Method for constructing concrete structure and concrete structure

Abstract

To provide a construction method for reinforced concrete structures with a high degree of freedom in productivity and shape.SOLUTION: A reinforcing member forming step of injecting material M from injection nozzles 201 of an additional manufacturing apparatus to form a reinforcing member 30, and a concrete deposited portion forming step in which concrete fluid 121 is injected from an injection nozzle 202 of the additional manufacturing apparatus and the concrete fluid comes into contact with the reinforcing member and to be deposited so as to form a concrete deposited portion 80, are alternately and a plurality of times performed to form a concrete structure.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a method for constructing a concrete structure and a concrete structure. [Background technology]

[0002] For example, when constructing a concrete structure such as a bridge pier, first, scaffolding is assembled. After that, reinforcing bars are assembled in the foundation, formwork is assembled so as to surround the reinforcing bars, and concrete is poured into the formwork. After the concrete has cured and hardened, the formwork is dismantled (for example, see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2011-214290 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, assembling and dismantling scaffolding when constructing a concrete structure is a cumbersome task, and is one of the factors that hinders the improvement of productivity in the construction method of concrete structures. In addition, conventional reinforcing members such as reinforcing bars are long, large, and strong, which may reduce the work efficiency during construction and the degree of freedom in the shape of the concrete structure.

[0005] The present invention has been made in consideration of the above circumstances, and provides a concrete structure construction method and a concrete structure which increase productivity and freedom in the shape of the concrete structure. [Means for solving the problem]

[0006] The method for constructing a concrete structure according to the present invention includes a reinforcing member forming step of forming a reinforcing member by injecting a reinforcing material from a first injection nozzle of an additive manufacturing device, and a concrete deposit forming step of injecting a concrete fluid from an injection nozzle of the additive manufacturing device and forming a concrete deposit in which the concrete fluid is in contact with the reinforcing member and accumulated, and the concrete deposit forming step is performed alternately and multiple times to form a concrete structure. The reinforcing member is formed of a plurality of elongated vertical portions protruding upward from the construction surface, and a plurality of horizontal portions arranged so as to connect adjacent vertical portions to each other.

[0007] According to the above-mentioned method for constructing a concrete structure, a reinforcing member is formed in the reinforcing member forming step, and as soon as the reinforcing member is stabilized by hardening or the like, a concrete deposit forming step is performed to form a concrete deposit in contact with the stabilized reinforcing member. By adjusting the injection amount and injection speed of the reinforcing material injected from the first injection nozzle and adjusting the number of times the reinforcing member forming step and the concrete deposit forming step are alternately performed until the concrete structure is completed, a concrete structure of any shape can be easily constructed. In addition, the length of the reinforcing material injected from the first injection nozzle and protruding from the construction surface or the hardened concrete fluid can be made shorter than that of conventional reinforcing bars, etc. This eliminates the need for binding tools for bundling multiple reinforcing bars, etc., or supports for supporting long reinforcing bars, etc., as in conventional construction using reinforcing bars, and improves work efficiency during construction.

[0008] In the concrete structure construction method of the present invention, the reinforcing member may have an elongated shape, and in the reinforcing member forming step, the reinforcing member may be formed so that the width thereof changes continuously along the axial direction of the reinforcing member.

[0009] According to the above-mentioned method for constructing a concrete structure, the axial width of the reinforcing member can be continuously changed to match the shape of the concrete structure. For example, the width of the reinforcing member can be increased at a position where the concrete structure needs to be most reinforced, and the width of the reinforcing member can be adjusted from that position to match the reinforcement level required at each position of the concrete structure.

[0010] In the concrete structure construction method of the present invention, the reinforcing member may have an elongated shape, and in the reinforcing member forming step, the reinforcing member may be formed so that its cross-sectional shape changes continuously along the axial direction of the reinforcing member.

[0011] According to the above-mentioned method for constructing a concrete structure, the cross-sectional shape of the reinforcing member in the axial direction can be continuously changed to match the shape of the concrete structure. The cross-sectional shape of the reinforcing member can be changed to match the degree of reinforcement, detailed shape, decoration, etc. required at each position of the concrete structure.

[0012] In the method for constructing a concrete structure according to the present invention, a diffusion angle of the concrete fluid injected from the injection nozzle may be larger than a diffusion angle of the reinforcing material injected from the first injection nozzle.

[0013] According to the above-mentioned method for constructing a concrete structure, the reinforcing material is injected from the first injection nozzle at a diffusion angle smaller than that of the concrete fluid and layered, and the concrete fluid is injected from the injection nozzle at a diffusion angle larger than that of the reinforcing material, thereby easily forming a concrete structure that is in contact with the reinforcing member and has any size and shape.

[0014] The method for constructing a concrete structure according to the present invention further includes a fixing member formation process in which a fixing material is injected from a second injection nozzle of an additive manufacturing device to form a fixing member, and in the concrete deposit formation process, the concrete fluid may be fixed to the fixing member while being layered in contact with the reinforcing member and the fixing member.

[0015] According to the above-mentioned method for constructing a concrete structure, the anchoring member is formed in the anchoring member forming step, and the concrete fluid can be layered while being fixed to the anchoring member in the concrete pile forming step. As a result, in the concrete pile forming step, the concrete fluid can be layered efficiently, and the concrete structure can be easily formed.

[0016] The concrete structure according to the present invention is formed by the above-mentioned concrete structure construction method. According to the above-described concrete structure, even if the reinforcing member has a shape that would be difficult to construct when using standard reinforcing bars or the like as reinforcing members as in the conventional method, it is possible to form a reinforcing member of a desired shape and a concrete structure equipped with this reinforcing member by adjusting the amount and injection speed of the reinforcing material injected from the first injection nozzle. Effect of the Invention

[0017] According to the present invention, it is possible to increase the productivity and the degree of freedom in the shape of a concrete structure. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a side view of a concrete structure according to a first embodiment of the present invention. [Diagram 2] 2 is a cross-sectional view of the concrete structure shown in FIG. 1, taken along line ZZ in FIG. 1. [Diagram 3] FIG. 2 is a side view for explaining a construction method for the concrete structure shown in FIG. [Figure 4] FIG. 2 is a side view for explaining a construction method for the concrete structure shown in FIG. [Diagram 5] FIG. 2 is a diagram of a concrete structure according to a second embodiment of the present invention, and is a cross-sectional view taken along line ZZ in FIG. [Figure 6] FIG. 6 is a side view for explaining a construction method for the concrete structure shown in FIG. 5. [Figure 7] FIG. 6 is a side view for explaining a construction method for the concrete structure shown in FIG. 5. [Figure 8] FIG. 6 is a side view for explaining a construction method for the concrete structure shown in FIG. 5. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of a concrete structure construction method and a concrete structure according to the present invention will be described with reference to the drawings.

[0020] (First embodiment) First, the configuration of a concrete structure 11 according to a first embodiment of the present invention and a method for constructing the concrete structure 11 will be described.

[0021] [Concrete structure composition] 1 and 2, the concrete structure 11 includes a concrete body 21 and a reinforcing member 30. The concrete structure 11 of the first embodiment is a columnar body used in civil engineering structures, buildings, etc. (not shown), and extends along a direction D1 that is approximately perpendicular to a construction surface P such as the ground or the surface of a foundation. The concrete structure 11 is formed in a substantially rectangular column shape.

[0022] The concrete body 21 is formed by layering and hardening a concrete flow material 121 sprayed from a spray nozzle 202 (see FIG. 4) of an additive manufacturing device. For example, a hydraulic mixture is used as the material of the concrete body 21. The material of the concrete body 21 and the concrete flow material 121 include various cement-based materials such as cement paste, mortar, and concrete, and geopolymer compositions.

[0023] The reinforcing member 30 is embedded inside the concrete body 21 and serves as a core material for the concrete body 21. In the first embodiment, the reinforcing member 30 includes a plurality of vertical portions 31 and a plurality of horizontal portions 32. The vertical portions 31 protrude upward from the construction surface P, extend along the D1 direction, and have an elongated shape with the D1 direction as the axial direction. The horizontal portions 32 extend along the D2 direction and the D3 direction that intersect with the D1 direction, and have an elongated shape with the D2 direction or the D3 direction as the axial direction.

[0024] When viewed in a plan view along the D1 direction, the multiple vertical portions 31 are arranged at predetermined intervals from one another so as to trace the contour of the concrete structure 11 inside the contour of the concrete structure 11. Hereinafter, the case of viewing along the D1 direction may be simply referred to as a "plan view," and the case of viewing from a direction intersecting the Z direction, such as from the D2 direction or D3 direction, may be simply referred to as a "side view."

[0025] Each of the horizontal portions 32 is formed to connect and support adjacent vertical portions 31, 31. Furthermore, the horizontal portions 32 are arranged at different positions in the D1 direction at predetermined intervals. That is, each of the horizontal portions 32 extends in a direction different from the vertical portions 31 and intersects with the vertical portions 31.

[0026] The material of the reinforcing member 30 includes a metal material such as iron, and further includes an adhesive that can be hardened under predetermined conditions as necessary. The metal material is not particularly limited as long as it is a main body capable of reinforcing the concrete body 21 of the concrete structure 11. It is preferable that the adhesive is capable of fluidizing the metal material while containing the metal material to an extent that the metal material can be ejected from the ejection nozzle and can be formed into a desired shape. The adhesive may be, for example, a thermoplastic binder, an adhesive that hardens when exposed to air for a certain period of time, or an ultraviolet-curing resin that hardens when exposed to ultraviolet light.

[0027] [Concrete structure construction method] The method for constructing a concrete structure according to the first embodiment is a method for constructing the above-mentioned concrete structure 11, and includes at least a reinforcing member forming step and a concrete deposit forming step.

[0028] First, in the first reinforcing member formation process, a reinforcing member 30 is formed on the construction surface P. As shown in Fig. 3, a material (reinforcing material) M of the reinforcing member 30 is injected along the D1 direction from an injection nozzle (first injection nozzle) 201 of an additive manufacturing device for forming the reinforcing member by a so-called layering method, and a plurality of vertical portions 31 are formed in a predetermined arrangement (see Figs. 1 and 2). As the additive manufacturing device and injection nozzle 201 for forming the reinforcing member, a so-called metal 3D printer and metal injection nozzle can be applied.

[0029] More specifically, material M is injected from injection nozzle 201 at predetermined intervals from each other in direction D2 or D3 (direction D2 in FIG. 3) and in accordance with the shape of concrete structure 11, and injection nozzle 201 is moved upward from construction surface P along direction D1 to stack material M in the direction D1. Material M stacked in the direction D1 becomes stable by hardening or the like when it meets predetermined conditions such as exposure to air for a certain period of time or more, and forms multiple vertical portions 31. Here, being stable means that it is in a state where it will not deform or break due to its own weight or gravity.

[0030] 3, vertical portions 31 arranged at intervals in the D2 and D3 directions are formed substantially simultaneously by injecting material M in parallel from multiple injection nozzles 201. Note that multiple vertical portions 31 may be formed sequentially by injecting material M from a single injection nozzle 201.

[0031] In FIG. 3, the material M is injected from each of the multiple injection nozzles 201 at a substantially constant injection amount and a substantially constant injection speed. Therefore, the width W31 of the vertical portion 31 in the D1 direction is substantially constant. The injection amount and injection speed of the material M injected from the injection nozzle 201 may be increased or decreased while the injection surface of the injection nozzle 201 is moved upward from the application surface P along the D1 direction. If the injection speed of the material M is substantially constant, the width W31 of the vertical portion 31 increases as the injection amount of the material M increases. If the injection amount of the material M decreases, the width W31 of the vertical portion 31 decreases. If the injection amount of the material M is substantially constant, the width W31 of the vertical portion 31 decreases as the injection speed of the material M increases. If the injection speed of the material M decreases, the width W31 of the vertical portion 31 increases.

[0032] Next, although not shown, material M is injected from the injection nozzle 201 of the additive manufacturing device for forming the reinforcing member along the D2 direction or the D3 direction, and adjacent vertical portions 31, 31 in the D2 direction or the D3 direction are laminated so as to connect them to form a plurality of horizontal portions 32. When the material M is injected along the D2 direction or the D3 direction, the injection amount and injection speed of the material M are set in consideration of the time t until the material M hardens and stabilizes to such an extent that it does not fall even when affected by gravity after being injected from the injection nozzle outlet. The shorter the time t, the wider the allowable interval between the vertical portions 31, 31 in the D2 direction or the D3 direction can be.

[0033] When material M is injected from each of the multiple injection nozzles 201, the cross-sectional shape of each of the vertical portions 31 and horizontal portions 32 can be changed by continuously changing the injection amount, injection speed, and injection outlet shape of the material M.

[0034] Next, taking into consideration the characteristics of material M and the conditions for stabilization, at least the multiple vertical portions 31 and horizontal portions 32 within the range of length H31 in the D1 direction are stabilized under predetermined conditions. For example, if material M is hardened and stabilized by being exposed to air for a certain period of time, the injection amount and injection speed of material M and the movement of injection nozzle 201 in the Z direction are adjusted according to time t. If material M is hardened and stabilized by being heated, hot air is applied to the side of material M injected from injection nozzle 201 as necessary.

[0035] Next, in a first concrete deposit forming step, as shown in Fig. 4, a concrete deposit 80 is formed in contact with the vertical portion (reinforcing member) 31 and the horizontal portion (reinforcing member) 32 (not shown). In the concrete deposit forming step, a concrete flow material 121 is sprayed from a spray nozzle 202 of an additive manufacturing device for spraying concrete toward the vertical portion 31 and the horizontal portion 32 by a so-called spraying method. The sprayed concrete flow material 121 fills the vertical portion 31 and the horizontal portion 32, and is deposited to a height approximately equal to the length H31 from the construction surface P, thereby forming the concrete deposit 80.

[0036] A known injection nozzle can be applied as the additive manufacturing device and injection nozzle 202 for injection of concrete, such as a spraying device used for reinforcing the inner walls of a tunnel. A spread angle θ2 formed with respect to the center of the traveling direction of the concrete fluid 121 injected from the injection nozzle 202 is larger than a spread angle θ1 formed with respect to the center of the traveling direction of the material M injected from the injection nozzle 201. A plurality of injection ports are formed in the injection nozzle 202 at intervals from each other. Each of the injection ports of the injection nozzle 202 is smaller than the injection port of the injection nozzle 201.

[0037] After the first concrete pile formation process or simultaneously with the first concrete pile formation process, a second reinforcing member formation process is performed. In the second reinforcing member formation process, as shown in Fig. 4, a material (reinforcing material) M is injected from an injection nozzle 201 along the D1 direction onto the upper end of each of the already stabilized vertical portions 31. In addition, the material M is injected from the injection nozzle 201 of the additive manufacturing device for forming the reinforcing member along the D2 direction or the D3 direction, and the vertical portions 31, 31 adjacent to each other in the D2 direction or the D3 direction are laminated so as to connect them to form a plurality of horizontal portions 32.

[0038] Next, in a second concrete deposit portion forming step, concrete fluid 121 is sprayed from spray nozzle 202 onto concrete deposit portion 80 formed in the first concrete deposit portion forming step, and toward vertical portion 31 and horizontal portion 32 formed in the second reinforcing member forming step. As a result, concrete deposit portion 80 in contact with vertical portion (reinforcing member) 31 and horizontal portion (reinforcing member) 32 (not shown) formed in the second reinforcing member forming step is deposited on top of concrete deposit portion 80 formed in the first concrete deposit portion forming step.

[0039] Thereafter, the above-mentioned reinforcing member forming process and the concrete deposit portion forming process are alternately performed K times (K is a natural number of 2 or more). "Alternately" means that the concrete deposit portion 80 contacting at least the plurality of stably formed vertical portions 31 and horizontal portions 32 of the material M injected from the injection nozzle 201 is formed stepwise over a plurality of times. One "reinforcing member forming process" means forming a plurality of vertical portions 31 and horizontal portions 32 (the horizontal portion 32 may not be included depending on the size of the range) within a predetermined range in the D1 direction, the D2 direction, and the D3 direction. Therefore, the case where the injection of the material M from the injection nozzle 201 is performed continuously without interruption, the concrete flow material 121 is injected from the injection nozzle 202 onto the plurality of vertical portions 31 and horizontal portions 32 of the injected material M that are stable within a predetermined range, and the concrete deposit portion 80 contacting the plurality of vertical portions 31 and horizontal portions 32 is intermittently formed along the moving direction of the injection nozzle 201 is also included in the case where the reinforcing member forming process and the concrete deposit portion forming process are performed alternately and multiple times. That is, as the kth (k is a natural number between 1 and K) reinforcing member forming step, after the (k-1)th concrete pile portion forming step or simultaneously with the (k-1)th concrete pile portion forming step, the material M is injected from the injection nozzle 201 to connect to the multiple vertical portions 31 and multiple horizontal portions 32 formed in the (k-1)th reinforcing member forming step, and laminated. In this way, the kth multiple vertical portions 31 and multiple horizontal portions 32 connected to the (k-1)th multiple vertical portions 31 and multiple horizontal portions 32 are formed.

[0040] Next, as the kth concrete deposit portion forming step, the concrete fluid 121 is sprayed from the spray nozzle 202 of the additive manufacturing device for spraying concrete toward the vertical portions 31 and horizontal portions 32 that have been stabilized after the kth reinforcing member forming step, and the concrete fluid 121 is deposited on the concrete deposit portion 80 formed in the (k-1)th concrete deposit portion forming step. This forms the kth concrete deposit portion 80 that is in contact with the kth multiple vertical portions 31 and multiple horizontal portions 32 and is integrated with the (k-1)th concrete deposit portion 80.

[0041] By alternately performing the reinforcing member forming process and the concrete deposit forming process K times, the multiple vertical portions 31 and horizontal portions 32 from the first to the Kth times form the reinforcing member 30, and the concrete deposit portions 80 from the first to the Kth times form the concrete main body 21, and the concrete structure 11 is completed.

[0042] The lengths of the vertical portion 31 and the horizontal portion 32 for the number of times K and the kth time are appropriately set in consideration of the shape of the concrete structure 11. For example, if a suitable length Hd of the vertical portion 31 in the D1 direction for each time is known in advance through a preliminary experiment or the like, a concrete structure 11 having a total length Ht in the D1 direction can be formed by alternately performing the reinforcing member forming step and the concrete deposit portion forming step approximately (Ht / Hd) times.

[0043] In addition, the length of each of the vertical portion 31 and the horizontal portion 32 for the kth time may be constant from the first time to the Kth time, or may not be constant. For example, when the material M is injected from the injection nozzle 201 in the D2 direction, the D3 direction, or an arbitrary direction intersecting the D1 direction and the horizontal direction, the material M is subjected to gravity in a direction that causes it to fall onto the application surface P, especially until it is stabilized. Therefore, when the material M is injected from the injection nozzle 201 in an arbitrary direction including a horizontal component, for example, as in the horizontal portion 32, the length of the material M injected and stabilized each time can be made shorter than when the material M is injected from the injection nozzle 201 only in the D1 direction, as in the vertical portion 31.

[0044] According to the concrete structure construction method of the first embodiment described above, the vertical portions 31 and horizontal portions 32 of the reinforcing member 30 are formed in the reinforcing member forming step, and once the vertical portions 31 and horizontal portions 32 have stabilized by hardening or the like, the concrete deposit portion forming step can form the concrete deposit portion 80 that contacts the vertical portions 31 and horizontal portions 32. According to the concrete structure construction method of the first embodiment, a concrete structure 11 of any shape can be easily constructed by adjusting the injection amount and injection speed of the material M injected from the injection nozzle 201, the number of times K the reinforcing member forming step and the concrete deposit portion forming step are performed, and the respective lengths of the vertical portions 31 and horizontal portions 32 for each step.

[0045] The length of each of the kth vertical portion 31 and horizontal portion 32 injected from the injection nozzle 201 and protruding in a predetermined direction from the construction surface P or the (k-1)th concrete pile 80 can be set freely and shorter than reinforcing members such as reinforcing bars used in conventional concrete structure construction methods. Therefore, the kth vertical portion 31 and horizontal portion 32 are more likely to stand on their own. This makes it unnecessary to use tying devices for bundling multiple reinforcing bars together or supports for supporting long reinforcing bars, as in conventional construction using reinforcing bars, and improves work efficiency during construction of the concrete structure 11.

[0046] Also, unlike in the case of the conventional construction of concrete structures, there is no need to assemble scaffolding in advance or to dismantle the scaffolding after the completion of the concrete structure 11, thereby improving the productivity of the concrete structure 11. Furthermore, by connecting the additive manufacturing device or the injection nozzle 201 and the jet nozzle 202 to a robot device or an automatic traveling device to enable automatic operation, it becomes possible to construct the concrete structure 11 at night when workers are resting, or in places or environments where it is difficult for workers to work, thereby further improving the productivity of the concrete structure 11. Therefore, according to the method of constructing a concrete structure of the first embodiment, it is possible to increase the productivity of the concrete structure 11 and the degree of freedom in the shape thereof.

[0047] In addition, in the reinforcing member forming step of the concrete structure construction method of the first embodiment, the width of the vertical portion (reinforcing member) 31 in the D1 direction (axial direction) where the reinforcing member 30 is formed and the width of the horizontal portion (reinforcing member) 32 in the D2 direction or D3 direction (axial direction) can be continuously changed along the axial direction. According to the concrete structure construction method of the first embodiment, the width of the vertical portion 31 and the horizontal portion 32 of the reinforcing member 30 can be continuously changed according to the shape of the concrete structure 11, for example, the width of the reinforcing member 30 can be increased at a position in the concrete structure 11 where the degree of reinforcement is considered to be the highest, and the width of the reinforcing member 30 can be decreased from that position toward the periphery. That is, the width of the reinforcing member 30 can be adjusted according to the degree of reinforcement required at each position of the concrete structure 11.

[0048] Furthermore, in the reinforcing member forming step of the concrete structure construction method of the first embodiment, the cross-sectional shape of the vertical portion 31 in the D1 direction and the cross-sectional shape of the horizontal portion 32 in the D2 or D3 direction can be continuously changed along the axial direction. According to the concrete structure construction method of the first embodiment, the cross-sectional shape of the reinforcing member 30 can be easily and freely changed in the axial direction in accordance with the degree of reinforcement, detailed shape, decoration, etc. required at each position of the concrete structure 11.

[0049] Furthermore, in the method for constructing a concrete structure of the first embodiment, the diffusion angle θ2 of the concrete flow 121 injected from the injection nozzle 202 is smaller than the diffusion angle θ1 of the material M injected from the injection nozzle 201. According to the method for constructing a concrete structure of the first embodiment, the material M can be injected from the injection nozzle 201 at a diffusion angle narrower than that of the concrete flow 121 and layered in a predetermined direction. By injecting the concrete flow 121 from the injection nozzle 202 at a diffusion angle wider than the width of the material M, a concrete pile 80 that is in contact with the vertical portion 31 and the horizontal portion 32 and has any size can be smoothly formed.

[0050] The concrete structure 11 of the first embodiment includes a concrete body 21 and a reinforcing member 30 embedded in the concrete body 21, and is formed by the above-mentioned method for constructing a concrete structure. According to the above-mentioned method for constructing a concrete structure 11, even if the reinforcing member 30 has a shape that is difficult to construct when a fixed and long reinforcing bar or the like is used as a reinforcing member as in the past, the reinforcing member 30 can be formed in a desired shape while adjusting the injection amount and injection speed of the material M from the injection nozzle 201. According to the above-mentioned method for constructing a concrete structure 11, a concrete pile portion 80 in a desired shape can be formed while adjusting the injection amount, injection speed, injection angle, etc. of the concrete flow material 121 from the injection nozzle 202. Therefore, according to the concrete structure 11 of the first embodiment, the productivity during construction and the degree of freedom in shape can be increased.

[0051] Second embodiment Next, the configuration of a concrete structure and a method for constructing a concrete structure according to a second embodiment of the present invention will be described. Note that in the following description of the configuration of the concrete structure and the method for constructing a concrete structure of the second embodiment, only the contents different from the configuration of the concrete structure 11 and the method for constructing a concrete structure of the first embodiment will be described, and the contents overlapping with the configuration of the concrete structure 11 and the method for constructing a concrete structure of the first embodiment will be omitted. Also, in the concrete structure of the second embodiment below, the same reference numerals will be used for the components common to the configuration of the concrete structure 11 of the first embodiment.

[0052] [Concrete structure composition] As shown in Fig. 5, a concrete structure 12 according to a second embodiment of the present invention includes an anchoring member 40 in addition to a concrete body 21 and a reinforcing member 30. The concrete structure 12 is a columnar body used in civil engineering structures, buildings, etc. (not shown), and extends along a direction D1 that is approximately perpendicular to a construction surface P. The concrete structure 12 is formed in a substantially rectangular column shape.

[0053] The fixing member 40 is disposed at a position different from at least the reinforcing member 30, and in the second embodiment, is disposed within an area surrounded by the reinforcing member 30 in a plan view. The fixing member 40 extends in a straight line along the D2 direction as shown in Fig. 5, and, although not shown, extends upward from the construction surface P along the D1 direction in the same manner as the vertical portion 31.

[0054] The fixing member 40 is a member that fixes the concrete fluid 121 sprayed from the spray nozzle 202 of the additive manufacturing device for spraying concrete to itself. "Fixing to itself" means that at least a part of the concrete fluid 121 sprayed from the spray nozzle 202 toward the fixing member 40 first adheres to the surface or the like of the fixing member 40, and the concrete fluid 121 sprayed from the spray nozzle 202 can be subsequently layered on the concrete fluid 121 that has adhered to the surface or the like.

[0055] The fixing member 40 is formed by injecting the fixing material Q from the injection nozzle (second injection nozzle) 203 (see FIG. 6) described later so as to draw a desired shape, and stabilizing by hardening, etc. The desired shape may be, for example, a two-dimensional net-like shape formed in a plane including the D1 direction and the D2 direction, a three-dimensional net-like shape in which the two-dimensional net-like shape spreads in the D3 direction, a two-dimensional or three-dimensional lattice shape, or the like. It is preferable that a plurality of holes are formed in the fixing member 40. The area of ​​the hole is smaller than the area of ​​the gap surrounded by the vertical parts 31, 31 adjacent to each other in the D2 direction or the D3 direction and the horizontal parts 32, 32 adjacent to each other in the D1 direction. When the hole is formed, as described above, the early stage concrete flow material 121 injected from the injection nozzle 202 passes through the hole, and the area of ​​the hole is gradually reduced by the adhesion of the concrete flow material 121 to the surface of the fixing member 40, and the intermediate stage or later concrete flow material 121 injected from the injection nozzle 202 is efficiently fixed to the outer periphery of the hole. The shape of the fixing member 40 is not particularly limited as long as it is a shape that can fix the concrete fluid 121 sprayed from the spray nozzle 202 to the fixing member 40 itself.

[0056] The material (anchoring material) Q of the anchoring member 40 may be the same as the material M of the reinforcing member 30. When the material Q is the same as the material M, the anchoring member 40 also functions as a reinforcing member for the concrete structure 12. The material Q includes, for example, a base material such as coarse aggregate, resin, or gypsum capable of exhibiting an anchoring force for the concrete flow material 121, and an adhesive material that can be hardened under predetermined conditions as necessary. The adhesive material is not particularly limited as long as it can flow the base material to an extent that it can be ejected from the ejection nozzle 203 while containing the base material, and can form a desired shape. The adhesive material may be, for example, a thermoplastic binder, a material that hardens by drying when exposed to air for a certain period of time or more, or an ultraviolet-curing resin that hardens by irradiation with ultraviolet light.

[0057] [Concrete structure construction method] The method for constructing a concrete structure of the second embodiment is a method for constructing the above-mentioned concrete structure 12, and includes at least a reinforcing member formation step and a concrete deposit formation step similar to the method for constructing a concrete structure of the first embodiment, as well as an anchoring member formation step.

[0058] The anchoring member forming process is performed multiple times alternately with the concrete deposit portion forming process, or before the concrete deposit portion forming process. In the second embodiment, the anchoring member forming process is performed multiple times alternately with the concrete deposit portion forming process, substantially simultaneously with the reinforcing member forming process. In the second embodiment, taking into consideration that the anchoring member 40 is formed within an area surrounded by the reinforcing member 30 in a plan view, the anchoring member forming process is performed slightly prior to the reinforcing member forming process in the D1 direction in order to ensure ease of movement of the injection nozzle 203.

[0059] As shown in FIG. 6, in the first fixing member formation process, material Q is injected from an injection nozzle 203 of an additive manufacturing device for injecting a fixing material in a so-called layered manner, and material Q is stabilized to form a fixing member 40. For example, the fixing member 40 is formed by connecting an arbitrary number of minute polyhedrons (regular tetrahedrons in FIG. 6) in each of the directions D1, D2, and D3 within the installation area of ​​the fixing member 40. The injection nozzle 203 can inject and stabilize material Q while moving so as to trace all sides of the aforementioned polyhedron. The stabilized material Q constitutes the fixing member 40. In the fixing member 40 having such a shape, holes are formed in the parts corresponding to the respective faces of the aforementioned polyhedron.

[0060] 7, when the material Q has been stacked to a certain length (height) in the D1 direction, a first reinforcing member formation process is performed in the same manner as in the concrete structure construction method of the first embodiment, to form a plurality of vertical portions 31 each having an approximate length H31 in the D1 direction. Although not shown, the material M may be injected from an injection nozzle of an additive manufacturing device for forming reinforcing members along the D2 or D3 direction to appropriately form a plurality of horizontal portions 32.

[0061] Next, as shown in FIG. 8, a first concrete deposit forming step is performed in the same manner as in the construction method of the concrete structure of the first embodiment. In the concrete deposit forming step of the second embodiment, a concrete flow material 121 is sprayed from a spray nozzle 202 of an additive manufacturing device for spraying concrete toward the fixing member 40 (i.e., the stable material Q). The concrete flow material 121 sprayed from the spray nozzle 202 passes through the aforementioned hole of the fixing member 40 and is gradually layered on the portion corresponding to the edge of the polyhedron. The area of ​​the hole is gradually reduced by the layering of the concrete flow material 121, and the concrete flow material 121 sprayed from the spray nozzle 202 is efficiently layered on the outer periphery of the hole and is fixed to the fixing member 40 as a whole. As a result, a concrete deposit 80 is formed in contact with at least the lower end of the fixing member 40.

[0062] Furthermore, the concrete flow material 121 is sprayed from the spray nozzle 202 toward the anchoring member 40, filling in the vertical portions 31 and horizontal portions 32 formed in the first reinforcing member forming step, and is piled up to a height approximately equal to the length H31 from the construction surface P, forming the concrete pileup portion 80. That is, in the first concrete pileup portion forming step of the second embodiment, the concrete flow material 121 sprayed from the spray nozzle 202 is fixed to the anchoring member 40, and is layered so as to contact the vertical portions 31 and horizontal portions 32 (i.e., the reinforcing member 30) and the anchoring member 40.

[0063] Next, the above-mentioned anchoring member forming step and reinforcing member forming step and the concrete pile portion forming step are alternately performed K times. That is, as the kth anchoring member forming step and reinforcing member forming step, after the (k-1)th concrete pile portion forming step or simultaneously with the (k-1)th concrete pile portion forming step, the material Q is injected from the injection nozzle 203 in a connected state to the stable material Q formed in the (k-1)th anchoring member forming step, and the anchoring member 40 is extended in the D1 direction. Also, the material M is injected from the injection nozzle 201 in a connected state to the vertical portion 31 and the multiple horizontal portions 32 formed in the (k-1)th reinforcing member forming step, and stacked.

[0064] Next, as the kth concrete deposit portion forming step, the concrete fluid 121 is sprayed from the spray nozzle 202 of the additive manufacturing device for spraying concrete toward the anchoring member 40 formed in the kth anchoring member forming step by extending in the D1 direction, and the concrete fluid 121 is deposited on the concrete deposit portion 80 formed in the (k-1)th concrete deposit portion forming step. This forms the kth concrete deposit portion 80 that is fixed to the anchoring member 40 formed in the kth anchoring member forming step, contacts the kth vertical portions 31 and the kth horizontal portions 32, and is integral with the (k-1)th concrete deposit portion 80.

[0065] By alternately performing the anchoring member formation process, the reinforcing member formation process, and the concrete deposit formation process K times, the formation range of the stable material Q is extended and the anchoring member 40 is formed, and similarly to the construction method of the concrete structure of the first embodiment, the reinforcing member 30 and the concrete main body 21 are formed, and the concrete structure 12 is completed.

[0066] According to the concrete structure 12 and the method for constructing a concrete structure of the second embodiment described above, by having a configuration similar to that of the concrete structure 11 and the method for constructing a concrete structure of the first embodiment, it is possible to obtain the same effects as those of the concrete structure 11 and the method for constructing a concrete structure of the first embodiment.

[0067] Moreover, the method for constructing a concrete structure according to the second embodiment includes, in addition to each step of the method for constructing a concrete structure according to the first embodiment, an anchoring member forming step of forming an anchoring member 40 by injecting a material Q from an injection nozzle 203 of an additive manufacturing apparatus for injecting an anchoring member. In the method for constructing a concrete structure according to the second embodiment, in the concrete pile-up portion forming step, the concrete flow material 121 injected from the injection nozzle 202 is fixed to the anchoring member 40 and layered so as to contact the vertical portion 31 and the horizontal portion 32. According to the method for constructing a concrete structure according to the second embodiment, in the concrete pile-up portion forming step, the concrete flow material 121 is fixed to the anchoring member 40 and layered efficiently, so that the concrete structure 12 can be easily formed.

[0068] Although the embodiment of the present invention has been described in detail above, the present invention is not limited to the specific embodiment. Various modifications of the present invention are possible within the scope of the gist of the present invention described in the claims.

[0069] For example, the shape of the concrete structure according to the present invention is not limited to a quadrangular prism (corner prism) like the concrete structures 11 and 12, but may be a triangular prism, a hexagonal prism, or a cylinder, or may be a complex shape having a complex curved surface or any non-flat surface that can be formed by additive manufacturing technology. Furthermore, the concrete structure according to the present invention is not limited to a columnar body, but may be, for example, a beam or a wall member, and broadly includes structures that can be formed from concrete.

[0070] The shape of the reinforcing member for the concrete structure according to the present invention is not limited to a shape consisting of only the vertical portion 31 and the horizontal portion 32. In order to improve the self-supporting property of the reinforcing member 30, the reinforcing member 30 may have an inclined portion 33 shown by a two-dot chain line in FIG. 1 in addition to the vertical portion 31 and the horizontal portion 32. The inclined portion 33 has an elongated shape whose axial direction is an inclination direction that overlaps with the D2 direction when viewed from the D3 direction and intersects with the D1 direction when viewed from the side. The inclined portion 33 diagonally crosses a gap surrounded by the vertical portions 31, 31 adjacent to each other in the D2 direction or the D3 direction and the horizontal portions 32, 32 adjacent to each other in the D1 direction in a side view, and connects the intersection positions of the vertical portions 31 and the horizontal portions 32 diagonally across the gap. In addition, the reinforcing member may be formed in a net shape so as to trace all the sides of an arbitrary number of minute polyhedrons connected in each of the D1 direction, D2 direction, and D3 direction, as described with respect to the anchoring member. The reinforcing member may have a truss shape or truss structure composed of an assembly of triangles as basic units, for example. By having the reinforcing member have a truss shape, the load is effectively distributed in the direction of the surface including the basic unit triangle, improving the shape retention ability of the concrete structure.

[0071] Although not shown, for example, in the reinforcing member formation step, material M may be injected from injection nozzle 201 along an oblique direction (direction) intersecting the vertical and horizontal directions to enhance the self-supporting property of the reinforcing member. Furthermore, the reinforcing member may have any shape as long as it can be formed from material M injected from injection nozzle 201 in a layered manner, and may, for example, have a curved shape or may be formed in a spiral shape. The concrete structure according to the present invention may include a concrete body 21 and a reinforcing member 30 embedded in concrete body 21 and extending in a straight or curved shape in an oblique direction.

[0072] If the surface of the hardened concrete fluid 121 after being sprayed from the spray nozzle 202 becomes rougher than required for the concrete structure, a finishing spray nozzle having multiple spray holes smaller than the spray hole of the spray nozzle 202 may be used to finely spray new concrete fluid onto the outer surface of the concrete fluid 121, following the area where the concrete fluid 121 has been sprayed.

[0073] In each of the above-mentioned embodiments, the nozzles of the additive manufacturing device for injecting the reinforcing material, the additive manufacturing device for spraying the concrete fluid, and the additive manufacturing device for injecting the fixing material are different nozzles. However, as long as the injection of the materials M and Q and the spraying of the concrete fluid 121 can be performed as described in each of the reinforcing member forming process, the concrete deposit forming process, and the fixing member forming process, the same nozzle may be used to form the reinforcing member 30, the concrete deposit 80, and the fixing member 40. For example, as the same nozzle, a nozzle in which the ejection ports of the materials M and Q are formed at approximately the center of the ejection surface of the nozzle as viewed from the traveling direction of the ejection from the nozzle, and the ejection ports of the concrete fluid having a smaller diameter than the ejection ports are formed around the ejection port on the ejection surface is considered.

[0074] The material of the reinforcing member of the concrete structure according to the present invention is not limited to various metal materials, and may be continuous fiber or fiber reinforced plastic (FRP), etc. The material of the reinforcing member is not particularly limited as long as it satisfies suitable conditions such as a predetermined strength and an adhesive property to the concrete flow material 121.

[0075] Furthermore, each of the above-mentioned injection nozzles 201, 203 and the injection nozzle 202 is not limited to being attached to a robot arm or an automatic traveling device of a robot device, but may also be attached to, for example, a portal crane, a backhoe, or an attachment of various construction machines. [Explanation of symbols]

[0076] 11, 12 Concrete structures 30 Reinforcement member 40 Fixing member 80 Concrete pile 201 Injection nozzle (first injection nozzle) 202 Injection nozzle 203 Injection nozzle (second injection nozzle) 121 Concrete Fluid D1, D2, D3 direction (axial direction) M material (reinforcement material) Q material (fixing material)

Claims

1. a reinforcing member forming step of injecting a reinforcing material from a first injection nozzle of an additive manufacturing device to form a reinforcing member; a concrete deposit forming step of spraying a concrete fluid from a spray nozzle of an additive manufacturing apparatus, and forming a concrete deposit in which the concrete fluid is in contact with the reinforcing member; and repeating the steps alternately multiple times to form a concrete structure. The reinforcing member is formed in a net shape so as to trace all edges of an arbitrary number of minute polyhedrons connected in each direction in three dimensions. Methods for constructing concrete structures.

2. A diffusion angle of the concrete fluid injected from the injection nozzle is greater than a diffusion angle of the reinforcing material injected from the first injection nozzle. A method for constructing a concrete structure according to claim 1.

3. Further, a fixing member forming step is provided in which a fixing material is ejected from a second ejection nozzle of the additive manufacturing device to form a fixing member; In the concrete deposit portion forming step, the concrete fluid is deposited in contact with the reinforcing member and the anchoring member while being anchored to the anchoring member. A method for constructing a concrete structure according to claim 1 or 2.

4. A concrete structure formed by the method for constructing a concrete structure according to any one of claims 1 to 3, Concrete structure.

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