Construction method and earthen floor structure

Abstract

To provide a construction method for an earthen floor with which cracks are unlikely to occur and work period can be reduced, and an earthen floor structure.SOLUTION: A floor structure 20 includes a hydraulic composition layer 23 containing a structure having a predetermined height as earthen floor part 30 and a ground layer that supports the hydraulic composition layer 23 from below. The ground layer is composed of a roadbed foundation 21 and a waterproof layer 22. The hydraulic composition layer 23 has a puffed part 29 integrally formed with the earthen floor part 30 between the lowest level 30L of the earthen floor part 30 and the upper surface 22a of the waterproof layer 22, which is the highest level of the ground layer.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a construction method for constructing an earthen floor structure, and to an earthen floor structure. [Background technology]

[0002] In factories and other facilities, structures formed by pouring concrete as a hydraulic composition have traditionally served as earthen floors. Patent Document 1, for example, discloses a method for constructing such earthen floors by installing formwork capable of integrally forming foundation beams and the earthen floor, and then pouring concrete into the formwork. This formwork is composed of a formwork for the foundation beams and a formwork for the earthen floor. The formwork for the foundation beams is installed on basal concrete and is composed of an outer formwork plate and an inner formwork plate whose top surface is lower than that of the outer formwork plate. The formwork for the earthen floor is made of reinforcing fiber strands and is arranged in an area inside the inner formwork plate. The formwork for the earthen floor is laminated on a polyethylene film that covers crushed stone laid on the ground from above. The top surface of the formwork for the earthen floor is located at the same level as the top surface of the inner formwork. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-69895 Summary of the Invention [Problem to be solved by the invention]

[0004] In addition to the method described in Patent Document 1, other known construction methods for earthen floors installed on the ground include pouring concrete on top of basin concrete poured on the ground. However, these construction methods reduce the thickness of the earthen floor that can be counted in the structural strength, making it prone to cracking. Furthermore, because the basin concrete and the floor are poured in separate processes, this lengthens the construction period. [Means for solving the problem]

[0005] The construction method that solves the above problem is a construction method for constructing an earthen floor structure including a structure of a predetermined height as an earthen floor portion by pouring a hydraulic composition in a fluid state, and includes a base layer installation step of installing a base layer that supports the poured hydraulic composition in a fluid state from below, and a pouring step of pouring the hydraulic composition in a fluid state up to the highest level of the structure so that a raised portion is formed between the lowest level of the structure and the highest level of the base layer.

[0006] The floor structure that solves the above problem comprises a hydraulic composition layer including a structure of a predetermined height as an earthen floor portion, and a base layer that supports the hydraulic composition layer from below, and the hydraulic composition layer has a raised portion formed integrally with the structure between the lowest level of the structure and the highest level of the base layer.

[0007] As described above, by providing a raised portion integrally formed with the structure between the structure and the base layer, the structural strength can be improved and the strength of the hydraulic composition layer can be increased. As a result, cracks are less likely to occur in the structure, i.e., the earthen floor. In addition, since there is no need to pour basal concrete, the construction period can be shortened.

[0008] The construction method having the above configuration preferably includes, between the base layer installation step and the casting step, a wire mesh installation step of installing a wire mesh in the portion where the floor will be formed, and a reinforcing bar installation step of installing reinforcing bars in the portion where the floor will be formed, the floor section 30. This increases the strength of the structure and the floor, further increasing the strength of the hydraulic composition layer. As a result, cracks in the floor section become even less likely to occur.

[0009] In the construction method having the above configuration, it is preferable that in the wire mesh installation process, the wire mesh is supported on the base layer via a mesh spacer, and in the reinforcement process, the reinforcing bars are supported on the base layer via a reinforcing bar spacer.

[0010] As a result, before the hydraulic composition is poured, the wire mesh and reinforcing bars are supported on the base layer via separate spacers, so that even if workers work on top of the reinforcing bars, the reinforcing bars can be prevented from shifting out of position.

[0011] In the construction method of the above configuration, it is preferable that the reinforcing bars include a first reinforcing bar and a second reinforcing bar located above the first reinforcing bar, and the reinforcement process includes a first reinforcement process of supporting the first reinforcing bar on the base layer via a spacer for the first reinforcing bar, and a second reinforcement process of supporting the second reinforcing bar on the base layer via a spacer for the second reinforcing bar.

[0012] This further increases the strength of the hydraulic composition layer. Furthermore, because the first reinforcing bar and the second reinforcing bar are supported on the base layer via separate spacers before the hydraulic composition is poured, it is possible to prevent the second reinforcing bar from shifting out of position even if a worker works on top of the second reinforcing bar when pouring the hydraulic composition.

[0013] In the construction method having the above configuration, the base layer may be installed in an area sandwiched between a plurality of beams installed on the ground in the base layer installation step, and the hydraulic composition may be poured up to above the top level of the plurality of beams in the pouring step. This allows all of the portions of the hydraulic composition layer formed in the space sandwiched between the plurality of beams to be used as raised portions.

[0014] In the earthen floor structure having the above-mentioned configuration, the structural body and the raised portion are integrally formed into a structural floor member, which increases the thickness of the hydraulic composition layer and provides structural integrity, thereby improving strength.

[0015] In the earthen floor structure having the above-mentioned configuration, the base layer preferably has a waterproof layer located directly below the hydraulic composition layer, which prevents water from penetrating from the ground into the hydraulic composition layer, thereby ensuring the structural strength of the hydraulic composition of a predetermined composition and blend.

[0016] In the earthen floor structure having the above-described configuration, it is preferable that the hydraulic composition layer has a wire mesh in the portion where the raised portion is formed, and has a first reinforcing bar and a second reinforcing bar located above the first reinforcing bar in the portion where the earthen floor portion is formed.

[0017] According to the above configuration, the hydraulic composition layer has a structure having the first reinforcing bars and the second reinforcing bars, and a raised portion reinforced with wire mesh, which together form a structural floor member, thereby further improving the strength. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 1 is a cross-sectional view showing a schematic configuration of one embodiment of an earthen floor structure. [Figure 2] 1 is a flowchart showing an embodiment of a construction method. [Figure 3] (a) Cross-sectional view showing the state after the wire mesh installation process is completed, (b) oblique view showing the general configuration of the reinforcing bar with spacers, (c) cross-sectional view showing the state after the first reinforcement process is completed, (d) cross-sectional view showing the state after the second reinforcement process is completed. DETAILED DESCRIPTION OF THE INVENTION

[0019] An embodiment of an earthen floor structure and its construction method will be described with reference to Figures 1 to 3. In the following, one direction on a horizontal plane is referred to as the vertical direction, and a direction perpendicular to the vertical direction is referred to as the horizontal direction. Also, a direction perpendicular to the horizontal plane is referred to as the up-down direction.

[0020] As shown in Figure 1, the earth floor structure 20 is applied to the lowest floor of a building. The earth floor structure 20 is supported by a plurality of foundation beams 12 installed on the ground 11. The plurality of foundation beams 12 are installed at positions according to the formation range of the earth floor structure 20. The earth floor structure 20 includes a roadbed substructure 21 and a waterproof layer 22 that constitute the base layer, and a hydraulic composition layer 23 that is supported from below by the base layer. The earth floor structure 20 includes a wire mesh 25, a first reinforcing bar 26, and a second reinforcing bar 27 inside the hydraulic composition layer 23.

[0021] The roadbed substructure 21 is layered on the ground 11 in an area sandwiched between the plurality of foundation beams 12. The roadbed substructure 21 is made of a material harder than the ground 11, such as crushed stone. The waterproof layer 22 is laminated on the roadbed base 21. An upper surface 22a of the waterproof layer 22 is the highest level of the base layer. The waterproof layer 22 prevents water from penetrating from the ground 11 into the hydraulic composition layer 23. The waterproof layer 22 is composed of one waterproof sheet or multiple waterproof sheets. An example of a waterproof sheet is made of polyethylene. The waterproof layer 22 preferably has moisture permeability. This allows excess moisture in the hydraulic composition layer 23 to be absorbed by the ground 11 while preventing water from penetrating from the ground 11 into the hydraulic composition layer 23.

[0022] The hydraulic composition layer 23 is laminated on the waterproof layer 22. The hydraulic composition layer 23 is formed by hardening a hydraulic composition that has been cast with a wire mesh 25, a first reinforcing bar 26, and a second reinforcing bar 27 arranged therein. The hydraulic composition is a fluid obtained by kneading at least hydraulic powder with water, and is, for example, concrete obtained by kneading water with a cement mixture in which cement, which is hydraulic powder, is mixed with aggregate such as gravel or sand.

[0023] The hydraulic composition layer 23 has an integrally formed eave section 29 and an earthen floor section 30. The eave section 29 and the earthen floor section 30 together form a structural floor member. The eave section 29 is the section where the wire mesh 25 is arranged and is a eave section for the earthen floor section 30. The earthen floor section 30 is the section where the first reinforcing bars 26 and the second reinforcing bars 27 are arranged. The earthen floor section 30 is a structure whose thickness, amount of reinforcement, etc. are designed based on a strength calculation performed in advance. The lowest level 30L of the earthen floor section 30 is located between the wire mesh 25 and the first reinforcing bars 26 in the vertical direction. In this embodiment, the lowest level 30L is the same level as the top level of the foundation beams 12.

[0024] The wire mesh 25 is a lattice-like member formed by connecting vertical wires 31, which are metal rod-shaped members extending vertically, and horizontal wires 32, which are metal rod-shaped members extending horizontally. Before the hydraulic composition is poured, the wire mesh 25 is supported on the waterproof layer 22 via mesh spacers 33. While supported on the waterproof layer 22 via the mesh spacers 33, the wire mesh 25 has a strength that allows workers to move over the wire mesh 25.

[0025] The first reinforcing bars 26 are located above the wire mesh 25. The first reinforcing bars 26 are lattice-shaped members in which first vertical reinforcing bars 36 extending vertically and first horizontal reinforcing bars 37 extending horizontally are connected. The first horizontal reinforcing bars 37 are disposed below the first vertical reinforcing bars 36. The first horizontal reinforcing bars 37 are the lower end reinforcing bars installed in the portion where the hydraulic composition layer 23 is formed. The first vertical reinforcing bars 36 and the first horizontal reinforcing bars 37 are, for example, deformed reinforcing bars.

[0026] Before the hydraulic composition is poured, the first reinforcing bars 26 are supported on the waterproof layer 22 via the first reinforcing bar spacers 38. The first reinforcing bars 26 have sufficient strength to allow workers to move over the first reinforcing bars 26 while being supported on the waterproof layer 22 via the first reinforcing bar spacers 38.

[0027] The second reinforcing bars 27 are located above the first reinforcing bars 26. The second reinforcing bars 27 are lattice-shaped members in which second vertical reinforcing bars 41 extending vertically and second horizontal reinforcing bars 42 extending horizontally are connected. The second horizontal reinforcing bars 42 are disposed above the second vertical reinforcing bars 41. The second horizontal reinforcing bars 42 are the upper end reinforcing bars installed in the portion where the hydraulic composition layer 23 is formed. The second vertical reinforcing bars 41 and the second horizontal reinforcing bars 42 are, for example, deformed reinforcing bars.

[0028] Before the hydraulic composition is poured, the second reinforcing bars 27 are supported on the waterproof layer 22 via the second reinforcing bar spacers 43. The second reinforcing bars 27 have sufficient strength to allow workers to move on the second reinforcing bars 27 while being supported on the waterproof layer 22 via the second reinforcing bar spacers 43.

[0029] 2 and 3, a construction method for the earth floor structure will be described. The construction method for the earth floor structure 20 includes a ground compaction step (step S101), a subgrade base formation step (step S102), a waterproof layer formation step (step S103), a wire mesh installation step (step S104), a first reinforcement step (step S105), a second reinforcement step (step S106), and a concrete pouring step (step S107). Foundation beams 12 are installed on the ground 11 according to the construction range of the earth floor structure 20. Each foundation beam 12 is installed so that its top level is located on the same horizontal plane.

[0030] In the ground compaction process (step S101), a compaction machine is used to compact the ground 11 in the area sandwiched between the foundation beams 12. This eliminates voids from the surface layer of the ground 11 in the area where the earth floor structure 20 is formed and corrects unevenness in the ground 11.

[0031] In the roadbed base forming step (step S102), crushed stones are laid in the area sandwiched between the foundation beams 12, and then the crushed stones are compacted to form the roadbed base 21. In the waterproof layer forming process (step S103), a waterproof sheet is laid on the roadbed substructure 21 to form the waterproof layer 22. Specifically, if the waterproof layer 22 is made up of a single waterproof sheet, the waterproof sheet is laid on the roadbed substructure 21. If the waterproof layer 22 is made up of multiple waterproof sheets, the multiple waterproof sheets are laid on the roadbed substructure 21 without any gaps. The roadbed substructure forming process (step S102) and the waterproof layer forming process (step S103) constitute a substructure layer installation process in which a substructure layer is installed.

[0032] As shown in FIG. 3(a), in the wire mesh installation step (step S104), a wire mesh 25 is installed above the waterproof layer 22. In this embodiment, the wire mesh 25 is placed on the waterproof layer 22, and then a mesh spacer 33 is sandwiched between the waterproof layer 22 and the wire mesh 25, thereby installing the wire mesh 25 above the waterproof layer 22. If the mesh spacer 33 is made of metal, the mesh spacer 33 may be joined to the wire mesh 25.

[0033] In the first reinforcement arrangement process (step S105) and the second reinforcement arrangement process (step S106), a reinforcing bar with spacers 50 having the structure shown in FIG. 3(b) is used. The reinforcing bar with spacers 50 is composed of a reinforcing bar spacer 51 and a reinforcing bar 52. The reinforcing bar with spacers 50 is a component in which a U-shaped reinforcing bar spacer 51 is joined to the reinforcing bar 52 at a predetermined interval. The reinforcing bar 52 is joined to the apex of the reinforcing bar spacer 51. The reinforcing bar with spacers 50 is a component in which the height position of the reinforcing bar 52 can be adjusted.

[0034] As shown in FIG. 3(c), in the first reinforcement arrangement step (step S105), first reinforcing bars 26 are installed above the wire mesh 25. Specifically, first reinforcing bar spacers 38, each having reinforcing bars 52 to be placed between them, are arranged side by side on the foundation beams 12, and then first horizontal reinforcing bars 37 are arranged so as to be supported by the reinforcing bars 52. Directly above the foundation beams 12, the first horizontal reinforcing bars 37 are arranged on a mortar spacer (not shown) placed on the foundation beams 12. Then, first vertical reinforcing bars 36 are arranged so as to be supported by the first horizontal reinforcing bars 37. Then, the reinforcing bars 52, first vertical reinforcing bars 36, and first horizontal reinforcing bars 37 are connected using a connector such as a wire. As a result, the first reinforcing bars 26, supported by the waterproof layer 22 via the first reinforcing bar spacers 38, are installed above the wire mesh 25. Since the first horizontal bar 37 located on the lower side is connected to the reinforcing bar 52 of the first reinforcing bar spacer 38, the installation work of the first reinforcing bar 26 is made easier and the height of the first reinforcing bar spacer 38 can be reduced.

[0035] As shown in FIG. 3(d), in the second reinforcement arrangement step (step S106), second reinforcing bars 27 are installed above the wire mesh 25. Specifically, spacer-equipped reinforcing bars, each having a plurality of second reinforcing bar spacers 43 joined to second vertical reinforcing bars 41, are arranged side by side. Second horizontal reinforcing bars 42 are then arranged on top of the arranged second vertical reinforcing bars 41, and the second vertical reinforcing bars 41 and the second horizontal reinforcing bars 42 are then connected using a connector such as a wire. As a result, the second reinforcing bars 27, which are supported by the waterproof layer 22 via the second reinforcing bar spacers 43, are installed above the first reinforcing bars 26. Since the second reinforcing bar spacers 43 are joined to the second vertical reinforcing bars 41 located below, the installation of the second reinforcing bars 27 is facilitated and the height of the second reinforcing bar spacers 43 can be reduced.

[0036] In the casting step (step S107), the hydraulic composition in a fluid state is cast and hardened to form the hydraulic composition layer 23. Specifically, the hydraulic composition is cast to a predetermined height (the highest level of the earthen floor portion 30) so that the wire mesh 25 and the reinforcing bars 26, 27 are embedded, and the cast hydraulic composition is vibrated. Then, the surface of the cast hydraulic composition is leveled, and the hydraulic composition is cured and hardened. As a result, the hydraulic composition layer 23 in which the wire mesh 25, the first reinforcing bars 26, and the second reinforcing bars 27 are embedded is formed, as shown in FIG. 1.

[0037] (action) In the earthen floor structure 20, the hydraulic composition layer 23 has an earthen floor portion 30, as well as a raised portion 29 between the earthen floor portion 30 and the waterproof layer 22. The earthen floor portion 30 and the raised portion 29 are formed by hardening hydraulic compositions poured at the same time, and are integrated together. The raised portion 29 is formed in the space surrounded by the foundation beams 12. The thickness of the entire hydraulic composition layer 23 increases by the amount of the raised portion 29.

[0038] The effects of this embodiment will be described. (1) In the earthen floor structure 20, the thickness of the entire hydraulic composition layer 23 is increased by the raised portion 29 integrated with the earthen floor portion 30. This increases the strength of the hydraulic composition layer 23, making the earthen floor portion 30 less likely to crack.

[0039] (2) In the earthen floor structure 20, the hydraulic composition layer 23 having the earthen floor portion 30 and the raised portion 29 is formed in a single casting process. As a result, the construction period can be shortened compared to, for example, the case where basal concrete is formed in the casting portion of the hydraulic composition layer 23.

[0040] (3) Since the lowest level 30L of the earthen floor portion 30 is the same level as the top level of the foundation beams 12, all of the portions of the hydraulic composition layer 23 in the space sandwiched between the foundation beams 12 can be used as the raised portion 29. This can further increase the strength of the hydraulic composition layer 23.

[0041] (4) The embedded wire mesh 25 can increase the strength of the raised portion 29. This can further increase the strength of the hydraulic composition layer 23. (5) The first reinforcing bars 26 and the second reinforcing bars 27 are embedded in the earth floor portion 30, thereby increasing the strength of the earth floor portion 30. This further increases the strength of the hydraulic composition layer 23.

[0042] (6) In the earthen floor structure 20, the wire mesh 25, the first reinforcing bar 26, and the second reinforcing bar 27 are supported on the waterproof layer 22 by separate spacers. This prevents the reinforcing bars 26 and 27 from shifting out of position even if a worker works on the first reinforcing bar 26 or the second reinforcing bar 27.

[0043] This embodiment can be modified as follows: This embodiment and the following modifications can be combined and implemented within the scope of technical compatibility. The first reinforcing bar 26 may be supported by the wire mesh 25 via a spacer.

[0044] The second reinforcing bars 27 may be supported by the first reinforcing bars 26 or the wire mesh 25 via a spacer. Reinforcing bars do not have to be buried in the earth floor. Also, if reinforcing bars are buried in the earth floor floor portion 30, only the first reinforcing bar 26 may be buried, or three or more reinforcing bars at different levels may be buried.

[0045] The wire mesh 25 does not have to be embedded in the raised portion 29. Also, a plurality of wire meshes may be embedded in the raised portion 29 at different levels. The lowest level 30L of the earth floor portion 30 may be lower than the top level of the foundation beams 12 or may be higher than the top level of the foundation beams 12.

[0046] The hydraulic composition is not limited to concrete, as long as it is a fluid mixture of hydraulic powder and water. For example, the hydraulic composition may be a mortar such as Slimcrete (registered trademark), or may be a mixture of fibers (fiber-reinforced concrete material). [Explanation of symbols]

[0047] 11...ground, 12...foundation beam, 20...floor structure, 21...subgrade base that constitutes the base layer, 22...waterproof layer that constitutes the base layer, 22a...top surface as the highest level, 23...hydraulic composition layer, 25...wire mesh, 26...first reinforcing bar, 27...second reinforcing bar, 29...floor section, 30...floor section as structure, 30L...lowest level, 31...vertical wire, 32...horizontal wire, 33...mesh spacer, 36...first vertical bar, 37...first horizontal bar, 38...spacer for first reinforcing bar, 41...second vertical bar, 42...second horizontal bar, 43...spacer for second reinforcing bar, 50...reinforcing bar with spacer, 51...spacer for reinforcing bar, 52...reinforcing bar.

Claims

1. A construction method for constructing an earthen floor structure including a structure of a predetermined height as an earthen floor by pouring a hydraulic composition in a fluid state, a base layer installation step of installing a base layer that supports the poured hydraulic composition from below; and a pouring step of pouring a fluid hydraulic composition up to the highest level of the structure so that a raised portion is formed between the lowest level of the structure and the highest level of the base layer, Between the base layer installation step and the casting step, a wire mesh installation step of installing a wire mesh in the portion where the raised portion is formed; and a reinforcing bar arrangement process for installing reinforcing bars in the portion where the earth floor section is to be formed. In the wire mesh installation step, the wire mesh is supported on the base layer via a mesh spacer, In the reinforcing bar arrangement step, the reinforcing bar is supported on the base layer via a reinforcing bar spacer. Construction method.

2. A construction method for constructing an earthen floor structure including a structure of a predetermined height as an earthen floor by pouring a hydraulic composition in a fluid state, a base layer installation step of installing a base layer that supports the poured hydraulic composition from below; and a pouring step of pouring a fluid hydraulic composition up to the highest level of the structure so that a raised portion is formed between the lowest level of the structure and the highest level of the base layer, Between the base layer installation step and the casting step, a wire mesh installation step of installing a wire mesh in the portion where the raised portion is formed; and a reinforcing bar arrangement process for installing reinforcing bars in the portion where the earth floor section is to be formed. The reinforcing bars include a first reinforcing bar and a second reinforcing bar located above the first reinforcing bar, The reinforcement step includes: a first reinforcing bar arrangement step of supporting the first reinforcing bar on the base layer via a first reinforcing bar spacer; and a second reinforcing bar arrangement step of supporting the second reinforcing bar on the base layer via a second reinforcing bar spacer. Construction method.

3. In the base layer installation step, the base layer is installed in an area sandwiched between a plurality of beams installed on the ground, In the casting step, the hydraulic composition is cast up to above the top end level of the plurality of beams. The construction method according to claim 1 or 2.

4. a hydraulic composition layer including a structure of a predetermined height as an earthen floor; a base layer that supports the hydraulic composition layer from below, The hydraulic composition layer is a raised portion integrally formed with the structure between the lowest level of the structure and the highest level of the base layer; A wire mesh is installed in the portion where the raised portion is formed and supported on the base layer via a mesh spacer; and a reinforcing bar installed in the portion where the earthen floor is to be formed and supported on the base layer via a reinforcing bar spacer. Earthen floor structure.

5. a hydraulic composition layer including a structure of a predetermined height as an earthen floor; a base layer that supports the hydraulic composition layer from below, The hydraulic composition layer is a raised portion integrally formed with the structure between the lowest level of the structure and the highest level of the base layer; A wire mesh installed in the portion where the raised portion is formed; and a reinforcing bar installed in the portion forming the earthen floor portion, The reinforcing bar is a first reinforcing bar supported on the base layer via a first reinforcing bar spacer; a second reinforcing bar supported on the base layer via a second reinforcing bar spacer, the second reinforcing bar being positioned above the first reinforcing bar. Earthen floor structure.

6. The base layer is installed in an area sandwiched between a plurality of beams installed on the ground, The hydraulic composition layer is provided above the top end level of the plurality of beams. The earthen floor structure according to claim 4 or 5.

7. The structure and the raised portion integrally form a structural floor member. The earthen floor structure according to any one of claims 4 to 6.

8. The base layer has a waterproof layer located directly below the hydraulic composition layer. The earthen floor structure according to any one of claims 4 to 7.

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