Foundation and foundation molding die

Abstract

To provide technical means capable of constructing a house foundation with high heat insulation properties simply and with a small number of steps by eliminating the need for complicated and time-consuming work of preparing a formwork and cleaning work after removing the formwork, and flexibly adapting to differences in building shapes.SOLUTION: A peripheral wall is formed by laying unitized outer peripheral blocks 1 each having a straight wall portion 11 and a seat portion 12 integrally formed below it, a heat insulating material 2 is erected inside the peripheral wall using spacing retainers 3 attached to an upper end of the straight wall portion 11 and a boundary between the straight wall portion and the seat portion, and a formwork 18 of an outer peripheral foundation 10 is assembled. A formwork of an inner foundation 4 is placed using a downward-facing U-shaped inner block 42 with an upper opening 43, steel bars are placed on a top surface of a site and in voids in the outer peripheral foundation and the inner foundation, and then ready-mixed concrete is poured between the outer peripheral blocks and the heat insulating material and into the upper opening to allow it to harden.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] This invention relates to foundations for buildings, particularly foundations suitable for wooden buildings, and to a foundation structure using precast concrete that functions as a formwork for cast-in-place concrete and becomes part of the foundation structure. [Background technology]

[0002] Conventionally, the formwork used to build foundations at construction sites is made of wood (plywood panels) or steel (metal forms), and the formwork is assembled on-site, the necessary rebar is placed, and then ready-mixed concrete is poured and cured for a certain period of time until it reaches the required strength.The formwork is then removed (demolished) and the house foundation is constructed.

[0003] Today's homes require high airtightness and insulation performance in order to save energy, and housing manufacturers and construction companies use a wide variety of materials and construction methods to meet these requirements.

[0004] However, measures to meet these various demands have been concentrated on the house itself, leaving behind improvements to the performance of the foundations that form the foundation and improvements to construction methods. As a result, house foundations are built using outdated methods and construction methods, and measures to prevent condensation, which affects durability, are being carried out using makeshift methods that increase the amount of work required. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 4-44522 [Patent Document 2] Japanese Patent Application Publication No. 10-331172 [Patent Document 3] Japanese Patent Application Publication No. 2018-178695 Summary of the Invention [Problem to be solved by the invention]

[0006] When building foundations using wooden formwork, it is necessary to manufacture and process (cut and prepare) the formwork to suit each individual site, and the scrap wood and sawdust generated during the process must be incinerated. Furthermore, it takes time and space to collect and carry away the removed formwork, clean it up by removing any concrete that has adhered to it, and then put it away and store it. Furthermore, wooden formwork can only be used three to five times, so once it can no longer be used, it becomes waste, and the parts that were discarded must be made new and replaced.

[0007] The production of formwork requires the specialized knowledge and experience of formwork carpenters, but there is also the problem that the number of skilled formwork carpenters with specialized knowledge and experience is decreasing with each generation.

[0008] On the other hand, when constructing foundations using steel formwork, it is necessary to select and determine the type, specifications, and quantity of formwork required for each individual site, and then prepare it. After removing the formwork, it must be collected and taken home, cleaned to remove any adhering concrete, treated with anti-rust agents, and then put away and stored, which requires time and space, just like with wooden formwork.

[0009] Furthermore, when preparing steel formwork, it takes several years of experience to be able to read the drawings of the foundation to be constructed and select and determine the necessary formwork.

[0010] Furthermore, to achieve high insulation in the floors of wooden buildings, it is necessary to take measures against condensation on the outer foundation and underfloor, which are the boundary between the outside air and the space under the floor.To prevent condensation on the inside of the straight walls caused by the temperature difference between inside and outside the outer foundation, whether the form is made of wood or steel, foam urethane insulation is attached to the inside of the form before assembly, and is integrated with the poured ready-mixed concrete, and the form is then removed after hardening.Alternatively, foam urethane insulation is attached to the inside of the form when preparing the form, but both wooden and steel formwork require assembly work at each site.

[0011] Another post-construction method is to use adhesive to attach the insulation to the inside of the straight wall of the perimeter foundation after the fresh concrete has hardened and the formwork has been removed, and then press it in place.However, when using post-construction, the formwork joints and unevenness must be finished with high precision to within a few millimeters.If the unevenness is large, plastering work such as applying mortar as preparatory work will be required.

[0012] The objective of this invention is to provide a technical means for solving the various problems of the prior art, namely, eliminating the need for complicated and time-consuming formwork preparation work and cleaning work after formwork removal, and for flexibly adapting to differences in building shapes, and for constructing a housing foundation with high thermal insulation properties simply and with a small number of steps. [Means for solving the problem]

[0013] This invention solves the above-mentioned problems by providing a housing foundation that is a mixture of various materials and ingredients that make up the foundation, specifically a housing foundation that is a mixture of precast concrete products (hereinafter also referred to as "blocks"), reinforcing bars, cast-in-place concrete (ready-mixed concrete), and heat insulating materials.

[0014] The outer periphery (periphery foundation) of the house foundation of this invention is installed and assembled at each individual site using unitized outer periphery blocks 1 and heat insulating materials such as urethane foam.

[0015] The peripheral block 1 is a block of a predetermined length that includes a straight wall portion 11 and a seat portion 12 that is integrally formed below the straight wall portion. A plurality of inserts (insert nuts or bolts) are erected or embedded at predetermined intervals along the length of the block on the outside of the upper end of the straight wall portion 11 and on the inside of the boundary between the straight wall portion 11 and the seat portion 12.

[0016] The formwork 18 for the perimeter foundation 10 is assembled by laying the required number of outer perimeter blocks 1 on each straight section, with corner blocks 1a and 1b interposed at the corners, and then erecting insulation material 2 on the inside of the perimeter wall and maintaining the distance between the outer perimeter blocks 1 and the insulation material 2 with spacing retainers 3 (3a, 3b) attached to inserts 16 and 17.

[0017] The inner foundation 4 installed inside the outer perimeter foundation 10 is similar to the outer perimeter foundation 10, and is made by using a factory-fabricated unitized inner block 42 with a downward U-shaped cross section having an opening 43 on the top surface and a base block 41, with the inner block 42 erected on top of the base block 41 placed in the required location. The space formed under the inner block 42 between adjacent base blocks 41 becomes a void that connects the reinforcing bars 34 placed inside the inner block 42 with the reinforcing bars 35 in the poured concrete layer 5.

[0018] The formwork 18 for the outer foundation and the inner foundation 4 formed using the above procedure are assembled, and reinforcing bars 35, 31, 34 are placed on the top surface of the site and in the voids within the formwork for the outer foundation 10 and the inner foundation 4. After that, ready-mixed concrete is poured into the voids between the outer block 1 and the insulation material 2 and into the top opening 43 of the inner block 42 and allowed to harden. After that, the support frame 21 and the spacing retainer 3a at the top end of the outer foundation are removed, and the foundation for the house is completed, which is an integrated construction of each material, namely the outer block 1, corner blocks 1a, 1b, insulation material 2, inner block 42, base block 41, poured concrete layer 5, the reinforcing bars 31, 34, 35 placed between them, and the poured ready-mixed concrete. [Effects of the Invention]

[0019] The foundation of this invention can be easily designed and constructed by anyone, even if they are not skilled, because the type, number and arrangement of pre-unitized blocks can be determined based on the foundation plan, and the prepared blocks can be laid based on the layout installation drawing.

[0020] Furthermore, because the formwork becomes part of the constructed foundation, no construction waste (wood scraps, sawdust, etc.) is generated, and no advance preparations such as production, selection, loading, and transportation are required. Furthermore, there is no need to remove or dismantle the formwork after the ready-mixed concrete poured on-site has hardened, so work on erecting the shed can proceed quickly.

[0021] Furthermore, there is no need for post-processing such as sorting, loading, carrying out, cleaning and tidying up the removed formwork, there is no need to manage and store formwork collected from each individual site, and there is no need to dispose of formwork that can no longer be used. This eliminates the need for work such as advance preparation, dismantling of formwork and post-processing during the process of building a house foundation, which reduces the number of people and labor required and shortens the construction period, resulting in overall cost reductions.

[0022] Furthermore, the one-piece molding method results in a high-performance housing foundation with thermal insulation, which prevents condensation and corrosion of the housing structural materials (wood). [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a plan view showing an embodiment of a residential foundation according to the present invention. [Figure 2] Enlarged cross-sectional view of part AA in Figure 1 [Figure 3] Side view of the perimeter block in Figure 2 [Figure 4] FIG. 3 is a perspective view of the outer peripheral block of FIG. 2 as seen from the outside. [Figure 5] FIG. 3 is a perspective view of the outer peripheral block of FIG. 2 as seen from the inside. [Figure 6] Perspective view of a convex block [Figure 7] Perspective view of a reentrant block [Figure 8] View of the outer base mold from the inside [Figure 9] Perspective view of the upper spacing retaining metal fitting [Figure 10] Perspective view of the lower spacing retaining bracket [Figure 11] Perspective view of the inner block [Figure 12] Perspective view of the base block DETAILED DESCRIPTION OF THE INVENTION

[0024] An embodiment of the present invention will be described below with reference to the drawings. Figure 1 is a plan view of a residential foundation, and Figure 2 is a cross-sectional view taken along line AA in Figure 1. Reference numeral 10 denotes a perimeter foundation, 4 denotes an inner foundation, and 5 denotes a poured concrete layer covering the ground surface in the area surrounded by the perimeter foundation 10. The perimeter foundation 10 and the inner foundation 4 are constructed by pouring ready mixed concrete into a formwork mainly made of concrete blocks, and are integrated with the formwork.

[0025] The perimeter foundation 10 is an integrated structure formed by pouring ready-mixed concrete into the empty spaces of a formwork 18 formed by perimeter blocks 1 arranged in a row to match the length of the straight section and insulation materials 2 erected at intervals between the blocks.

[0026] As shown in Figures 1 to 5, each outer peripheral block 1 is a block formed by integrating a straight wall portion 11 and a seat portion 12, and the seat portion 12 is a block of a predetermined length that includes a straight wall extension portion 13 extending downward from the lower edge of the straight wall portion 11, a seat surface 14 extending horizontally from the lower edge of the extension portion, and an inner upright portion 15 extending upward a short distance from the tip edge of the seat surface.

[0027] Inserts (insert nuts or bolts) 16, 17 are provided at a predetermined distance in the longitudinal direction of the block on the outside of the upper end of the straight wall portion 11 of the perimeter block 1 and on the inside of the boundary between the straight wall portion 11 and the seat portion 12. The upper end of the inner upright portion 15 is located lower than the lower insert 17. The base ends of spacing fittings 3 (3a, 3b) for maintaining the distance between the perimeter block 1 and the insulating material 2 facing it are fixed to the inserts 16, 17. The spacing fittings 3 at the upper end of the straight wall portion are removed after the concrete poured between the perimeter block 1 and the insulating material 2 has hardened.

[0028] At the corners of the outer foundation 10, a convex block 1a having a right-angled vertical wall portion 11a and a bottom surface 14a as shown in Figure 6, and a concave block 1b consisting of an inner upright portion 15b perpendicular to the bottom surface 14b as shown in Figure 7 are placed.

[0029] Before the ready-mixed concrete is poured, the insulation material 2 is attached to a support frame 21 to maintain it in an upright position, and the position of the support frame 21, i.e., the distance between the straight wall portion 11 of the outer periphery block and the insulation material 2, is determined by spacing fittings 3 extending from the outer periphery block 1. The support frame 21 shown in Figure 8 is formed from multiple steel members arranged in a grid pattern, but it may also be in the form of a single plate.

[0030] In consideration of portability, the support frame 21 of the embodiment has a structure in which vertical crossbars 22 and horizontal crossbars 23 are assembled in a grid pattern at each site. That is, as shown in Figure 9, the vertical crossbars 22 are integral with the upper gap retainers 3a, and the horizontal crossbars 23 are engaged with horizontal crossbar receiving portions 25, 26 provided on the vertical crossbars 22, so that the structure can be assembled and disassembled at the site.

[0031] The perimeter foundation 10 is constructed by arranging perimeter blocks 1 longitudinally on a perimeter concrete ground 51 formed on a crushed stone layer 50, pouring ready-mixed concrete between the blocks 1 and the insulating materials 2 erected at intervals on the inside, and integrating the blocks 1, the insulating materials 2, and the poured concrete layer 5.

[0032] The inner foundation 4 is constructed by erecting an inner block 42 with a downward-facing U-shaped cross section and an opening on the top surface on base blocks 41 placed at appropriate intervals on the inner concrete ground 54, which is constructed at the same time as the outer concrete ground 51, and the reinforcing bars 34 in the inner block are connected to the reinforcing bars 35 in the poured concrete layer 5 inserted into the base block from the part where the base block 41 is not installed.

[0033] The inner foundation 4 is formed by pouring ready mixed concrete through the top opening 43 of the inner block 42, which serves as the formwork, and integrating it with the inner block 42. The reinforcing bars 34 in the inner block are connected to the reinforcing bars 35 in the poured concrete layer 5 that are inserted into the base block from the part where the base block 41 is not installed. The base block 41 is buried in the poured concrete layer 5.

[0034] The solid foundation of this invention is (1) Excavating the ground on the outer side of the exterior wall of the building and forming a crushed stone layer 50 in the excavated area and in the area where concrete is poured inside the excavated area; (2) Form concrete foundations 51, 54 at the bottom of the excavation and at the location where the inner foundation 4 is located. (3) Place the outer block 1 on the concrete ground 51 of the excavation section and place the base block 41 on the inner concrete ground. (4) Place reinforcing bars 31, 34, and 35 in the outer foundation 10, inner foundation 4, and solid concrete layer 5; (5) Attach the spacing retaining brackets 3a and 3b to the outer periphery block 1, (6) An inner block 42 is erected between the base blocks 41, 41. (7) The support frame 21 is engaged with the spacing retaining metal fittings 3a and 3b and erected, and the heat insulating material 2 is attached to the support frame 21. (8) Pour the solid concrete layer 5; (9) Pour ready-mixed concrete between the top opening 43 of the inner block 42 and the outer block 1 and the heat insulating material 2 to integrate it with the concrete layer 5. (10) After the concrete has hardened, remove the spacing retaining metal fittings 3a at the top of the outer foundation, and if necessary, remove the support frame 21. It is constructed in this process. [Explanation of symbols]

[0035] 1(1a, 1b) Periphery block 2. Insulation 3(3a, 3b) Spacing retainer 4. Internal foundation 5. Solid concrete layer 10 Perimeter foundation 11 Straight wall section 12 Seat 16, 17 Insert 18 Periphery base forming mold 21 Support frame 31, 34, 35 Reinforced concrete 41 units block 42 Inner Block 43 Concrete injection opening 51 Periphery concrete ground 54 Internal concrete ground

Claims

1. a periphery block including a straight wall portion (11) that forms the outer surface of the periphery foundation (10) and a seat portion (12) that is integrally formed at the bottom of the straight wall portion and placed on the periphery concrete ground (51); a support frame (21) erected at a distance from the inner surface of the straight wall portion (11) and a heat insulating material (2) attached to the straight wall side of the support frame; The outer periphery foundation forming mold for a building is provided with a spacing retainer (3) that extends inward from the upper end of the straight wall portion and the boundary between the straight wall portion (11) and the seat portion (12) to prevent the support frame from moving toward the opposite straight wall portion.

2. A slab foundation comprising a perimeter foundation (10) formed using the perimeter foundation forming mold (18) according to claim 1, arranged along the exterior wall of a building, and a slab concrete layer (5) poured onto the ground surface surrounded by the perimeter foundation and integrated with the perimeter foundation.

3. An inner foundation forming mold consisting of a base block (41) placed on the internal concrete ground (54) and an inner block (42) with a downward U-shaped cross section and a concrete injection opening (43) on the upper surface, which is erected on multiple base blocks.

4. A mat foundation comprising an outer perimeter foundation (10) formed using the outer perimeter foundation forming mold (18) described in claim 1, an inner foundation (4) formed using the inner foundation forming mold described in claim 3, and a mat concrete layer (5) integrated with the outer perimeter foundation and the inner foundation.

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