Precast concrete slab and its manufacturing method

Abstract

The present invention provides a precast concrete slab that is useful as a surface material for test courses on uneven surfaces, minimizing the difference between performance tests on actual uneven road surfaces and performance tests on test courses with uneven surfaces that replicate those surfaces. [Solution] The precast concrete slab of the present invention is used as a surface material for a test course for uneven road surfaces, and its surface has an uneven surface, including fine irregularities.

Description

【Technical Field】 【0001】 The present invention relates to precast concrete slabs and a method for manufacturing the same. 【Background Art】 【0002】 As test courses for testing the performance of automobiles, various road surfaces are constructed. For example, a road surface with a specific slip friction resistance value for examining the braking performance of an automobile, the grip force of a tire, etc., an inclined plane for examining the center of gravity, inclination, etc. of an automobile, and an uneven road surface for examining the ride comfort of the suspension, rigidity of each part, noise, tire performance, etc. of an automobile. The uneven road surface is constructed by imitating a road surface with irregularities formed by deterioration, settlement, wear, etc. 【0003】 Conventionally, as a method of constructing by imitating an uneven road surface, a photograph is taken, distances and heights are measured, a mold is made with gypsum, etc., and based on the data, in a test course, a person raises cement, etc. here and there on a smooth road surface to reproduce it. 【0004】 Patent Document 1 discloses a method of reproducing an uneven road surface by measuring the surface shape of the uneven road surface, producing a mold for reproducing the surface shape, manufacturing a surface layer material of a precast concrete slab using the mold, and installing the manufactured surface layer material on a base layer. 【Prior Art Documents】 【Patent Documents】 【0005】 【Patent Document 1】 Japanese Patent Application Laid-Open No. 2022-102046 【Summary of the Invention】 【Problems to be Solved by the Invention】 【0006】 The present invention provides a precast concrete slab and a method for manufacturing the same that are useful as a surface material for test courses on uneven surfaces, and that minimize differences between performance tests on actual uneven road surfaces and performance tests on test courses with uneven road surfaces that replicate those surfaces. [Means for solving the problem] 【0007】 The present inventors have found that a precast concrete slab having the following characteristics and a method for manufacturing the same can solve the above problems. 【0008】 《Aspect 1》 In one embodiment, the present invention is This invention relates to a precast concrete slab used as a surface material for a test course for uneven road surfaces, wherein the surface has an uneven surface resembling an uneven road surface, and also has fine irregularities. 【0009】 The inventors noticed that even when an uneven road surface is created by faithfully reproducing the shape of an actual uneven road surface, there may be differences in the results between performance tests conducted on the resulting test course and performance tests conducted on an actual uneven road surface. 【0010】 Further investigation by the inventors revealed that performance tests were less likely to show differences on uneven road surfaces using conventional methods, while performance tests were more likely to show differences on uneven road surfaces formed as described in Patent Document 1. 【0011】 Several causes were considered, but the inventors believed that the difference lay in the roughness of their surfaces, as actual uneven road surfaces are made of asphalt pavement, and while uneven road surfaces obtained by conventional methods are formed from asphalt mixtures, uneven road surfaces obtained by the method described in Patent Document 1 are formed from precast concrete slabs. Therefore, the inventors roughened the surface of the precast concrete slab used in Patent Document 1, which reduced the discrepancy between the results of performance tests on a test course and performance tests on actual uneven road surfaces, thus completing the uneven road surface of the present invention. 【0012】 In other words, while uneven road surfaces formed by precast concrete slabs have irregularities due to their unevenness, the importance of the frictional force generated between the tire and the road surface and / or the minute inputs to the tire from the fine irregularities of the road surface were not considered, and the idea of ​​roughening the uneven surface was not considered. However, it has been found that in reality, irregularities due to unevenness alone are not sufficient to generate sufficient frictional force and / or minute inputs, and that in addition to irregularities due to unevenness, it is necessary to have fine irregularities due to surface roughening treatment or the like. 【0013】 《Aspect 2》 In one embodiment, the present invention is The present invention relates to the above-mentioned precast concrete slab, wherein the aforementioned fine irregularities are formed by a surface roughening treatment. 【0014】 According to this embodiment, the surface has substantially the same surface characteristics as those formed by surface roughening treatments known in the art, such as broom finishing, on concrete pavement, thereby enabling the application of appropriate frictional force and / or minute input to the surface. 【0015】 《Aspect 3》 In one embodiment, the present invention is The present invention relates to a precast concrete slab in which the maximum height of the uneven road surface-like irregularities is 20 mm or more, and the average depth of the fine irregularities is 3 mm or less. 【0016】 According to this embodiment, when the height of the unevenness of the uneven road surface and the fine unevenness caused by the surface roughening treatment are within this range, it is useful as a precast concrete slab for uneven road surfaces used as a surface layer for test courses. 【0017】 Appearance 4 In one embodiment, the present invention is This relates to an uneven road surface that includes a base layer and the above-mentioned precast concrete slab as a surface layer material. 【0018】 The uneven road surface according to this embodiment is extremely useful because it can easily obtain performance test results equivalent to those of performance tests of vehicles, tires, etc. obtained on actual uneven road surfaces. 【0019】 《Aspect 5》 In one embodiment, the present invention is a method for manufacturing a precast concrete slab used as a surface layer material for the uneven road surface test course, comprising: a measuring step of measuring the shape of an existing uneven road surface, and a surface layer material manufacturing step of manufacturing a precast concrete slab used for the surface layer material based on the three-dimensional data obtained in the measuring step, wherein the precast concrete slab has unevenness in the form of an uneven road surface and has fine unevenness, and relates to a method for manufacturing a precast concrete slab. 【0020】 According to this embodiment, the above precast concrete slab can be manufactured relatively easily and faithfully reproduce the shape of an existing uneven road surface. 【0021】 《Aspect 6》 In one embodiment, the present invention where the surface layer material manufacturing step includes a mold manufacturing step of manufacturing a mold for reproducing the shape of the existing uneven road surface, a mold roughening treatment step of performing a roughening treatment for transferring the fine unevenness to the surface of the mold, and a surface layer material forming step of forming a precast concrete slab used for the surface layer material using the roughened mold and relates to the method for manufacturing the above precast concrete slab. 【0022】 According to this embodiment, by performing a roughening treatment for transferring fine unevenness to the surface of the mold, the above precast concrete slab can be manufactured relatively easily compared to the case of manufacturing the precast concrete slab with a mold and then performing the roughening treatment. 【0023】 《Aspect 7》 The present invention relates to a method for manufacturing a precast concrete slab, wherein the mold is made of expanded polystyrene, and the surface roughening treatment is performed by cutting the surface of the mold using a machining center. 【0024】 According to this embodiment, since the surface of the expanded polystyrene can be easily roughened using a machining center, the above-mentioned precast concrete slab can be manufactured relatively easily. [Effects of the Invention] 【0025】 According to the present invention, it is possible to provide a precast concrete slab and a method for manufacturing the same that are useful as a surface material for test courses on uneven road surfaces, which minimizes the difference between performance tests on actual uneven road surfaces and performance tests on test courses with uneven road surfaces that replicate them. [Brief explanation of the drawing] 【0026】 [Figure 1] Figure 1 shows a photograph of a precast concrete slab with an uneven surface resembling a road surface. [Figure 2] Figure 2 is a magnified photograph of Figure 1, showing the fine irregularities of the precast concrete slab. [Figure 3] Figure 3 shows one embodiment of a precast concrete slab connecting structure. [Figure 4] Figure 4 shows one embodiment of a precast concrete slab used in a precast concrete slab connecting structure. [Figure 5] Figure 5 shows a flowchart illustrating one embodiment of a method for constructing an uneven road surface. [Figure 6] Figure 6 schematically shows one embodiment of the surface material installation process S3. [Figure 7] Figure 7 shows a photograph of the mold used to manufacture a precast concrete slab with an uneven surface resembling a road surface. [Figure 8]Figure 8 is a magnified photograph of Figure 7, showing the fine irregularities of the mold used to manufacture the precast concrete slab. [Modes for carrying out the invention] 【0027】 The present invention will be specifically described using the following embodiments as examples, but the present invention is not limited thereto. Unless otherwise specified, configurations well known to those skilled in the art can be used for each embodiment. 【0028】 In this specification, "upward" and "downward" refer to the opposite and positive directions of gravity, respectively. In this specification, "lengthwise" refers to the direction in which a vehicle moves on the road surface, and "widthwise" refers to the direction perpendicular to the lengthwise direction. "Horizontal" refers to the lengthwise and / or widthwise directions. 【0029】 Precast concrete panels The precast concrete slab of the present invention is a precast concrete slab used as a surface material for a test course for uneven road surfaces, wherein its surface has an uneven surface-like texture and also has fine irregularities. 【0030】 The surface of the precast concrete slab has an uneven, road-like surface. Figure 1 shows an actual photograph of one embodiment of a precast concrete slab having an uneven, road-like surface. As shown in Figure 1, the uneven, road-like surface is formed only over a portion of the width and length of the precast concrete slab, for example, by forming a single recess or protrusion over a range of 10 mm to 100 mm or 20 mm to 80 mm in the width and length directions, respectively. 【0031】 The uneven surface irregularities have a height appropriate for use as an uneven surface on a test course. For example, the maximum height of the uneven surface irregularities can be 10 mm or more, 15 mm or more, 20 mm or more, 25 mm or more, or 30 mm or more, and can be 100 mm or less, 80 mm or less, 50 mm or less, 40 mm or less, or 30 mm or less. Here, the maximum height of the uneven surface irregularities is determined by the difference between the highest point in the upward direction and the lowest point in the downward direction of the irregularity waveform data obtained by measuring the uneven surface reproduced by a 3D laser scanner. 【0032】 The surface of the precast concrete slab has fine irregularities. Figure 2 is a magnified photograph of Figure 1, showing the fine irregularities of the precast concrete slab. The fine irregularities are not particularly limited as long as they can provide the tires of the vehicle used in the performance test with appropriate frictional force and / or minute input equivalent to that of an actual uneven road surface. 【0033】 Examples of such surface roughening treatments include well-known roughening treatments used in concrete pavement, such as broom finish, exposed aggregate finish, cutting, aggregate-containing paint coating, and shot blasting. It is preferable that the surface of the precast concrete slab has irregularities equivalent to those formed by these surface roughening treatments. In particular, it is preferable that the surface of the precast concrete slab has irregularities equivalent to those formed by a broom finish. 【0034】 The average depth of such fine irregularities may be less than 5 mm, 3 mm or less, 2 mm or less, or 1 mm or less, and may be 0.1 mm or more, 0.5 mm or more, 1.0 mm or more, or 1.5 mm or more. Here, the average depth of the fine irregularities is measured by a method compliant with the "Method for Measuring the Texture Depth of Pavement Surfaces Using Sand (Sand Patching Method)" in the Pavement and Survey Testing Methods Handbook (Japan Road Association). However, if this method is inappropriate, it may also be determined by a multi-road profiler or CT meter. 【0035】 The precast concrete slab 10 may have a width dimension of 0.5m or more, 1.0m or more, or 1.5m or more, and may be 5.0m or less, 3.0m or less, or 2.0m or less. Furthermore, the precast concrete slab 10 may have a length dimension of 2.0m or more, 3.0m or more, or 4.0m or more, and may be 10.0m or less, 8.0m or less, or 5.0m or less. 【0036】 Precast concrete slabs can be used as surface material for test courses for uneven surfaces, and can constitute an uneven surface including the surface material and base layer. In this specification, "used as surface material for test courses for uneven surfaces" means that they can be used as surface material for test courses for uneven surfaces. On the other hand, the present invention also relates to a method of using such precast concrete slabs as surface material for test courses for uneven surfaces. 【0037】 Precast concrete slab connecting structure Figure 3 shows one embodiment of a precast concrete slab connecting structure. Figure 4 shows one embodiment of a precast concrete slab used in the precast concrete slab connecting structure. Note that the fine irregularities are omitted in the precast concrete slab in Figure 4. 【0038】 The precast concrete slab connecting structure 100 includes a first precast concrete slab 11, a second precast concrete slab 12, and a connecting member 20 that connects them, wherein the connecting member 20 has at least two fixing parts 21a, 21b, 22a, and 22b on the first and second precast concrete slabs 11 and 12, respectively. 【0039】 In this embodiment, since each connecting structure of the precast concrete slabs has two fixing parts, when one of the precast concrete slabs receives a load from above, sinking of the loaded precast concrete slab is less likely to occur. Furthermore, in this embodiment, the precast concrete slabs can be connected by connectors without using grout, and the connectors can also be removed, making it easy to release the connection between the first and second precast concrete slabs and move them from their installed location. 【0040】 As shown in Figure 3, the precast concrete slab connecting structure 100 includes a first precast concrete slab 11, a second precast concrete slab 12, and a connecting member 20 that connects them. The connecting member 20 may have a first outer fixing portion 21a and a first inner fixing portion 21b on the first precast concrete slab 11, and a second outer fixing portion 22a and a second inner fixing portion 22b on the second precast concrete slab 12. 【0041】 The four fixing parts of the connector 20, namely the first outer fixing part 21a, the first inner fixing part 21b, the second outer fixing part 22a, and the second inner fixing part 22b, are positioned substantially horizontally in the longitudinal direction. This makes it less likely for the precast concrete slab to sink even when a downward load is applied to it. Here, "positioned substantially horizontally" means that there is no large difference in position in the vertical direction, but a difference in position in the vertical direction is acceptable as long as the advantageous effects of this embodiment can be obtained. For example, the outer fixing parts 21a, 22a and the inner fixing parts 21b, 22b may have a difference in position in the vertical direction of 5.0 cm or less, 3.0 cm or less, 2.0 cm or less, 1.0 cm or less, or 0.5 cm or less, respectively. 【0042】 However, the fixing parts of the connector 20 are not limited to this embodiment as long as there are at least two fixing parts on each of the first and second precast concrete slabs 11 and 12. For example, three fixing parts on each of the first and second precast concrete slabs 11 and 12 may be arranged in a triangular shape, or three fixing parts on each may be arranged substantially horizontally in the longitudinal direction, or there may be four or more fixing parts. However, in order to balance the ease of handling during connection work and strength, it is preferable that there are two fixing parts on each of the first and second precast concrete slabs 11 and 12. 【0043】 In this embodiment, the connector 20 is housed in first and second recesses 11c and 12c formed on the longitudinal sides of the first and second precast concrete slabs 11 and 12. This embodiment prevents injury to people, vehicles, etc., passing along the side of the connecting structure. Therefore, it is preferable that the depth of the first and second recesses 11c and 12c be such that the connector 20 does not protrude from the sides of the first and second precast concrete slabs 11 and 12. For example, the first and second recesses 11c and 12c may have a depth of 0.5 cm or more, 1.0 cm or more, 2.0 cm or more, or 3.0 cm or more in the width direction of the first and second precast concrete slabs 11 and 12, or a depth of 10.0 cm or less, 5.0 cm or less, or 3.0 cm or less. 【0044】 As shown in Figure 3, one end of the first recess 11c in the longitudinal direction is the longitudinal end of the first precast concrete slab 11. The same applies to the second recess 12c. Furthermore, the first recess 11c and the second recess 12c are substantially the same depth in the width direction throughout their entirety. This allows the connecting plate 23 to be positioned along the longitudinal direction of the first and second precast concrete slabs 11 and 12. 【0045】 In the embodiment shown in Figure 3, the other end of the first recess 11c in the longitudinal direction extends to a point midway along the length of the first precast concrete slab 11, but it may extend to the other end of the first precast concrete slab 11 in the longitudinal direction. However, by having the other end of the first recess 11c in the longitudinal direction extend to a point midway along the length of the first precast concrete slab 11, and the other end of the second recess 12c in the longitudinal direction also extend to a point midway along the length of the second precast concrete slab 12, the connecting plate 23 can be extended to substantially the entire area of ​​the first recess 11c and the second recess 12c. 【0046】 In the embodiment shown in Figure 3, the lower end of the first recess 11c formed in the first precast concrete slab 11 is the lower end of the first precast concrete slab 11, and the upper end of the first recess 11c extends to a position midway up the first precast concrete slab 11. The second recess 12c is similar. As a result, the connecting plate 23 fits into the first recess 11c and the second recess 12c, and in addition to the four fixing parts, the connecting plate 23 can also prevent the first and second precast concrete slabs 11 and 12 from sinking. 【0047】 The area of ​​the first recess 11c and the second recess 12c extending in the longitudinal and vertical directions is, for example, 10 cm². 2 More than 30cm 2 More than 50cm 2 Above, or 100cm 2 It may be greater than or equal to 500cm 2 Below, 300cm 2 Below, 200cm 2 The following, or 100cm 2 The following is also acceptable. 【0048】 In this embodiment, all fixing parts of the connector 20 are fixed with fixing bolts, but the embodiment is not limited to this. However, fixing with fixing bolts is advantageous because even after the precast concrete slabs have been connected to form a connected structure, the connection can be released to adjust the height of the precast concrete slabs, move them, etc. 【0049】 Figure 4 shows the precast concrete slab 10 with the connector 20 from Figure 3 removed. The precast concrete slab 10 has a recess 10c formed therein, and there are outer receiving parts 10a and inner receiving parts 10b for receiving the outer and inner fixing parts. The outer receiving parts 10a and inner receiving parts 10b may be embedded nuts, for example, if the fixing part is a fixing bolt. 【0050】 A jointing material 30 is inserted between the first and second precast concrete slabs 11 and 12. The jointing material 30 is not particularly limited as long as it can be used as a cushioning material, but for example, a foamed resin sheet can be used. 【0051】 Method for manufacturing precast concrete panels The manufacturing method of the present invention is a method for obtaining precast concrete slabs and connecting structures as described above. Therefore, the configurations of the precast concrete slabs and connecting structures obtained by the manufacturing method of the present invention can be referenced from the configurations of the precast concrete slabs and connecting structures described above. 【0052】 Figure 5 shows a flowchart of one embodiment of a method for manufacturing precast concrete slabs, connecting structures, and uneven road surfaces. Figure 6 schematically shows one embodiment of the surface material installation process S3 in the manufacturing method. 【0053】 The present invention provides a method for manufacturing a precast concrete slab, which includes a measurement step S1 for measuring the shape of an existing uneven road surface, and a surface material manufacturing step S2 for manufacturing a precast concrete slab to be used as a surface material based on the three-dimensional data obtained in the measurement step. Furthermore, the present invention provides a method for manufacturing an uneven road surface, which further includes a surface material installation step S3 for installing the surface material on a base layer. 【0054】 <Measurement process S1> In the measurement process S1 for measuring the shape of an existing uneven road surface, first, the shape of the existing uneven road surface is divided into multiple blocks, and for each of the divided blocks, a first 3D data acquisition process S1a is performed in which a 3D laser scanner is used to measure and obtain first 3D data. 【0055】 The 3D laser scanner used here is a measuring instrument commonly used in this field, which can acquire the 3D coordinates of the surface shape by irradiating the object to be measured with a laser. It can measure quickly and non-contact using a laser, and can obtain high-density, planar point cloud data. The 3D coordinates can be calculated from the distance to the object and the irradiation angle, which are determined from the laser reflection time. The data obtained with the 3D laser scanner may be adjusted to avoid excessively high measurement accuracy, or the obtained data may be corrected, so that only the shape of the uneven surface is reproduced, ignoring fine roughness and other imperfections. 【0056】 The shape of an existing uneven road surface can be virtually divided into multiple blocks. For example, the shape of an existing uneven road surface can be divided lengthwise into sections at 20m, 10m, 5m, or 3m intervals, and measured with a 3D laser scanner to obtain the first 3D data. On the other hand, the widthwise direction of the uneven road surface can be divided and measured or not. Since the accuracy of the first 3D data decreases at positions far from the 3D laser scanner, the accuracy of the first 3D data can be made relatively high by dividing and measuring within the ranges described above. 【0057】 In the measurement step S1, a reference point setting step S1b is performed to set at least one measurement reference point for each of the divided blocks. The reference point setting step S1b may be performed before the first 3D data acquisition step S1a, and 3D data may be acquired in the first 3D data acquisition step S1a for the set measurement reference points, or the reference point setting step S1b may be performed after the first 3D data acquisition step S1a, and points of the 3D data acquired by the 3D laser scanner may be defined as measurement reference points. 【0058】 Measurement reference points can be established on the boundaries of the divided blocks of uneven road surface. For example, if the shape of an existing uneven road surface is divided lengthwise into two blocks, a first block and a second block, the first and second blocks will have the same boundary line on a plane in the widthwise and vertical directions. At least one measurement reference point can be established on this boundary line, and 3D data can be acquired at that measurement reference point using a 3D laser scanner and other methods to correct the data. The corrected data from the measurement reference point on the boundary can then be used as common 3D data for each of the divided blocks, thereby reducing the number of measurements required to obtain the second 3D data. Furthermore, even if the shape of the existing uneven road surface is divided into multiple fine sections for measurement, 3D data of the existing uneven road surface can be acquired with high accuracy even at the dividing surfaces. 【0059】 In measurement step S1, a second 3D data acquisition step S1c may be performed to obtain second 3D data by measuring the 3D shape at at least one set measurement reference point using a method different from that of a 3D laser scanner. Here, the method different from that of a 3D laser scanner is not particularly limited as long as it can measure the 3D data with high accuracy, but for example, it may be measurement using a leveling instrument that is simple and capable of high-precision measurement. 【0060】 The inventors noticed that when attempting to reproduce an uneven road surface, the reproduction accuracy sometimes suffers. Because the irregularities of an uneven road surface are not very large, this decrease in reproduction accuracy is not very noticeable, but it cannot be ignored from the standpoint of reproducing an existing uneven road surface with extreme fidelity. 【0061】 The inventors then diligently investigated whether the cause of this problem was the measurement accuracy of the existing uneven road surface, the inability to accurately manufacture the mold from the measurement data, the inability to accurately manufacture the surface material from the mold, or the accuracy of the installation of the surface material on the base layer. They found that the biggest factor was the measurement accuracy of the existing uneven road surface. 【0062】 In particular, the accuracy of the reproduced uneven road surface tended to decrease at positions far from the 3D laser scanner used to measure the existing uneven road surface. It was found that when the shape of the existing uneven road surface is divided into multiple sections in the longitudinal direction and the 3D data is combined, the 3D data combined with errors in the longitudinal direction will result in large errors during the process of multiple combinations. 【0063】 To address this issue, it was found that accuracy could be significantly improved by first obtaining 3D data using a 3D laser scanner, then obtaining 3D data by measuring the 3D shape using a method different from the 3D laser scanner, and finally correcting the 3D data with the 3D data from the 3D scanner. 【0064】 Examples of leveling instruments include: a leveling instrument that combines a tripod and a leveling rod to directly observe the difference in elevation between points; a theodolite instrument that uses a lens to identify a target object and measures the horizontal and vertical angles from a reference point by rotating it horizontally and vertically; and a total station instrument that combines a light-wave distance meter and a theodolite to simultaneously measure angles and distances. 【0065】 In measurement step S1, a 3D data correction step S1d can be performed, in which the first 3D data is corrected using the second 3D data. Here, since the first 3D data obtained by the 3D laser scanner may contain errors, the second 3D data obtained by a leveling instrument or the like can be treated as the correct data at the measurement reference point. 【0066】 In the 3D data correction process S1d, the first 3D data that could not be replaced by the second 3D data can be corrected according to the distance from the origin to the measurement reference point. 【0067】 For example, suppose that for the first block divided into 10m intervals along the length, the value at the origin in the Z direction is (0.000), and the value at a point 10m away measured by a 3D laser scanner is (0.102). If we consider the value at a point 10m away measured by a method other than the 3D laser scanner to be (0.100) as the true value, then the error at 10m away can be evaluated as an absolute value of (0.002) or as a percentage error of 2%. Now, if the measurement result at 5m from the origin by the 3D laser scanner is (0.312), we can consider that an error of half the error at 10m has occurred as an absolute value, and correct the measurement result at 5m away by half of (0.002), which is (0.001), to get (0.311). Alternatively, we can consider that an error of half of 2%, which is 1%, has occurred, and correct the measurement result at 5m away to (0.30888). In this way, the first 3D data, excluding the measurement reference point, can be gradually corrected according to the distance from the origin to the measurement reference point. 【0068】 When multiple measurement reference points are set within a single block, the method for correcting errors can be arbitrarily and reasonably determined. For example, in a block of length 10m, if the Z-direction values ​​of the first 3D data at the origin, 5m away, and 10m away are (0.000), (0.312), and (0.102), respectively, and the Z-direction values ​​of the second 3D data are (0.000), (0.310), and (0.101), respectively, then the Z-direction values ​​can be corrected by (0.0004) per meter from the origin to 5m away, and by (0.0002) per meter from 5m away to 10m away. These correction methods can be implemented relatively easily through programming. 【0069】 <Surface material manufacturing process S2> After the measurement process described above, a surface material manufacturing process S2 is performed to manufacture a precast concrete slab to be used as a surface material based on the obtained 3D data. The method for manufacturing the surface material is not particularly limited as long as it uses 3D data, and a 3D printer or the like can be used, but typically it may include a mold manufacturing process S2a in which a mold is made to reproduce the shape of an existing uneven road surface using 3D data, and a surface material molding process S2b in which a precast concrete slab having an uneven shape is formed using the mold. 【0070】 Here, the fine irregularities on the surface of the precast concrete slab may be formed by performing a roughening treatment to transfer the fine irregularities to the surface of the mold, or by performing a roughening treatment on the surface of a precast concrete slab obtained using a mold that has not been roughened. The roughening of the mold may be performed at the same time as the mold is made, or it may be performed on the mold after it has been made. Therefore, the mold roughening treatment step S2a' may be performed after or simultaneously with the mold making step S2a, followed by the surface material forming step S2b, or the surface material forming step S2b may be performed after the mold making step S2a, followed by the roughening treatment step S2b' to roughen the surface material. 【0071】 In the mold making process S2a, for example, the 3D data obtained in the measurement process S1 can be converted into mold processing data, and then the foamed resin or the like can be 3D cut using the mold processing data. However, in the mold making process S2a, the means are not particularly limited as long as a mold having the inverted shape of the uneven road surface to be reproduced can be made. For example, a mold having the inverted shape of the uneven road surface may be made using a 3D printer. 【0072】 In the mold making process S2a, the mold of the uneven road surface to be reproduced can be made by dividing it in the length direction and / or width direction. In this case, the length and / or width of the division may be the same as the size of the block divided in the measurement process S1, or it may be different. 【0073】 If the surface material forming process S2b and the surface roughening process S2b' are performed after the mold making process S2a, the surface material can be formed in the surface material forming process S2b by the same process as in the manufacture of a normal precast concrete slab, except that the mold obtained in the mold making process S2a is used. 【0074】 For example, in the surface material forming step S2b, the surface material can be formed by laying the mold obtained in the mold making step S2a inside a steel formwork, pouring concrete into the steel formwork, and curing it. In this case, the mold obtained in the mold making step S2a is laid inside the steel formwork so that the surface having an uneven, inverted shape faces upward. Furthermore, by arranging reinforcing bars in the steel formwork, the surface material can be obtained as reinforced concrete. In addition, the steel formwork may be configured to form injection holes in the surface material for injecting the grout material described later, and / or to allow the installation of connectors in the surface material for connecting divided surface material sections. 【0075】 In the surface material forming process S2b, the surface material for the uneven road surface to be reproduced can be manufactured by dividing it in the length and / or width directions. In this case, the length and / or width of the divisions may be the same as the size of the blocks divided in the measurement process S1 and / or the molds made by dividing them in the mold manufacturing process S2a, or they may be different in size. For example, multiple divided molds may be laid out in a formwork made of steel or the like to form a single surface material. The size of the divided surface material can be determined considering transportation to the construction site, etc. 【0076】 In the surface roughening process S2b', the surface of the precast concrete slab can be roughened by known surface roughening treatments such as cutting, aggregate-containing paint coating, and shot blasting, thereby forming a surface with fine irregularities. 【0077】 If the mold roughening process S2a' and the surface material molding process S2b are performed after the mold manufacturing process S2a, the surface roughening process can be performed on the surface of the mold that will form the surface of the surface material. The mold roughening process S2a' can be performed, for example, by constructing the surface of the mold that will form the surface of the surface material with a resin such as expanded polystyrene, and then cutting the surface of the resin such as expanded polystyrene using a machining center. 【0078】 Furthermore, when the mold roughening process S2a' is performed simultaneously with the mold fabrication process S2a, the surface can be made of a resin such as expanded polystyrene, and by adjusting the drill diameter of the machining center, the surface of the expanded polystyrene or other resin can be cut to remove uneven road-like irregularities as well as fine irregularities. 【0079】 Figure 7 shows a photograph of the polystyrene foam mold used to manufacture the precast concrete slab that forms the surface of the surface layer material. Figure 8 is a magnified photograph of Figure 7, showing the fine irregularities of the polystyrene foam mold that were cut by a machining center. 【0080】 Machining using a machining center can be controlled to create uneven, road-like irregularities on the die, as well as fine irregularities. The settings for the blade, conditions, etc., can be appropriately adjusted by a person skilled in the art. 【0081】 In the surface material forming process S2b, the surface material can be formed by the same process as in the manufacture of a normal precast concrete slab, except that the mold obtained in the mold roughening process S2a' is used. 【0082】 <Surface material installation process S3> In the present invention, after the surface material manufacturing step S2 described above, a surface material installation step S3 is performed in which the surface material is installed on the base layer. The surface material installation step S3 is not particularly limited as long as the surface material is installed in a manner that reproduces the existing uneven road surface. For example, the surface material installation step S3 may include a height adjustment step S3a, in which a height adjuster is installed between the base layer and the surface material to adjust the height; a backup material installation step S3b, in which backup material is installed at the outer positions in the width direction and length direction of the plane on which the surface material of the base layer is placed; a grout injection step S3c, in which grout material is injected between the base layer and the surface material; a grout hardening step S3d, in which the injected grout material is hardened; and a surface material connecting step S3e, in which each surface material is connected in the length direction. 【0083】 Figure 6 schematically shows one embodiment of the surface material installation process S3. In this embodiment, two surface materials 15 and 16 are installed adjacent to each other on the base layer 101, spaced apart in the width direction. Although not shown, the two surface materials 15 and 16 are installed adjacent to each other without spacing in the length direction. The two surface materials 15 and 16 can be installed so that the two tires of a vehicle pass over each of the surface materials 15 and 16. 【0084】 In the initial state, the heights of the surface materials 15 and 16 on top of the base layer 101 are not aligned. Therefore, in the height adjustment process S3a, the heights of the surface materials 15 and 16 on top of the base layer 101 are adjusted using height adjusters 31 and 32. Here, two height adjusters 31 and 32 are installed in the width direction between the base layer 101 and the two surface materials 15 and 16. However, the surface materials 15 and 16 can also be divided into multiple sections in the length direction, and multiple height adjusters 31 and 32 can also be installed in the length direction on a single surface material. In this height adjustment process S3a, the heights of the surface materials 15 and 16 are aligned. 【0085】 In the backup material installation step S3b, backup materials 41 and 42 are installed on the outer side of the surface materials 15 and 16 in the width direction on the base layer 101. Sponge-like porous resin material can be used as the backup materials 41 and 42. The backup materials 41 and 42 may be installed on the outer side of the surface materials 15 and 16 in both the width and length directions, or the sponge-like backup materials 41 and 42 may be pressed between the surface materials 15 and 16 and the base layer 101. The backup materials 41 and 42 do not need to surround each surface material 15 and 16 individually, and can surround multiple surface materials 15 and 16 together. 【0086】 In the grout injection process S3c, grout material 50a is injected between the base layer 101 and the surface layers 15 and 16. When injecting, backup materials 41 and 42 are not installed at the injection site, and can be installed after injection. Mortar can be used as the grout material. The injection site of the grout material 50a is not particularly limited and may be injected through grout injection holes provided at the ends of the surface layers 15 and 16, or it may be injected between the two surface layers 15 and 16. 【0087】 In this embodiment, the grout material 50a is injected between the two surface materials 15 and 16. However, a backup material may also be placed between the two surface materials 15 and 16 in the width direction and length direction, and the grout material 50a may be injected at other locations, for example, through the grout material injection holes described above. 【0088】 The presence of backup materials 41 and 42 allows the grout material 50a to have a relatively low viscosity, preventing it from flowing out between the base layer 101 and the surface layers 15 and 16. This enables the grout material 50a to be injected without any gaps between the base layer 101 and the surface layers 15 and 16. 【0089】 Furthermore, it is preferable that the height adjusters 31 and 32 are configured so that the height of the surface materials 15 and 16 can be finely adjusted even after the grout material 50a has hardened. The configuration of such height adjusters 31 and 32 is not particularly limited, but by using a jack type for the height adjusters 31 and 32 and filling the screw portion of the jack with grease, it is possible to easily adjust the height of the height adjusters 31 and 32 even after the grout material 50a has hardened. This makes it possible to correct the tilt even if the connected surface materials 15 and 16 are slightly tilted in the longitudinal direction. 【0090】 Finally, by hardening the injected grout material 50a in the grout material hardening process S3d, surface materials 15 and 16 fixed to the base layer 101 with hardened grout material 50b can be obtained, thereby reproducing an uneven road surface. In Figure 6, the backup materials 41 and 42 are not removed in the grout material hardening process S3d, but these may be removed in this grout material hardening process S3d. 【0091】 The surface material joining process S3e allows the surface materials 15 and 16 to be joined by the connecting devices 20. This process can be performed in any of the above processes, or it can be performed in the grout material hardening process S3d. Note that the connecting devices 20 for the surface materials 15 and 16 extend in the longitudinal direction and are therefore not shown in Figure 6. [Explanation of symbols] 【0092】 10, 11, 12, 15, 16... Precast concrete slab (surface material) 10a, 10b... receiving part 10c, 11c, 12c… recessed 20…Connector 21a, 21b, 22a, 22b...Fixed part 23…Connecting plate 30… Joint material 31, 32... Height adjuster 41, 42… Backup material 50a, 50b…Grout material 100...Connected structure 101...Base layer

Claims

[Claim 1] A precast concrete slab used as a surface material for a test course for uneven road surfaces, wherein the surface has an uneven surface and also has fine irregularities. [Claim 2] The precast concrete panel according to claim 1, wherein the aforementioned fine irregularities are formed by a surface roughening treatment. [Claim 3] The precast concrete slab according to claim 1, wherein the maximum height of the uneven road surface is 20 mm or more, and the average depth of the fine irregularities is 3 mm or less. [Claim 4] An uneven road surface comprising a base layer and a precast concrete slab for uneven road surfaces as described in claim 1. [Claim 5] A method for manufacturing a precast concrete slab according to claim 1, A measurement process for measuring the shape of an existing uneven road surface, and A surface material manufacturing process for manufacturing a precast concrete slab used for the surface material, based on the three-dimensional data obtained by the measurement process. A method for manufacturing precast concrete panels, including [the specified element]. [Claim 6] The above surface material manufacturing process is, A mold-making process for creating a mold to reproduce the shape of the existing uneven road surface, A mold roughening process, which involves performing a roughening treatment to transfer the fine irregularities onto the surface of the mold, and Surface material forming process: Forming a precast concrete slab to be used as the surface material using the roughened mold. A method for manufacturing a precast concrete panel according to claim 5, including the method described in claim 5. [Claim 7] The method for manufacturing a precast concrete slab according to claim 6, wherein the mold is made of expanded polystyrene, and the surface roughening treatment is performed by cutting the surface of the mold using a machining center.

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