Manufacturing method for PCa products using a top vibrator

Abstract

To provide a crown vibrator capable of compacting concrete, and simultaneously, smoothly leveling a crown so as to be finished, and a method for producing a PCa product using the same.SOLUTION: A method for producing a PCa product in which concrete is installed into a flask of the PCa product to smoothly finish a surface made into a crown has a process in which concrete is installed into the flask, thereafter, a crown vibrator obtained by connecting a smooth bottom plate longer than a short side length of the flask to a vibration device is stretched along a short side direction over the flask, and while vibrating the crown vibrator by the vibration device to compact the concrete, the smooth bottom plate of the crown vibrator is moved along a long side direction of the flask, so that the compacting of the concrete and the leveling of the surface are simultaneously performed.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a top end vibrator that can compact concrete while simultaneously smoothing and finishing the top end, and a manufacturing method for PCa products using the same. [Background technology]

[0002] PCa (precast) products such as PCa floor slabs are made by applying the necessary reinforcement to formwork in a factory, pouring concrete into it, compacting it with a vibrator, etc., and letting the concrete harden after a certain amount of time has passed to become a PCa product. In addition, after the concrete has hardened to a certain extent, the top surface of PCa products needs to be smoothed with a trowel before it hardens completely.

[0003] For example, Patent Document 1 discloses a method for manufacturing a PCa product, which comprises the steps of pouring a mixture of concrete raw materials containing hydraulic cement, color aggregate, pigment, and water onto a table vibrator that constitutes the bottom surface of a concrete pouring space, pouring and spreading the mixture onto the table of the table vibrator under the vibration and compacting action of the table vibrator, and forming a surface layer portion of a hardened concrete body having a specific gravity of 2.3 or more, stopping the table vibrator and allowing a predetermined drying and hardening time to elapse, further pouring lightweight concrete onto the surface layer portion to form a back layer portion of the hardened concrete body having a specific gravity of 2.1 or less as a back layer of the surface layer portion, and removing the concrete molded body having a multi-layer structure of the surface layer portion and back layer portion, and then performing a surface treatment on the exterior surface of the surface layer portion to expose a part of the color aggregate on the exterior surface (see claim 1 of Patent Document 1, paragraphs

[0020] to

[0035] of the specification, and Figures 1 to 4 of the drawings, etc.).

[0004] However, the PC panel manufacturing method described in Patent Document 1 is a PC panel manufacturing method for manufacturing PC panels with a highly decorative multi-layer structure, and if the surface of the top edge that does not come into contact with the formwork is to be finished smoothly rather than by sandblasting, it is still necessary to smooth it out with a trowel.

[0005] Furthermore, as a vibrator for compacting concrete, in addition to ordinary rod-shaped vibrators, Patent Document 2 discloses a method of compacting concrete by attaching a punching metal with many holes to an ordinary rod-shaped vibrator (see Figures 4 to 6 of the drawings in Patent Document 2, etc.).

[0006] However, although the vibrator described in Patent Document 2 can compact the concrete, it cannot smooth it out, so it was necessary for a skilled worker such as a plasterer to use a trowel to smooth out the surface of the top of the concrete while separately assessing the hardening state of the concrete.

[0007] In particular, when the concrete being poured is high-strength concrete, the aggregate does not sink, so it is necessary to press it down with a wooden trowel to sink the aggregate, and then to finish it again smooth with a metal trowel. This is not only time-consuming, but also requires that only experienced workers can complete the work. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] JP 2009-196333 A [Patent Document 2] Publication No. 4-54268 Summary of the Invention [Problem to be solved by the invention]

[0009] Therefore, the present invention has been devised in consideration of the above-mentioned problems, and its object is to provide a top end vibrator that can compact concrete while simultaneously smoothing and finishing the top end, and a manufacturing method for PCa products using the same. [Means for solving the problem]

[0010] The method for manufacturing a PCa product using the top end vibrator according to claim 1 is a method for manufacturing a PCa product in which concrete is poured into a formwork for a PCa product to finish the surface that will become the top end smoothly, At the same time, a general rod vibrator was used to compact the concrete. Then, a top vibrator with a smooth bottom plate longer than the short side length of the formwork and connected to a vibration device is hung above the formwork in the short side direction, and the top vibrator is vibrated by the vibration device to compact the concrete while the smooth bottom plate of the top vibrator is moved along the long side direction of the formwork, thereby simultaneously compacting the concrete and smoothing the surface that will become the top end.

[0011] The manufacturing method for a PCa product using the top end vibrator of claim 2 is characterized in that, in the manufacturing method for a PCa product using the top end vibrator of claim 1, after high-strength concrete is poured into the formwork, the top end vibrator is used to simultaneously compact the high-strength concrete and level the surface. Effect of the Invention

[0014] Claim 1~ 2 According to the invention, when manufacturing PCa products, the concrete can be compacted and the top surface can be finished smoothly. This eliminates the need for a skilled worker to be present during pouring of the concrete, determine the degree of hardening of the concrete, and smooth the top surface of the concrete with a trowel, which can resolve the worker shortage and reduce the manufacturing cost of PCa products.

[0015] In particular, according to the invention of claim 2, the problem of aggregates in high-strength concrete not sinking easily can be solved by applying vibrations evenly to the surface of the concrete, which not only makes it possible to compact it, but also allows the top surface to be finished at the same time. [Brief description of the drawings]

[0017] [Figure 1] FIG. 1 is a side view showing a top end vibrator according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a vertical cross-sectional view of a formwork for a PCa product showing the use of the top end vibrator. [Diagram 3] FIG. 3 is a process explanatory diagram showing the formwork assembly process of the manufacturing method for a PCa product using the top end vibrator according to this embodiment. [Figure 4] FIG. 4 is a process explanatory diagram showing the reinforcing bar arrangement process of the manufacturing method of the PCa product using the above-mentioned top end vibrator. [Diagram 5] FIG. 5 is a process explanatory diagram showing the concrete pouring process of the manufacturing method of the PCa product using the above-mentioned top end vibrator. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Hereinafter, one embodiment of a method for manufacturing a PCa product using a top end vibrator according to the present invention will be described in detail with reference to the drawings.

[0019] First, a top vibrator 1 according to an embodiment of the present invention will be described with reference to Figures 1 and 2. Figure 1 is a side view showing a top vibrator 1 according to an embodiment of the present invention, and Figure 2 is a vertical cross-sectional view of a formwork K for a PCa product showing a state in which the top vibrator 1 according to this embodiment is in use. In the figure, the X direction is the short side direction of the formwork K for the PCa product, and the Y direction is the long side direction. The Z direction is the up-down direction (same below).

[0020] As shown in Fig. 1, the top vibrator 1 according to this embodiment is a device consisting of a rod-shaped vibrator 2 and a square pipe 3 connected and fixed to the rod-shaped vibrator 2. The top vibrator 1 has the function of compacting the concrete C1 poured into the formwork K and smoothing the surface that will become the top end.

[0021] (Rod vibrator) This rod-shaped vibrator 2 is a commercially available handy electric rod-type vibrator without a flexible resin tube portion, as shown in Fig. 1. This rod-shaped vibrator 2 is composed of a vibrator body 21 having an electric motor 20 as a vibration device, a rod portion 22 attached to the tip of the vibrator body 21, a handle 23 attached to the rear end of the vibrator body 21, and the like.

[0022] This rod-shaped vibrator 2 has a vibration device that generates a vibration force by rotating an eccentric weight (not shown) provided in a vibration part 24 of a rod part 22 with an electric motor 20. Of course, the rod-shaped vibrator 2 is not limited to a handheld type, and may be any vibrator that has a vibration device that generates a vibration force, such as a high-frequency vibrator, and has a vibrating rod-shaped vibration part such as the rod part 22.

[0023] (Square tube) The square tube 3 according to this embodiment is an aluminum square tube with a longitudinal length H1 and a rectangular cross section perpendicular to the longitudinal direction, as shown in Fig. 1. As shown in Fig. 2, this square tube 3 is attached to the rod-shaped vibrator 2 so that the long side direction of the rectangular cross section is in the vertical direction Z perpendicular to the formwork K so that it is less likely to bend. In addition, the length H1 of this square tube 3 needs to be longer than the length H2 in the short side direction X of the formwork K for the PCa product, since it is used by being placed on the formwork K for the PCa product.

[0024] However, this square tube 3 is not limited to an aluminum square tube, and can be a metal strip such as a grooved frame or an L-shaped angle having a predetermined strength, such as an ordinary steel material. In other words, the member connected to the vibration device of the vibrator according to the present invention is a strip that can transmit the vibration of the vibrator to the concrete, and it is sufficient that it has a smooth bottom plate with a smooth bottom surface that can level the top surface of the concrete.

[0025] As shown in Figs. 1 and 2, the rod-shaped vibrator 2 and the square tube 3 are firmly connected and fixed by the rod portion 22 and the connecting fitting 4, and by the handle 23 and the cable tie 5, respectively, so that the vibration generated by the rod-shaped vibrator 2 is transmitted to the square tube 3.

[0026] In the above description, the top vibrator 1 is an aluminum square tube 3 connected to a commercially available rod-shaped vibrator 2. However, the top vibrator 1 is not limited to a commercially available vibrator, and may be a metal strip having a smooth bottom plate with a smooth bottom surface and longer than the length H2 of the short side direction X of the formwork K, which is directly connected to the vibration device that generates the excitation force.

[0027] Next, a method for manufacturing a PCa product using the top end vibrator 1 according to an embodiment of the present invention (hereinafter, simply referred to as a method for manufacturing a PCa product) will be described with reference to Figs. 2 to 5. A PCa floor slab will be taken as an example of the PCa product. Of course, the PCa product is not limited to a PCa floor slab, and the method can be applied to a PCa product that is manufactured by pouring and hardening concrete in a factory or the like beforehand, and then transported to the site.

[0028] (1. Formwork assembly process) As shown in Fig. 3, in the manufacturing method of the PCa product according to this embodiment, first, a form assembly process is performed to assemble a form K having a rectangular shape in plan view for the PCa floor slab. Fig. 3 is a process explanatory diagram showing the form assembly process of the manufacturing method of the PCa product using the top end vibrator according to this embodiment.

[0029] (2. Reinforcement process) As shown in Fig. 4, in the manufacturing method of the PCa product according to this embodiment, a reinforcing bar arrangement process is then carried out to arrange predetermined reinforcing bars S (deformed steel bars) in the formwork K assembled in the formwork assembly process. Fig. 4 is a process explanatory diagram showing the reinforcing bar arrangement process in the manufacturing method of the PCa product according to this embodiment.

[0030] (3. Concrete pouring process) As shown in Fig. 5, the method for manufacturing a PCa product according to this embodiment next includes a concrete pouring step of pouring concrete C1 into a formwork K in which a predetermined number of reinforcing bars S are arranged. Fig. 5 is a process explanatory diagram showing the concrete pouring step of the method for manufacturing a PCa product according to this embodiment.

[0031] In this process, high-strength concrete C1 is poured. According to the Japan Society of Civil Engineers' Standard Specifications for Concrete, high-strength concrete has a design strength of 50 to 100 N / mm 2 As mentioned in the background art, when the concrete to be placed is high-strength concrete, there is a problem that the aggregate does not sink easily. Of course, it goes without saying that normal-strength concrete can also be placed in this process.

[0032] In general, when pouring concrete, a handheld electric vibrator or a high-frequency vibrator such as the rod vibrator 2 is used to compact the concrete as it is being poured, causing the aggregate to sink. However, when pouring high-strength concrete, such a rod vibrator alone can only sink the aggregate in the immediate vicinity of the part where the rod vibrator was inserted. For this reason, when pouring high-strength concrete in the past, it was necessary to press down with a wooden trowel to sink the aggregate and remove the marks where the rod vibrator was inserted, and then finish it off smoothly with a metal trowel.

[0033] (4. Top edge finishing process) In the method for manufacturing a PCa product according to this embodiment, as in the conventional method, concrete is poured and compacted using a general rod-shaped vibrator such as the rod-shaped vibrator 2 described above. However, as shown in Fig. 2, in the method for manufacturing a PCa product according to this embodiment, next, a top vibrator 1 is used to compact the high-strength concrete poured into the formwork K, and a top finishing process is performed to smooth the surface that will become the top end.

[0034] In this process, the square pipe 3 of the top vibrator 1 is suspended over the formwork K along the short side direction X, and the square pipe 3 is vibrated by a vibrating device to compact the poured high-strength concrete C1 while moving the square pipe 3 along the long side direction Y of the formwork K. Since the square pipe 3 is made of aluminum, it is lightweight and easy to handle, reducing the physical burden on workers and allowing anyone to easily finish the surface.

[0035] Furthermore, as described above, the square tube 3 is a frame body with an effective cross section that is rectangular with no open ends, and is placed so that its long side direction is in the vertical direction Z perpendicular to the formwork K. For this reason, even though the square tube 3 is made of lightweight aluminum, it is less likely to bend, and the top edge of the PC deck can be finished smoothly without undulations or unevenness.

[0036] In this way, in this process, the surface of the poured high-strength concrete C1 is locally vibrated by the top vibrator 1 to sink the aggregate of the high-strength concrete C1, while being leveled by the flat bottom surface of the square pipe 3. This eliminates the need for a skilled worker to be present during the pouring of the concrete, determine the degree of hardening of the concrete, and smooth the top surface of the concrete with a trowel. This makes it possible to alleviate the labor shortage and reduce the manufacturing costs of PCa products.

[0037] It should be noted that after this process or its completion, it is acceptable to finish the top edge of the PC deck with a metal trowel or other trowel to make it flat again. This is because the top edge of the PC deck can be finished even more smoothly and neatly. However, even in this case, according to the manufacturing method of the PCa product according to this embodiment, unlike the conventional manufacturing method, the aggregate does not sink, so it is clear that the workload of pressing down with a wooden trowel to sink the aggregate and then finishing it off smoothly with a metal trowel is reduced.

[0038] According to the top end vibrator 1 and the manufacturing method of a PCa product using the top end vibrator 1 described above, when manufacturing a PCa product, even if the concrete is high strength concrete, the concrete can be compacted reliably and the surface that will become the top end can be finished smoothly. Therefore, it is no longer necessary for a skilled worker to be present at the pouring of the concrete, determine the hardening state of the concrete, and smooth the surface of the top end of the concrete with a trowel. Therefore, according to this manufacturing method of a PCa product, it is possible to solve the worker shortage and reduce the manufacturing cost of PCa products.

[0039] In addition, since the square tube 3 of the top vibrator 1 is made of aluminum, it is lightweight and easy to handle, reducing the physical burden on the worker and allowing anyone to easily finish the surface.

[0040] Although the manufacturing method of the PCa product using the top end vibrator according to the embodiment of the present invention has been described in detail above, the above-mentioned and illustrated embodiments are merely specific embodiments for carrying out the present invention. Therefore, the technical scope of the present invention should not be interpreted in a limited manner based on these.

[0041] In particular, although PCa slabs have been given as an example of a PCa product, the present invention is not limited to PCa slabs and can be applied to any PCa product in which concrete is poured and hardened in advance at a factory or the like, manufactured, and transported to the site. However, since the surface of the present invention can be easily finished, the present invention can be particularly effectively applied to plate-shaped PCa products with a wide top surface area, such as PCa slabs. [Explanation of symbols]

[0042] 1: Top vibrator 2: Rod-shaped vibrator 20: Electric motor (vibration device) 21: Vibrator body (vibration device) 22: Rod part 23: Handle 24: Vibration unit (vibration device) 3: Square tube (smooth bottom) H1: Length of the rectangular tube in the longitudinal direction 4: Connection fittings 5: Cable ties K: Formwork (for PCa products) H2: Length of the short side of the formwork S: Reinforced concrete C1: High-strength concrete (concrete)

Claims

1. A method for manufacturing a PCa product in which concrete is poured into a formwork for the PCa product to finish the top surface smoothly, After pouring concrete into the formwork and compacting it with a general rod-shaped vibrator, a top vibrator with a smooth bottom plate longer than the short side length of the formwork and connected to a vibration device is placed over the formwork along the short side direction, and the top vibrator is vibrated by the vibration device to compact the concrete while the smooth bottom plate of the top vibrator is moved along the long side direction of the formwork, thereby simultaneously compacting the concrete and smoothing the surface that will become the top end. A manufacturing method for PCa products using a top end vibrator characterized by the above.

2. After pouring high-strength concrete into the formwork, the top vibrator is used to simultaneously compact the high-strength concrete and level the surface. A method for manufacturing a PCa product using the top end vibrator according to claim 1.

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