Construction method of superstructure

Abstract

To provide a construction method of a superstructure which can efficiently construct a superstructure that is supported by being fixed to a substructure.SOLUTION: Shape data D1 is acquired for a surface of an object place of a substructure 10 where a bottom form 1A is installed which forms a bottom surface of a superstructure 20, and based on the acquired shape data D1, an opposing part 2 is produced at least along the surface of the object place of the bottom form 1A. Then, in a state where the opposing part 2 is made to oppose to the surface of the object place, the bottom form 1A is installed with respect to the substructure 10. After installing a side form 1B for forming a side surface of the superstructure 20 outside of the substructure 10, a filler 22 is filled in a space surrounded by the bottom form 1A, the side form 1B, and the substructure 10, and the filler 22 is solidified. Thereby, the superstructure 20 is constructed which is supported by being fixed to the substructure 10.SELECTED DRAWING: Figure 11

Description

Technical Field

[0001] The present invention relates to a method for constructing superstructure, and more particularly, to a method for efficiently constructing a superstructure that is fixed and supported by a substructure.

Background Art

[0002] In the construction of a superstructure fixed and supported by a substructure, it is necessary to install a bottom formwork in accordance with the shape of the surface of the substructure so that no gap is formed between the surface of the substructure and the bottom formwork that forms the bottom surface of the superstructure. Specifically, for example, in the construction of a superstructure on top of a sheet pile wall that is erected on the underwater ground, a bottom formwork (bottom plate) is installed in the middle of the sheet pile wall in the vertical direction, and the bottom formwork needs to be installed in accordance with the shape of the surface of the sheet pile wall (see, for example, Patent Document 1).

[0003] In the operation of driving sheet piles into the underwater 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 there are variations depending on 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 repeatedly processed and adjusted the position of the bottom plate while installing the bottom plate on the sheet pile wall so as to match the shape of the connection portion between the joints of adjacent sheet piles and the surface of the main body portion of each sheet pile continuous with the connection portion. However, this method requires a lot of labor and time for the installation work of the bottom formwork at the construction site, so the work efficiency is low, and workers also need high craftsmanship and many years of practical experience.

Prior Art Documents

Patent Documents

[0005] Patent Document 1 Japanese Patent Laid-Open No. 7-97860 Summary of the Invention Problems to be Solved by the Invention

[0006] An object of the present invention is to provide a method for constructing an upper structure that can efficiently construct an upper structure fixed and supported by a lower structure. Means for Solving the Problems

[0007] In order to achieve the above object, a method for constructing an upper structure according to the present invention is a method for constructing an upper structure fixed and supported by a lower structure, wherein shape data of the surface of a target portion of the lower structure is acquired, and based on the acquired shape data, at least an opposing portion along the surface of the target portion of the lower structure of a bottom formwork for forming the bottom surface of the upper structure is produced, the bottom formwork is installed with respect to the lower structure in a state where the opposing portion is opposed to the surface of the target portion, and after a side formwork for forming the side surface of the upper structure is installed outside the lower structure, a filling material is filled into a space surrounded by the bottom formwork, the side formwork, and the lower structure, and the filling material is solidified, thereby constructing the upper structure. Effects of the Invention

[0008] According to the present invention, by acquiring shape data of the surface of a target portion of a lower structure and producing at least an opposing portion along the surface of the target portion of the lower structure of a bottom formwork for forming the bottom surface of the upper structure based on the acquired shape data, a bottom formwork that fits the target portion of the lower structure can be easily and efficiently produced regardless of the skill of an operator. And the construction work of the formwork of the upper structure is completed only by installing the bottom formwork with respect to the lower structure in a state where the opposing portion of the bottom formwork is opposed to the surface of the target portion of the lower structure and installing a side formwork for forming the side surface of the upper structure outside the lower structure. After that, by filling a filling material into a space surrounded by the bottom formwork, the side formwork, and the lower structure and solidifying the filling material, the upper structure can be easily and efficiently constructed regardless of the skill of an operator. Brief Description of the Drawings

[0009]

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Modes for Carrying Out the Invention

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

[0011] The construction method of the upper structure of the present invention can be adopted in various construction works for constructing an upper structure that is fixed and supported by a lower structure. As illustrated in FIGS. 14 and 15, in this embodiment, the lower structure 10 is a sheet pile wall 10A erected on the ground in the water area Wa on the side of the existing revetment Qa before construction, and an example is given of the case of constructing a concrete upper structure 20 that is fixed and supported on 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 an upper structure 20 whose lower part is located in the water and upper part is located above the water. In the figure, the extending direction of the lower structure 10 in the horizontal direction is the X direction, the width direction orthogonal to the extending direction of the lower structure 10 in the horizontal direction is the Y direction, and the vertical direction is the Z direction.

[0012] As illustrated in FIGS. 1 and 2, the sheet pile wall 10A, which is the substructure 10, 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 in 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. 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 that is 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.

[0013] 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 pipe body. In this embodiment, a lid 12 is installed at the top end of the main body part 11a of the sheet pile 11.

[0014] In the work of driving the sheet pile 11 into the ground, it is difficult to drive all the sheet piles 11 without displacement 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 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 fixed shape and vary according to the relative positional relationship between adjacent sheet piles 11.

[0015] As illustrated in FIGS. 14 and 15, in the construction of constructing the superstructure 20 with respect to the substructure 10, for the substructure 10, a bottom formwork 1A for forming the bottom surface of the superstructure 20 and a side formwork 1B for forming the side surface of the superstructure 20 are installed. However, it is necessary to install the bottom formwork 1A according to the shape of the surface of the target part of the substructure 10 so that no gap is formed between the surface of the target part of the substructure 10 where the bottom formwork 1A is installed and the bottom formwork 1A. In the present invention, a bottom formwork 1A that fits the shape of the surface of the target part of the substructure 10 is manufactured by the method described below.

[0016] As illustrated in FIGS. 1 and 2, in the present invention, shape data of the surface of the target location of the substructure 10 where the bottom formwork 1A is installed is acquired. In this embodiment, since the bottom formwork 1A is installed underwater on the water area Wa side of the sheet pile wall 10A, shape data of the target location located underwater in 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.

[0017] For the operation of acquiring the shape data of the surface of the target location of the substructure 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 and acquires three-dimensional shape data of the target object. When a 3D scanner is used as the shape data acquisition device 30, the substructure 10 is irradiated with a laser by the 3D scanner from above or the side of the substructure 10, and three-dimensional survey detection data is acquired as the shape data of the surface of the substructure 10. When a photographing device is used as the shape data acquisition device 30, the substructure 10 is photographed from above or the side of the substructure 10, and image data is acquired as the shape data of the surface of the substructure 10.

[0018] When a flying object 31 such as a multicopter (so-called drone) equipped with the shape data acquisition device 30 is used as in this embodiment, the shape data of the surface of the substructure 10 can be easily and efficiently acquired even on water or at a high place. When the flying object 31 is used, the shape data of the surface of the substructure 10 is acquired while acquiring the position information of the flying object 31 using a GNSS device or the like that acquires the position information of the flying object 31. For example, the shape data acquisition device 30 can be installed on the arm of a crane to acquire the shape data of the surface of the substructure 10.

[0019] Each sheet pile 11 that constitutes the sheet pile wall 10A is manufactured according to a certain standard. Therefore, when the lower structure 10 is the sheet pile wall 10A as in this embodiment, it is also possible to obtain the shape data of one side surface of the sheet pile wall 10A and calculate and obtain the shape data of the surface of the target location located on the other side of the sheet pile wall 10A based on the shape data of the connection part 11b and the main body part 11a of the sheet pile 11 that has been grasped in advance.

[0020] In this embodiment, the shape data of the outer side of the connection part between the connection parts 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 part 11a of each sheet pile 11 continuous with the connection part are obtained. Based on the shape data of the surface on the back side of the target location and the shape data of the connection part 11b and the main body part 11a of the sheet pile 11 that have been grasped in advance, the shape data of the surface of the target location is calculated, so that the shape data of the target location can be indirectly obtained. When the back side of the target location of the sheet pile wall 10A faces the 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 obtained, so that the shape data of the surface of the target location can be easily obtained.

[0021] In the present invention, based on the obtained shape data of the surface of the target location of the lower structure 10, at least the opposing part 2 along the surface of the target location of the bottom formwork 1A that forms the bottom surface of the upper structure 20 is produced. In this embodiment, the case where the bottom formwork 1A having the opposing part 2 described above is produced using a 3D printer is exemplified.

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

[0023] FIG. 3 illustrates a case where the shape data D1 of the surface of the target portion of the lower formwork 10 (sheet pile wall 10A) is displayed as two-dimensional image data on the monitor 32a of the arithmetic unit 32. In the shape data D1 of FIG. 3, the shape of the bottom formwork 1A to be fabricated is indicated by the hatched portion in plan view. When calculating and obtaining the shape data D1 of the surface of the target portion located on the other side of the sheet pile wall 10A based on the shape data of one 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 have been grasped in advance, the arithmetic unit 32 is used to calculate the shape data D1 of the surface of the target portion described above.

[0024] The creation of the three-dimensional model data D2 of the bottom formwork 1A may be performed by an operator creating the three-dimensional model data D2 based on the shape data D1 using known 3D modeling software, or, for example, a program for automatically generating the three-dimensional model data D2 based on the shape data D1 may be incorporated, 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 portion 2 along the outer side of the connecting portion between the joint portions 11b of adjacent sheet piles 11 and the outer surface of the main body portion 11a of each sheet pile 11 continuous with the connecting portion 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, a 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 at the lower part of the surface on the opposite side of the opposing portion 2 of 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 produced by the three-dimensional printer 33. In this embodiment, a case of using a three-dimensional printer 33 of a lamination method in which a three-dimensional object is produced 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. When using the modeling material 4 in which reinforcing fibers are mixed in the mortar, a high-strength and lightweight bottom formwork 1A can be produced. 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, a case where the entire bottom formwork 1A is produced by the three-dimensional printer 33 is illustrated. However, for example, the opposing portion 2 along at least the surface of the target portion of the formwork 1 (bottom formwork 1A) can be produced by the three-dimensional printer 33, and portions other than the opposing portion 2 of the formwork 1 can be produced by other methods without using the three-dimensional printer 33. For example, when producing the bottom formwork 1A to be installed on the sheet pile wall 10A as in this embodiment, the opposing portion 2 of the bottom formwork 1A along the outer side portion of the connecting portion between the joint portions 11b of the adjacent sheet piles 11 and the outer surface of the main body portion 11a of each sheet pile 11 continuous with the connecting portion can be produced by at least the three-dimensional printer 33, and the other portions can also be produced by other methods.

[0028] Specifically, for example, with respect to a plate-like body constituting a part of the bottom formwork 1A, a pre-solidification portion including the opposing portion 2 produced by the three-dimensional printer 33 is attached, and this portion is solidified, whereby this portion and the plate-like body can be integrated. In other words, with respect to the plate-like body, the modeling material 4 is attached by the three-dimensional printer 33, and the modeling material 4 is solidified, whereby the formwork 1 in which the modeling material 4 and the plate-like body are integrated can be produced.

[0029] Further, for example, by joining a solidified divided body that constitutes a part of the bottom formwork 1A including the opposing portion 2 produced by the three-dimensional printer 33 and a plate-like body that constitutes the other part of the bottom formwork 1A produced separately from the divided body, it is also possible to produce the bottom formwork 1A in which the divided body made of the modeling material 4 and the plate-like body are integrated. For joining the divided body and the plate-like body, for example, a joining tool, an adhesive, or the like is used.

[0030] 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 lower work 10 where each formwork 1 is installed, but the shape of the portions other than the opposing portions 2 of the formwork 1 can be standardized in advance. Therefore, as described above, when the formwork 1 is produced using a plate-like body that constitutes a part or all of the standardizable portions other than the opposing portions 2 of the formwork 1, it becomes more advantageous for efficiently producing the formwork 1.

[0031] As the above-described plate-like body, 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 producing the bottom formwork 1A, the plate-like body can be produced in advance by the three-dimensional printer 33 and stocked. By using the plate-like body, the amount of the modeling material 4 required for producing the bottom formwork 1A can be reduced, and the usage time of the three-dimensional printer 33 required for producing each bottom formwork 1A can also be shortened. By reducing the amount of the modeling material 4 used when producing the bottom formwork 1A, the time required until the modeling material 4 constituting the bottom formwork 1A solidifies can also be shortened.

[0032] When producing the bottom formwork 1A using the three-dimensional printer 33, for example, a metal reinforcing member can be embedded in the portion of the bottom formwork 1A produced by the three-dimensional printer 33. As the reinforcing member, for example, a plate-like member, a net-like member, a rod-like member, or the like made of metal is used. By embedding a metal reinforcing member in the bottom formwork 1A, it is advantageous for improving the strength and durability of the bottom formwork 1A. In particular, when using a metal net-like member as the reinforcing member, the adhesiveness between the modeling member 4 and the reinforcing member can be increased, which is more advantageous for improving the strength and durability of the bottom formwork 1A.

[0033] As illustrated in FIGS. 5 to 7, in this embodiment, a support frame 5 used for installing the bottom formwork 1A on the lower part work 10 (sheet pile wall 10A) is attached to the upper part of the bottom formwork 1A. When attaching the support frame 5 to the bottom formwork 1A, at least a part of the joining tool 5e used for joining the bottom formwork 1A and the support frame 5 is embedded in the pre-curing part (pre-curing modeling material 4) produced by the three-dimensional printer 33, and by curing this part, this part and the embedded joining tool 5e are integrated, and the joining tool 5e can be easily and stably fixed to the bottom formwork 1A.

[0034] When using, for example, an anchor as the joining tool 5e, the lower part of the anchor is embedded in the pre-curing part produced by the three-dimensional printer 33, and the upper part of the anchor protrudes above the formwork 1, and the modeling material 4 is cured. The joining tool 5e can also be attached to the formwork 1 after the modeling material 4 has cured. The work of producing the bottom formwork 1A by the three-dimensional printer 33 and the work of attaching the support frame 5 to the bottom formwork 1A may be carried out at the construction site where the lower part work 10 is located, or may be carried out at a factory or the like outside the construction site.

[0035] As illustrated in FIGS. 5 to 7, the support frame 5 of this embodiment is provided on the upper part of 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 tool) of the crane are provided at a plurality of locations on the upper part of the support frame 5.

[0036] In this embodiment, one vertical frame 5a is erected near the opposing portion 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 portion 2 in the Y direction than the central vertical frame 5a. The lower end portions of the respective vertical frames 5a are fixed to the upper part of the bottom formwork 1A by joining tools 5e. Two cross frames 5c are joined to the upper part of the single vertical frame 5a at the center in the X direction with an interval in the Y direction. Horizontal frames 5b extending toward the opposing portion 2 side are joined to the upper parts of the other two vertical frames 5a, respectively.

[0037] A reinforcing frame 5d extending in an inclined direction is provided at the lower part of the central vertical frame 5a, with the lower end fixed to the upper part of the bottom formwork 1A and the 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 for connecting the other two vertical frames 5a are provided at intervals in the Z direction. In this embodiment, suspension 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 section steel or a metal frame member.

[0038] The configuration of the support frame 5 only needs to be a configuration capable of suspending the bottom formwork 1A with respect to the lower structure 10, and is not limited to the configuration illustrated in this embodiment. The number and arrangement of the vertical frames 5a, horizontal frames 5b, cross frames 5c, reinforcing frames 5d, and suspension tools 5f constituting the support frame 5 can be appropriately determined according to the shape of the lower structure 10 and the bottom formwork 1A.

[0039] As illustrated in FIGS. 8 to 10, in the operation of installing the bottom formwork 1A with respect to the lower structure 10, the bottom formwork 1A is installed with respect to the lower structure 10 in a state where the opposing portion 2 faces the surface of the target location of the lower structure 10. In this embodiment, a wire rope (sling) of a crane is connected to the suspension 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 above the water area Wa on the target location side of the sheet pile wall 10A from the existing revetment Qa by the crane, and the support frame 5 and the bottom formwork 1A are lifted above the sheet pile wall 10A.

[0040] Next, while gradually lowering the support frame 5 and the bottom formwork 1A by a crane, the bottom formwork 1A is moved toward the target location on the sheet pile wall 10A. Then, with the opposing portion 2 of the bottom formwork 1A facing the surface of the target location on the sheet pile wall 10A, each horizontal frame 5b and the cross-frame 5c that make up 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 cross-frame 5c) to the sheet pile wall 10A (lid 12), the bottom formwork 1A is fixed to the sheet pile wall 10A.

[0041] In this embodiment, the opposing portion 2 of the bottom formwork 1A is fitted into the outer side of the connecting portion between the joint portions 11b of adjacent sheet piles 11 and the outer surface of the main body portion 11a of each sheet pile 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 cross-frame 5c is fixed on one side sheet pile 11, and the other end is fixed on the other side sheet pile 11.

[0042] As illustrated in FIGS. 11 to 13, similarly, the bottom formwork 1A and the support frame 5 are installed between adjacent sheet piles 11. The X-direction ends of adjacent bottom formworks 1A are brought into contact with each other. Then, the side formwork 1B forming the side surface of the upper structure 20 is installed outside the lower structure 10. In this embodiment, a concrete panel is used as the side formwork 1B to be left together with the upper 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 end of each side formwork 1B is set at a position higher than the upper end of the sheet pile wall 10A.

[0043] 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 fixtures 6 (such as bolts) extending in the Y direction. More specifically, in this embodiment, engagement holes are provided in advance in each sheet pile 11 before installing the side formwork 1B. Then, after installing the side formwork 1B, the fixture 6 is inserted into the through holes provided in the side formwork 1B, the end of the fixture 6 on the sheet pile wall 10A side is engaged with the engagement hole provided in the sheet pile 11, and the end of the fixture 6 on the side formwork 1B side is fixed to the side formwork 1B, thereby fixing the side formwork 1B to the sheet pile wall 10A.

[0044] 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 fixtures 6 (such as bolts) extending in the Y direction. More specifically, in this embodiment, a groove is formed at the position where the side formwork 1B of the existing revetment Qa is to be installed, crushed stone is spread in the groove, and a support base is installed on the crushed stone. Then, the side formwork 1B is placed on the support base and the lower part of the side formwork 1B is fixed to the support base, and the engaging tool fixed on the sheet pile wall 10A and the side formwork 1B are joined by the fixture 6, thereby fixing the side formwork 1B to the sheet pile wall 10A. Through the above operations, the installation work of the formwork (bottom formwork 1A and side formwork 1B) for forming the upper structure 20 is completed.

[0045] As illustrated in FIG. 12, if necessary, 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. Note that in FIG. 11 and FIG. 14 described below, the reinforcing bars 21 are omitted from the illustration for the sake of clarity of the figure. The arrangement and fixing method of the side formwork 1B with respect to the lower structure 10 are not limited to the configuration of this embodiment, and various other configurations can be adopted.

[0046] Next, as illustrated in FIGS. 14 and 15, the space surrounded by the bottom formwork 1A, the side formwork 1B on the water area Wa side, and the lower work 10 (sheet pile wall 10A) is filled with the filling material 22, and the space surrounded by the side formwork 1B on the existing revetment Qa side and the lower work 10 is also filled with the filling material 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 Qa side is also filled with the filling material 22. Then, by solidifying the filling material 22, the upper work 20 is constructed. When constructing the upper work 20 made of concrete, fresh concrete is placed as the filling material 22. In this embodiment, the support frame 5 is embedded in the filling material 22, and the bottom formwork 1A and the side formwork 1B remain as they are together with the upper work 20. Thus, the construction work of the upper work 20 is completed. In this embodiment, the upper work 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 level on the existing revetment Qa side of the upper work 20 and the upper end of the upper work 20, after the completion of the filling work of the filling material 22, the earth and sand are backfilled on the ground of the existing revetment Qa as necessary.

[0047] As described above, according to the present invention, the shape data D1 of the surface of the target portion of the lower work 10 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 lower work 10 of the bottom formwork 1A forming the bottom surface of the upper work 20 is produced. Thus, the bottom formwork 1A that fits the target portion of the lower work 10 can be easily and efficiently produced regardless of the skill of the operator. Then, the formwork construction work is completed by installing the bottom formwork 1A with the opposing portion 2 facing the surface of the target portion of the lower work 10 with respect to the lower work 10 and installing the side formwork 1B forming the side surface of the upper work 20 outside the lower work 10. After that, the space surrounded by the bottom formwork 1A, the side formwork 1B, and the lower work 10 is filled with the filling material 22, and by solidifying the filling material 22, the upper work 20 can be easily and efficiently constructed regardless of the skill of the operator.

[0048] Particularly, when the substructure 10 is erected in the water area Wa as in this embodiment and the bottom formwork 1A is installed at the target location of the substructure 10 located underwater, in the conventional construction method, it is necessary to repeatedly perform at the construction site the work of surveying the surface shape of the target location of the substructure 10 by a diver and the work of processing the bottom plate so as to match the surface shape of the target location of the substructure 10. Therefore, a lot of labor and time are required for the installation work of the bottom formwork 1A at the construction site, and workers such as divers who perform the installation work of the bottom formwork 1A need a high level of craftsmanship and many years of practical experience.

[0049] On the other hand, in the present invention, for the work of acquiring the shape data D1 of the surface of the target location of the substructure 10 using the shape data acquisition device 30, the flying object 31, etc., and for the work of manufacturing the opposing part 2 of the bottom formwork 1A 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 workers with relatively little practical experience can easily carry out the work. By adopting the present invention, the burden on the diver can also be significantly reduced.

[0050] Similarly, even when the target location of the substructure 10 where the bottom formwork 1A is installed is at a high place, in the conventional construction method, it is necessary for the worker at the high place to repeatedly perform the processing and position adjustment of the bottom plate so as to match the surface shape of the target location of the substructure 10, but 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.

[0051] In the present invention, particularly, when the at least opposing portions 2 of the bottom formwork 1A are produced using a three-dimensional printer 33, the bottom formwork 1A can be produced very efficiently. Operations such as creating three-dimensional model data D2 of the bottom formwork 1A based on the shape data D1 and producing the bottom formwork 1A using the three-dimensional printer 33 can be easily carried out even by workers with relatively little practical experience, just by receiving training for about several days. Also, operations such as creating three-dimensional model data D2 of the bottom formwork 1A based on the shape data D1 and producing the bottom formwork 1A using the three-dimensional printer 33 can be carried out at a factory or the like outside the construction site. Therefore, compared with the conventional construction method, it is possible to significantly reduce the man-hours and working time at the construction site required for constructing the upper structure 20, and it is possible to significantly reduce the number and restricted time of workers and divers working at the construction site. This is a very great merit for those skilled in the art.

[0052] As for the conventional uses and advantages of three-dimensional printers, it was considered that the shaped object itself could be directly produced without using molds or formworks. Therefore, also in the construction industry, as methods of using three-dimensional printers, various construction methods have been proposed to construct the building itself by laminating shaping materials on the ground using a large three-dimensional printer. On the other hand, the method of producing the opposing portions 2 of the bottom formwork 1A using the three-dimensional printer 33 in the present invention is a new idea that has not existed in the past and shows new possibilities of the three-dimensional printer 33 in the construction industry.

[0053] When using a 3D scanner as the shape data acquisition device 30 to acquire the shape data D1 of the surface of the target location of the lower structure 10, highly accurate shape data D1 (detection data) of the surface of the target location of the lower structure 10 can be easily and efficiently acquired. Even when using a photographing device as the shape data acquisition device 30 to photograph the lower structure 10 from above or the side of the lower structure 10, highly accurate shape data D1 (image data) of the surface of the target location of the lower structure 10 can be easily and efficiently acquired. Therefore, when using at least one of the detection data acquired by the 3D scanner or the image data acquired by the photographing device as the shape data D1, it is advantageous for accurately manufacturing the opposing portion 2 of the bottom formwork 1A along the surface of the target location of the lower structure 10 by the 3D printer 33. When using both the detection data acquired by the 3D scanner and the image data acquired by the photographing device as the shape data D1, it is advantageous for more accurately manufacturing the opposing portion 2 of the formwork 1 along the surface of the target location of the lower structure 10.

[0054] If a configuration is adopted in which the shape data D1 of the surface of the target location of the lower structure 10 is acquired from above or the side of the lower structure 10 using the flying object 31 or the crane equipped with the shape data acquisition device 30, the shape data D1 of the surface of the target location of the lower structure 10 can be easily and efficiently acquired even when the target location of the lower structure 10 faces the water area Wa or when the target location of the lower structure 10 is at a high place.

[0055] As in this embodiment, by attaching a support frame 5 that extends upward with respect to the bottom formwork 1A and fixing the upper part of the support frame 5 to the upper part of the lower structure 10, a configuration is adopted in which the bottom formwork 1A is suspended with respect to the lower structure 10 by the support frame 5. This is advantageous for very easily and efficiently performing the installation work of the bottom formwork 1A with respect to the lower structure 10. In particular, when installing the bottom formwork 1A in water, there is no need to perform the work of attaching a bracket for the diver to support the bottom formwork 1A with respect to the lower structure 10 in the water or the work of fixing the bottom formwork 1A to the bracket. Therefore, the man-hours of the diving work by the diver and the burden on the diver can be significantly reduced.

[0056] Incidentally, as in this embodiment, when a suspension tool 5f is provided on the support frame 5 and the support frame 5 and the bottom formwork 1A are installed on the lower structure 10 using a crane, the bottom formwork 1A can be efficiently installed on the lower structure 10. However, for example, when the support frame 5 and the bottom formwork 1A are relatively lightweight, the operator can also hold the support frame 5 and the bottom formwork 1A by hand and install them on the lower structure 10.

[0057] In this embodiment, the case where the opposing portion 2 of the bottom formwork 1A is left together with the constructed upper structure 20 is exemplified. However, in the present invention, for example, the opposing portion 2 of the bottom formwork 1A can be configured to be removed without being left in the constructed upper structure 20. When the opposing portion 2 of the bottom formwork 1A is left together with the constructed upper structure 20, the opposing portion 2 of the bottom formwork 1A can be left as a part of the upper structure 20, or the opposing portion 2 of the bottom formwork 1A can be left without being a part of the upper structure 20. In other words, the opposing portion 2 of the bottom formwork 1A may be left in a state recognized as a part of the upper structure 20, or may be left as a pure bottom formwork 1A.

[0058] FIG. 16 illustrates a state in which, in the operation of installing the bottom formwork 1A with respect to the lower structure 10 (sheet pile wall 10A), the bottom formwork 1A with the vertical frame 5a attached is arranged on the side of the lower structure 10 in a state where the vertical frame 5a, which constitutes the support frame 5, is separated from the horizontal frame 5b and the cross-bridge frame 5c. There may be obstacles such as protrusions in the lower structure 10, and it may be difficult to install the bottom formwork 1A with respect to the lower structure 10 in a state where the vertical frame 5a, the horizontal frame 5b, and the cross-bridge frame 5c are integrated. In such a case, as illustrated in FIG. 16, in a state where the vertical frame 5a is separated from the horizontal frame 5b and the cross-bridge frame 5c, the bottom formwork 1A with the vertical frame 5a attached is arranged on the side of the lower structure 10, and the vertical frame 5a and the bottom formwork 1A are suspended by a crane or an operator. Then, the horizontal frame 5b and the cross-bridge frame 5c are respectively joined to the vertical frame 5a, and the respective horizontal frames 5b and cross-bridge frames 5c are installed on the lower structure 10, whereby the bottom formwork 1A and the support frame 5 can also be fixed to the lower structure 10.

[0059] In the embodiment illustrated in FIG. 17, a case is illustrated in which the bottom formwork 1A having the opposing portion 2 produced by the method of the present invention is used in combination with the standardized bottom plate 1C that forms the bottom surface of the upper structure 20 used in the conventional construction method. As in this embodiment, for example, in a location where the positional relationship between adjacent sheet piles 11 is not deviated from the planned driving target position, even with the conventional construction method using the bracket 7 attached to the lower structure 10 and the standardized bottom plate 1C, the bottom plate 1C can be installed without performing processing or the like on the bottom plate 1C, so the conventional construction method is adopted. And in a deformed target location where the positional relationship between adjacent sheet piles 11 is deviated from the planned driving target position and the number of man-hours is increased with the conventional construction method, the bottom formwork 1A having the opposing portion 2 produced by the method of the present invention is installed. Thus, the construction method of the present invention can also be used in combination with the conventional construction method.

[0060] As in the embodiment illustrated in FIG. 18, in the present invention, for example, a bottom formwork 1A extending over three or more sheet piles 11 can be fabricated and installed with respect to the lower work 10 (sheet pile wall 10A). In the present invention, it is also possible to accurately fabricate the bottom formwork 1A extending over three or more sheet piles 11. When fabricating 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 lower work 10 (sheet pile wall 10A) can be reduced, which is advantageous for reducing the man-hours required for constructing the upper work 20.

[0061] In the embodiment illustrated above, the case of constructing the upper work 20 with respect to the lower work 10 standing in the water area Wa was exemplified, but the present invention can also be applied to the construction of the upper work 20 with respect to the lower work 10 standing on land. Further, in the embodiment illustrated above, the case where the sheet pile 11 constituting the sheet pile wall 10A is a steel pipe sheet pile was exemplified, but 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 configuration of the embodiment illustrated above. For example, even 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, the present invention can be adopted.

[0062] Also, in the above, as a preferred embodiment of the present invention, the case of fabricating the opposing portion 2 of the bottom formwork 1A using the three-dimensional printer 33 based on the acquired shape data D1 was exemplified. However, for example, the opposing portion 2 of the bottom formwork 1A may be fabricated by other methods without using the three-dimensional printer 33 based on the acquired shape data D1.

[0063] As illustrated in FIG. 19, the present invention can be adopted not only when the substructure 10 is a sheet pile wall 10A, but also when the substructure 10 has other structures, for example, a substructure 10 composed of piles 10B. FIG. 19 illustrates a case where the substructure 10 is composed of a plurality of piles 10B driven at intervals from each other. In this case, as the shape data D1 of the surface of the target location of the substructure 10, the shape data D1 of the outer surfaces of adjacent piles 10B are acquired, and a bottom formwork 1A having an opposing portion 2 along the outer surfaces of the adjacent piles 10B is produced. Thereafter, in the same manner as the embodiment exemplified above, an upper structure 20 with the piles 10B as the substructure 10 can be constructed. Thus, the present invention can be adopted not only when the substructure 10 is a sheet pile wall 10A, but also for substructures 10 with various structures.

Explanation of Signs

[0064] 1A Bottom formwork 1B Side formwork 1C Bottom plate 2 Opposing portion 3 Groove portion 4 Molding material 5 Support frame 5a Vertical frame 5b Horizontal frame 5c Cross frame 5d Reinforcing frame 5e Joining tool 5f Hanging tool 6 Fixture 7 Bracket 10 Substructure 10A Sheet pile wall 10B Pile 11 Sheet pile 11a Main body portion 11b Joint portion 12 Lid 20 Upper structure 21 Steel bar 22 Filling material 30 Shape data acquisition device 31 Flying body 32 Arithmetic unit 32a Monitor 33 3D printer 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 constructing an upper structure that is fixed and supported by a lower structure, shape data of the surface of a target location of the lower structure is acquired, and based on the acquired shape data, at least an opposing portion along the surface of the target location of a bottom formwork for forming the bottom surface of the upper structure is produced. With the opposing portion facing the surface of the target location, the bottom formwork is installed with respect to the lower structure. After installing a side formwork for forming the side surface of the upper structure outside the lower structure, a filling material is filled into the space surrounded by the bottom formwork, the side formwork, and the lower structure, and the filling material is solidified to construct the upper structure. A method for constructing an upper structure, characterized by the above.

2. The method for constructing an upper structure according to claim 1, wherein at least the opposing portion of the bottom formwork is produced using a 3D printer.

3. In the operation of installing the bottom formwork with respect to the lower structure, a support frame extending upward is attached to the bottom formwork, and the upper portion of the support frame is fixed to the upper portion of the lower structure, so that the bottom formwork is suspended with respect to the lower structure by the support frame. The method for constructing an upper structure according to claim 1 or 2.

4. The method for constructing an upper structure according to claim 1 or 2, wherein the lower structure is erected in water, and the bottom formwork is installed in water with the opposing portion of the produced bottom formwork facing the surface of the target location located in the water.

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

6. The method for constructing an upper structure according to claim 1 or 2, wherein the lower structure is a sheet pile wall in which a plurality of sheet piles are connected via a joint portion, and the target location includes a connection portion between the joint portions of the adjacent sheet piles and a part of the surface of the main body portion of the adjacent sheet piles.

7. The method for constructing an upper structure according to claim 1 or 2, wherein the opposing portion is left to remain together with the constructed upper structure.

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