Member formation method

Abstract

The prent invention provides a member formation method or the like that facilitates construction. The present invention includes executing: a step for arranging a plurality of panel parts 12 formed of a steel material side by side in a plane when forming an earthquake-resistant wall that includes the panel parts 12 and concrete, and joining adjacent panel parts 12 by welding; and a step for filling the concrete into an internal space formed by the plurality of panel parts 12. The adjacent panel parts 12 are joined by performing vertical automatic welding while raising a welding device 3 including the metal to the welding site.

Description

Component forming method

[0001] The present invention relates to a method for forming a member such as a wall of a building.

[0002] Patent Documents 1 and 2 describe walls in which concrete is filled between steel panels. In the walls described in Patent Documents 1 and 2, the panels are aligned in the extension direction of the wall and joined together using splice plates and bolts.

[0003] In other words, adjacent panels in the extension direction are joined together by placing splice plates on the inside and outside of the panels that span both panels, and tightening bolts inserted into each panel and the inner and outer splice plates.

[0004] JP 2022-131243 A JP 2022-131245 A

[0005] However, the joining method using splice plates and bolts requires tightening bolts when joining panels together, which is time-consuming. In particular, the above-mentioned wall structures are often large-scale, requiring a large number of bolt tightening operations.

[0006] The present invention has been made in view of the above problems, and has an object to provide a member forming method and the like that makes construction easier.

[0007] In order to solve the above-mentioned problems, the present invention is a component formation method for forming a component of a building having panel sections formed from steel and concrete, the component formation method comprising the steps of arranging a plurality of the panel sections side by side on a plane and joining adjacent panel sections together by welding, and filling the internal space formed by the plurality of panel sections with the concrete, wherein the adjacent panel sections are joined together by performing vertical automatic welding while raising a welding device including a backing for the welding points.

[0008] In this invention, when joining multiple panels by filling the internal space formed by steel panels with concrete to form building walls and other components, vertical automatic welding, which has not been used in the construction industry until now, is applied. Vertical automatic welding allows for automatic one-pass welding while raising the welding device, including the backing metal, to the welding point, making the joining of panels faster, less labor-intensive, and easier.

[0009] In the panel section, it is desirable that steel reinforcing members be provided on the inner surface of the rectangular panel body along the side edges of the panel body, and that the reinforcing members on the opposing side edges of adjacent panel sections be used as backing members during vertical automatic welding. It is also desirable that the reinforcing members on the opposing side edges of adjacent panel sections be fastened together with fasteners. Furthermore, it is also desirable that adjacent panel sections be joined together by vertical automatic welding with a large heat input, or that a steel plate be placed between the reinforcing member and the panel body to increase the weld cross-sectional area. In the panel section, the reinforcing members can reinforce the panel body and also function as backing members during welding. Fastening the reinforcing members of adjacent panel sections together with fasteners can prevent the reinforcing members (backing members) from individually distorting during welding, which can lead to welding defects. Furthermore, by performing vertical automatic welding with a large heat input, panel sections can be joined together effectively, and when the panel body is relatively thin, arranging the above-mentioned plate material increases the actual thickness of the panel body, increasing the weld cross-sectional area and making it easier to ensure welding quality.

[0010] The member is a wall, and a plurality of the panel sections are arranged in a line in the extension direction of the wall on both sides of the wall thickness direction of the wall, the concrete is filled in the internal space between the panel sections on both sides of the wall thickness direction of the wall, and the panel sections adjacent in the extension direction of the wall are joined by performing vertical automatic welding while raising the welding device outside the panel sections. The member is typically a wall, and can be formed by pouring concrete into the internal space between the panel sections on both sides of the wall thickness direction. By arranging a plurality of panel sections in a line in the extension direction of the wall, each panel section can be made smaller, making construction easier. The panel sections adjacent in the extension direction of the wall can be joined by the above-mentioned vertical automatic welding method.

[0011] It is also desirable to place end tabs on the adjacent panel sections so as to straddle the panel sections, so that the welds between the adjacent panel sections reach the end tabs, and then remove the end tabs together with the welds on the surfaces of the end tabs after welding the adjacent panel sections together. This places the weld termination, which is prone to weld defects, on the end tabs rather than on the panel sections, improving the quality of the welds between the panel sections and eliminating the need for repair welding.

[0012] When performing vertical automatic welding, it is desirable to use a lifting type aerial work platform as the work stage. Vertical automatic welding allows for automatic one-pass welding, which saves labor and increases speed, so there is no need to use a full-scale scaffolding, and a user-friendly lifting type aerial work platform can be used as the work stage.

[0013] The present invention can provide a member forming method and the like that allows for easy construction.

[0014] A diagram showing a seismic wall 1. A diagram showing a foundation 2. A diagram showing a base 11 of a seismic wall 1. A diagram showing a panel portion 12 of the seismic wall 1. A diagram showing the inner surface of the panel portion 12. A diagram showing welds 14, 15 and a connecting material 16. A diagram showing vertical automatic welding. An example of joining multiple panel portions 12 in advance. A diagram showing a weld 126 and a corner cut portion 127. An example of increasing the weld cross-sectional area. A diagram showing an end tab 18. A diagram showing an aerial work platform 5.

[0015] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0016] 1 is a diagram showing a shear wall 1, which is a building component formed by a component forming method according to an embodiment of the present invention. The shear wall 1 is a wall body erected on a foundation 2.

[0017] The foundation 2 is a member made of reinforced concrete, and reinforcing bars (not shown) and anchor bolts 21 (see FIG. 2), which will be described later, are embedded inside the foundation 2.

[0018] The earthquake-resistant wall 1 has a base 11 fixed to the installation surface on the foundation 2 and a panel portion 12 provided on the base 11, the height of the panel portion 12 being greater than the height of the base 11. The panel portions 12 are provided on both sides of the earthquake-resistant wall 1 in the wall thickness direction (see symbol a), and concrete Con is filled between the panel portions 12 and in the internal space of the base 11.

[0019] The base 11 is a box-shaped member made of steel, and the panel 12 is a plate-shaped member also made of steel. A plurality of bases 11 and panel 12 are arranged side by side in a plane so as to be adjacent to each other in the extension direction (see symbol b) of the earthquake-resistant wall 1. The length of the base 11 in the extension direction is greater than the length of the panel 12 in the extension direction. Details of the base 11 and the panel 12 will be described later.

[0020] Adjacent base portions 11 in the extension direction of the earthquake-resistant wall 1 are joined by welding at vertical welds 13, and adjacent panel portions 12 in the extension direction of the earthquake-resistant wall 1 are joined by welding at vertical welds 14. The base portions 11 and panel portions 12 are also joined by welding at horizontal welds 15.

[0021] (2. Method of forming the earthquake-resistant wall 1) When forming the earthquake-resistant wall 1, first, the foundation 2 of the earthquake-resistant wall 1 is constructed as shown in Figure 2. As described above, the foundation 2 is a reinforced concrete member, and reinforcing bars (not shown) and anchor bolts 21 are embedded inside it. The upper ends of the anchor bolts 21 protrude upward from the top surface of the foundation 2. A plurality of anchor bolts 21 are arranged at intervals in the wall thickness direction and extension direction of the earthquake-resistant wall 1.

[0022] After the foundation 2 is constructed, the base 11 is fixed to the upper surface of the foundation 2 as shown in Figure 3. The base 11 is provided with side plates 111 and a bottom plate 112 on both sides of the earthquake-resistant wall 1 in the wall thickness direction, and the side plates 111 on both sides of the earthquake-resistant wall 1 in the wall thickness direction are connected to each other by tie plates 113.

[0023] The side plates 111 and the bottom plate 112 are strip-shaped plates made of steel. The bottom plate 112 is arranged along the extension direction of the shear wall 1 with its plate surface oriented horizontally. The side plates 111 are fixed to the outer edges of the top surface of the bottom plate 112 and are arranged along the extension direction of the shear wall 1 with their plate surface oriented vertically. The side plates 111 and the bottom plate 112 are arranged in an L-shape in the cross section of the shear wall 1 in the wall thickness direction. At the upper end of the side plate 111, an angle bar 114 extending in the extension direction of the shear wall 1 is attached to the inner surface of the side plate 111. Although not shown, a similar angle bar is also attached vertically to the inner surface of the side plate 111 at the end of the side plate 111 in the extension direction of the shear wall 1. Note that the term "outside (outer side, outer surface)" refers to the exterior side of the shear wall 1 in the wall thickness direction, and the term "inside (inner side, inner surface)" refers to the interior side of the shear wall 1 in the wall thickness direction.

[0024] The bottom plate 112 has a plurality of holes (not shown) at planar positions corresponding to the anchor bolts 21, and the upper ends of the anchor bolts 21 protruding from the foundation 2 are passed through the respective holes. The base 11 is fixed to the upper surface of the foundation 2 by tightening nuts 22 onto the protruding portions of the anchor bolts 21 protruding from the bottom plate 112.

[0025] The tie plates 113 are strip-shaped plate materials, and are made of steel plates or H-section members. The tie plates 113 are arranged along the thickness direction of the shear wall 1 with their plate surfaces oriented vertically, and both ends are fixed to the side plates 111 on both sides of the thickness direction of the shear wall 1. Multiple tie plates 113 are arranged at intervals in the extension direction of the shear wall 1.

[0026] In this embodiment, multiple bases 11 are arranged in a line in the extension direction of the earthquake-resistant wall 1, and after each base 11 is erected and fixed onto the foundation 2, the side plates 111 of adjacent bases 11 in the extension direction are welded together from the outside at welds 13 to join them.

[0027] After the base 11 is placed on the foundation 2 in the manner described above, the panel 12 of the earthquake-resistant wall 1 is erected from above, and the panel 12 is placed on the base 11 as shown in FIG.

[0028] 5 is a view of the inner surface of the panel portion 12. The panel portion 12 is a rectangular plate-shaped panel body 121 with angle irons 122 provided along the four sides, namely the top, bottom, and both side edges of the panel body 121. The angle irons 122 are steel reinforcing members that maintain the shape of the panel body 121 and are provided on the inner surface of the panel body 121. The angle irons 122 also serve as protective members that prevent damage to the peripheral edges of the panel body 121.

[0029] Ribs 123 and studs 124 are also provided on the inner surface of the panel body 121. The ribs 123 are rectangular plate-shaped members that protrude inward from the panel body 121 and are provided continuously in the vertical direction from the upper end to the lower end of the panel body 121. The studs 124 are provided to protrude inward from the panel body 121 and improve the unity between the panel portion 12 and the concrete Con of the shear wall 1. Multiple ribs 123 are arranged at intervals in the extension direction of the shear wall 1 (corresponding to the left-right direction in Figure 5). Multiple studs 124 are arranged at intervals in the extension direction and vertical direction of the shear wall 1.

[0030] The panel section 12 is fixed to the base section 11 by fastening the angle iron 122 at the bottom of the panel section 12 to the angle iron 114 of the base section 11 using fasteners such as bolts (not shown). As shown in Figure 4, in this embodiment, a plurality of panel sections 12 are arranged side by side in the extension direction of the earthquake-resistant wall 1, and the angle irons 122 at the sides of adjacent panel sections 12 in the extension direction are joined together using fasteners 125 such as bolts and nuts (see Figure 7(b) described below). The panel sections 12 on both sides in the wall thickness direction are erected separately and fixed to the base section 11.

[0031] After the panel sections 12 are thus installed on the base section 11, the panel sections 12 on both sides in the wall thickness direction are connected by connecting members 16, as shown in Figure 6. The connecting members 16 are strip-shaped plate materials made of steel plates. The connecting members 16 are arranged along the wall thickness direction of the earthquake-resistant wall 1 with the plate surface oriented vertically, and both ends of the connecting members 16 are fixed with bolts or the like to the ribs 123 of the panel sections 12 on both sides in the wall thickness direction.

[0032] The panel body 121 of each panel section 12 is welded to the side plate 111 of the base section 11 from the outside at welds 15, and the panel bodies 121 of adjacent panel sections 12 in the extension direction of the earthquake-resistant wall 1 are welded to each other from the outside at welds 14. The welding work of the welds 14, 15 may be performed in either order.

[0033] The welding work at the weld 14 is performed by vertical automatic welding with a large heat input. As shown in FIG. 7( a), vertical automatic welding is a technique in which a welding device 3 including a weld pad for the welded portion is raised along a rail 4, automatically forming the weld 14 between the panel bodies 121 vertically upward in one pass. Known methods include electroslag welding (see, for example, Japanese Patent Application Laid-Open No. 09-108841), which performs welding by resistance heating of molten slag, and electrogas arc welding (see, for example, Japanese Patent Application Laid-Open No. 10-118771). Examples of welding devices that can be used for the welding device 3 include SESLA (registered trademark) and SEGARC (registered trademark) manufactured by Kobe Steel, Ltd. Vertical automatic welding is a technique commonly used in the shipbuilding industry, but the present invention applies it to the construction industry.

[0034] As shown in Figure 7(b), welding work at the welded portion 14 is performed using angle irons 122 attached to the sides of the panel body 121 as backing materials. Adjacent angle irons 122 in the extension direction of the earthquake-resistant wall 1 (corresponding to the left-right direction in Figure 7(b)) are joined together using fasteners 125 such as bolts and nuts, as described above. This prevents the angle irons (backing materials) 122 from individually warping during welding, which can lead to welding defects.

[0035] Welding at the welds 13 and 15 can be performed using conventional techniques. After welding at the welds 14 and 15, concrete concrete is poured between the panel sections 12 on both sides in the wall thickness direction and into the internal space of the base 11. This completes the shear wall 1 shown in FIG. 1 . If necessary, the steps from FIG. 4 onward can be repeated to install upper panel sections 12 on top of the panel sections 12 on both sides in the wall thickness direction and fill the space between the upper panel sections 12 with concrete concrete, thereby raising the shear wall 1 vertically upward. Alternatively, concrete concrete may be filled into the internal space of the base 11 before installing the panel sections 12, and then concrete concrete may be filled into the internal space between the panel sections 12 on both sides in the wall thickness direction after installing the panel sections 12.

[0036] As described above, in this embodiment, when filling the internal space formed by the steel panel sections 12 with concrete Con, vertical automatic welding, which has not been used in the construction industry until now, is used to join multiple panel sections 12. Vertical automatic welding allows automatic one-pass welding while raising the welding device 3 including the backing metal to the welding point, which reduces the labor required to join the panel sections 12 and increases the speed, making the work easier.

[0037] In particular, in this embodiment, the earthquake-resistant wall 1 can be formed by pouring concrete Con into the internal space between the panel sections 12 on both sides in the wall thickness direction. By arranging a plurality of panel sections 12 side by side in the extension direction of the earthquake-resistant wall 1, each panel section 12 can be made smaller, making construction easier. Adjacent panel sections 12 in the extension direction of the earthquake-resistant wall 1 can be joined by the above-mentioned vertical automatic welding.

[0038] Furthermore, in the panel portion 12, the above-mentioned angle irons 122 can reinforce the panel body 121, and the angle irons 122 can also function as backing materials during welding. Vertical automatic welding performs a single-pass welding process, so deformation of the panel body 121 due to differences in thermal expansion before and after welding is smaller than with conventional multi-pass welding methods, and the angle irons 122 can be used as reinforcing materials with a simple configuration. Furthermore, fastening the angle irons 122 of adjacent panel portions 12 together with fasteners 125 can prevent the angle irons 122 (backing materials) from individually distorting during welding, which can lead to welding defects. Furthermore, performing vertical automatic welding with a large heat input allows adjacent panel portions 12 to be joined together effectively.

[0039] However, the present invention is not limited to the above-described embodiment. For example, when installing the panel sections 12, it is desirable to weld the panel bodies 121 of the multiple panel sections 12 together at the welds 14 in advance in a work yard or the like, as shown in Figure 8, and then erect the multiple panel sections 12 as a single unit. This reduces the labor required for constructing the shear wall 1. Welding at the welds 14 can be performed using the vertical automatic welding method described above with the panel sections 12 standing upright, or by conventional welding methods with the panel sections 12 laid horizontally. Alternatively, the panel sections 12 on both sides of the shear wall 1 in the wall thickness direction may be connected by ties 16 and erected as a single unit.

[0040] In this embodiment, the integrated base 11 having the side plates 111 and bottom plate 112 on both sides in the wall thickness direction is erected and fixed on the foundation 2, but it is also possible to erect and fix a unit in which the side plate 111 and bottom plate 112 on one side in the wall thickness direction are integrated with another unit in which the side plate 111 and bottom plate 112 on the other side in the wall thickness direction separately on the foundation 2, and then connect the side plates 111 on both sides in the wall thickness direction with the tie plate 113. It is also possible to erect and fix a unit in which the side plate 111, bottom plate 112, and part of the length of the tie plate 113 on one side in the wall thickness direction are integrated with another unit in which the side plate 111, bottom plate 112, and remaining length of the tie plate 113 on the other side in the wall thickness direction are integrated separately on the foundation 2, and then connect the tie plates 113 of both units with bolts and nuts.

[0041] In this embodiment, the pair of angle irons 122 used as backing materials are fastened together with fasteners 125 to prevent them from being individually distorted during welding, but as shown in Fig. 9(a), the outer ends of the opposing surfaces of both angle irons 122 may be tack-welded together at welds 126 before welding at welds 14. Also, as shown in Fig. 9(b), corner chamfers 127 may be provided at the outer ends of the opposing surfaces of both angle irons 122 to reduce distortion of the angle irons 122 during welding.

[0042] In electroslag welding and the like, ensuring a sufficient weld cross-sectional area is important for stabilizing the weld quality, and is typically used for plate materials with a thickness of 16 mm or more. If the panel body 121 is thinner, in order to ensure a certain level of weld cross-sectional area, the opposing sides of the panel bodies 121 of adjacent panel parts 12 may be formed with a weld groove shape in which the root spacing w and groove angle α are enlarged compared to the example in Figure 7(b), as shown in Figure 10(a).

[0043] As shown in FIG. 10( b), a groove widening plate 19 may be placed between the angle iron 122 and the panel body 121 to increase the weld cross-sectional area. The groove widening plate 19 is a steel plate, and its end face on the weld 14 side is sloped along the groove angle α of the panel body 121. By increasing the effective thickness of the panel body 121 using the groove widening plate 19, the weld cross-sectional area can be increased without increasing the groove angle α (the root spacing w between the panel bodies 121 is wider than in the example of FIG. 7( b)). The technique shown in FIGS. 10( a) and 10(b) makes it easier to increase the weld cross-sectional area and ensure welding quality, even for panel bodies 121 that are relatively thin, approximately 9 mm or more and less than 16 mm.

[0044] 11(a), during welding at the weld 14, an end tab 18 may be placed on the panel 12 so as to straddle the adjacent panel 12, and the weld 14 may be extended to reach this end tab 18. After welding, as shown in FIG. 11(b), the end tab 18 is removed together with the weld 14 formed on the surface. This places the weld termination, which is prone to weld defects, on the end tab 18 rather than on the panel 12, improving the quality of the weld between the panel 12 and eliminating the need for repair welding.

[0045] Steel plates are used for the end tabs 18. The end tabs 18 can be detachably fixed to the panel body 121 or the angle irons 122 of the panel section 12 by, for example, bolts or magnets, which can improve the efficiency of the installation work of the end tabs 18 at high altitudes.

[0046] 12 may be used as a work stage to perform a series of operations, such as welding preparation, welding work, welding confirmation, post-processing, and finish painting, during welding at the welded portion 14. The work stage 51 of the work platform 5 is positioned outside the panel portion 12, and is raised as the welding progresses. In conventional welding methods, workers manually perform multi-pass welding, which requires the construction of a full-scale scaffold around the welding location to serve as a work stage. However, vertical automatic welding is a method that can automatically perform one-pass welding, which reduces the labor required and increases the speed of welding. This eliminates the need for a full-scale scaffold, and the user-friendly work platform 5 can be used as a work stage.

[0047] In this embodiment, the earthquake-resistant wall 1 is formed on the foundation 2, but it may also be formed on the slab of an upper floor, and the installation surface of the earthquake-resistant wall 1 is not limited to the upper surface of the foundation 2. The configuration of the earthquake-resistant wall 1 is also not particularly limited. For example, in this embodiment, the panel portion 12 is erected on the base portion 11, but the panel portion 12 may also be erected directly on a bottom plate 112 fixed to the installation surface on the foundation 2 or slab.

[0048] Furthermore, the shapes of the base 11 and the panel 12 are not limited to those described above. For example, the studs 124 are provided as needed, and may be omitted in some cases. Furthermore, structural steel other than the angle irons 122 or various other steel materials may be used as reinforcing materials for the panel body 121. In this embodiment, the side plates 111 and bottom plate 112 of the base 11 are arranged in an L-shape, but the side plates 111 may also be provided upright on the bottom plate 112 in an upside-down T-shape.

[0049] In this embodiment, the panel sections 12 are joined together by vertical automatic welding when the shear wall 1 is formed, but the joining method (vertical automatic welding) of the panel sections 12 of this embodiment can also be applied when a wall other than the shear wall 1 is formed from the panel sections 12 and the concrete Con for the interior space thereof. Furthermore, the joining method of the panel sections 12 of this embodiment can also be applied when a building component other than a wall is formed from the panel sections 12 and the concrete Con for the interior space thereof. An example of such a joining method is a column.

[0050] While the preferred embodiments of the present invention have been described above with reference to the accompanying drawings, the present invention is not limited to these examples. It is clear that those skilled in the art can conceive of various modifications or alterations within the scope of the technical ideas disclosed herein, and it is understood that these modifications also fall within the technical scope of the present invention.

[0051] 1: Earthquake-resistant wall 2: Foundation 3: Welding equipment 4: Rail 5: Aerial work platform 11: Base 12: Panel section 13, 14, 15: Welded section 121: Panel body 122: Angle iron 125: Fastener

Claims

1. A method for forming building components having panel sections formed from steel and concrete, the method comprising the steps of: arranging a plurality of the panel sections side by side on a plane and joining adjacent panel sections by welding; and filling the internal space formed by the plurality of panel sections with the concrete, wherein the adjacent panel sections are joined by vertical automatic welding while raising a welding device including a backing for the welding points.

2. A method for forming a member according to claim 1, characterized in that in the panel section, steel reinforcing members are provided on the inner surface of the panel body along the side edges of the rectangular plate-shaped panel body, and the reinforcing members on the opposing side edges of adjacent panel sections are used as backing materials during vertical automatic welding.

3. The method for forming a member according to claim 1, wherein the member is a wall, a plurality of the panel sections are arranged in a line in the extension direction of the wall on both sides of the wall thickness direction of the wall, the concrete is filled into the internal space between the panel sections on both sides of the wall thickness direction of the wall, and the panel sections adjacent to each other in the extension direction of the wall are joined by vertical automatic welding while raising the welding device outside the panel sections.

4. A method for forming a member according to claim 2, wherein the reinforcing members on opposing sides of adjacent panel portions are fastened together by fasteners.

5. A method for forming a member according to claim 2, characterized in that adjacent panel portions are joined together by vertical automatic welding with a large heat input.

6. The method for forming a member according to claim 2, wherein a steel plate is disposed between the reinforcing member and the panel body to increase the cross-sectional area of the weld.

7. A method for forming a component as described in claim 1, characterized in that an end tab is placed on top of the panel portion so as to straddle the adjacent panel portion, the weld between the adjacent panel portions reaches the end tab, and after welding the adjacent panel portions together, the end tab is removed together with the weld on the surface of the end tab.

8. The method for forming a member according to claim 1, wherein a liftable aerial work platform is used as a work stage when performing vertical automatic welding.

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