of the horizontal template 100 becomes the installation surface of the wall panel. Then, as shown in FIG. 9, the upper surface of this horizontal template 100 is used to attach the HD metal fittings 300 to the protruding parts of the HD anchors 230, and the vertical frame P is fixed using this HD metal fittings 300, and the wall panel WP is properly installed as shown in FIG. 11.

[0018] According to the present invention, as shown in Fig. 10A, the support frame 210 can be adjusted in height via the height adjustment bolt 221 of the anchor washer 220, so that even if the level of the basin concrete FG is not horizontal, the horizontal template 100 can be positioned horizontally without using a liner or the like. Also, since the anchor support 200 is fastened and fixed on the basin concrete FG by the diagonal brace member 250, it is firmly fixed even when subjected to external forces caused by pouring concrete, and since the horizontal template 100 is exposed on the top surface of the foundation, it provides an appropriate horizontal level for the installation surface of the wall panel WP. Therefore, according to the foundation construction method of the present invention, not only is it easy to align the panel ground surface with the top end of the angle, but it is also possible to form an accurate underground beam structure, as shown in Fig. 10B. [Explanation of symbols]

[0019] 100 Horizontal Templates 200 Anchor Post 220 Anchor washer 250 Bracing members 300 HD Hardware

Claims

1. A foundation construction method for constructing a steel house, comprising the steps of: (A) setting out the corners of the wall core (running core) on a basing concrete; (B) erecting a plurality of anchor posts along the wall core (running core) using first anchor washers in a height-adjustable manner, and supporting the anchor posts with diagonal bracing members extending from second anchor washers fixed on a running core away from the first anchor washers; (C) fixing a horizontal template extending along the wall core (running core) to the tips of the anchor posts by adjusting it to the horizontal level; (D) installing HD anchors and shear anchors at predetermined positions on the horizontal template, and then (E) pouring concrete with these anchor sets installed inside; and (F) using the upper surface of the horizontal template as the top end and as the wall panel installation surface.

2. 3. The foundation construction method according to claim 2, wherein the anchor column (200) comprises a column frame (210) having legs made of angle material and a first anchor washer (220).

3. The foundation construction method according to claim 1, wherein the anchor post (200) has an upper end connected to the horizontal template (100) by a connecting means such as a bolt nut, and a lower end having a connecting flange portion, and is combined with a first anchor washer (220) and a threaded rod (221) so as to be height adjustable.

4. 2. The foundation construction method according to claim 1, wherein the first anchor washer (220) is fixed to the upright piece by welding or the like and has an upright male threaded rod (221).

5. 2. The foundation construction method according to claim 1, wherein the diagonal brace member 250 has a configuration in which a second anchor washer 251 is fixed on a wall core (passage core) line away from the first anchor washer 220 of the anchor post 200, and an upper part of the anchor post and the second anchor washer are connected and fastened via a turnbuckle 254 or the like.

6. The horizontal template 100 is an angle bar, which is a non-curved frame material, and is a long material extending in the longitudinal direction, with a pair of short angle bars having their ends sandwiched between angle joint materials and connected with bolts and nuts, etc.

7. The anchor set for carrying out foundation construction according to claim 1 includes a horizontal template 100 made of an angle material that forms the installation surface of a wall panel, an anchor support 200 having a support frame 210 made of an angle material that is fixed on a basing concrete via a first anchor washer 220 so as to be height adjustable, an HD anchor 300 attached to the horizontal template 100, a shear anchor 310 also attached to the horizontal template 100, a bracing member 250 that holds the anchor support upright, and a second anchor that fixes the bracing member on the basing concrete. and a washer 251, wherein the horizontal template 100 has set holes 101 for HD anchors and set holes 102 for shear anchors used for joining to an installation wall panel, as well as holes 103 for venting air and checking concrete filling when pouring concrete, while the anchor support 200 is formed by connecting a support frame 210 and a first anchor washer 220 via a height adjustment screw rod 221, and the diagonal brace member 250 is fastened between an upper portion of the support frame 210 and a second anchor washer via a turnbuckle 254.

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