Slab construction method

Abstract

To provide a construction method for a slab for efficiently forming the slab in a free shape, and the slab.SOLUTION: Layers made of mortar discharged from a nozzle while the nozzle is moved are stacked to form a stacked piece member. The piece member is arranged on a skeleton wall part 11 in a tilted state with a stacking direction Dv1 of the piece member horizontal so as to constitute at least a part of a lower member 21 included in a slab 20.SELECTED DRAWING: Figure 3

Description

Technical Field

[0006] , ,

[0001] This disclosure relates to the construction method of slabs that make up floors, roofs, etc. In the law It relates to.

Background Art

[0002] In buildings, floors and roofs may be formed by slabs having a substantially flat plate shape (see, for example, Patent Document 1). This slab is configured by laying a deck plate on beams connected on a plurality of columns and then placing concrete on the deck plate.

[0003] In recent years, structures using three-dimensional (3D) printers have been constructed. In this 3D printer, a structure having a three-dimensional shape is formed by moving a nozzle while discharging a material from the nozzle to form a layer and gradually stacking the formed layers (see, for example, Non-Patent Document 1). In Non-Patent Document 1, a bench is formed with a 3D printer.

Prior Art Documents

Patent Documents

[0007] The slab construction method that solves the above problem is a lower plate member And, a high-strength concrete member with higher tensile strength than mortar A method for constructing a slab, comprising: forming a laminated member by stacking layers formed from the mortar discharged from the nozzle while moving the nozzle; and arranging the laminated member on the structure in a tilted state so that the stacking direction of the laminated member is horizontal, thereby forming at least a part of the lower plate member. Then, by using the lower plate member as a formwork on the bottom surface and pouring high-strength concrete onto the lower plate member, the high-strength concrete member and the lower plate member are integrated and formed. [Effects of the Invention]

[0009] According to the present invention, slabs of any shape can be efficiently formed. [Brief explanation of the drawing]

[0010] [Figure 1] This is a perspective view of the house in the embodiment. [Figure 2] This is a cross-sectional view of the house in the embodiment. [Figure 3] This is a cross-sectional view of the slab of a house in an embodiment. [Figure 4] This is a cross-sectional view of a house, including a bottom view of the slab in an embodiment. [Figure 5] This is a perspective view of the piece members constituting the slab in the embodiment. [Figure 6] This is a top view of the piece members that constitute the slab in the embodiment. [Figure 7] This is a front view of a piece member constituting a slab in the embodiment. [Figure 8] This is a schematic diagram illustrating the shape of the slab's protruding portion in the embodiment. [Figure 9]It is an explanatory diagram of the structure of the formation support system in the embodiment. [Figure 10] It is an explanatory diagram of the hardware configuration in the embodiment. [Figure 11] It is a flowchart of the processing procedure of the discharge path generation process in the embodiment. [Figure 12] It is an explanatory diagram during the formation of the piece member in the embodiment. [Figure 13] It is an explanatory diagram during the formation of the piece member in the embodiment. [Figure 14] It is an explanatory diagram during the formation of the piece member in the embodiment. [Figure 15] It is a flowchart of the processing procedure of the construction method of the slab in the embodiment. [Figure 16] It is a perspective view of the piece member constituting the slab in the modification example. [Figure 17] It is a cross-sectional view of the building body excluding the slab in the modification example. [Figure 18] It is a cross-sectional view in which the slab is arranged on the building body in the modification example.

Mode for Carrying Out the Invention

[0011] Hereinafter, with reference to FIGS. 1 to 15, a construction method of a slab will be described. [[ID=三十六]] Law A specific embodiment will be described. In this embodiment, a house equipped with a slab is constructed as a building. Here, the slab functions as a roof slab on the first floor and a floor slab on the rooftop.

[0012] FIGS. 1 and 2 are a perspective view and a front cross-sectional view of the house 10 in this embodiment. FIG. 3 is an enlarged cross-sectional view of a part of the slab 20 in FIG. 2, and FIG. 4 is a cross-sectional view of the house 10 at a height where the bottom surface of the slab 20 can be seen. As shown in Figure 1, the house 10 of this embodiment is a single-story building with a rooftop that has a roughly cylindrical overall shape with a spindle-shaped plane. The house 10 comprises a structural wall 11, a rooftop side wall 13, a slab 20, a staircase 16, a staircase side wall 17, and a boundary side wall 18. The staircase 16 is the part that constitutes the stairs for ascending from the ground to the upper surface of the slab 20, and is formed along the structural wall 11. The staircase side wall 17 forms the side wall of the staircase 16 on the side opposite to the structural wall 11. The boundary side wall 18 is installed on the upper surface of the slab 20 at the boundary between the staircase 16 and the slab 20.

[0013] As shown in Figure 2, the structural wall 11 is constructed using multiple wall members 11a, 11b, 11c, and 11d to form a roughly triangular opening 10d. The opening 10d forms an entrance to the interior space on the first floor of the house 10.

[0014] Each wall member 11a to 11d is formed in a roughly arc shape and is constructed by layering mortar extruded from a moving nozzle using a three-dimensional (3D) printer, as described later. The wall members 11a to 11d surround the interior space of the first floor and, when stacked, constitute the structural wall 11. Reinforcing bars 12 are embedded in the wall members 11a to 11d at multiple spaced positions where they abut in the vertical direction. In addition, insulation material (not shown) is provided on the inside (interior space side) of each wall member 11a to 11d.

[0015] A protruding portion 10a is formed at the upper end of the wall member 11d that constitutes the uppermost part of the structural wall 11. This protruding portion 10a is a part that projects upward on the outer circumference of the upper end of the wall member 11d. Furthermore, the end of the slab 20 is positioned inside the protruding portion 10a at the upper end of the wall member 11d. The rooftop side wall section 13 is positioned above the protruding portion 10a of the wall member 11d by being stacked on top of it.

[0016] As shown in Figure 3, the slab 20 comprises a lower member 21, a high-strength concrete member 22, a heat insulating member 24, and a coating portion 25. The lower member 21 is a lower plate member made of mortar (concrete) that functions like a deck plate. Details of this lower member 21 will be described later. The high-strength concrete member 22 is a member with higher strength than the lower member 21 and is made of a cement-based material mixed with fibers (fiber-reinforced concrete material), such as Slimcrete®.

[0017] The thermal insulation member 24 is a member made of a material having thermal insulation properties, such as rigid polyurethane foam. The coated portion 25 is the part that has a protective film for waterproofing. The coated portion 25 is formed, for example, by applying a paint made of urethane rubber material or acrylic urethane material.

[0018] (Lower member 21) The lower member 21 of the slab 20 has linear protrusions R1 and R2 that project from the underside. These protrusions R1 and R2 are positioned along the stress lines using a topology optimization method. Here, topology optimization is a methodology for determining the optimal shape and form of a structure based on mathematical and mechanical principles. By using this topology optimization, the slab 20 can be made lighter without reducing its load-bearing capacity by thinning the parts other than those along the stress lines (parts that have little effect on load support).

[0019] As shown in Figure 4, the lower member 21 is constructed by connecting multiple piece members 211, 212, 213, 214, 215, 216, ..., 21n, which serve as laminated forming members, in an arranged state. In this case, each piece member 211 to 21n is formed to a height (for example, within 60 cm) to which mortar can be laminated in the 3D printer 40 described later. Here, the height to which mortar can be laminated is a height at which the bottom layer does not collapse significantly (beyond the allowable range) under its own weight even when the top layer is formed. Furthermore, in this embodiment, each piece member 211 to 21n is formed to a weight (for example, several hundred kilograms or less) that is easy to transport.

[0020] Figure 5 is a perspective view of the piece member 215 in Figure 4. Figures 6 and 7 are the top view and front view of the piece member 215. As shown in Figure 5, the piece member 215 has a shape in which protruding portions R1, R2, and R3 project toward the first direction D1 relative to the overall plate-like portion P1. Protruding portion R1 is a projection provided in a position that extends horizontally when the piece members 215 are stacked to form the piece member 215. This protruding portion R1 has a vertical portion R1v that projects relative to the plate-like portion P1, and inclined portions R1s formed above and below this vertical portion R1v. The inclined portions R1s are inclined at, for example, 40 degrees or 60 degrees.

[0021] Figure 8 is a schematic longitudinal cross-section illustrating the structure of the protruding section R1. Because the protruding section R1 projects toward the first direction (projection direction) D1, the discharge position of the mortar to be layered is gradually shifted toward the first direction D1, forming the inclined section R1s. Then, after the vertical section R1v is formed by stacking the mortar vertically at a position shifted toward the first direction D1 from the plate-like section P1, the inclined section R1s is formed by layering the mortar at a position gradually shifted toward the opposite side of the first direction D1. This prevents the layered mortar from descending under its own weight before hardening.

[0022] As shown in Figure 5, the protruding portion R2 is a projection that extends linearly in a substantially vertical direction from the bottom layer when the piece members 215 are stacked to form the piece member. This protruding portion R2 protrudes at a substantially right angle (90 degrees) to the plate-like portion P1. In this embodiment, the protruding portion R2 of the piece member 215 is slightly inclined as it goes upwards. In this case, similar to the protruding portion R1, it is formed in a shape that gradually inclines in the direction of inclination and in the opposite direction (horizontal direction) so that it does not descend under its own weight before the mortar hardens.

[0023] The protruding portion R3 is a curved projection that extends diagonally when the piece member 215 is formed by extruding mortar from a nozzle and layering it using a 3D printer 40. It has a vertical portion R3v and inclined portions R3s located above and below it. The inclined portions R3s of this protruding portion R3 have a shape in which the slope widens as the direction of extension approaches horizontal. This prevents the layered mortar from sinking due to its own weight before hardening, similar to the protruding portion R1.

[0024] As shown in Figures 6 and 8, the overall shape of the piece member 215 described above is constructed by arranging the first side portion 26 and the second side portion 27 of the same width so that they abut against each other. Here, the first side portion 26 is located on the side from which the protruding portions R1 to R3 protrude. The first side portion 26 and the second side portion 27 are constructed by stacking each layer of a series of closed shapes (drawn in a single stroke).

[0025] <Configuration of 3D printer 40 and creation support server 60> Next, using Figures 9 and 10, we will describe the 3D printer 40 and creation support server 60 that form the aforementioned wall members 11a to 11d and piece members 211 to 21n.

[0026] (Example hardware configuration) Figure 10 shows an example of the hardware configuration of the information processing device H10, which functions as a control device 50 for the 3D printer 40 and a creation support server 60, etc.

[0027] The information processing device H10 includes a communication device H11, an input device H12, a display device H13, a storage device H14, and a processor H15. Note that this hardware configuration is an example, and other hardware may be included.

[0028] Communication device H11 is an interface that establishes a communication path with other devices and performs data transmission and reception, such as a network interface or a wireless interface.

[0029] The input device H12 is a device that receives input from users such as designers, and is such as a mouse or keyboard. The display device H13 is a display or touch panel that displays various information.

[0030] The storage device H14 is a storage unit (for example, the ejection path storage unit 62 described later) that stores data and various programs for executing various functions of the control device 50 and the creation support server 60. Examples of storage devices H14 include ROM, RAM, and hard disks.

[0031] The processor H15 uses programs and data stored in the memory device H14 to control various processes in the user terminal (not shown), the control device 50, and the creation support server 60 (for example, the processes in the control units 51 and 61 described later). An example of the processor H15 is a CPU or MPU. This processor H15 loads programs stored in ROM or the like into RAM and executes various processes corresponding to various operations. For example, when the application programs of the control device 50 and the creation support server 60 are started, the processor H15 operates the processes that execute the various operations described later.

[0032] The processor H15 is not limited to performing all of its operations through software processing. For example, the processor H15 may include dedicated hardware circuits (e.g., application-specific integrated circuits: ASICs) that perform hardware processing for at least some of the operations it performs. In other words, the processor H15 may be configured as follows:

[0033] • One or more processors that operate according to a computer program (software), • One or more dedicated hardware circuits that perform at least some of the various processes, • Circuits that include combinations of those elements.

[0034] A processor includes a CPU and memory such as RAM and ROM, where memory stores program code or instructions configured to cause the CPU to perform processing. Memory, or computer-readable media, includes any available media that can be accessed by a general-purpose or dedicated computer.

[0035] (Functions of 3D printer 40 and creation support server 60) The 3D printer 40 of this embodiment, shown in Figure 9, includes a nozzle 41 as an extrusion unit, a robot arm 45, and a control device 50.

[0036] The nozzle 41 has an open discharge port 41a at its tip. In this embodiment, the discharge port 41a faces downward. The end of the nozzle 41 opposite the discharge port 41a is connected to the end of a hose 42. The hose 42 is connected to a pressure pump (not shown). Due to the pressure from this pressure pump, the mortar supplied to the nozzle 41 via the hose 42 is discharged downward from the discharge port 41a.

[0037] A robot arm 45 is attached to the nozzle 41 via a mounting portion 44. The nozzle 41 is supported by the robot arm 45 and moves horizontally and vertically according to the movement of the robot arm 45. The movement of the robot arm 45 is controlled by instructions from the control unit 51 of the control device 50. In this embodiment, the control unit 51 controls the robot arm 45 so that the direction of mortar discharge from the nozzle 41 is always downward, even when it is moving.

[0038] The control device 50 includes a control unit 51 that performs the member formation process. Therefore, by executing the member formation program stored in the memory unit, the control unit 51 functions as a stacking management unit 511, a movement control unit 512, and a discharge amount control unit 513.

[0039] The lamination management unit 511 performs processing to manage the path and height of the mortar to be laminated in order to form the wall members 11a to 11d and piece members 211 to 21n. The lamination management unit 511 counts the number of layers L1 stacked in the lamination direction Dv1 (number of layers), stores the current number of mortar layers, and stops the movement of the nozzle 41 when the final number of layers is reached.

[0040] The movement control unit 512 performs processing to control the movement of the robot arm 45 that moves the nozzle 41 according to the path. The discharge volume control unit 513 controls the pump that pumps the mortar and performs a process to control the amount of mortar discharged from the nozzle 41.

[0041] (Configuration of creation support server 60) Next, we will describe the configuration of the creation support server 60 as a formation support system. The creation support server 60 is a computer terminal that determines the movement path of the nozzle 41. This creation support server 60 includes a control unit 61 and an ejection path storage unit 62. The creation support server 60 is connected to the control unit 50 of the 3D printer 40.

[0042] The control unit 61 functions as a shape identification unit 611 and a path creation unit 612 by executing a path determination program stored in the memory unit. The shape identification unit 611 identifies the shape to be created by the 3D printer 40. In this embodiment, the shape identification unit 611 acquires the shape of the structural wall portion 11 and the lower member 21 of the slab 20. The shape identification unit 611 then divides the acquired shape and generates the shapes of each component (wall members 11a to 11d and piece members 211 to 21n) to be formed by the 3D printer 40.

[0043] The path creation unit 612 creates a single-stroke path to form each member using the shape of each member obtained. For example, when forming piece members 211 to 21n, the path creation unit 612 generates a closed path that forms two contacting path sections (first side section 26 and second side section 27). In this case, the two path sections are formed with an extrusion width (width that forms the first side section 26 and second side section 27) that is half the thickness of each piece member 211 to 21n.

[0044] The discharge path storage unit 62 records path management data for the nozzles 41 that form each component. This path management data is recorded when a single-stroke path is created by the path creation unit 612. The path management data includes data related to the path according to the component identifier, discharge width, and number of layers.

[0045] The component identifier data area stores data related to identifiers used to identify each component. The discharge width data area records data to determine the width of the mortar discharged from the nozzle 41 to form this component. In the path data area corresponding to the number of layers, the path of the nozzle 41 of the 3D printer 40 at each layer is recorded, in relation to the number of layers, in order to form this component.

[0046] <10 methods of building a house> Next, the construction method of the house 10 will be described. In this case, first, the wall members 11a to 11d of the structural wall section 11, the members constituting the rooftop side wall section 13, and the piece members 211 to 21n of the lower member 21 of the slab 20 are formed using a 3D printer 40. Here, the formation of the lower member 21 will be described. Note that the wall members 11a to 11d obtained by dividing the structural wall section 11 and the members constituting the rooftop side wall section 13 are formed in the same way as the piece members 211 to 21n of the lower member 21, so their explanation will be omitted.

[0047] (Discharge path generation process) First, as shown in Figure 11, the control unit 61 of the creation support server 60 performs the process of acquiring the shape of the piece members (step S11). Specifically, the shape identification unit 611 of the control unit 61 acquires the shape of the lower member 21 of the slab 20 from the drawings of the house 10 stored in the data server (not shown) according to the user's instructions. Then, according to the user's instructions, the shape identification unit 611 disassembles the lower member 21 into individual piece members 211 to 21n. Here, the shape identification unit 611 uses the size and volume of the lower member 21 to estimate its weight and disassembles it into piece members 211 to 21n of a size that can be formed by the 3D printer 40. Then, the shape identification unit 611 identifies the shape of each disassembled piece member 211 to 21n using the shape of the lower member 21 and stores it in the creation support server 60.

[0048] Next, the stored piece members 211 to 21n are identified one by one, and the following process is repeated for each piece member 211 to 21n. The control unit 61 of the creation support server 60 performs a process to identify the shape of each layer of the piece member (step S12). Specifically, the path creation unit 612 of the control unit 61 divides the acquired shape of the piece member vertically (height direction) according to the thickness (height position) of each stored layer. Then, it identifies the horizontal shape on the plane at the height of the midpoint of each divided thickness (height position) as the shape to be created in that layer.

[0049] Then, the control unit 61 of the creation support server 60 sequentially identifies one of the formed layers as the layer to be processed. Then, the process of generating route management data is executed for the identified processing target layer (step S13). Specifically, the route creation unit 612 of the control unit 61 generates a route that traces the shape identified in step S12 with a double line, associates it with the number of layers of the processing target layer, and stores it in memory (storage device H14). The above process is repeated for all layers being processed.

[0050] Here, we illustrate the path of the piece member 215 shown in Figure 7. Figure 12 shows the path RT1 along the cross-sectional line L12 of the piece member 215. Figure 13 shows the path RT2 at the cross-sectional line L13 above the cross-sectional line L12 of the piece member 215.

[0051] Figure 14 shows the path RT3 along the cross-sectional line L14 above the cross-sectional line L13 of the piece member 215. In all three paths RT1, RT2, and RT3, the first side portion 26 and the second side portion 27 are formed in a loop shape by contact with each other.

[0052] When route generation is complete at all levels, the control unit 61 of the creation support server 60 performs the process of storing route management data (step S14). Specifically, the route creation unit 612 of the control unit 61 generates route management data to which the member identifier of the target piece member is attached. Then, the route creation unit 612 includes the route data associated with the number of levels stored in the storage device H14 in the route management data, and then records this route management data in the output route storage unit 62.

[0053] Subsequently, the control unit 61 of the creation support server 60 transmits the route management data stored in the ejection route storage unit 62 to the control device 50 of the 3D printer 40 before forming each piece member 211 to 21n. The control device 50 of the 3D printer 40 stores the acquired route management data.

[0054] (Method for forming piece members 211-21n) Subsequently, the 3D printer 40 performs a component formation process according to the control unit 51 of the control device 50. Here, the layer management unit 511 of the control unit 51 controls the movement control unit 512 and the discharge amount control unit 513 using the stored path management data.

[0055] Specifically, the movement control unit 512 moves the robot arm 45 while discharging mortar from the nozzle 41. In this case, the discharge volume control unit 513 of the control unit 51 adjusts the discharge volume from the pump and the movement speed of the nozzle 41 so that the amount of mortar is equal to the discharge width of the path management data. Then, the layer management unit 511 of the control unit 51 moves the nozzle 41 along the path of the path management data corresponding to the number of layers. When one layer is formed in this way, the height of the nozzle 41 is raised by the amount of one layer, and then the nozzle 41 is moved again along the path of the path management data to form another layer, and this process is repeated.

[0056] Subsequently, the mortar discharged from the nozzle 41 is stacked in the stacking direction Dv1 until it reaches the final height. This stops the movement of the nozzle 41 and the discharge of mortar from the nozzle 41. Then, as the mortar hardens, each piece is formed.

[0057] (Construction method for slab 20) Next, we will explain the construction method of slab 20 using Figure 15. Here, before constructing the slab 20, the wall members 11a to 11d formed using the 3D printer 40 described above are arranged and stacked to form the structural wall section 11. Furthermore, the members constituting the rooftop side wall section 13 are stacked and fixed on top of the wall members 11d.

[0058] Next, the piece members are laid (step S21). Specifically, shoring to support each piece member 211~21n is installed inside the structural wall 11. In this case, the shoring may support the piece members 211~21n via protruding portions R1~R3 ​​that project downwards from the piece members 211~21n. Then, the piece members 211~21n are arranged on top of the shoring, connected so that no gaps are left between them.

[0059] In this case, as shown in Figure 3, the piece members 211 to 21n, which are arranged along the inner edge of the wall member 11d of the structural wall 11, have their ends resting on the upper surface of the wall member 11d inside the protruding portion 10a. In this case, the stacking direction Dv1 of the piece members 211 to 21n is arranged to be horizontal. Note that tape may be applied to the lower surface of the connecting portion of the piece members 211 to 21n. As a result, the lower member 21 is formed by the piece members 211 to 21n and placed on top of the structural wall 11.

[0060] Next, high-strength concrete is poured onto the lower member 21 (step S22). Specifically, the lower member 21 is used as the formwork on the bottom, and the protruding portion 10a of the wall member 11d is used as the formwork on the side, and fiber-reinforced concrete material is filled into the interior. Subsequently, as this fiber-reinforced concrete material hardens, a high-strength concrete member 22 is formed on the upper surface of the lower member 21 inside the protruding portion 10a. In this case, the high-strength concrete member 22 is integrated with the lower member 21.

[0061] Next, the insulating material and waterproofing material are laid (step S23). Specifically, the insulating material 24 is laid on top of the high-strength concrete material 22. Furthermore, a protective waterproofing film is applied on top of the insulating material 24 to form a coated film portion 25.

[0062] Next, the shoring that supported slab 20 is removed. With this, slab 20 is completed. Subsequently, an insulating material is installed on the inside of the structural wall section 11. Furthermore, the staircase section 16, the staircase side wall section 17, and the boundary side wall section 18 are installed. With these steps completed, the house 10 is finished.

[0063] (action) In this embodiment, the piece members 211 to 21n constituting the lower member 21 of the slab 20 were formed by stacking layers formed by moving the nozzle 41 while discharging mortar from the nozzle 41. This formation method makes it possible to form the lower member 21 with piece members 211 to 21n having protruding portions R1 to R3 at arbitrary locations on the plate-like portion P1.

[0064] According to this embodiment, the following effects can be obtained. (1) In this embodiment, the piece members 211 to 21n constituting the lower member 21 of the slab 20 were formed by stacking layers formed by moving the nozzle 41 while discharging mortar from the nozzle 41. This formation method allows the lower member 21 to be formed efficiently in any shape.

[0065] (2) In this embodiment, when the piece members 211 to 21n are laid on their sides on the structural wall 11 so that the stacking direction Dv1 is horizontal, the protruding parts R1 to R3 protrude downward. As a result, the high-strength concrete member 22 in the part through which the stress line determined by topology optimization passes can be made thicker (higher), so that the slab 20 can be made lighter without reducing the load-bearing capacity of the slab 20.

[0066] (3) In this embodiment, the lower member 21 of the slab 20 is constructed by arranging piece members 211 to 21n that are divided into sizes that can be formed by the 3D printer 40. This prevents each piece member 211 to 21n from becoming heavy, and allows the lower member 21 to be formed in the desired divided shape. In this case, the lower layer is created to a size that prevents the lower layer from being significantly crushed by its own weight even when the uppermost layer is formed, thus suppressing deformation of the piece members 211 to 21n during their creation.

[0067] (4) In this embodiment, the slab 20 is formed by placing the lower member 21 across the upper surface of the wall member 11d, and then pouring fiber-reinforced concrete on top of the lower member 21 to form a high-strength concrete member 22. This ensures the strength of the slab 20.

[0068] (5) In this embodiment, the piece members 211 to 21n are provided with inclined portions R1s on the protruding portions R1 that are positioned above the lowest layer. This prevents the stacked mortar from being deformed by the weight of the protruding portions R1 as it descends before it hardens.

[0069] (6) In this embodiment, the lower member 21 is spanned across the end of the wall member 11d of the structural wall 11. This allows the high-strength concrete member 22 to be surrounded by the protruding portion 10a of the wall member 11d when pouring, thus eliminating the need to arrange pouring members around it.

[0070] This embodiment can be implemented with the following modifications. This embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically. In the above embodiment, the lower member 21, constructed by layering mortar using a 3D printer 40, was placed on the structural wall 11, and then the high-strength concrete member 22 was formed on top of the lower member 21. Alternatively, a slab integrating the lower member and the high-strength concrete member may be formed from precast concrete.

[0071] For example, as shown in Figure 16, the slab 70 is composed of an outer body portion 71 and an internal structure 72. The outer body portion 71 is composed of a frame shape with a roughly rectangular cross-section, forming a space 70s inside. The outer body portion 71 is formed using a 3D printer 40, similar to the piece member 215, by stacking layers formed from mortar extruded from the nozzle 41 while moving the nozzle 41, in a continuous stacking direction Dv1.

[0072] The internal structure 72 is a member with higher strength than the outer body portion 71, and, like the high-strength concrete member 22, is composed of a cement-based material mixed with fibers (fiber-reinforced concrete material). The internal structure 72 is filled into the space 70s of the completed outer body portion 71 and then hardened to become integrated with the outer body portion 71.

[0073] Figure 17 shows the building 80 before the slab 70 is placed. The building 80 comprises structural wall sections 81 and column members 85. Rooftop side wall sections 83 are provided on the outer periphery of the upper surface of the structural wall sections 81. In addition, thermal insulation members 81a are provided on the inside of the structural wall sections 81.

[0074] Then, as shown in Figure 18, the slab 20 is placed on its side above the inner end of the structural wall portion 81 and above the column member 85. In this case, the stacking direction Dv1 of the outer body portion 71 of the slab 20 becomes horizontal. Reinforcing bars 82 may be provided between the column member 85 and the slab 70. Furthermore, an insulating member 75 may be placed on top of the slab 70. Thus, when slab 70 is constructed from precast concrete, the hardening time of high-strength concrete can be omitted on site.

[0075] In the above embodiment, the lower member 21 of the slab 20 is entirely formed of piece members 211 to 21n formed by stacking layers (mortar lamination) by moving the nozzle 41 while discharging mortar from the nozzle 41. The lower member 21 of the slab 20 is not limited to being entirely made of mortar lamination; only a part of the lower member 21 may be made of piece members formed by mortar lamination. In this case, piece members of parts with complex shapes may be formed by mortar lamination. The remaining parts of the slab may be made using conventional deck plates or wooden plates.

[0076] In the above embodiment, the slab is provided so as to span across the upper surface of the wall member 11d of the structural wall 11. The slab may also be placed on structural elements other than the structural wall 11, such as beams. Furthermore, the structural elements on which the slab is placed are not limited to those formed by the 3D printer 40, but may be constructed by any construction method.

[0077] In the above embodiment, the high-strength concrete member 22 of the slab 20 was used as the side formwork, and the protruding portion of the wall member 11d of the structural wall 11 was used. The high-strength concrete member 22 formed on the lower member 21 may also be constructed using a normal concrete pouring formwork on the side.

[0078] In the above embodiment, the lower member 21 of the slab 20 is supported by scaffolding. After the high-strength concrete member 22 is integrally formed on the lower member 21, the scaffolding is removed. Depending on the size of the piece members, the building may be constructed by placing the slab directly on the structure without providing scaffolding.

[0079] The piece members 211 to 21n of the lower member 21 in the above embodiment have linearly projecting protrusions R1 to R3 when the slab 20 is laid down. The piece members are not limited to having linearly projecting protrusions R1 to R3, but may also have block-shaped projections, or projections that protrude upward when the slab 20 is laid down. Furthermore, the piece members may be configured as substantially flat plates without projections.

[0080] In the above embodiment, protruding portions R1 to R3 are formed on the lower member 21 at positions through which stress lines obtained using topology optimization pass. The protrusions formed on the lower member are not limited to arrangements that take stress into consideration, but may also be provided for design purposes, for example.

[0081] Next, the technical concepts that can be understood from the above embodiments and alternative examples are described below. (a) The method for constructing a slab according to claim 2, wherein the laminated forming member comprises a closed outer body portion having an internal space and an internal structure portion in which high-strength mortar having a tensile strength higher than that of the mortar is filled into the internal space, and the outer body portion is formed by stacking layers formed of mortar discharged from the nozzle while moving the nozzle.

[0082] (b) The method for constructing a slab according to any one of claims 1 to 3 or (a), characterized in that the lower plate member is constructed by arranging a plurality of the laminated forming members in a laid-down state.

[0083] (c) A method for constructing a building comprising a frame and a slab disposed on the frame and having a lower plate member, wherein the lower plate member has a laminated forming member formed by stacking layers of mortar discharged from a nozzle while moving the nozzle, and at least a part of the lower plate member is formed by arranging the laminated forming member on the frame in a tilted state such that the stacking direction of the laminated forming member is horizontal.

[0084] (d) A lower plate member used in the lower part of a slab placed on a structural frame, characterized in that it is formed by stacking layers of mortar discharged from a nozzle while moving the nozzle. [Explanation of Symbols]

[0085] Dv1…Layering direction, D1…First direction, L1…Layer, L12,L13,L14…Sectional line, P1…Plate-like part, RT1,RT2,RT3…Path, R1,R2,R3…Protruding part, R1s,R3s…Inclined part, R1v…Vertical part, 10…House as a building, 10a…Protruding part, 10d…Opening, 11,81…Structural wall part, 11a,11b,11c,11d…Wall member, 12,82…Reinforcement bar, 13,83…Rooftop side wall part, 16…Staircase part, 17…Staircase side wall part, 18…Boundary side wall part, 20,70…Slab, 21…Lower member as lower plate member, 22…High-strength concrete member, 24,75,81a…Section Thermal component, 25...coated film part, 26...first side part, 27...second side part, 40...3D printer, 41...nozzle, 41a...discharge port, 42...hose, 44...mounting part, 45...robot arm, 50...control device, 51,61...control unit, 60...creation support server, 62...discharge path memory unit, 70s...space, 71...outer body part, 72...internal structure, 80...building as a structure, 85...column member, 211,212,213,214,215,216,21n...piece member as laminated forming member, 511...lamination management unit, 512...movement control unit, 513...discharge amount control unit, 611...shape identification unit, 612...path creation unit.

Claims

1. A method for constructing a slab comprising a lower plate member and a high-strength concrete member having higher tensile strength than mortar, A laminated member is formed by stacking layers of mortar discharged from the nozzle while moving the nozzle. At least a portion of the lower plate member is formed by arranging the laminated forming member on the structure in a tilted state so that the stacking direction of the laminated forming member is horizontal, A method for constructing a slab, characterized in that the lower plate member is used as a formwork on the lower surface, and high-strength concrete is poured onto the lower plate member, thereby integrating the high-strength concrete member and the lower plate member.

2. When forming the aforementioned mortar by laminating it, a protrusion formed at a position higher than the lowest layer of the laminated member is formed by laminating the mortar while gradually shifting it so that it is inclined in the direction of the protrusion. The method for constructing a slab according to claim 1, characterized in that the lamination forming member is arranged such that the protruding portion protrudes downward when positioned on the structural body.

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