Manufacturing method of form

Abstract

To provide a manufacturing method of form which can efficiently manufacture a form for concrete placing used in construction of a concrete structure placed with respect to a structure.SOLUTION: Shape data D1 is acquired for the surface of an object place of a structure 10 in which a concrete structure 20 is placed, and based on the acquired shape data D1, an opposing part 2 at least along the surface of the object place of a frame 1 for concrete placing used in construction of the concrete structure 20 is manufactured by a three-dimensional printer 33.SELECTED DRAWING: Figure 8

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a formwork for concrete placement, and more particularly, to a method for manufacturing a formwork that can efficiently manufacture a formwork for concrete placement used for constructing a concrete structure attached to a structure.

Background Art

[0002] In the construction of building a concrete structure attached to a structure, it is necessary to install a formwork according to the shape of the surface of the structure so that no gap is formed between the surface of the structure and the formwork for forming the concrete structure. Specifically, for example, in the construction of building an upper structure as a concrete structure on top of a sheet pile wall standing on the bottom ground, a bottom formwork (bottom plate) is installed midway in the vertical direction of the sheet pile wall, and the bottom formwork needs to be installed according to the shape of the surface of the sheet pile wall (see, for example, Patent Document 1).

[0003] In the work of driving sheet piles into the bottom ground, it is difficult to drive all the sheet piles without deviation with respect to the planned driving target position, and a certain degree of play (clearance) is provided in the connection structure between the joints provided on the sheet piles. Therefore, the surface shapes of the connection portions between the joints of adjacent sheet piles and the main body portions of the respective sheet piles continuous with the connection portions are not of a constant shape and vary according to the relative positional relationship between adjacent sheet piles.

[0004] Conventionally, a bottom plate having a fixed shape standardized as a bottom formwork has been used, and on-site workers have installed the bottom plate on the sheet pile wall while repeatedly performing processing and position adjustment of the bottom plate so as to conform to the surface shapes of the connection portions between the joints of adjacent sheet piles and the main body portions of the respective sheet piles continuous with the connection portions. However, this method requires a lot of labor and time for the formwork installation work at the construction site, resulting in low work efficiency, and also requires highly skilled craftsmanship and many years of practical experience for the workers.

Prior Art Documents

Patent Document

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] An object of the present invention is to provide a method for manufacturing a formwork for placing concrete, which can efficiently manufacture a formwork for constructing a concrete structure attached to a structure.

Means for Solving the Problems

[0007] In order to achieve the above object, a method for manufacturing a formwork according to the present invention is a method for manufacturing a formwork for placing concrete used for constructing a concrete structure attached to a structure, wherein shape data of the surface of a target portion of the structure is acquired, and at least an opposing portion along the surface of the target portion of the formwork is manufactured by a three-dimensional printer based on the acquired shape data.

Effects of the Invention

[0008] According to the present invention, by acquiring shape data of the surface of a target portion of a structure to which a concrete structure is attached, and manufacturing at least an opposing portion along the surface of the target portion of the formwork for placing concrete used for constructing the concrete structure by a three-dimensional printer based on the acquired shape data, a formwork that fits the target portion of the structure can be easily and efficiently manufactured regardless of the skill of the operator.

Brief Description of the Drawings

[0009]

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Embodiments for Carrying Out the Invention

[0010] Hereinafter, the formwork fabrication method of the present invention will be described based on the embodiments shown in the drawings.

[0011] The present invention is a method for fabricating a formwork for concrete placement used in the construction of a concrete structure attached to a structure. The present invention can be adopted in various construction works for attaching a concrete structure to a structure.

[0012] As illustrated in FIGS. 12 and 13, in this embodiment, the structure 10 is a sheet pile wall 10A erected on the ground in the water area Wa on the side of an existing revetment Qa before construction, and an example is given of the case where an upper structure 20A is attached as a concrete structure 20 to the upper part of the sheet pile wall 10A. Note that when the sheet pile wall 10A is installed on the side of the existing revetment Qa, the existing revetment Qa has lost its function as a revetment, but for the sake of convenience of explanation, it will be described as the existing revetment Qa hereinafter. In this embodiment, an example is given of the case of constructing a concrete structure 20 (upper structure 20A) whose lower part is located in water and upper part is located above water. In the drawing, the extending direction of the structure 10 in the horizontal direction is the X direction, the width direction orthogonal to the extending direction of the structure 10 in the horizontal direction is the Y direction, and the vertical direction is the Z direction.

[0013] As illustrated in FIGS. 1 and 2, the sheet pile wall 10A is composed of a plurality of sheet piles 11 connected to each other. The lower part of each sheet pile 11 is driven into the ground of the water area Wa on the side of the existing revetment Qa. The upper part of the sheet pile 11 is located above the water surface. The sheet pile 11 has joint parts 11b on one side and the other side of the main body part 11a respectively. By engaging the joint part 11b on the other side of another sheet pile 11 driven adjacent to the sheet pile 11 with the joint part 11b on one side of the sheet pile 11, the adjacent sheet piles 11 are connected to each other.

[0014] In this embodiment, the case where the sheet pile 11 is a steel pipe sheet pile is exemplified. The main body part 11a of this sheet pile 11 is composed of a circular tubular steel pipe, and each of the joint parts 11b on one side and the other side has a structure in which a slit is formed in the circular tube body. In this embodiment, a lid 12 is installed at the top end of the main body part 11a of the sheet pile 11.

[0015] In the operation of driving the sheet pile 11 into the ground, it is difficult to drive all the sheet piles 11 without deviation with respect to the planned driving target position, and a certain degree of play (clearance) is provided in the connection structure between the joint parts 11b. Therefore, the outer shapes of the outer sides of the connection parts between the joint parts 11b of the adjacent sheet piles 11 and the outer side surfaces of the main body parts 11a of the respective sheet piles 11 continuous with the connection parts are not of a constant shape, and there are variations according to the relative positional relationship between the adjacent sheet piles 11.

[0016] As illustrated in FIGS. 12 and 13, in the construction of the concrete structure 20 attached to the structure 10, in the construction of forming the concrete structure 20, the formwork 1 forming the concrete structure 20 needs to be installed in accordance with the shape of the surface of the target location of the structure 10 so that no gap is formed between the formwork 1 and the surface of the target location of the structure 10 where the formwork 1 is installed. In this embodiment, for the sheet pile wall 10A, as the formwork 1 for forming the upper structure 20A, a bottom formwork 1A forming the bottom surface of the upper structure 20A and a side formwork 1B forming the side surface of the upper structure 20A are installed. However, the bottom formwork 1A needs to be installed in accordance with the shape of the surface of the target location of the sheet pile wall 10A. In the present invention, the formwork 1 that fits the shape of the surface of the target location of the structure 10 is manufactured by the method described below. In this embodiment, the case of manufacturing the bottom formwork 1A installed for the sheet pile wall 10A is illustrated.

[0017] As illustrated in FIGS. 1 and 2, in the present invention, the shape data of the surface of the target location of the structure 10 where the formwork 1 is installed is acquired. In this embodiment, the shape data of the surface of the target location of the sheet pile wall 10A where the bottom formwork 1A is installed is acquired. In this embodiment, since the bottom formwork 1A is installed in the water on the water area Wa side of the sheet pile wall 10A, the shape data of the target location located in the water of the sheet pile wall 10A is acquired. Since the shape of the surface of the sheet pile wall 10A is constant in the vertical direction, in this embodiment, by acquiring the shape data of the upper surface of the sheet pile wall 10A located above the water, the shape data of the surface of the target location is indirectly acquired.

[0018] For the operation of obtaining the shape data of the surface of the target location of the structure 10 (sheet pile wall 10A), for example, a shape data acquisition device 30 such as a 3D scanner or a photographing device is used. A 3D scanner is a device that irradiates a target object with a laser to obtain three-dimensional shape data of the target object. When using a 3D scanner as the shape data acquisition device 30, the structure 10 is irradiated with a laser by the 3D scanner from above or the side of the structure 10, and three-dimensional survey detection data is obtained as the shape data of the surface of the structure 10. When using a photographing device as the shape data acquisition device 30, the structure 10 is photographed from above or the side of the structure 10, and image data is obtained as the shape data of the surface of the structure 10.

[0019] When using a flying object 31 such as a multicopter (so-called drone) equipped with the shape data acquisition device 30 as in this embodiment, the shape data of the surface of the structure 10 can be easily and efficiently obtained even on water or at a high place. When using the flying object 31, the position information of the flying object 31 is obtained using a GNSS device or the like that obtains the position information of the flying object 31, and the shape data of the surface of the structure 10 is obtained. For example, the shape data acquisition device 30 can also be installed on the arm of a crane to obtain the shape data of the surface of the structure 10.

[0020] Each sheet pile 11 constituting the sheet pile wall 10A is manufactured according to a certain standard. Therefore, when the structure 10 is the sheet pile wall 10A as in this embodiment, it is also possible to obtain the shape data of the surface on one side of the sheet pile wall 10A, and based on the shape data of the surface on one side and the shape data of the joint part 11b and the main body part 11a of the sheet pile 11 that have been grasped in advance, calculate and obtain the shape data of the surface of the target location located on the other side of the sheet pile wall 10A.

[0021] In this embodiment, the shape data of the outer side of the connecting portion between the joint portions 11b of the adjacent sheet piles 11 on the back side of the target location in the sheet pile wall 10A and the outer surface of the main body portion 11a of each sheet pile 11 continuous with the connecting portion is acquired. Based on the shape data of the surface on the back side of the target location, and the shape data of the joint portion 11b and the main body portion 11a of the sheet pile 11 that has been grasped in advance, the shape data of the surface of the target location is calculated, thereby indirectly acquiring the shape data of the target location. When the back side of the target location of the sheet pile wall 10A faces land such as the existing revetment Qa as in this embodiment, the shape data acquisition device 30 is arranged on the land on the back side of the target location of the sheet pile wall 10A, and the shape data of the surface on the back side of the target location in the sheet pile wall 10A is acquired, so that the shape data of the surface of the target location can be easily acquired.

[0022] As illustrated in FIG. 3, the acquired shape data D1 of the surface of the target location is input to an arithmetic device 32 configured by a computer or the like. Then, using the arithmetic device 32, based on the shape data D1, three-dimensional model data D2 of the formwork 1 (bottom formwork 1A) having the opposing portion 2 along the surface of the target location is created.

[0023] FIG. 3 exemplifies the case where the shape data D1 of the surface of the target location of the structure 10 (sheet pile wall 10A) is displayed as two-dimensional image data on the monitor 32a of the arithmetic device 32. In the shape data D1 of FIG. 3, the shape of the bottom formwork 1A to be fabricated in plan view is indicated by the hatched portion. When calculating and acquiring the shape data D1 of the surface of the target location located on the other side of the sheet pile wall 10A based on the shape data of one side surface of the sheet pile wall 10A and the shape data of the joint portion 11b and the main body portion 11a of the sheet pile 11 that has been grasped in advance, the arithmetic device 32 is used to calculate the shape data D1 of the surface of the target location described above.

[0024] The three-dimensional model data D2 of the formwork 1 (bottom formwork 1A) may be created by an operator using known 3D modeling software based on the shape data D1, or, for example, a program may be configured to automatically generate the three-dimensional model data D2 based on the shape data D1, and the three-dimensional model data D2 may be automatically generated from the shape data D1 by that program.

[0025] In this embodiment, three-dimensional model data D2 of the bottom formwork 1A having the opposing portions 2 along the outer surfaces of the outer portions of the connecting portions between the joint portions 11b of the adjacent sheet piles 11 and the main body portions 11a of the respective sheet piles 11 continuous with the connecting portions is created. The shape of the portion other than the opposing portion 2 of the bottom formwork 1A can be appropriately determined according to the shape of the bottom surface of the concrete structure 20 to be constructed. In this embodiment, the case of fabricating the bottom formwork 1A arranged across two adjacent sheet piles 11 is illustrated. In this embodiment, a groove portion 3 is provided in the lower part of the surface on the opposite side of the opposing portion 2 in the bottom formwork 1A, and the lower part of the surface on the opposite side of the opposing portion 2 is formed in a shape like a beam slab structure. Providing such a groove portion 3 in the bottom formwork 1A can reduce the weight of the bottom formwork 1A while ensuring its strength.

[0026] Next, as illustrated in FIG. 4, the three-dimensional model data D2 of the formwork 1 (bottom formwork 1A) created using the arithmetic unit 32 is input into the three-dimensional printer 33, and the bottom formwork 1A is fabricated by the three-dimensional printer 33. In this embodiment, the case of using a three-dimensional printer 33 of a lamination method in which a three-dimensional object is fabricated by laminating the modeling material 4 while moving a nozzle capable of discharging the modeling material 4 is illustrated. As the modeling material 4, for example, mortar, resin, pellets (a material obtained by mixing wood powder and resin), metal, or the like is used. By using the modeling material 4 in which reinforcing fibers are mixed in the mortar, a high-strength and lightweight bottom formwork 1A can be fabricated. In the present invention, not limited to the three-dimensional printer 33 of the lamination method, for example, other types of three-dimensional printers 33 such as a stereolithography method, an inkjet method, a powder sintering method, and a powder fixing method can also be used.

[0027] In this embodiment, the case where the entire bottom formwork 1A is produced by the 3D printer 33 is exemplified. However, in the present invention, the opposing part 2 along at least the surface of the target location of the formwork 1 (bottom formwork 1A) is produced by the 3D printer 33. For example, when producing the bottom formwork 1A installed on the sheet pile wall 10A as in this embodiment, the opposing part 2 of the bottom formwork 1A along the outer side of the connecting part between the joint parts 11b of adjacent sheet piles 11 and the outer surface of the main body part 11a of each sheet pile 11 continuous with the connecting part is produced by at least the 3D printer 33. In the present invention, parts other than the opposing part 2 of the formwork 1 can be produced by other methods without using the 3D printer 33, for example.

[0028] As illustrated in FIGS. 5 to 7, in this embodiment, the support frame 5 used for installing the formwork 1 (bottom formwork 1A) on the structure 10 (sheet pile wall 10A) is attached to the formwork 1. When providing the support frame 5 on the formwork 1, at least a part of the joining tool 5e used for joining the formwork 1 and the support frame 5 is embedded in the pre-solidification part (pre-solidification modeling material 4) produced by the 3D printer 33, and by solidifying this part, this part and the embedded joining tool 5e are integrated, so that the joining tool 5e can be simply and stably fixed to the formwork 1.

[0029] When using an anchor, for example, as the joining tool 5e, the lower part of the anchor is embedded in the pre-solidification part produced by the 3D printer 33, and the upper part of the anchor protrudes above the formwork 1, and the modeling material 4 is solidified. The joining tool 5e can also be attached to the formwork 1 after the modeling material 4 is solidified. The work of producing the bottom formwork 1A by the 3D printer 33 and the work of attaching the support frame 5 to the bottom formwork 1A may be performed at the construction site where the structure 10 is located, or may be performed at a factory or the like outside the construction site.

[0030] As illustrated in FIGS. 5 to 7, the support frame 5 of this embodiment is provided above the bottom formwork 1A and extends upward. The support frame 5 of this embodiment includes a vertical frame 5a extending in the Z direction, a horizontal frame 5b fixed to the upper part of the vertical frame 5a and extending in the Y direction, and a cross-frame 5c fixed to the upper part of the vertical frame 5a and extending in the X direction. A plurality of hanging tools 5f that can connect the support frame 5 to the wire rope (hanging fixture) of a crane are provided at a plurality of locations on the upper part of the support frame 5.

[0031] In this embodiment, one vertical frame 5a is erected near the opposing part 2 at the center in the X direction of the bottom formwork 1A. Two vertical frames 5a are erected at intervals in the X direction at positions farther from the opposing part 2 in the Y direction than the central vertical frame 5a. The lower end of each vertical frame 5a is fixed to the upper part of the bottom formwork 1A by a joining tool 5e. Two cross-frames 5c are joined to the upper part of the central vertical frame 5a in the X direction at intervals. Horizontal frames 5b extending toward the opposing part 2 are joined to the upper parts of the other two vertical frames 5a, respectively.

[0032] A reinforcing frame 5d extending obliquely is provided at the lower part of the central vertical frame 5a, with its lower end fixed to the upper part of the bottom formwork 1A and its upper end joined to the middle of the central vertical frame 5a in the Z direction. A plurality of reinforcing frames 5d extending in the X direction and connecting the other two vertical frames 5a are provided at intervals in the Z direction. In this embodiment, hanging tools 5f are arranged at a plurality of locations on the upper parts of the respective horizontal frames 5b. Each frame member constituting the support frame 5 can be constituted by, for example, a steel section or a metal frame member.

[0033] The configuration of the support frame 5 only needs to be a configuration in which the formwork 1 can be suspended from the structure 10, and is not limited to the configuration illustrated in this embodiment. The number and arrangement of the vertical frame 5a, horizontal frame 5b, cross-frame 5c, reinforcing frame 5d, and hanging tool 5f constituting the support frame 5 can be appropriately determined according to the shape of the structure 10 and the formwork 1 (bottom formwork 1A).

[0034] As illustrated in FIGS. 8 to 10, in the operation of installing the bottom formwork 1A with respect to the structure 10, the bottom formwork 1A is installed with respect to the structure 10 in a state where the facing portion 2 is facing the surface of the target portion of the structure 10. In this embodiment, a wire rope (hanging fitting) of a crane is connected to the hanging tool 5f of the support frame 5 attached to the bottom formwork 1A. Then, the bottom formwork 1A and the support frame 5 are moved by the crane above the water area Wa on the target portion side of the sheet pile wall 10A from the existing revetment Qa, and the support frame 5 and the bottom formwork 1A are lifted above the sheet pile wall 10A.

[0035] Next, while gradually lowering the support frame 5 and the bottom formwork 1A by the crane, the bottom formwork 1A is moved toward the target portion of the sheet pile wall 10A. Then, the facing portion 2 of the bottom formwork 1A is made to face the surface of the target portion of the sheet pile wall 10A, and the respective horizontal frames 5b and the bridging frames 5c constituting the support frame 5 are placed on the sheet pile wall 10A (lid 12). Then, by fixing the support frame 5 (horizontal frame 5b and bridging frame 5c) to the sheet pile wall 10A (lid 12), the bottom formwork 1A is fixed to the sheet pile wall 10A.

[0036] In this embodiment, the facing portion 2 of the bottom formwork 1A is fitted to the outer side of the connecting portion between the joint portions 11b of adjacent sheet piles 11 and the outer surfaces of the main body portions 11a of the respective sheet piles 11 continuous with the connecting portion. One side horizontal frame 5b is placed on one side sheet pile 11, and the other side horizontal frame 5b is fixed on the other side sheet pile 11. One end of each bridging frame 5c is fixed on one side sheet pile 11, and the other end is fixed on the other side sheet pile 11.

[0037] As illustrated in Fig. 11, the bottom formwork 1A and the support frame 5 are similarly installed between each adjacent sheet pile 11. The X-direction ends of the adjacent bottom formworks 1A are brought into contact with each other. Then, the side formwork 1B that forms the side surface of the concrete structure 20 is installed outside the structure 10. In this embodiment, a concrete panel is used as the side formwork 1B to be left together with a part of the concrete structure 20. In this embodiment, the side formwork 1B is installed on the water area Wa side and the existing revetment Qa side of the sheet pile wall 10A, respectively. In this embodiment, the upper ends of the respective side formworks 1B are set at positions higher than the upper end of the sheet pile wall 10A.

[0038] The side formwork 1B arranged on the water area Wa side is installed on the bottom formwork 1A, and the side formwork 1B is fixed to the sheet pile wall 10A (sheet pile 11) using the fixture 6 (such as a bolt) extending in the Y direction. The side formwork 1B arranged on the existing revetment Qa side is installed on the ground of the existing revetment Qa, and the side formwork 1B is fixed to the sheet pile wall 10A (sheet pile 11) using the fixture 6 (such as a bolt) extending in the Y direction. Through the above operations, the installation work of the formwork 1 (bottom formwork 1A and side formwork 1B) for concrete placement used for constructing the concrete structure 20 is completed.

[0039] Next, as illustrated in FIGS. 12 and 13, the space surrounded by the bottom formwork 1A, the side formwork 1B on the water area Wa side, and the structure 10 (sheet pile wall 10A) is filled with concrete 22 (fresh concrete), and the space surrounded by the side formwork 1B on the existing revetment Qa side and the structure 10 is also filled with concrete 22. In this embodiment, the space above the sheet pile wall 10A surrounded by the side formwork 1 on the water area Wa side and the side formwork 1B on the existing revetment Q side is also filled with concrete 22. Then, by solidifying the concrete 22, the concrete structure 20 is constructed. In this embodiment, the support frame 5 is embedded in the concrete 22, and the bottom formwork 1A and the side formwork 1B are left as they are together with the concrete structure 20. Thus, the construction work of the concrete structure 20 is completed. In this embodiment, the concrete structure 20 and the sheet pile wall 10A are used as the revetment Qb after construction. When eliminating or reducing the height difference between the ground height on the existing revetment Qa side of the concrete structure 20 and the upper end of the concrete structure 20, after the completion of the filling work of the concrete 22, the earth and sand are backfilled on the ground of the existing revetment Qa as necessary.

[0040] As illustrated in FIG. 13, if necessary, before filling the concrete 22, a plurality of reinforcing bars 21 extending in the X direction and a plurality of reinforcing bars 21 extending in the Y direction may be arranged above the sheet pile wall 10A. In FIG. 12, the reinforcing bars 21 are omitted from the illustration for the sake of clarity of the drawing.

[0041] Thus, according to the present invention, the shape data D1 of the surface of the target portion of the structure 10 to which the concrete structure 20 is to be attached is acquired, and based on the acquired shape data D1, at least the opposing portion 2 along the surface of the target portion of the structure 10 of the formwork 1 for placing concrete used for constructing the concrete structure 20 is produced by the 3D printer 33. Thereby, the formwork 1 that fits the target portion of the structure 10 can be easily and efficiently produced regardless of the skill of the operator.

[0042] Particularly when installing the formwork 1 (bottom formwork 1A) underwater with respect to the structure 10 facing the water area Wa as in this embodiment, in the conventional construction method, it was necessary to repeatedly perform on the construction site the work of surveying the shape of the surface of the target location of the structure 10 by a diver and the work of processing the bottom plate so as to match the shape of the surface of the target location of the structure 10. Therefore, a great deal of labor and time were required for the installation work of the formwork 1 (bottom formwork 1A) at the construction site, and a high level of craftsmanship and many years of practical experience were required for workers such as divers who perform the installation work of the formwork 1.

[0043] In contrast, in the present invention, for the work of acquiring the shape data D1 of the surface of the target location of the structure 10 using the shape data acquisition device 30, the flying object 31, etc., and for the work of manufacturing the formwork 1 (bottom formwork 1A) by the 3D printer 33 based on the acquired shape data D1, compared with the conventional construction method, a high level of craftsmanship and many years of practical experience are not required, and even a worker with relatively little practical experience can easily carry out the work by receiving training for about several days. By manufacturing the formwork 1 (bottom formwork 1A) having the opposing portion 2 along the surface of the target location of the structure 10, the installation work of the formwork 1 at the construction site can also be easily carried out with a small number of man-hours. Therefore, by adopting the present invention, the burden on the diver can be significantly reduced.

[0044] Also, the work of creating the 3D model data D2 of the bottom formwork 1A based on the shape data D1 in the present invention and the work of manufacturing the bottom formwork 1A by the 3D printer 33 can be carried out at a factory or the like outside the construction site. Therefore, the present invention can significantly reduce the man-hours and working time at the construction site required for constructing the concrete structure 20 compared with the conventional construction method, and can significantly reduce the number and restraint time of workers and divers working at the construction site. This is a very great merit for those skilled in the art.

[0045] Similarly, even when the target location of the structure 10 where the formwork 1 is installed is at a high place, in the conventional construction method, the worker had to repeatedly perform processing and position adjustment of the bottom plate at a high place so as to match the shape of the surface of the target location of the structure 10. However, in the present invention, it is not necessary to perform such complicated high-place work. Therefore, the present invention has very high versatility and is very useful for those skilled in the art.

[0046] As the uses and advantages of the conventional 3D printer, it was considered that the shaped object itself could be directly produced without using a mold or formwork. Therefore, also in the construction industry, as a method of using a 3D printer, various construction methods have been proposed in which a large 3D printer is used to laminate a molding material on the ground to construct the building itself. On the other hand, the method of manufacturing the opposing portion 2 of the formwork 1 along the surface of the target location of the structure 10 using the 3D printer 33 of the present invention is a new idea that has not existed in the past and shows new possibilities of the 3D printer 33 in the construction industry.

[0047] When the shape data acquisition device 30 uses a 3D scanner to acquire the shape data D1 of the surface of the target location of the structure 10, the highly accurate shape data D1 (detection data) of the surface of the target location of the structure 10 can be easily and efficiently acquired. Even when the structure 10 is photographed from above or the side of the structure 10 using a photographing device as the shape data acquisition device 30, the highly accurate shape data D1 (image data) of the surface of the target location of the structure 10 can be easily and efficiently acquired. Therefore, when at least one of the detection data acquired by the 3D scanner or the image data acquired by the photographing device is used as the shape data D1, it is advantageous for the 3D printer 33 to accurately manufacture the opposing portion 2 of the formwork 1 along the surface of the target location of the structure 10. When both the detection data acquired by the 3D scanner and the image data acquired by the photographing device are used as the shape data D1, it is advantageous for the 3D printer 33 to more accurately manufacture the opposing portion 2 of the formwork 1 along the surface of the target location of the structure 10.

[0048] When the shape data acquisition device 30 is mounted on the flying object 31 or the crane, and the shape data D1 of the surface of the target location of the structure 10 is acquired from above or the side of the structure 10, the shape data D1 of the surface of the target location of the structure 10 can be easily and efficiently acquired even when the target location of the structure 10 faces the water area Wa or when the target location of the structure 10 is at a high place.

[0049] In this embodiment, the case where the opposing portion 2 of the formwork 1 (bottom formwork 1A) is left together with the constructed upper work 20 is exemplified. However, in the present invention, for example, the opposing portion 2 of the formwork 1 may be configured to be removed without being left in the constructed concrete structure 20. When the opposing portion 2 of the formwork 1 is left together with the constructed concrete structure 20, the opposing portion 2 of the formwork 1 may be left as a part of the concrete structure 20, or the opposing portion 2 of the formwork 1 may be left without being a part of the concrete structure 20. In other words, the opposing portion 2 of the formwork 1 may be left in a state recognized as a part of the concrete structure 20, or may be left as a pure formwork 1.

[0050] FIG. 14 illustrates a state in which the bottom formwork 1A with the vertical frame 5a attached is arranged on the side of the structure 10 in a state where the vertical frame 5a, the horizontal frame 5b, and the bridging frame 5c constituting the support frame 5 are separated in the operation of installing the bottom formwork 1A on the structure 10 (sheet pile wall 10A).

[0051] When there are obstacles such as protrusions on the structure 10 and it is difficult to install the bottom formwork 1A on the structure 10 with the vertical frame 5a, the horizontal frame 5b, and the cross-linking frame 5c integrated, in such a case, as illustrated in FIG. 14, with the vertical frame 5a, the horizontal frame 5b, and the cross-linking frame 5c separated, install the bottom formwork 1A with the vertical frame 5a attached to the structure 10, and suspend the vertical frame 5a and the bottom formwork 1A with a crane or an operator. Then, join the horizontal frame 5b and the cross-linking frame 5c to the vertical frame 5a respectively, and install the respective horizontal frames 5b and cross-linking frames 5c on the structure 10, thereby fixing the bottom formwork 1A and the support frame 5 to the structure 10 as well.

[0052] As illustrated in FIG. 15, in the present invention, for example, a metal reinforcing member 7 can also be embedded in a portion produced by the three-dimensional printer 33 of the formwork 1. As the reinforcing member 7, for example, a plate-like member, a net-like member, a rod-like member, etc. made of metal are used. FIG. 15 illustrates a case where a net-like member made of metal is embedded in the formwork 1 as the reinforcing member 7.

[0053] The reinforcing member 7 can be arranged at a position exposed on the surface of the formwork 1 or at a position not exposed on the surface of the formwork 1. For example, when arranging the reinforcing member 7 on the surface of the formwork 1, place the reinforcing member 7 on the workbench of the three-dimensional printer 33 before laminating the shaping material 4 with the three-dimensional printer 33. Then, laminate the shaping material 4 with the three-dimensional printer 33 on the reinforcing member 7 to produce a formwork 1 with the reinforcing member 7 embedded on the surface. Alternatively, form the formwork 1 with the three-dimensional printer 33, and before the shaping material 4 constituting the formwork 1 is completely solidified, press the reinforcing member 7 against the surface of the formwork 1 to embed the reinforcing member 7 on the surface of the formwork 1.

[0054] When embedding the reinforcing member 7 in a state where it is not exposed on the surface of the formwork 1, after laminating the modeling material 4 with the three-dimensional printer 33 to fabricate the lower part of the formwork 1, the three-dimensional printer 33 is temporarily stopped. Then, the reinforcing member 7 is placed on the modeling material 4 that constitutes the lower part of the formwork 1 before it completely solidifies. After that, the three-dimensional printer 33 is operated again to laminate the modeling material 4 on the reinforcing member 7, and a formwork 1 with the reinforcing member 7 embedded inside the modeling material 4 is fabricated.

[0055] By using the three-dimensional printer 33, as described above, the formwork 1 with the reinforcing member 7 embedded can be easily fabricated. Embedding the metal reinforcing member 7 in the formwork 1 is advantageous for improving the strength and durability of the formwork 1. In particular, when using a metal mesh member as the reinforcing member 7, the adhesiveness between the modeling member 4 and the reinforcing member 7 can be increased, which is more advantageous for improving the strength and durability of the formwork 1.

[0056] As in the embodiment illustrated in FIG. 16, in the present invention, for example, with respect to the plate-like body 8 that constitutes a part of the formwork 1 (bottom formwork 1A), the part before solidification including the opposing part 2 fabricated by the three-dimensional printer 33 is attached, and this part is solidified, thereby integrating this part and the plate-like body 8. In other words, by attaching the modeling material 4 to the plate-like body 8 with the three-dimensional printer 33 and solidifying the modeling material 4, a formwork 1 in which the modeling material 4 and the plate-like body 8 are integrated can also be fabricated. The plate-like body 8 can be arranged at a position exposed on the surface of the formwork 1 or at a position not exposed on the surface of the formwork 1.

[0057] As illustrated in FIG. 17, in the present invention, for example, a solidified divided body 1a that constitutes a part of the formwork 1 (bottom formwork 1A) including the opposing part 2 fabricated by the three-dimensional printer 33 is joined to a plate-like body 8 that constitutes the other part of the formwork 1 fabricated separately from the divided body 1a, thereby fabricating a formwork 1 in which the divided body 1a fabricated with the modeling material 4 and the plate-like body 8 are integrated. For joining the divided body 1a and the plate-like body 8, for example, a joining tool, an adhesive, or the like is used.

[0058] In the present invention, the opposing portions 2 of the formwork 1 are formed in a shape along the surface of the target location of the structure 10 on which each formwork 1 is installed. However, the shape of the portions other than the opposing portions 2 of the formwork 1 can be standardized in advance. Therefore, when manufacturing the formwork 1 using the plate-like body 8 that constitutes part or all of the standardizable portions other than the opposing portions 2 of the formwork 1, as in the embodiment illustrated in FIG. 16 or the embodiment illustrated in FIG. 17, it becomes more advantageous for efficiently manufacturing the formwork 1.

[0059] As the plate-like body 8, for example, a plate-like member made of metal, a plate-like member formed of precast concrete, a plate-like member made of resin, or the like can be used. For example, before manufacturing the formwork 1, the plate-like body 8 can be manufactured in advance using a three-dimensional printer 33 and stocked. By using the plate-like body 8, the amount of the modeling material 4 required during the manufacturing of the formwork 1 can be reduced, and the usage time of the three-dimensional printer 33 required for manufacturing each formwork 1 can also be shortened. By reducing the amount of the modeling material 4 used during the manufacturing of the formwork 1, the time required until the modeling material 4 constituting the formwork 1 solidifies can also be shortened.

[0060] As in the embodiment illustrated in FIG. 18, in the present invention, for example, as the formwork 1, a bottom formwork 1A extending over three or more sheet piles 11 can be manufactured. In the present invention, it is also possible to accurately manufacture the bottom formwork 1A extending over three or more sheet piles 11. When manufacturing the bottom formwork 1A extending over three or more sheet piles 11, the number of installation operations of the bottom formwork 1A with respect to the structure 10 can be reduced, which is advantageous for reducing the man-hours required for constructing the concrete structure 20.

[0061] In the above-exemplified embodiments, the case where the sheet pile 11 constituting the sheet pile wall 10A is a steel pipe sheet pile is exemplified. However, the shape of the main body portion 11a of the sheet pile 11 and the shape of the joint portion 11b of the sheet pile 11 are not limited to the configurations of the above-exemplified embodiments. For example, the present invention can also be adopted when the sheet pile 11 is another type of sheet pile such as a steel sheet pile in which the main body portion 11a is plate-shaped.

[0062] Further, as in the embodiment illustrated in FIG. 19, the present invention is not limited to the case where the structure 10 is a sheet pile wall 10A, and can also be adopted when the structure 10 is a structure 10 having another structure, such as a structure 10 composed of piles 10B. In the embodiment illustrated in FIG. 19, the structure 10 is composed of a plurality of piles 10B driven at intervals from each other, and as the shape data D1 of the surface of the target portion of the structure 10, the shape data D1 of the respective surfaces of the adjacent piles 10B are acquired, and a bottom formwork 1A having an opposing portion 2 along the surfaces of the target portions of the adjacent piles 10B is produced by a 3D printer 33. Thus, the present invention can be adopted not only when the structure 10 is a sheet pile wall 10A, but also for structures 10 having various structures.

[0063] As illustrated in FIG. 20, the present invention can be adopted not only when producing the bottom formwork 1A, but also when producing a side formwork 1B having an opposing portion 2 along the surface of the target portion of the structure 10. In the embodiment illustrated in FIG. 20, the structure 10 is a wall body 10C, the shape data D1 of the surface of the target portion of the wall body 10C is acquired, and a side formwork 1B having an opposing portion 2 along the surface of the target portion of the wall body 10C is produced by a 3D printer 33. In this embodiment, the case where the divided body 1a including the opposing portion 2 produced by the 3D printer 33 and the plate-like body 8 are joined to produce the side formwork 1B is illustrated. Thus, even when producing a side formwork 1B that fits a wall body 10C or the like having an irregular surface shape, the method for producing the formwork 1 of the present invention can be adopted, so the present invention is very versatile and useful.

Explanation of Reference Numerals

[0064] 1 Formwork 1A Bottom formwork 1B Side formwork 1a Divided body 2 Opposing portion 3 Groove portion 4 Modeling material 5 Support frame 5a Vertical frame 5b Horizontal frame 5c Cross-frame 5d Reinforcing frame 5e joint tool 5f sling 6 fixture 7 reinforcing member 8 plate-like body 10 structure 10A sheet pile wall 10B pile 10C wall body 11 sheet pile 11a main body part 11b joint part 12 lid 20 concrete structure 20A upper work 21 reinforcing bar 22 concrete 30 shape data acquisition device 31 flying object 32 arithmetic unit 32a monitor 33 3D printer 33a tank Qa Existing revetment (before construction) Qb Revetment (after construction) Wa Water area D1 Shape data D2 3D model data

Claims

1. In a method for manufacturing a formwork for placing concrete used for constructing a concrete structure attached to a structure, a method for manufacturing a formwork, characterized in that shape data of the surface of a target portion of the structure is acquired, and at least an opposing portion along the surface of the target portion of the formwork is manufactured by a 3D printer based on the acquired shape data.

2. The method for manufacturing a formwork according to claim 1, wherein at least one of detection data acquired by a 3D scanner or image data acquired by an imaging device is used as the shape data.

3. The method for manufacturing a formwork according to claim 1 or 2, wherein a metal reinforcing member is embedded in a portion manufactured by the 3D printer.

4. The formwork has a joining tool for a support frame used for installing the formwork on the structure, and at least a part of the joining tool is embedded in a portion before solidification manufactured by the 3D printer, and this portion is solidified, so that at least a part of this portion and the embedded joining tool are integrated. The method for manufacturing a formwork according to claim 1 or 2.

5. For a plate-like body constituting a part of the formwork, a portion before solidification including the opposing portion manufactured by the 3D printer is attached, and this portion is solidified, so that this portion and the plate-like body are integrated. The method for manufacturing a formwork according to claim 1 or 2.

6. A method for manufacturing a formwork according to claim 1 or 2, wherein a solidified divided body constituting a part of the formwork including the opposing portion manufactured by the 3D printer is joined to a plate-like body constituting other parts of the formwork manufactured separately from the divided body.

7. The structure is a sheet pile wall in which a plurality of sheet piles are connected via a joint portion, and the target portion includes a connecting portion between the joint portions of adjacent sheet piles and a part of the surface of the main body portion of the adjacent sheet piles. The method for manufacturing a formwork according to claim 1 or 2.

8. Shape data of the surface on one side of the sheet pile wall is acquired, and based on the shape data of the surface on one side and shape data of the joint portion and the main body portion of the sheet pile grasped in advance, shape data of the surface of the target portion located on the other side of the sheet pile wall is calculated and acquired. The method for manufacturing a formwork according to claim 7.

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