Wall structure with external heat insulation, and construction method of the same

Abstract

To firmly support a fiber-reinforced mortar layer with excellent strength in a wall structure with an external heat insulation specification.SOLUTION: A wall structure of an external heat insulation includes a skeleton, a heat insulating material layer covering an outer surface of the skeleton, and a fiber-reinforced mortar layer covering an outer periphery of the heat insulating material layer. The fiber-reinforced mortar layer comprises fiber-mixed mortar mixed with short reinforcing fibers, and a plurality of reinforcing sheets embedded in the fiber-mixed mortar and made of fiber reinforcing material with a plurality of openings forming a mesh-like structure. An anchor member fixed to the skeleton penetrates the heat insulating material layer and at least the lowest reinforcing sheet in the fiber-reinforced mortar layer, and a flange member with a diameter larger than the opening in the reinforcing sheet is provided at its end.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a wall structure with external thermal insulation. [Background technology]

[0002] In so-called externally insulated walls, insulation materials such as polyethylene foam are generally attached to the outside of the building frame, and the surface is finished with mortar, tiles, etc. This method is not limited to wooden buildings, but is also widely used in steel-framed and reinforced concrete buildings.

[0003] For example, Patent Document 1 discloses a wall structure in which foam resin insulation is fixed to a temporary formwork reinforced with truss bars, lath (metal lath, wire lath, etc.) is provided on the outside of the formwork for attaching exterior materials, and this is connected to the temporary formwork with anchor members, concrete is poured into the temporary formwork, and exterior materials such as mortar and tiles are attached to the lath. In this case, the anchor members are fixed to the truss bars of the temporary formwork and penetrate the insulation to be attached to the lath. The anchor member is attached to the lath by threading a guide member onto a tapping screw at the tip of the anchor member, and the male thread on the outer periphery of the guide member is screwed into the lath to secure it. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 10-205032 Summary of the Invention [Problem to be solved by the invention]

[0005] Incidentally, fiber-reinforced mortar, typified by glass fiber reinforced cement, which is made by adding alkali-resistant glass fibers to cement to increase its strength, has been widely used as a building material because it has excellent strength and can be formed into a desired aesthetic and creative appearance. When this fiber-reinforced mortar layer is used in a wall with external insulation specifications as in Patent Document 1, there is a risk that the exterior material in Patent Document 1 will fall off if it is simply formed from fiber-reinforced mortar, so improvements are required.

[0006] The present invention has been made in view of the above circumstances, and has an object to provide strong support for a fiber-reinforced mortar layer, which has excellent strength, in a wall structure with external insulation specifications. [Means for solving the problem]

[0007] The externally insulated wall structure of the present invention comprises a skeleton, a thermal insulation layer covering the outer surface of the skeleton, and a fiber-reinforced mortar layer covering the outer surface of the thermal insulation layer, wherein the fiber-reinforced mortar layer comprises fiber-mixed mortar containing short reinforcing fibers mixed therein, and a plurality of reinforcing sheets made of fiber reinforcing material embedded in the fiber-mixed mortar and having a plurality of openings forming a mesh-like structure; An anchor member fixed to the main body penetrates the insulation layer and at least the lowest layer of the reinforcing sheet in the fiber-reinforced mortar layer, and a flange member with a diameter larger than the opening in the reinforcing sheet is provided at its end.

[0008] In this external insulation wall structure, the fiber-reinforced mortar layer has excellent strength, and the large-diameter collar of the anchor member fixed to the skeleton is positioned outside the bottom reinforcing sheet in the fiber-reinforced mortar layer, so the fiber-reinforced mortar layer is firmly held to the skeleton by the anchor member and can be prevented from falling off. In this case, by burying the reinforcing sheet, a thin but strong fiber-reinforced mortar layer can be created. Furthermore, the outer surface of the fiber-reinforced mortar layer can be formed into a desired shape, such as a curved surface, resulting in a wall structure with an excellent design.

[0009] In the external insulation wall structure of the present invention, the flange member of the anchor member may be disposed between a plurality of the reinforcing sheets. The fiber-reinforced mortar layer can be firmly fixed not only in the surface direction but also in the axial direction of the anchor member, thereby reliably preventing it from falling off.

[0010] Furthermore, in the area where the flange member of the anchor member is located, the multiple reinforcing sheets are bent in the thickness direction of the fiber-reinforced mortar layer and deformed so that the spacing between the reinforcing sheets is smaller than the spacing between the reinforcing sheets in the area where the anchor member is not provided. The density of the reinforcing sheet increases in the area where the collar member of the anchor member is disposed, thereby achieving further improvement in strength.

[0011] Furthermore, the collar member of the anchor member may be accommodated in a recess formed in the surface of the fiber reinforced mortar layer. The outer surface of the fiber-reinforced mortar layer can be finished smoothly, and when a finishing layer is formed thereon, the finishing layer can be made thin.

[0012] In the externally insulated wall structure of the present invention, the insulating layer may be made of spray foam.

[0013] Spray foam, for example, is primarily composed of polyurethane resin and is foamed while being sprayed onto the exterior surface of the building frame. Unlike molded bodies made using a mold, it accumulates in the order in which it is sprayed, allowing for the formation of an uneven surface. Meanwhile, the fiber-mixed mortar in the fiber-reinforced mortar layer layered on top of this insulation layer is a mixture of cement, fine aggregate, water, short fibers for reinforcing the mortar, etc., and when this fiber-mixed mortar is applied by a worker using a trowel or the like using the so-called hand layup method, the fiber-mixed mortar penetrates into the unevenness of the insulation layer surface, and together with its anchoring effect, it firmly integrates the insulation layer and the fiber-reinforced mortar layer.

[0014] In the external thermal insulation wall structure of the present invention, a finishing layer made of mortar that does not contain the short fibers may be formed on the fiber-reinforced mortar layer.

[0015] In the fiber-reinforced mortar layer, some of the short fibers may protrude from the surface, but by forming a finishing layer on top of them, the surface can be finished to be smooth.

[0016] In the externally insulated wall structure of the present invention, at least a portion of the outer surface of the fiber-reinforced mortar layer may be formed into a curved surface.

[0017] By stacking fiber-reinforced mortar layers using the hand layup method, it is possible to form a curved surface, making it suitable for use in a variety of architectural designs.

[0018] The method for constructing an externally insulated wall structure of the present invention comprises a skeleton construction step of constructing a skeleton and fixing anchor members to the outer surface of the skeleton, a thermal insulation layer formation step of forming a thermal insulation layer covering the outer surface of the skeleton with the anchor members penetrated therethrough, and a fiber reinforced mortar layer formation step of forming a fiber reinforced mortar layer covering the outer surface of the thermal insulation layer, The fiber-reinforced mortar layer forming process involves depositing fiber-mixed mortar containing short fibers, arranging multiple reinforcing sheets made of fiber reinforcing material with multiple openings in a mesh pattern so that these fiber reinforcing materials are embedded in the fiber-mixed mortar, and arranging the ends of anchor members protruding from the insulation layer so that they penetrate at least one of the reinforcing sheets, and providing the ends of the anchor members with flange members having a diameter larger than the openings in the reinforcing sheets.

[0019] In the construction method for an externally insulated wall structure of the present invention, the collar member of the anchor member may be placed between the plurality of reinforcing sheets and embedded in the fiber-mixed mortar. In addition, by attaching the flange member to the tip of the anchor member, the multiple reinforcing sheets can be bent in the thickness direction of the fiber-reinforced mortar layer and deformed so that the spacing between the reinforcing sheets is smaller than the spacing in areas where the anchor member is not provided.

[0020] In the construction method for an externally insulated wall structure of the present invention, the insulation layer forming process preferably forms the insulation layer by spraying a fluidized insulation material onto the outer surface of the body, causing it to foam and accumulate.

[0021] Because this insulation layer is made of sprayed foam, the surface is formed with an uneven shape, and the fiber-reinforced mortar layer deposited on top of it penetrates into the unevenness of the insulation layer, and together with the effect of the anchor member, it is firmly integrated.

[0022] In the construction method for an externally insulated wall structure of the present invention, at least a portion of the outer surface of the fiber-reinforced mortar layer may be formed into a curved surface.

[0023] By stacking fiber-reinforced mortar layers using the hand layup method, it is possible to form a curved surface, which can be applied to a variety of architectural designs. In this case, if the outer surface of the skeleton or the outer surface of the thermal insulation layer has a curved surface, the outer surface of the fiber-reinforced mortar layer can be formed on a curved surface that follows the curved surface. Furthermore, regardless of the shape of the outer surface of the skeleton or the thermal insulation layer (even if it is a flat surface), it is also possible to form a curved surface on the outer surface of the fiber-reinforced mortar layer. Furthermore, by forming the heat insulating layer by spray foaming, the outer surface can be formed into a curved surface. [Effects of the Invention]

[0024] According to the present invention, the fiber-reinforced mortar layer has excellent strength, and the large-diameter flange member of the anchor member fixed to the main body is positioned outside the lowest reinforcing sheet in the fiber-reinforced mortar layer, so the fiber-reinforced mortar layer is firmly held to the main body by the anchor member and can be prevented from falling off, and the fiber-reinforced mortar layer, which has excellent strength, can be firmly supported in a wall structure with external insulation specifications. [Brief explanation of the drawings]

[0025] [Figure 1]1 is a cross-sectional view showing an external insulation wall structure according to a first embodiment of the present invention. [Figure 2] 2 is an enlarged cross-sectional view of a portion surrounded by a dashed-dotted frame A in FIG. 1. [Figure 3] 3 is a perspective view showing an example of a reinforcing sheet disposed in a fiber-reinforced mortar layer of the first embodiment. FIG. [Figure 4] FIG. 2 is a cross-sectional view of the exterior insulation wall structure construction method according to the first embodiment, showing the state after the skeleton has been constructed. [Figure 5] 5 is an enlarged cross-sectional view similar to FIG. 2 showing a state in which a heat insulating layer has been formed following the state shown in FIG. 4. FIG. [Figure 6] FIG. 6 is an enlarged cross-sectional view of a state in which a first layer of a fiber-reinforced mortar layer has been formed following the state shown in FIG. 5. [Figure 7] FIG. 7 is an enlarged cross-sectional view showing a state in which the first layer is covered with a reinforcing sheet, following the state shown in FIG. 6. [Figure 8] FIG. 8 is an enlarged cross-sectional view of a state in which a second fiber-reinforced mortar layer is formed on the reinforcing sheet following the state shown in FIG. 7. [Figure 9] 10 is a cross-sectional view showing an example of the use of a gauge element that can be used when depositing fiber-mixed mortar. FIG. [Figure 10] FIG. 2 is an enlarged cross-sectional view of the entire fiber-reinforced mortar layer. [Figure 11] 11 is an enlarged cross-sectional view showing a state in which a collar member is attached and fixed to the tip end of the anchor member, following the state shown in FIG. 10. FIG. [Figure 12] FIG. 2 is a cross-sectional view similar to FIG. 1, showing an example in which the external heat insulating wall structure of the first embodiment is formed on a curved surface. [Figure 13] FIG. 4 is a cross-sectional view showing an external insulation wall structure according to a second embodiment of the present invention. [Figure 14] FIG. 10 is a cross-sectional view showing the external insulation wall structure of the second embodiment in the middle of construction. [Figure 15] FIG. 10 is a cross-sectional view showing an external insulation wall structure according to a third embodiment of the present invention. [Figure 16] FIG. 10 is a cross-sectional view showing a state in the middle of construction of an external insulation wall structure according to a fourth embodiment of the present invention. [Figure 17]17 is a cross-sectional view showing a state in which a spacer member is removed and a collar member is attached from the state shown in FIG. 16. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0026] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0027] [External insulation wall structure of the first embodiment] 1 and 2, the externally insulated wall 1 of the first embodiment comprises a skeleton 2, a thermal insulation layer 3 covering the outer surface of the skeleton 2, a fiber-reinforced mortar layer 4 covering the outer periphery of the thermal insulation layer 3, an outer surface finishing layer (finishing layer of the present invention) 5 covering the outer surface of the fiber-reinforced mortar layer 4, and an inner surface finishing layer 6 covering the inner surface of the skeleton 2, and is an overall structure in which the thermal insulation layer 3 and the fiber-reinforced mortar layer 4, which are arranged on the outside of the skeleton 2, are joined by anchor members 7 protruding from the skeleton 2. Each element will be described in detail below.

[0028] (body) In the illustrated example, the skeleton 2 is a truss wall formed by the so-called truss wall construction method, in which a truss unit 17 is constructed on top of a mesh formwork 11 using lower chords 12, lattice 13, vertical reinforcement 14, horizontal reinforcement 15, and upper chords 16, and concrete 18 is poured to form an integrated structure. The truss unit 17 is constructed by diagonally connecting the lower chords 12 and the upper chords 16 with the lattice 13, and by joining the vertical reinforcement 14 and horizontal reinforcement 15 between the two chords 12, 16. Concrete 18 is poured inside the truss unit 17, and the mesh formwork 11 is used as the formwork during pouring. This mesh formwork 11 is left in place on the truss wall. Additionally, a plurality of anchor members 7 are fixedly attached to the truss unit 17 and protrude outward from the outer surface of the skeleton 2. The anchor members 7 will be described later.

[0029] In the present invention, the skeleton is not limited to the above-mentioned truss wall configuration, as long as it forms the skeleton of a wall structure, but may be a skeleton made of ordinary reinforced concrete, steel frame, wood, etc.

[0030] (Inner surface finish layer) The inner surface finishing layer 6 is formed on the inside of the mesh formwork 11 of the skeleton 2 by a mortar layer, a plaster layer, etc., and faces, for example, the living space.

[0031] (insulation layer) The insulation layer 3 is made of a foam such as polyurethane foam, and in this embodiment, it is constructed by spray foaming at the construction site as described below. Therefore, the outer surface of the insulation layer 3 is generally formed into a flat shape if the outer surface of the skeleton 2 is flat, or into a curved or uneven outer surface that follows the outer surface of the skeleton 2 if the outer surface of the skeleton 2 is curved or uneven. Of course, regardless of the shape of the outer surface of the skeleton 2 (even if the outer surface of the skeleton 2 is flat), it is possible to form the outer surface of the insulation layer 3 into a curved or uneven shape.

[0032] Moreover, since the heat insulating material layer 3 is formed by successive deposition while being sprayed, the outer surface of the heat insulating material layer 3 itself is formed with minute irregularities regardless of the shape of the outer surface of the building body 2 (curved or flat). The thickness of the heat insulating layer 3 is not particularly limited, but is formed to be, for example, 5 mm or more and 40 mm or less.

[0033] (fiber reinforced mortar layer) The fiber-reinforced mortar layer 4 includes fiber-mixed mortar 21 containing short reinforcing fibers, and a plurality of reinforcing sheets 22 made of a mesh-like fiber reinforcing material embedded in the fiber-mixed mortar 21. The overall thickness is not particularly limited, but is formed to be 5 mm to 50 mm. This thickness is preferably 15 mm to 35 mm.

[0034] The fiber-mixed mortar 21 is a layered hardened mixture (fiber-mixed mortar material) made by kneading cement, fine aggregate, water, and short fibers for reinforcing the mortar. The mixture may also contain admixtures such as silica fume, slag, fly ash, and dolomite, as well as shrinkage-reducing agents, water-reducing agents, and other additives.

[0035] The cement that can be used includes ordinary Portland cement, early-strength Portland cement, extra-early-strength Portland cement, moderate-heat Portland cement, low-heat Portland cement, sulfate-resistant Portland cement, ordinary Portland cement (low alkali type), early-strength Portland cement (low alkali type), and extra-early-strength Portland cement (low alkali type) as specified in JIS R 5210. Low-alkali cements other than JIS R 5210 may also be used.

[0036] Admixtures such as silica fume, slag, fly ash, and dolomite may also be included. Fiber-mixed mortar may also contain shrinkage-reducing agents, water-reducing agents, and other additives. Examples of water-reducing agents include naphthalene sulfonate-formalin high condensate salts and polycarboxylic acid ether compounds, and shrinkage-reducing agents include alkylene oxide compounds of lower alcohols.

[0037] The reinforcing short fibers are not limited to any particular material, but may be glass, carbon, or steel fibers, and preferably are chopped strands made by bundling multiple fibers together. Chopped strands are obtained by cutting roving into predetermined lengths of 6.0 mm, 9.0 mm, 13.0 mm, 19.0 mm, or 25.0 mm, and are preferably made of alkali-resistant AR glass fibers (JIS R3410) containing 16% or more of zirconia. In other words, glass fiber reinforced cement, which is made of mortar or concrete reinforced with alkali-resistant glass fibers containing 16% or more zirconia, can be effectively used as this fiber-mixed mortar, and the short fibers are embedded in the mortar in an unoriented manner (three-dimensionally).

[0038] On the other hand, the reinforcing sheet 22 is configured as a continuous fiber reinforcing material formed by weaving or knitting long fibers such as alkali-resistant glass fibers into a mesh shape. The long fibers are made of yarns or rovings such as glass fibers, carbon fibers, or aramid fibers, and preferably a sheet made of woven yarns or rovings made by bundling alkali-resistant AR glass fibers containing 16% or more zirconia is used. Yarns are made by bundling monofilaments with a binder, and rovings are made by bundling yarns, and the chopped strands are usually made by chopping rovings to a predetermined length. A plurality of reinforcing sheets 20 are embedded in the fiber reinforced mortar layer 4, extending in the surface direction thereof and arranged at intervals.

[0039] Furthermore, since the reinforcing sheet 22 is mesh-like, it has a plurality of openings 23 as shown in FIG. 3. The openings 23 are preferably large (dimensions) such that at least a portion of the aggregate and short fibers of the fiber-mixed mortar 21 can penetrate and partially, preferably entirely, pass through the reinforcing sheet 22. The reinforcing sheet 22 shown in FIG. 3 is formed in a lattice shape with a plurality of openings 23. The size and shape of the openings 23 are not limited, but may be, for example, 5.0 mm square or 10.0 mm square. Mortar penetrates the openings 23 of the reinforcing sheet 22. Chopped strands in the mortar also penetrate the openings 23. The reinforcing sheet 22 can also be a continuous fiber reinforcing material formed in a lattice shape using fiber-reinforced plastics.

[0040] Furthermore, the reinforcing sheet 22 is not limited to those in which reinforcing long fibers extend in one direction or those in which long fibers extend in two directions. It may also be those in which long or short fibers are randomly oriented, and thin so-called continuous strand mats or chopped strand mats may be used. The fibers constituting chopped strand mats and continuous strand mats are, for example, long fibers (yarns, rovings) or short fibers (chopped strands) made of glass fibers (JIS K7010:E glass) containing 0.8% or less alkali (NaO, KO) or alkali-resistant AR glass fibers containing 16% or more zirconia. Chopped strand mats can be made of multiple chopped strands oriented two-dimensionally and held together in a sheet shape with a binder. Continuous strand mats can also be made of continuous yarns or rovings stacked in the thickness direction and held together in a sheet shape with a binder.

[0041] The reinforcing sheet 22 of the present invention is not limited to the above configuration, and may be made of wire mesh, lath, carbon fiber, or a net made of basalt fiber (a type of fiber developed for civil engineering). Furthermore, the reinforcing sheet 22 is not limited to those with long reinforcing fibers extending in one direction or those with long reinforcing fibers extending in two directions. It may also be made of long or short fibers randomly arranged, and thin materials such as continuous strand mats or chopped strand mats may be used. The fibers constituting chopped strand mats and continuous strand mats are, for example, long fibers (yarns, rovings) or short fibers (chopped strands) made by bundling together glass fibers (JIS K7010:E glass) containing 0.8% or less of alkali (NaO, KO) or alkali-resistant AR glass fibers containing 16% or more of zirconia. The chopped strand mat may be made of a plurality of chopped strands oriented two-dimensionally and held together in a sheet shape with a binder, while the continuous strand mat may be made of continuous yarns or rovings stacked in the thickness direction and held together in a sheet shape with a binder.

[0042] The number of reinforcing sheets 22 is not limited to that shown in the illustration, but may be, for example, 2 to 20 sheets, preferably 3 to 15 sheets.

[0043] (anchor member) The anchor members 7 are composed of bolts fixed to, for example, the mesh formwork 11 of the skeleton 2, and multiple anchor members 7 are embedded at intervals in the surface direction of the skeleton 2, penetrating the skeleton 2 in the thickness direction. Therefore, the anchor members 7 protrude from the outer surface of the skeleton 2 in a direction perpendicular to the outer surface, penetrate the insulation material layer 3 and the fiber-reinforced mortar layer 4, and are embedded in the outer surface finishing layer 5. This anchor member 7 is entirely covered by a resin tube 25 to prevent the insulation layer 3 and fiber-reinforced mortar layer 4 from getting into the bolt thread groove (the tube is omitted in Figure 1; the same applies to Figure 12 described below).

[0044] In this case, a plurality of reinforcing sheets 22 are embedded in the fiber-reinforced mortar layer 4, and the anchor member 7 penetrates these reinforcing sheets 22 and protrudes to the outer surface of the fiber-reinforced mortar layer 4. At least the tip of this anchor member 7 is formed into a male thread portion 7a, and a washer-equipped nut 26 serving as a collar member is screwed onto the male thread portion 7a. Naturally, the nut 26a of this washer-equipped nut 26 has a larger diameter than the male thread portion (shank) 7a of the anchor member 7 and is also formed with a larger diameter than the opening 23 of the reinforcing sheet 22. Therefore, the washer-equipped nut (collar member) 26 is provided at the tip of the anchor member 7 in a state where it expands in the radial direction, and when this collar member 26 is screwed onto the male thread portion 7a of the anchor member 7, it presses the fiber-reinforced mortar layer 4 and the heat insulating material layer 3 together with the reinforcing sheet 22 in the thickness direction.

[0045] In the first embodiment, the length of the anchor members 7 is set to a dimension that protrudes from the outer surface of the fiber-reinforced mortar layer 4 by a length equivalent to the thickness of the collar member 26, but the diameter and installation interval (pitch) of the anchor members 7 are not particularly limited and are set appropriately depending on the thickness of the fiber-reinforced mortar layer 4, etc. For example, it is recommended that the diameter of the anchor members 7 be 8 mm or more and 22 mm or less, and that they be arranged at a pitch of 300 mm or more and 1200 mm or less.

[0046] (exterior finishing layer) The exterior finish layer 5 is, for example, a layer of mortar made of cement, fine aggregate, and water, hardened without short fibers for mortar reinforcement, and finished to a smooth surface. This mixture may contain admixtures such as silica fume, slag, fly ash, and dolomite, as well as shrinkage-reducing agents, water-reducing agents, and other additives. Like fiber-mixed mortar, it uses cement, fine aggregate, and water, but the same mix of these materials may be used, or a different mix may be used. Admixtures and additives may or may not be included. Even if these materials are included, the mix of cement, fine aggregate, water, admixtures, and additives may be the same as or different from fiber-mixed mortar.

[0047] The flange member 26 is embedded in the outer surface finishing layer 5, and the outer surface is finished to a smooth surface. In this case, even if some of the mixed short fibers protrude from the surface of the fiber-reinforced mortar layer 4, the outer surface is finished to a smooth surface by forming the outer surface finishing layer 5 on top of them. If necessary, the outer surface finishing layer may be made of tiles or the like.

[0048] [Construction method of the first embodiment] Next, a method for constructing the external heat insulating wall structure thus constructed will be described. This externally insulated wall structure is constructed in the following order: framework construction, insulation layer formation, fiber-reinforced mortar layer formation, and exterior finish layer formation. The interior finish layer may be constructed at any time after the framework construction. Details are explained below in order of the steps.

[0049] (frame construction process) In this embodiment, the main body 2 is a normal truss wall, and as shown in Figure 4, it is constructed by constructing a truss unit 17 on top of a mesh formwork 11 using lower chords 12, lattice 13, vertical reinforcement 14, horizontal reinforcement 15, and upper chords 16, and then pouring concrete 18. In this case, when constructing the truss unit 17, anchor members 7 are fixed to the mesh formwork 11 or the like. A plurality of these anchor members 7 are provided at intervals in the surface direction of the skeleton 2, and are arranged so that each protrudes outward from the truss unit 17. Then, by pouring concrete 18 on top of the mesh formwork 11 of the truss unit 17, the base end of each anchor member 7 is embedded in the concrete 18, and the tip end is provided so that it protrudes from the layer of concrete 18. As shown in FIG. 5 and other figures, the anchor member 7 is inserted into a sleeve 25 made of resin.

[0050] (Insulating material layer forming process) As shown in Figure 5, an insulating layer 3 is formed on the outer surface of a building frame 2. This insulating layer 3 is constructed by pumping fluidized raw materials containing polyurethane resin, hardener, etc. from a tank and spraying them onto the surface of the building frame using a spray gun or similar device along with compressed air from a compressor. Because foams such as urethane foam have self-adhesive properties, spraying them firmly adheres the building frame surface and the deposits on it to each other without the need for adhesive, allowing these surfaces to be covered without gaps and forming a continuous insulating layer. In this case, the resin tube 25 is placed over the anchor member 7, so that the sprayed heat insulating material does not get into the threads of the anchor member 7.

[0051] In this insulation forming process, the insulation is formed by spraying and foaming the raw material onto the outer surface of the skeleton 2, so the outer surface is formed to a shape that conforms to the outer surface of the skeleton 2; if the skeleton 2 is flat, it will be a flat surface, and if it is curved, it will be a curved surface that conforms to that surface. In addition, since the raw material sprayed onto the surface of the skeleton 2 adheres while foaming locally, the surface is formed with minute irregularities, as shown in Figure 5, unlike molded bodies made using a mold. By controlling the degree of spraying, the degree of surface irregularities can also be controlled as desired.

[0052] (Fiber reinforced mortar layer formation process) In the fiber-reinforced mortar layer forming process, first, fiber-mixed mortar in a fluid state before hardening is applied to the outer surface of the insulation layer 3 to form a relatively thin first layer 21a that covers the outer surface of the insulation layer 3, as shown in Figure 6. The thickness of this first layer 21a is not particularly limited, but it is formed to be 0.5 mm or more and 30 mm or less. It is sufficient that the first layer 21a has a thickness that is thick enough to fill in any minute irregularities on the surface of the insulation layer 3. The fiber-mixed mortar 21 is applied by hand lay-up, in which an operator deposits the mortar to a predetermined thickness using a trowel or the like. This hand lay-up construction method can flexibly accommodate various shapes of the outer surface of the thermal insulation layer 3, since it is performed by hand.

[0053] By forming the first layer 21a of this fiber-mixed mortar 21, part of the fiber-mixed mortar 21 penetrates into the recesses in the outer surface of the insulation layer 3, and the unevenness is smoothed out by the fiber-mixed mortar 21, so that the outer surface of the first layer 21a is formed to be almost flat.

[0054] Next, as shown in Fig. 7, a reinforcing sheet 22 is placed on the surface of the first layer 21a, and then fluidized fiber-mixed mortar 21 is again applied and deposited on the reinforcing sheet 22, and the fiber-mixed mortar 21 is spread so as to embed the reinforcing sheet 22, forming a second layer as shown in Fig. 8. This second layer is also formed to a thickness of 0.5 mm to 30 mm. At this time, the fine aggregate and short fibers in the fiber-mixed mortar enter the openings 23 of the reinforcing sheet 22 and become embedded in the first layer 21a, and the first layer 21a and the second layer 21b are integrated via the openings 23 of the reinforcing sheet 22.

[0055] When depositing the fiber-mixed mortar, the work can be made easier by using a gauge member (gabari) 35 as shown in Figure 9. This gauge member 35 is, for example, a flat block with a rectangular cross section, and is used by placing it against the tips of the anchor members 7 protruding from the insulation layer 3. The anchor members 7 are installed with their protruding height from the skeleton 2 aligned, so by placing the gauge member 35 placed against the tips of the anchor members 7 so that it straddles each anchor member 7, one face 35a of the gauge member 35 abutting against the anchor member 7 is positioned at a fixed distance from the skeleton 2. Therefore, this surface 35a is used as the reference surface, and the fiber-mixed mortar is piled up to this surface (reference surface) 35a, or piled up to a position a predetermined distance away from the reference surface 35a toward the main body 2 as shown by the dotted line L1, or piled up to a position a predetermined distance away from the main body 2 as shown by L2, thereby making it possible to keep the pile height of the fiber-mixed mortar 21 constant.

[0056] In this way, the reinforcing sheets 22 are laid one on top of the other while alternately placing the reinforcing sheets 22 and applying the flowable fiber-mixed mortar 21, and the anchor members 7 protruding from the thermal insulation layer 3 are inserted into each reinforcing sheet 22, with their tips protruding outward from the fiber-reinforced mortar layer 4. By curing in this state, the fiber-reinforced mortar layer 4, in which multiple reinforcing sheets 22 are embedded in the fiber-mixed mortar 21, hardens, as shown in Figure 10.

[0057] After the fiber-reinforced mortar layer 4 has hardened, a washer-equipped nut is attached as a collar member 26 to the anchor member 7 protruding from its surface and screwed into the male threaded portion 7a, thereby pressing the insulation layer 3 and the fiber-reinforced mortar layer 4 in the axial direction of the anchor member 7, as shown in Figure 11. The resin tube 25 placed over the anchor member 7 is compressed in a direction that shortens its length by screwing the collar member 26 onto the male threaded portion 7a of the anchor member 7, and is left below (to the left in FIG. 11 ) the collar member 26. If the tube 25 is too long for the length of the anchor member 7, for example, the tip can be cut off when attaching the collar member 26.

[0058] (Outer surface finishing layer formation process) Finally, an outer surface finishing layer 5 made of mortar or the like that does not contain short fibers is formed on the fiber-reinforced mortar layer 4, and the collar member 26 is embedded in the outer surface finishing layer 5. Even if some of the short fibers protrude from the fiber-reinforced mortar layer 4, by forming this outer surface finishing layer 5, the short fibers are embedded in the outer surface finishing layer 5, and the surface of the outer surface finishing layer 5 is finished to a smooth surface.

[0059] In the external insulation wall structure constructed as described above, the fiber-reinforced mortar layer 4 is thin yet has excellent strength because it is made up of multiple reinforcing sheets 22 and fiber-mixed mortar 21 integrated together, and can firmly protect the underlying insulation layer 3. In this case, since the insulation layer 3 is made of sprayed foam, its outer surface is formed with an uneven surface, and the fiber-reinforced mortar layer 4 formed on top of it is built up by hand laying up the layers while workers apply the fiber-mixed mortar using a trowel or the like. Therefore, the fiber-mixed mortar 21 penetrates into the minute unevenness on the surface of the insulation layer 3, and the unevenness exerts an anchoring effect, firmly integrating the insulation layer 3 and the fiber-reinforced mortar layer 4 together.

[0060] Furthermore, the large-diameter collar member (nut with washer) 26 of the anchor member 7 fixed to the main body 2 presses the insulation layer 3 and the fiber-reinforced mortar layer 4 in the axial direction of the anchor member 7, thereby restricting not only the surface direction but also the axial movement of the anchor member 7, thereby firmly holding the insulation layer 3 and the fiber-reinforced mortar layer 4 to the main body 2 by the anchor member 7 and reliably preventing them from falling off. These synergistic effects result in an extremely high-strength exterior insulation wall structure.

[0061] [Modification of the first embodiment] In the above embodiment, the external heat insulating wall 1 is described as being flat, but the present invention can also be applied to an external heat insulating wall 41 having a curved surface, as shown in Fig. 12. In Fig. 12, elements common to those in Fig. 1 are designated by the same reference numerals to simplify the description. In Figure 12, this external insulation wall 41 is shown as an example curved diagonally downward, but it can also be used to construct walls in the shape of a spherical shell, a dome, or other shapes. In particular, because the insulation layer 3 is applied on-site by spray foaming, and the fiber-mixed mortar 21 of the fiber-reinforced mortar layer 4 is also applied on-site by hand layup, the outer surface can be formed into any curved surface, resulting in excellent design. Moreover, even in this case, not only the effect of the anchor members 7 themselves but also the anchor effect of the minute irregularities on the surface of the insulation layer 3 combine to create an external insulation wall structure with excellent strength.

[0062] In this case, in the external insulation wall 1 of the first embodiment, the insulation material of the insulation material layer 3 on the outside of the main body 2 and the fiber-mixed mortar 21 of the fiber-reinforced mortar layer 4 both have self-adhesive properties in a fluid state before hardening, so they do not easily fall off during construction.However, if the outer surface of the external insulation wall 41 is curved and formed facing downward, it is necessary to control the thickness and the weight formed at one time, etc., to prevent them from falling off during construction at the construction site. Furthermore, when finishing to a curved surface in this manner, the work can be made easier by forming the reference surface 35a of the gauge member 35 shown in Figure 9 along the desired curved surface and forming the fiber-reinforced mortar layer using that reference surface as a reference.

[0063] [External insulation wall structure of the second embodiment] In the external thermal insulation wall structure of the first embodiment, the tip of the anchor member 7 extending from the skeleton 2 is protruded outward from the fiber reinforced mortar layer 4 so as to press the outer surface of the fiber reinforced mortar layer 4. In the external insulation wall 42 of the second embodiment of the external insulation wall structure, as shown in Figure 13, the anchor member 7 penetrates the insulation material layer 3 and extends to a position halfway in the thickness direction of the fiber reinforced mortar layer 4, and the flange member 26 at the tip is provided inside the fiber reinforced mortar layer 4.

[0064] In this case, a plurality of reinforcing sheets 22 are embedded in the fiber-reinforced mortar layer 4, and the tip of the anchor member 7 penetrates the reinforcing sheet 22 on the thermal insulation layer 3 side, but does not reach the reinforcing sheet 22 on the outer surface side of the fiber-reinforced mortar layer 4, and is disposed between these reinforcing sheets 22. A nut with a washer is attached to the tip of this anchor member 7 as a collar member 26. Therefore, the collar member (nut with washer) 26 is provided in a state where it spreads out in the radial direction at a position between the plurality of reinforcing sheets 22.

[0065] Furthermore, since the anchor member 7 is positioned within the fiber-reinforced mortar layer 4 without protruding outward from the fiber-reinforced mortar layer 4, the outer surface of the fiber-reinforced mortar layer 4 can be formed into a smooth surface, and the outer surface finishing layer 5 above it does not need to be thick enough to embed the flange member 26 as in the first embodiment, so it can be finished with a thin wall.

[0066] Other structures are the same as those in the first embodiment, so the same reference numerals are used for common parts and the description thereof will be omitted (the same applies to the third and subsequent embodiments).

[0067] [Construction method of the second embodiment] In the external insulation wall structure of the second embodiment, the main body construction process and the insulation layer formation process are the same as those of the first embodiment, but in the fiber-reinforced mortar layer formation process, the tip of the anchor member 7 and the flange member 26 are embedded inside the fiber-reinforced mortar layer 4 as described above.

[0068] That is, in the fiber-reinforced mortar layer forming process, first, a first layer 21a is formed on the thermal insulation layer 3 as in the first embodiment, and then reinforcing sheets 22 are placed thereon alternately and fluid fiber-mixed mortar 21 is applied thereon. During this process, anchor members 7 protruding from the thermal insulation layer 3 are inserted through multiple reinforcing sheets 22 close to the thermal insulation layer 3, and a washer-equipped nut is attached to the tip of the anchor member 7 as a collar member 26. In FIG. 14 , the reinforcing sheet 22 is placed on the first layer 21a, and the second layer 21b and reinforcing sheet 22 are attached thereon, and then the collar member 26 is attached to the anchor member 7. Thereafter, similarly, the deposition of fluid fiber-mixed mortar and the placement of reinforcing sheets 22 are alternately performed, and then the fiber-mixed mortar 21 is cured, thereby forming a fiber-reinforced mortar layer 4 in which multiple reinforcing sheets 22 are embedded in the fiber-mixed mortar 21.

[0069] Note that the fiber-reinforced mortar layer 4 is constructed to the entire thickness with the collar member 26 embedded midway through the thickness of the fiber-reinforced mortar layer 4, and then the fiber-mixed mortar 21 of the fiber-reinforced mortar layer 4 is cured and hardened. However, the fiber-reinforced mortar layer 4 may be constructed up to a midway point in the thickness direction, cured and hardened with the tip of the anchor member 7 exposed, and then the collar member 26 may be attached to the exposed tip of the anchor member 7 and screwed into the male thread portion 7a, thereby pressing the hardened part of the fiber-mixed mortar in the thickness direction, and then the remaining part may be constructed. In this way, the fiber-reinforced mortar layer 4 may be constructed in two or more stages and stacked one on top of the other while being cured sequentially.

[0070] In the example shown in Figure 14, the fiber-mixed mortar is hardened with the second layer 21b deposited or with the reinforcing sheet 22 placed on top of it, and then the collar member 26 is attached. In this way, the collar member 26 presses the already hardened fiber-mixed mortar in the thickness direction, firmly integrating it with the insulation layer 3, and then the fiber-mixed mortar and the reinforcing sheet are stacked to complete the fiber-reinforced mortar layer 4 of a predetermined thickness.

[0071] 13 and 14, the flange members 26 are provided on the first layer 21a and the second layer 21b of the fiber-reinforced mortar layer 4, and therefore the anchor members 7 penetrate two reinforcing sheets 22. This example is not limiting, and the anchor members 7 may be provided so as to penetrate at least the first layer 21a and one reinforcing sheet (the lowermost reinforcing sheet) 22 thereon. [Third embodiment of external heat insulation wall structure] In the external insulation wall structure of the first embodiment, the tip of the anchor member 7 and the flange member 26 are arranged so as to protrude from the outer surface of the fiber-reinforced mortar layer 4, but in the external insulation wall structure of the third embodiment, they are arranged so as not to protrude from the outer surface of the fiber-reinforced mortar layer 4, as shown in Figure 15.

[0072] 15, the collar member 26 is disposed so that its upper surface is flush with the outer surface of the fiber-reinforced mortar layer 4. In this case, unlike the first and second embodiments, the nut 26a and washer 26b of the collar member 26 are disposed upside down (the washer 26b is disposed on top of the nut 26). Of course, the nut 26a may be disposed on top of the washer 26b, as in the first and second embodiments.

[0073] Furthermore, in the region where this collar member 26 is arranged, the multiple reinforcing sheets 22 are bent in the thickness direction of the fiber-reinforced mortar layer 4 and deformed so that the spacing between the reinforcing sheets 22 is smaller than the spacing between the reinforcing sheets 22 in regions where no anchor members 7 are provided. In other words, since the collar member 26 is arranged in a state where it is pressed from the outer surface of the fiber-reinforced mortar layer 4 to the inside, the thickness of the fiber-reinforced mortar layer 4 in that region is smaller than other regions (regions where no anchor members 7 are arranged), and the spacing between the reinforcing sheets 22 becomes small and dense.

[0074] Therefore, the density of the reinforcing sheet 22 increases in the area where the anchor member 7 is arranged, thereby further improving the strength. In addition, since the tip portion of the anchor member 7 and the collar member 26 are embedded in the fiber-reinforced mortar layer 4, the outer surface finishing layer 5 can be finished to be thin, as in the second embodiment.

[0075] [Construction method of the third embodiment] To construct the externally insulated wall structure of this third embodiment, after the framework construction process and the insulation layer formation process are performed, fluid fiber-mixed mortar 21 is applied to the insulation layer 3 to form a first layer 21a. Then, reinforcing sheets 22 are placed and fluid fiber-mixed mortar 21 is applied alternately to build up the required thickness. The anchor members 7 are set to a length equivalent to the required thickness, with their tips embedded in the fiber-mixed mortar 21. Before the fiber-mixed mortar 21 hardens, a collar member (a nut with a washer) 26 is attached to the tip of the anchor member 7. The collar member 26 is embedded in the fiber-mixed mortar 21, compressing the fiber-mixed mortar 21 around the anchor member 7 in the thickness direction. This bends the reinforcing sheet 22 at the anchor member 7, narrowing the gap more than other areas. The outer surfaces of the collar member 26 and the fiber-mixed mortar 21 are aligned. By curing the fiber-mixed mortar 21 in this state, the flange member 26 and the fiber-reinforced mortar layer 4 are finished flush with each other. Finally, an outer surface finishing layer 5 made of mortar or the like that does not contain short fibers is formed on the fiber-reinforced mortar layer 4 to complete the construction.

[0076] [External insulation wall structure of the fourth embodiment] In the third embodiment, the collar member 26 of the anchor member 7 is embedded near the outer surface of the fiber-reinforced mortar layer 4, so that the collar member 26 and the fiber-reinforced mortar layer 4 are flush with each other. Because the collar member 26 is attached before the fiber-reinforced mortar layer 4 hardens, the collar member 26 is in close contact with and integrated with the fiber-mixed mortar 21 of the fiber-reinforced mortar layer 4. In contrast, the external insulation wall structure of the fourth embodiment can be said to be similar in shape to the third embodiment in Figure 15 (for this reason, an overall cross-sectional view of the completed structure is omitted), but the collar member 26 of the anchor member 7 is housed within the recess 31 of the fiber-reinforced mortar layer 4 and is not in close contact with the fiber-mixed mortar 21.

[0077] That is, when forming the fiber-reinforced mortar layer 4, a spacer member 32 having the same shape as the collar member 26 is attached to the male thread portion 7a at the tip of the anchor member 7, and after the fiber-reinforced mortar layer 4 is formed up to the surface of this spacer member 32 and hardened as shown in Fig. 16, the spacer member 32 is removed from the tip of the anchor member 7 as shown by the arrow in Fig. 17, so that the portion occupied by the spacer member 32 becomes a recess 31, and the male thread portion 7a at the tip of the anchor member 7 is exposed and protrudes into the recess 31. The collar member 26 is then screwed onto the male thread portion 7a of the anchor member 7 so that it is housed in this recess 31. Since the fiber-mixed mortar 21 in the fiber-reinforced mortar layer 4 has hardened, by screwing the flange member 26 into the male thread portion 7a of the anchor member 7, the insulation layer 3 and the fiber-reinforced mortar layer 4 are pressed in the thickness direction and firmly fixed.

[0078] In each of the above embodiments, the insulation layer 3 is made of spray foam, but in the present invention, it does not necessarily have to be made of spray foam; a plate-shaped foam made by molding a foam such as polystyrene foam, polyurethane foam, polyethylene foam, or phenol foam may also be used. Furthermore, although all of the embodiments are examples of application to walls that extend substantially vertically, the present invention can also be applied to walls that extend horizontally or the like, as long as the walls enclose a predetermined space. [Explanation of symbols]

[0079] 1. Externally insulated walls 2 skeleton 3. Insulation layer 4 Fiber-reinforced mortar layer 5. Outer surface finishing layer (finishing layer) 6. Inner surface finish layer 7 Anchor member 7a Male thread 17 Truss unit 18 Concrete 20 Reinforcement sheet 21 Fiber-mixed mortar 21a First layer 21b Second layer 22 Reinforcement sheet 23 Aperture 25 tubes 26 Collar part (nut with washer) 31 Recess 32 Spacer member 35 Gauge material 41, 42, 43 External insulated wall

Claims

1. The present invention relates to a concrete structure having a skeleton, a heat insulating material layer covering the outer surface of the skeleton, and a fiber reinforced mortar layer covering the outer surface of the heat insulating material layer, wherein the fiber reinforced mortar layer comprises fiber mixed mortar containing short reinforcing fibers, and a plurality of reinforcing sheets made of fiber reinforcing material embedded in the fiber mixed mortar and having a plurality of openings forming a mesh-like structure; An external insulation wall structure characterized in that an anchor member fixed to the main body penetrates the insulation layer and at least the lowest layer of reinforcing sheet in the fiber-reinforced mortar layer, and a flange member with a diameter larger than the opening in the reinforcing sheet is provided at its end.

2. The external insulation wall structure according to claim 1 , wherein the flange member of the anchor member is disposed between a plurality of the reinforcing sheets.

3. The external insulation wall structure described in claim 1, characterized in that, in the area where the flange member of the anchor member is located, the multiple reinforcing sheets are bent in the thickness direction of the fiber-reinforced mortar layer and deformed so that the spacing between the reinforcing sheets is smaller than the spacing between the reinforcing sheets in the area where the anchor member is not provided.

4. 2. The external insulation wall structure according to claim 1, wherein the flange member of the anchor member is accommodated in a recess formed in the surface of the fiber-reinforced mortar layer.

5. 2. The exterior insulated wall structure of claim 1, wherein the insulation layer comprises spray foam.

6. 2. The external insulation wall structure according to claim 1, wherein a finishing layer made of mortar that does not contain short fibers is formed on the fiber-reinforced mortar layer.

7. 2. The external insulation wall structure according to claim 1, wherein at least a portion of the outer surface of the fiber-reinforced mortar layer is formed into a curved surface.

8. The method comprises a skeleton construction step of constructing a skeleton and fixing anchor members to the outer surface of the skeleton, a heat insulating layer formation step of forming a heat insulating layer covering the outer surface of the skeleton with the anchor members penetrated therethrough, and a fiber reinforced mortar layer formation step of forming a fiber reinforced mortar layer covering the outer surface of the heat insulating layer, The fiber-reinforced mortar layer forming process is a method for constructing an external insulation wall structure, characterized in that while depositing fiber-mixed mortar containing short fibers, a plurality of reinforcing sheets made of fiber reinforcing material with a plurality of openings are arranged so that these fiber reinforcing materials are embedded in the fiber-mixed mortar, and the ends of anchor members protruding from the insulation material layer are arranged so that they penetrate at least one of the reinforcing sheets, and a flange member with a diameter larger than the opening in the reinforcing sheet is provided at the end of the anchor member.

9. 9. The method for constructing an externally insulated wall structure according to claim 8, wherein the collar member of the anchor member is placed between a plurality of the reinforcing sheets and embedded in the fiber-mixed mortar.

10. A method for constructing an external insulation wall structure as described in claim 8, characterized in that by attaching the flange member to the tip of the anchor member, the multiple reinforcing sheets are bent in the thickness direction of the fiber-reinforced mortar layer and deformed so that the spacing between the reinforcing sheets is smaller than the spacing in areas where the anchor members are not installed.

11. A method for constructing an externally insulated wall structure as described in claim 8, characterized in that the insulation layer formation process forms the insulation layer by spraying a fluidized insulation material onto the outer surface of the body, foaming it, and depositing it.

12. 9. The method for constructing an externally insulated wall structure according to claim 8, wherein at least a portion of the outer surface of the fiber-reinforced mortar layer is formed into a curved surface.

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