Sleeve embedding construction method into cement structure, and manufacturing method of cement structure

Abstract

To easily form a through hole in a cement structure by using a sleeve even in a design where it is difficult to change a sleeve size and the thickness of a cement-based material is greater than that of a sleeve.SOLUTION: In a construction method in which a cylindrical sleeve 20 is embedded in a structure 1 made of a cement-based material to form a through hole in the structure 1, a protective cover 30 is removably attached to at least one side of an opening of the sleeve 20, the sleeve 20 with the protective cover 30 is placed inside a formwork 10 of the structure 1 so as to be sandwiched by the formwork 10, a cement-based material is poured into the formwork 10 and then allowed to solidify to form the structure 1 within the formwork 10, and subsequently the formwork 10 is removed. By removing the protective cover 30 as needed, a through hole is formed in the structure 1.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a construction method for forming a through-hole by embedding a sleeve in a cementitious structure, and also to a method for manufacturing a cementitious structure. [Background technology]

[0002] Conventionally, when constructing a structure such as a building (also called a "cement structure") using cement-based materials, a through hole is formed by embedding a sleeve in the wall, ceiling, eaves, etc. of the cement structure. Depending on the location where the through hole is formed, it is used as a vent by connecting a duct, or for laying electrical wiring, water pipes, gas pipes, etc.

[0003] A conventional method for forming a through hole in a cement structure is to first place a cylindrical sleeve made of metal or synthetic resin in a formwork assembled to fit the outer shape of the structure, pour raw cement-based material into the formwork, allow it to harden, and then remove the formwork (see, for example, Patent Document 1). After the through hole is formed, the sleeve can also be removed as needed. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-113844 Summary of the Invention [Problem to be solved by the invention]

[0005] In some cases, it may be necessary to form a vertical through-hole in a cementitious material, such as in the eaves soffit (also called the back of the eaves) of an exterior wall that extends from the top toward the exterior. In this case, a conventional method involves constructing a formwork corresponding to the lower portion of the eaves soffit, placing a sleeve on top of the formwork, and pouring raw cementitious material into the formwork so that the upper end of the sleeve protrudes above the surface of the cementitious material without constructing a formwork above the sleeve. However, this method cannot be used if the length of the sleeve cannot be made longer than the thickness of the cementitious material where it will be embedded, for example, due to material procurement difficulties or the inability to change the size of the sleeve. In other words, if the length of the sleeve is shorter than the thickness of the cementitious material where it will be embedded, the upper end of the sleeve will not protrude above the surface of the cementitious material. Therefore, if raw cementitious material is poured into the formwork in this state, the cementitious material will flow into the inside of the sleeve, preventing the formation of a through-hole.

[0006] The same applies when a pair of formworks are assembled on the top and bottom (or front and back) sides and a sleeve is installed between them. In other words, if the thickness of the cementitious material between the pair of formworks is designed to be thicker than the length of the sleeve, the raw cementitious material will flow into the inside of the sleeve, making construction difficult for the same reasons as with the eaves soffits mentioned above.

[0007] As described above, when it is difficult to change the sleeve size and the thickness of the cement-based material is designed to be thicker than the sleeve, it is difficult to form a through hole in the cement structure using the sleeve. Therefore, the main object of the present invention is to solve such a problem. [Means for solving the problem]

[0008] The inventors of the present invention have intensively studied means for solving the problems of the prior art described above, and have discovered that by attaching a curing lid to cover at least one of the openings of the sleeve, placing the sleeve and curing lid between a pair of forms, and then pouring raw cementitious material into the forms and allowing it to harden, it is possible to prevent the cementitious material from flowing into the sleeve and form a through-hole in a structure, even when it is difficult to change the size of the sleeve. Based on this discovery, the inventors have come to the conclusion that the problems of the prior art can be solved, and have completed the present invention. Specifically, the present invention comprises the following steps:

[0009] A first aspect of the present invention relates to a method for embedding a sleeve in a cement structure. In the method according to the present invention, a cylindrical sleeve 20 is embedded in a structure 1 made of a cementitious material, and a through-hole is formed in the structure 1. The cementitious material is a hardened body made of cement, such as concrete, mortar, or cement paste. In the method according to the present invention, a curing cover 30 is first detachably attached to at least one side of an opening 22 of the sleeve 20. The sleeve 20 with the curing cover 30 is then placed in a formwork 10 for the structure 1 so as to be sandwiched between the formwork 10. A cementitious material is then poured into the formwork 10 and allowed to harden. This forms a structure 1 made of a cementitious material in the formwork 10. The formwork 10 is then removed from the structure 1. This forms a through-hole in the structure 1 by removing the curing cover 30 as needed. In the present invention, removing the sleeve 20 from the structure 1 is not generally contemplated.

[0010] As in the above process, by placing the sleeve 20 inside a pair of formwork 10 with the opening 22 of the sleeve 20 covered with the curing lid 30, the curing lid 30 can prevent the raw cementitious material from flowing into the sleeve 20 even if the length of the sleeve 20 is shorter than the thickness of the cementitious material at the embedding portion. When placing the sleeve 20 inside the formwork 10, an adjustment frame member may be placed on one side of the opening 22 of the sleeve 20. Furthermore, by attaching the curing lid 30 to the sleeve 20, for example, when a through-hole extending vertically is formed by the sleeve 20, the curing lid 30 also functions as a lid to prevent objects or people from falling from the upper floor to the lower floor.

[0011] In the construction method according to the present invention, the curing lid 30 is preferably attached to the flange 23 of the sleeve 20 via a fastener 40. In this case, it is preferable to use a bolt 41 and a nut 42 as the fastener 40. In particular, it is preferable to use a long nut as the nut 42. A long nut refers to a nut whose length is longer than its maximum width. In this case, the nut 42 is embedded within the structure 1. In this way, by using a long nut to secure the sleeve 20 and the curing lid 30, the long nut is easily fixed to the structure 1 made of cement-based material.

[0012] In the construction method of the present invention, it is preferable to further attach a mesh member 50 to the opening 22 of the sleeve 20 on the side where the curing lid 30 is attached. This mesh member 50 is used, for example, to prevent insects, birds, animals, and other foreign objects from entering through the opening 22 of the sleeve 20. For example, in the past, when the sleeve 20 was embedded vertically in the eaves soffit 4 of the structure 1, attaching the bird-proof mesh member 50 to the sleeve 20 required setting up scaffolding under the eaves (below the eaves soffit 4) and manually attaching the mesh member 50 to the sleeve 20 at a high elevation. Furthermore, this attachment method also poses the problem of making the mesh member 50 easily visible from the outside, thereby detracting from the appearance of the structure 1. On the other hand, in the construction method of the present invention, for example, a step can be performed in which the mesh member 50 is sandwiched between the sleeve 20 and the curing lid 30, the sleeve 20 is placed in the formwork 10, and raw cement-based material is poured into the formwork. In this case, construction of the sleeve 20 and installation of the net member 50 can be performed simultaneously, which eliminates the need to set up scaffolding and separately install the net member 50 from the outside after construction of the sleeve 20. Furthermore, when the net member 50 is installed by being sandwiched between the sleeve 20 and the protective cover 30, the net member 50 becomes difficult to see from the outside, which improves the appearance of the structure 1.

[0013] The construction method according to the present invention may further comprise attaching a duct 60 to the opening 22 of the sleeve 20 on the side where the protective cover 30 is attached. This allows the opening 22 of the sleeve 20 to be used as an air vent (exhaust port and / or air intake port).

[0014] In the construction method according to the present invention, the sleeve 20 is preferably embedded in the eaves soffit 4 of the structure 1 at a position where the through-hole formed by the sleeve 20 functions as a vent that vertically connects the indoors and outdoors. The present invention is particularly suited to solving problems that arise when embedding the sleeve 20 in the eaves soffit 4.

[0015] A second aspect of the present invention relates to a method for manufacturing a cementitious material structure 1 having a through hole formed by a cylindrical sleeve 20. The manufacturing method according to the present invention includes the steps of removably attaching a curing lid 30 to at least one side of the opening 22 of the sleeve 20, placing the sleeve 20 with the curing lid 30 within the formwork 10 of the structure 1 so that the sleeve 20 is sandwiched between the formwork 10, pouring a cementitious material into the formwork 10 and allowing it to harden to form the structure 1 within the formwork 10, and removing the formwork 10 from the structure 1. Then, the curing lid 30 is removed as needed to form a through hole in the structure 1. [Effects of the Invention]

[0016] According to the present invention, even in a design in which it is difficult to change the sleeve size and the cement-based material is thicker than the sleeve, it is easy to form a through hole in the cement structure by using the sleeve. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a cross-sectional view showing a structure according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a perspective view mainly showing an example of a sleeve and a protective cover. [Figure 3] FIG. 3 is a cross-sectional view showing the first and second steps of the sleeve landfill construction method. [Figure 4] FIG. 4 is a cross-sectional view showing the third and fourth steps of the sleeve landfill construction method. [Figure 5] FIG. 5 is a cross-sectional view showing a fifth step of the sleeve landfill construction method. [Figure 6] FIG. 6 is a cross-sectional view showing a structure according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. The present invention is not limited to the embodiments described below, but also includes appropriate modifications of the embodiments below within the scope obvious to those skilled in the art. Note that each drawing is accompanied by an XYZ Cartesian coordinate system.

[0019] Fig. 1 shows a cementitious structure 1 according to a first embodiment of the present invention. In the example shown in Fig. 1, the cementitious structure 1 has an exterior wall 2 that separates the indoors from the outdoors, and further has eaves 3 formed above the exterior wall 2 that extend beyond the exterior wall 2 toward the outdoors. In Fig. 1, the eaves soffit corresponding to the underside of the eaves 3 is indicated by the reference numeral 4.

[0020] Such a structure 1 is basically formed by assembling a formwork 10 along the outer shape of the structure 1, pouring raw cementitious material into the formwork 10, and allowing the cementitious material to harden within the formwork 10. The shape and assembly method of the formwork 10 can be designed appropriately depending on the outer shape of the structure 1. In the embodiment shown in FIG. 1 , the formwork 10 mainly includes a pair of outer frame members 11 and inner frame members 12 arranged opposite each other to form the exterior wall 2, a pair of upper frame members 13 and lower frame members 14 arranged opposite each other to form the eaves soffit 4, and a pair of outer eaves frame members 16 and inner eaves frame members 17 arranged opposite each other to form the sloped portion of the eaves 3. In addition, in the portion corresponding to the eaves soffit 4, an adjustment frame member 15 is layered on top of the lower frame member 14. This adjustment frame member 15 is positioned taking into consideration adjustment of the installation height of the sleeve 20 (described later) and the design of the eaves soffit 4. The formwork 10 is made of, for example, plywood, battens, plastic, or polystyrene resin foam. A cementitious material is poured into the formwork 10 assembled in this manner from above. Examples of cementitious materials include concrete (a mixture of cement, water, fine aggregate, and coarse aggregate), mortar (a mixture of cement, water, and fine aggregate), and cement paste (a mixture of cement and water). In particular, concrete is preferably used as the cementitious material for the structure 1 that forms the exterior wall 2.

[0021] As shown in Fig. 1, a sleeve 20 for forming a through hole is embedded in the structure 1 with a protective cover 30 attached. In the embodiment of Fig. 1, the sleeve 20 with the protective cover 30 attached is embedded in the eaves soffit 4 of the structure 1, which projects outdoors from the exterior wall 2, and this sleeve 20 forms a through hole that penetrates vertically through the eaves soffit 4. The sleeve 20 and the protective cover 30 are arranged so as to be sandwiched between the upper frame material 13 and the lower frame material 14 that form the eaves soffit 4. In the example of Fig. 1, the sleeve 20 with the protective cover 30 directly abuts on the upper frame material 13 and the adjustment frame material 15 stacked on the lower frame material 14.

[0022] FIG. 2 shows an example of a sleeve 20, a protective cover 30, and a fastener 40. The materials of the sleeve 20 and the protective cover 30 are not particularly limited, and they may be made of metal or synthetic resin. In the example shown in FIG. 2, the sleeve 20 has a rectangular cylindrical side wall 21, and the space enclosed by the side wall 21 forms an opening 22. This opening 22 is connected in the height direction (Z-axis direction) of the sleeve 20. A flange 23 is formed on one side of the opening 22 of the sleeve 20, extending perpendicularly from the top of the side wall 21 toward the outer periphery. A rectangular protective cover 30 is butted against the flange 23 of the sleeve 20 and fastened with a fastener 40, thereby closing one side of the opening 22 of the sleeve 20 with the protective cover 30. In this embodiment, bolt holes 24 and 31 are formed in corresponding positions on the flange 23 of the sleeve 20 and the protective cover 30, respectively. The fastener 40 consists of a bolt 41 and a nut 42. Therefore, after stacking the sleeve 20 and the protective cover 30, a bolt 41 is inserted from one side of each bolt hole 24, 31 and the bolt 41 is tightened with a nut 42 from the opposite side, thereby removably fixing the protective cover 30 to the sleeve 20.

[0023] As shown in FIG. 2, a so-called long nut is used as the nut 42. A long nut is a nut whose length is longer than its maximum width. It is preferable to use a long nut whose length is at least four or five times the maximum width. The nut 42 is embedded in the cementitious material when the raw cementitious material is poured into the formwork 10, and is fixed by the solidified cementitious material. Therefore, using a relatively long nut as the nut 42 makes it easier for the nut 42 to be fixed in the cementitious material.

[0024] 2, the side wall 21 of the sleeve 20 may be provided with one or more anchors 25 that protrude perpendicularly from the side wall 21 toward the outer periphery. Anchors 25 may be, for example, plate-like members with an L-shaped cross section, one side of which is joined to the side wall 21 of the sleeve 20. The anchors 25 are embedded in the raw cementitious material when the raw cementitious material is poured into the formwork 10, and are fixed in place by the hardened cementitious material. Therefore, by attaching the anchors 25 to the sleeve 20, the sleeve 20 is more easily fixed in the cementitious material and is less likely to come off the hardened cementitious material (structure 1).

[0025] 2 shows an example in which the sleeve 20 is rectangular tubular and the protective cover 30 is also rectangular, but this is not limiting and, for example, it is also possible for the sleeve 20 to be cylindrical and the protective cover 30 to be circular, or for the sleeve 20 to be polygonal tubular and the protective cover 30 to be the same polygonal shape. Also, in FIG. 2, the protective cover 30 is attached to one side of the opening 22 of the sleeve 20, but this is not limiting and it is also possible for the protective cover 30 to be attached to both sides of the opening 22 of the sleeve 20.

[0026] 3 to 5, a method for manufacturing a structure 1 in which a sleeve 20 is embedded in a cement-based material and an example of use of the structure 1 will be described. First, as shown in Fig. 3(a), a curing lid 30 is attached to one side of the opening 22 of the sleeve 20 and detachably fixed with a fastener 40. This causes the opening 22 of the sleeve 20 to be blocked by the curing lid 30, preventing the cement-based material from flowing into the opening 22.

[0027] Next, as shown in FIG. 3(b), the sleeve 20 with the protective cover 30 is placed in the formwork 10. At this time, as also shown in FIG. 1, in this embodiment, the sleeve 20 is embedded in the eaves soffit 4 for the purpose of forming a vertical opening in the eaves soffit 4 of the structure 1. Therefore, the sleeve 20 with the protective cover 30 is installed between the upper frame member 13 and the lower frame member 14 that form the eaves soffit 4. Specifically, within the formwork 10, the sleeve 20 is in a state where the side of the opening 22 of the sleeve 20 that is blocked by the protective cover 30 faces the upper frame member 13, and the other side of the opening 22 faces the lower frame member 14.

[0028] Furthermore, as shown in FIG. 3(b), if the length of the sleeve 20 (i.e., the length from one end to the other of the opening 22) is less than the distance between the upper frame member 13 and the lower frame member 14 (i.e., the thickness of the eaves soffit 4), an adjustment frame member 15 may be placed on top of the lower frame member 14, and the sleeve 20 may be installed on top of the adjustment frame member 15. This adjustment frame member 15 allows the installation height of the sleeve 20 within the formwork 10 to be adjusted. In this case, one side of the opening 22 of the sleeve 20 is blocked by the protective cover 30, and the other side of the opening 22 is blocked by the adjustment frame member 15. Note that if the length of the sleeve 20 matches the distance between the upper frame member 13 and the lower frame member 14, the adjustment frame member 15 is unnecessary. In that case, one side of the opening 22 of the sleeve 20 is blocked by the protective cover 30, and the other side of the opening 22 is blocked by the lower frame member 14.

[0029] 3(b), when the sleeve 20 with the curing lid 30 is placed on the formwork 10, it is preferable to attach a packing 32 along the edge of the upper surface of the curing lid 30 to prevent the upper surface of the curing lid 30 from being covered with the raw cementitious material. That is, when the sleeve 20 is placed on the formwork 10, a gap may be formed between the curing lid 30 and the upper frame material 13, but by attaching a packing 32 made of, for example, sponge to this gap, it is possible to prevent the raw cementitious material from adhering to the curing lid 30 through this gap.

[0030] Next, as shown in Fig. 4(c), the raw cementitious material 1' is poured into the formwork 10. As a result, the area around the sleeve 20 is filled with the raw cementitious material 1', but the raw cementitious material 1' does not flow into the inside of the sleeve 20 or above the curing lid 30, so that space is maintained. The raw cementitious material 1' gradually hardens over time.

[0031] As shown in FIG. 4(d), the cementitious material solidifies to form a structure 1 made of the cementitious material. The formwork 10 is then removed from the structure 1. This results in a through hole being formed in the structure 1 at the portion corresponding to the opening 22 of the sleeve 20. In the example shown in FIG. 4(d), the curing lid 30 remains attached to the sleeve 20, so no through hole is actually formed, but the curing lid 30 can be freely attached and detached to the sleeve 20 using fasteners 40. Therefore, by removing the curing lid 30 from the sleeve 20, a through hole will appear in the structure 1.

[0032] FIG. 5 shows the structure 1 formed through the steps shown in FIGS. 3 and 4 with the mesh member 50 and duct 60 attached. As shown in FIG. 5, the protective cover 30 is removed from the sleeve 20 to expose the opening 22 (the opening through which the structure 1 is formed). Then, the mesh member 50 can be attached to the top of the opening 22 of the sleeve 20 where the protective cover 30 was originally attached. The mesh member 50 is used to prevent the intrusion of insects, birds, animals, and other foreign objects. A mesh-like member with a mesh size suitable for this purpose can be used as the mesh member 50. The fasteners 40 originally used to secure the sleeve 20 and the protective cover 30 can be used to secure the mesh member 50 to the sleeve 20. The mesh member 50 may be attached to the top of the sleeve 20 after the protective cover 30 has been removed after the structure 1 has been formed. Alternatively, the mesh member 50 may be sandwiched between the sleeve 20 and the protective cover 30 before the structure 1 is formed. By taking the procedure of placing the sleeve 20 with the mesh member 50 attached inside the formwork 10 and pouring raw cementitious material into the formwork 10, it is possible to omit the work of separately attaching the mesh member 50 after the formation of the structure 1, which is efficient. Also, by attaching the mesh member 50 to the upper part of the opening 22 of the sleeve 20, the mesh member 50 becomes less visible from the underside of the sleeve 20, such as under the eaves, and the appearance of the structure 1 can be improved.

[0033] Furthermore, after removing the protective cover 30 from the sleeve 20 to expose the opening 22 (the through-hole of the structure 1), the duct 60 is attached to the top of the opening 22 of the sleeve 20 to which the protective cover 30 was originally attached. When fixing the duct 60 to the sleeve 20, the fasteners 40 that were originally used to fix the sleeve 20 and the protective cover 30 can be used, as with the mesh member 50. Indoor air can be discharged to the outdoors or outdoor air can be taken indoors through this duct 60 and sleeve 20. In the example shown in FIG. 5, a flexible duct is used as the duct 60.

[0034] After the structure 1 is completed, a heat insulating material 70 such as urethane foam may be laid on top of the structure 1, for example.

[0035] Next, an example of a structure 1 according to a second embodiment of the present invention will be described with reference to FIG. 6. In the first embodiment (FIG. 1) described above, the sleeve 20 is embedded in the structure 1 to form a through-hole extending up and down (vertically) in the eaves soffit 4. On the other hand, in the second embodiment (FIG. 6), the sleeve 20 is also embedded in the outer wall of the structure 1 to form a through-hole extending left and right (horizontally) in the outer wall 2. When the sleeve 20 is embedded in the outer wall 2 as well, the sleeve 20 is sandwiched between the outer frame material 11 and the inner frame material 12 of the formwork 10, and then the raw cementitious material is poured into the formwork 10. In this way, the sleeve 20 may be embedded in both the eaves soffit 4 and the outer wall 2, or, although not shown, it is also possible to embed the sleeve 20 only in the outer wall 2. The construction method for embedding the sleeve 20 in the exterior wall 2 is also the same as that of the first embodiment (construction method for embedding the sleeve 20 in the eaves soffit 4), and therefore detailed description thereof will be omitted.

[0036] In the above description of the present invention, the embodiments of the present invention have been described with reference to the drawings in order to express the contents of the present invention. However, the present invention is not limited to the above embodiments, and includes modifications and improvements that are obvious to those skilled in the art based on the matters described in the present specification. [Explanation of symbols]

[0037] 1...Structure 1'...Raw cementitious material 2…Outer wall 3…Eaves 4...Eaves 10...Formwork 11...Outer frame material 12...Inner frame material 13...Upper frame material 14...Lower frame material 15...Adjustment frame material 16...Outer eaves frame material 17...Eaves frame material 20...Sleeve 21...Side wall 22...Opening 23...Flange 24...Bolt hole 25...Anchor 30...Protection cover 31...Bolt hole 32...Packing 40... Fastener 41... Bolt 42... Nut 50... Mesh member 60...Duct 70...Insulation

Claims

1. A construction method for forming a through hole in a structure made of a cement-based material by embedding a cylindrical sleeve in the structure, a step of removably attaching a protective cover to at least one side of the opening of the sleeve; a step of placing the sleeve with the curing lid in the formwork so as to be sandwiched by the formwork of the structure; forming the structure within the formwork by pouring the cementitious material into the formwork and then solidifying it; and removing the formwork, By removing the protective cover as needed, a through hole is formed in the structure. Construction method.

2. The curing cover is attached to the flange of the sleeve using bolts and nuts, The nut is a long nut whose length is longer than its maximum width, The nut is embedded in the structure. The construction method according to claim 1.

3. The method further includes a step of attaching a mesh member to the opening of the sleeve on the side where the protective lid is attached. The construction method according to claim 1 or 2.

4. The method further includes a step of attaching a duct to the opening of the sleeve on the side where the protective cover is attached. The construction method according to claim 1 or 2.

5. The sleeve is embedded in the eaves, where the through hole formed by the sleeve functions as a vent connecting the indoors and outdoors. The construction method according to claim 1 or 2.

6. A method for manufacturing a cementitious material structure having a through-hole formed by a cylindrical sleeve, comprising: a step of removably attaching a protective cover to at least one side of the opening of the sleeve; a step of placing the sleeve with the curing lid in the formwork so as to be sandwiched by the formwork of the structure; forming the structure within the formwork by pouring the cementitious material into the formwork and then solidifying it; and removing the formwork, By removing the protective cover as needed, a through hole is formed in the structure. A method for manufacturing a structure made of cement-based materials.

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