Concrete plant and method for constructing a concrete plant

Abstract

We propose a concrete plant that can be installed in a relatively small space, and a method for constructing this concrete plant. [Solution] The concrete plant 1 comprises an aggregate storage tank 2, a cement silo, a water storage tank, a mixing mixer 5, and an admixture storage tank. At least one of the cement silo, water storage tank, and mixing mixer 5 is located on a pier 3. On the other hand, the aggregate storage tank 2 is located on a base 6 formed below the main girder of the pier 3.

Description

Technical Field

[0001] The present invention relates to a concrete plant and a method for constructing a concrete plant.

Background Art

[0002] In construction work, when the distance from a concrete manufacturing plant is far, or when there are circumstances such as in tunnel construction where concrete is required day and night irregularly, a concrete plant may be installed on-site. If there is a concrete plant on-site, the time and labor required for transporting concrete can be omitted, and it becomes possible to place a large amount of concrete at once compared to the case of bringing in concrete from a concrete manufacturing plant.

[0003] In a concrete plant, materials such as aggregate, cement, admixture, and water are stored separately, and necessary amounts of the materials are put into a mixing mixer and kneaded to manufacture concrete. Therefore, a concrete plant includes an aggregate storage tank for storing aggregate, a cement silo for storing cement, an admixture storage tank for storing admixture, a water storage tank for storing water, a mixing mixer, etc. for mixing these materials.

[0004] For example, Patent Document 1 discloses a concrete plant in which aggregate storage tanks, aggregate hoppers, aggregate transport means, and a mixing mixer are installed within a building. In concrete plants, it is common to have multiple aggregate storage tanks in order to store coarse aggregate and fine aggregate separately. Furthermore, it is desirable that the aggregate storage tanks be formed at a low position so that aggregate transported by dump trucks or the like can be loaded into them. In addition, it is desirable that the concrete plant has space below the mixing mixer for transport vehicles (e.g., agitator trucks) to enter to transport the manufactured concrete. For this reason, in the concrete plant of Patent Document 1, multiple aggregate storage tanks, which are circular in plan view, are embedded in the ground, and the building surrounds these aggregate storage tanks, while also ensuring space below the mixing mixer for transport vehicles to enter. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2020-116877 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] Depending on the construction site, it may not be possible to secure land for installing a concrete plant like the one shown in Patent Document 1 due to constraints such as topography and surrounding facilities. The present invention aims to propose a concrete plant that can be installed in a relatively small space, and a method for constructing this concrete plant. [Means for solving the problem]

[0007] The first concrete plant of the present invention for solving the above problems comprises an aggregate storage tank, a cement silo, a water storage tank, and a mixing mixer, wherein at least one of the cement silo, the water storage tank, and the mixing mixer is provided on a pier (including a platform), and the aggregate storage tank is provided on a base formed below the girder of the pier.

[0008] The method for constructing this concrete plant comprises a pier and base formation step for forming a pier and base, a storage tank assembly step for assembling an aggregate storage tank, a storage tank installation step for installing the aggregate storage tank on the base, and an equipment installation step for installing at least one of a cement silo, a water tank, and a mixing mixer on the pier. The base is formed below the main girder of the pier. After assembling the aggregate storage tank on the deck of the pier, the aggregate storage tank is placed on the base by passing it through an opening formed in the deck of the pier.

[0009] According to this concrete plant and concrete plant construction method, even in a narrow work yard where it is not possible to secure land for arranging aggregate storage tanks, cement silos, water tanks, and mixing mixers side by side, a concrete plant can be formed on site by utilizing piers and platforms to make three-dimensional use of the limited space.

[0010] Furthermore, the second concrete plant of the present invention comprises an aggregate storage tank, a cement silo, a water storage tank, and a mixing mixer, wherein the aggregate storage tank has a rectangular cylindrical side wall formed in a rectangular shape in plan view, and a partition wall formed in a direction intersecting the long side of the side wall to divide the space enclosed by the side wall.

[0011] When a circular aggregate storage tank (cylindrical aggregate storage tank) is installed in a rectangular space in plan view, dead space is created at the four corners of the installation space. However, if the aggregate storage tank is rectangular in plan view, the dead space is reduced, and the amount of aggregate that can be stored increases. Therefore, it becomes possible to construct a concrete plant while making maximum use of the limited space. In addition, by making the aggregate storage tank rectangular in plan view, the required volume can be secured even if the depth of the tank is reduced compared to using multiple cylindrical containers. Furthermore, if the aggregate storage tank, which has a rectangular outer shape in plan view, is divided by a partition wall, the amount of stock can be increased compared to when two U-shaped aggregate storage tanks are installed side by side in plan view. In order to manufacture concrete, it is necessary to lift the aggregate from the aggregate storage tank using a bucket such as a clamshell. If the aggregate storage tank is deep, the distance over which the aggregate needs to be lifted is long, consuming time and electricity. Also, since the range of motion of the clamshell is limited, there is a limit to the depth of the aggregate storage tank, so the depth can be reduced by increasing the cross-sectional area.

[0012] The aggregate storage tank is formed by alternately stacking liner plates and reinforcing frames made of H-shaped steel, and it is preferable that the upper and lower ends of the liner plates are inserted into the space enclosed by the flanges and webs of the reinforcing frames arranged vertically. Furthermore, it is even more preferable that the vertically arranged liner plates are joined to each other via bolts that pass through the webs of the reinforcing frames. Even when the aggregate storage tank is placed exposed above ground, it is possible to store aggregate without requiring structures that reduce the internal volume, such as bracing, while ensuring self-supporting structure that can withstand internal pressure. [Effects of the Invention]

[0013] According to the present invention, a concrete plant can be formed in a relatively small space, and the labor and costs involved in plant construction can be minimized. [Brief explanation of the drawing]

[0014] [Figure 1] This is a plan view showing a concrete plant according to an embodiment of the present invention. [Figure 2] This is a front view of a concrete plant. [Figure 3] This is a side view of the concrete plant, seen from the left side. [Figure 4] This is a side view of the concrete plant, seen from the right side. [Figure 5] This diagram shows an aggregate storage tank, where (a) is a plan view and (b) is a side view. [Figure 6] This diagram shows a liner plate, where (a) is a cross-sectional view of a straight section, (b) is a front view of a straight section, (c) is a plan view of a straight section, (d) is a front view of a corner section, and (e) is a plan view of a corner section. [Figure 7] This is a plan view showing the corner members of a reinforcing ring, where (a) is the straight section, (b) is the corner section, and (c) is the intermediate section. [Figure 8] This is a flowchart showing the steps for constructing a concrete plant. [Modes for carrying out the invention]

[0015] In this embodiment, a concrete plant (batcher plant) 1 used to manufacture concrete or mortar at a construction site will be described. Figures 1 to 4 show the concrete plant 1. As shown in Figures 1 and 2, the concrete plant 1 is equipped with an aggregate storage tank 2, a cement silo, a water storage tank, a mixing mixer 5, and an admixture storage tank, and is constructed using a pier (platform) 3 and a base 6.

[0016] As shown in Figs. 2 to 4, the pier 3 includes a floor slab 31 forming the floor surface, girders 32 supporting the floor slab 31, and a plurality of piles (columns) 33, 33,... supporting the girders 32. A traveling path for transportation vehicles such as an agitator truck C1 and an aggregate transportation vehicle C2 is formed on the pier 3. The floor slab 31 of the present embodiment is formed by laying a plurality of covering plates on the girder 32 (main girder). Note that the configuration of the floor slab 31 is not limited. For example, it may be formed by laying precast members or by placing concrete. The girder 32 is formed of a steel material such as H-shaped steel and is supported by the piles 33. The girder 32 includes main girders arranged along the bridge axis direction of the pier 3 and cross girders (girder supports) arranged in a direction intersecting the main girders. The pile 33 constitutes the foundation of the pier 3 and is driven into the ground with its upper part protruding from the ground surface. The pile 33 is formed of, for example, a steel pipe or steel material. That is, the pile 33 is the foundation structure of the pier 3 and functions as a column supporting the floor slab 31, the girder 32, etc.

[0017] As shown in Figs. 2 to 4, a building 4 is formed on the pier 3 of the present embodiment. The building 4 includes a roof 41, a plurality of columns 42, 42,... supporting the roof 41, and walls and shutters (not shown). As shown in Figs. 2 and 3, a material input space 43 into which the agitator truck C1 can enter is formed in the building 4. Above the material input space 43, a mixer 5 is provided. The material manufactured by the mixer 5 is input into the agitator truck C1 parked in the material input space 43.

[0018] As shown in Fig. 4, the front side of the portion corresponding to the aggregate storage tank 2 in the building 4 is open so that the aggregate transportation vehicle C2 can supply aggregate to the aggregate storage tank 2. A shutter (not shown) is provided at the opening. As shown in Figs. 2 and 3, the mixer 5 is covered inside the building 4 formed on the pier 3.

[0019] A cement silo stores cement (solidifying agent) necessary for the production of concrete or mortar. As shown in Figure 3, the cement silo is connected to a mixing mixer 5 and supplies its contents (cement) to the mixing mixer 5.

[0020] The water tank stores the water necessary for the production of concrete or mortar. The water tank is connected to the mixing mixer 5 via a water supply pipe and supplies the mixing mixer 5 with the amount of water necessary for the production of concrete or mortar.

[0021] The admixture storage tank stores the admixtures necessary for the production of concrete or mortar. The admixture storage tank is connected to the mixing mixer 5, and the amount of admixture required for the production of concrete or mortar is supplied to the mixing mixer 5.

[0022] As shown in Figures 2 to 4, the aggregate storage tank 2 is installed on a base 6 formed at a position higher than the ground surface below the girder 32 of the pier 3. The base 6 is independent of the pier 3 and is supported by a plurality of base support columns 61 (foundation structure) erected in the ground. In this embodiment, the height of the upper end of the aggregate storage tank 2 is set to be at the same height as the upper surface of the deck slab 31 of the pier 3, but the upper end of the aggregate storage tank 2 may protrude upward from the upper surface of the deck slab 31, or it may be lower than the upper surface of the deck slab 31.

[0023] As shown in Figure 1, the aggregate storage tank 2 is a rectangular box-shaped container with an open top in plan view. The aggregate storage tank 2 has rectangular side walls 21 formed in a rectangular shape in plan view, and partition walls 22 formed in a direction intersecting the long side of the side walls 21, dividing the space enclosed by the side walls 21, thus exhibiting a Japanese character shape in plan view. The interior of the aggregate storage tank 2 (side walls 21) is divided by the partition walls 22 into a storage space 2a for coarse aggregate (gravel) and a storage space 2b for fine aggregate (sand).

[0024] As shown in Figure 5(b), the aggregate storage tank 2 is formed by alternately stacking liner plates 23 and reinforcing frames 24 made of H-shaped steel. The upper and lower ends of the liner plates 23 are inserted into the space enclosed by the flanges and webs of the reinforcing frames 24, which are arranged above and below each other. The liner plates 23 arranged above and below each other are joined via bolts that pass through the webs of the reinforcing frames 24.

[0025] As shown in Figures 6(a) to (e), the liner plate 23 is composed of a corrugated steel plate 25 and a strip-shaped steel plate 26 that surrounds the periphery of the corrugated steel plate 25. Bolt holes 26a are formed in the strip-shaped steel plate 26. Bolts that join the liner plates 23 together are inserted through the bolt holes 26a. In this embodiment, a straight liner plate 23 (liner plate 23a for general use) shown in Figures 6(b) and (c) and an L-shaped liner plate 23 (liner plate 23b for corners) provided at the corners of the aggregate storage tank 2 shown in Figures 6(d) and (e) are used.

[0026] As shown in Figure 5(a), the reinforcing frame 24 is formed by connecting a plurality of frame members 27. In this embodiment, as shown in Figures 7(a) to (c), a straight frame member 27a for the general section, an L-shaped frame member 27b for the corner section in plan view, and a T-shaped frame member 27c for the partition section in plan view are used. Bolt holes 24a are formed in the web of each frame member 27, corresponding to the positions of the bolt holes 26a of the liner plate 23.

[0027] The aggregate storage tank 2 of this embodiment first forms a square-shaped frame body and a U-shaped frame body by combining a general-part liner plate 23a and a corner-part liner plate 23b. Subsequently, with both ends of the U-shaped frame body abutted against the corners of the square-shaped frame body, they are combined in a gridiron shape to form a unit. Next, the aggregate storage tank 2 is formed by alternately laminating this unit of the liner plate 23 and the reinforcing frame 24 assembled in a gridiron shape. At the joint between the square-shaped frame body and the U-shaped frame body, the corner-part liner plate 23b of the square-shaped frame body and the general-part liner plate 23a of the U-shaped frame body are joined by being sandwiched by a partition-part frame member 27c in a T shape in plan view from above and below. Thereby, the aggregate storage tank 2 having a partition wall 22 is formed. Note that the method for forming the aggregate storage tank 2 is not limited. For example, a unit of the liner plate 23 assembled linearly (in a flat plate shape) may be inserted into the inner space of a unit of the liner plate 23 assembled in a rectangular shape.

[0028] As shown in FIGS. 2 and 4, above the aggregate storage tank 2 (above the building 4), a transport means 50 for transporting the aggregate stored in the aggregate storage tank 2 to the mixing mixer 5 is disposed. The transport means 50 includes a rail 51, a crane support girder 52, a crane 53, a hopper 54, a belt conveyor 55, and a bucket 56.

[0029] The rail 51 supports the crane support girder 52 and is horizontally spanned above the building 4 along the wall surface of the building 4 (see FIGS. 2 and 3). In this embodiment, a pair of rails 51, 51 extends in the longitudinal direction of the building 4 (the left-right direction in FIG. 2).

[0030] As shown in FIG. 3, the crane support girder 52 is horizontally spanned on a pair of rails 51, 51 and is movable in the longitudinal direction of the rail 51. That is, the crane support girder 52 is movable along the longitudinal direction of the building 4. The crane support girder 52 supports the crane 53.

[0031] The crane 53 is equipped with a traverse mechanism that allows it to move along the crane support girder 52. That is, the crane 53 is movable in the longitudinal direction of the crane support girder 52 (in the front-to-back direction of the aggregate storage tank 2). The crane 53 is also equipped with a lifting mechanism (such as a winch) that moves the bucket 56 up and down.

[0032] The hopper 54 grasps the aggregate from the aggregate storage tank 2 and drops it onto the upper surface of the belt conveyor 55. As shown in Figure 2, the concrete plant 1 of this embodiment is equipped with two hoppers 54, 54, one for fine aggregate and one for coarse aggregate. The belt conveyor 55 extends from below the hopper 54 to the mixing mixer 5 and transports the aggregate dropped from the hopper 54 to the mixing mixer 5.

[0033] Figure 8 shows the procedure for constructing concrete plant 1. As shown in Figure 8, the construction method for concrete plant 1 comprises a pier / base formation step S1, a storage tank assembly step S2, a storage tank installation step S3, and an equipment installation step S4.

[0034] In the pier and base formation process S1, the pier 3 and base 6 are formed. The pier 3 is formed by driving multiple piles 33 into the ground, then horizontally placing girders 32 (main girders, girder support girders, etc.) on the tops of these piles 33, and laying a covering plate on the upper surface of the girders 32. The base 6 is formed below the girders 32 of the pier 3. In this embodiment, the base 6 is formed below the deck slab 31 of the pier 3, in the space between the piles (supports) 33. The base 6 is formed by driving base support columns 61 into the ground and then fixing them to the tops of these base support columns 61.

[0035] In the storage tank assembly process S2, the aggregate storage tank 2 is assembled. The aggregate storage tank 2 is assembled on the deck slab 31 of the pier 3. The aggregate storage tank 2 is formed by assembling the liner plates 23 and alternately stacking the liner plates 23 and reinforcing frames 24.

[0036] In the storage tank installation process S3, the aggregate storage tank 2 is installed on the base 6. An opening is pre-formed in the deck slab 31 of the pier 3, corresponding to the installation location of the aggregate storage tank 2 (above the base 6). The aggregate storage tank 2, assembled on the deck slab 31, is lowered by a lifting machine such as a crane and placed on the base 6 by passing it through the opening. Once the aggregate storage tank 2 is placed on the base 6, the legs of the aggregate storage tank 2 are fixed to the base 6 as needed, and the upper part of the aggregate storage tank 2 is fixed to the deck slab 31.

[0037] In the equipment installation process S4, a building 4 is constructed on the pier 3, and a cement silo, water tank, mixing mixer 5, and admixture storage tank are installed. The arrangement of the cement silo, water tank, mixing mixer 5, and admixture storage tank can be determined as appropriate.

[0038] The concrete manufacturing method using the concrete plant 1 of this embodiment first involves supplying the required amounts of aggregate, cement (solidifying agent), water, and admixture to the mixing mixer 5 from the aggregate storage tank 2, cement silo, water storage tank, and admixture storage tank. Next, the materials are mixed in the mixing mixer 5 to produce concrete or mortar. The produced concrete or mortar is then transferred from the mixing mixer 5 to the agitator truck C1.

[0039] The supply of aggregate from the aggregate storage tank 2 to the mixing mixer 5 will be carried out according to the following procedure. First, the crane support girder 52 is moved laterally along the rail 51, and the crane 53 is moved back and forth along the crane support girder 52, thereby moving the crane 53 to a predetermined position above the aggregate storage tank 2. Next, the bucket 56 is lowered by the crane 53, and the aggregate in the aggregate storage tank 2 is collected by the bucket 56. After collecting the aggregate, the bucket 56 is raised. Subsequently, the crane 53 is moved back and forth along the crane support girder 52, and the crane support girder 52 is moved laterally along the rail 51, thereby moving the crane 53 (bucket 56) above the hopper 54. Once the crane 53 is above the hopper 54, the aggregate in the bucket 56 is loaded into the hopper 54. Then, a predetermined amount of aggregate is dropped from the hopper 54 onto the belt conveyor 55, and the aggregate is transported to the mixing mixer 5 by the belt conveyor 55.

[0040] According to the concrete plant 1 of this embodiment, even in a narrow work yard where it is not possible to secure land for arranging aggregate storage tanks 2, cement silos, water storage tanks, and mixing mixers 5 side by side, the concrete plant 1 can be formed on site by utilizing the pier (including a platform) 3, making three-dimensional use of the limited space.

[0041] In the concrete plant 1 of this embodiment, since the aggregate storage tank 2 is rectangular in plan view, the required volume can be secured even if the depth of the tank is reduced compared to conventional concrete plants that use multiple cylindrical containers. In order to manufacture concrete, it is necessary to lift the aggregate from the aggregate storage tank 2 using a bucket 56 such as a clamshell. If the aggregate storage tank 2 is deep, the distance over which the aggregate is lifted is long, consuming time and electricity. Also, since the range of motion of the clamshell is limited, there is a limit to the depth of the aggregate storage tank 2, so the depth can be reduced by increasing the cross-sectional area.

[0042] Furthermore, if a circular aggregate storage tank (cylindrical aggregate storage tank) is installed in a rectangular installation space, dead space will be created at the four corners of the installation space. However, since the aggregate storage tank 2 in this embodiment is rectangular in plan view, the dead space is reduced, and consequently, the amount of aggregate that can be stored increases. Therefore, it becomes possible to construct the concrete plant 1 while making maximum use of the limited space.

[0043] When two aggregate storage tanks 2, which are U-shaped in plan view, are placed side by side, the side walls of one aggregate storage tank 2 and the side walls of the other aggregate storage tank 2 are adjacent. However, by creating an aggregate storage tank 2 with a rectangular outer shape in plan view and dividing it with a partition wall 22, the amount of aggregate that can be stored can be increased compared to when two U-shaped aggregate storage tanks 2 are placed side by side. In addition, by providing a partition wall 22 inside the aggregate storage tank 2 to divide it, multiple types of aggregate (fine aggregate and coarse aggregate, etc.) can be stored separately.

[0044] By covering the aggregate storage tank 2 with a building 4 and installing a shutter on this building 4, it is possible to prevent rainwater from coming into contact with the aggregate inside the aggregate storage tank 2, thereby suppressing an increase in the moisture content of the aggregate.

[0045] Although embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above, and each of the above-mentioned components can be modified as appropriate without departing from the spirit of the present invention. For example, the size (volume) of the containers that make up the aggregate storage tank 2 can be determined as appropriate.

[0046] Furthermore, although the above embodiment described a case in which the aggregate storage tank 2 is divided into two by one partition wall 22, the number and arrangement of partition walls 22 are not limited and may be formed as appropriate. For example, the aggregate storage tank 2 may be divided into three or more by two or more partition walls 22. Also, partition walls 22 may be formed as needed.

[0047] The materials constituting the aggregate storage tank 2 are not limited to liner plates; for example, they may be made of concrete or steel, or they may be formed by combining precast concrete members.

[0048] The foundation structure of the base 6 is not limited to piles (base support columns 61), but may also be a concrete foundation or an embankment, for example. Furthermore, the base 6 may be supported by the piles (support columns) 33 of the pier 3. In other words, the base 6 may, in some cases, be a foundation structure integrated with the pier 3.

[0049] Building 4 may be constructed as needed. Similarly, the shutters of building 4 may be constructed as needed. The arrangement of cement silos, water tanks, and admixture storage tanks is not limited; for example, they may be placed outside or inside building 4. [Explanation of Symbols]

[0050] 1. Concrete plant 2. Aggregate storage tank 21 Side wall 22 Partition walls 23 Liner Plate 24 Reinforcement slots 3 Piers 31 Floor slab 32 digits 33 Pile (post) 4 buildings 5 Mixing Mixer 6 bases 61. Support column for base C1 Agitator Vehicle C2 Aggregate Transport Vehicle S1 Pier and base formation process S2 Storage tank assembly process S3 Storage tank installation process S4 Equipment installation process

Claims

1. A concrete plant comprising an aggregate storage tank, a cement silo, a water storage tank, and a mixing mixer, At least one of the cement silo, the water tank, and the mixing mixer is located on a pier. A concrete plant characterized in that the aggregate storage tank is provided on a base formed below the main girder of the pier.

2. A concrete plant comprising an aggregate storage tank, a cement silo, a water storage tank, and a mixing mixer, The aggregate storage tank has a rectangular cylindrical side wall formed in a rectangular shape in plan view, A concrete plant characterized by having a partition wall formed in a direction intersecting the long side of the side wall, thereby dividing the space enclosed by the side wall.

3. The aggregate storage tank is formed by alternately stacking liner plates and reinforcing frames made of H-shaped steel. The concrete plant according to claim 1 or claim 2, characterized in that the upper and lower ends of the liner plate are inserted into a space enclosed by the flanges and webs of the reinforcing frames arranged vertically.

4. The concrete plant according to claim 3, characterized in that the liner plates arranged vertically are joined together via bolts that pass through the web of the reinforcing frame.

5. Pier and base formation process for forming the pier and base, The storage tank assembly process involves assembling the aggregate storage tank, A storage tank installation step involves installing the aggregate storage tank on the base, A method for constructing a concrete plant, comprising: an equipment installation step of installing at least one of a cement silo, a water storage tank, and a mixing mixer on the aforementioned pier, The aforementioned base is formed below the main girder of the pier, In the storage tank assembly process, the aggregate storage tank is assembled on the pier. A method for constructing a concrete plant, characterized in that, in the storage tank installation step, the aggregate storage tank is placed on the base by passing it through an opening formed in the deck of the pier.

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