Method for manufacturing masonry structure and masonry structure

Abstract

This method for manufacturing a masonry structure includes a step for forming a reinforcement coating layer 20 on a wall surface of a masonry wall 10 in which a plurality of masonry materials 11 are arranged in the vertical direction and the horizontal direction. The step for forming the reinforcement coating layer 20 includes coating the wall surface with a coating material which includes a fibrous material 22 longer than the distance d1 between a discretionary first masonry material 11-1 and a second masonry material 11-2 adjacent to the first masonry material 11-1, which are of the plurality of masonry materials 11.

Description

Masonry structure manufacturing method and masonry structure

[0001] The present invention relates to a method for manufacturing a masonry structure and to a masonry structure.

[0002] Conventionally, a construction method has been known in which a fibrous reinforcing material is placed on the surface of a brick wall, and then a photosensitive resin is applied on top of the material and cured to reinforce the wall surface (see, for example, Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2003-293693

[0004] However, in the conventional method, the placement of the reinforcing material and the application of the photosensitive resin must be carried out in separate steps, which poses a problem of complex processes.

[0005] Therefore, the present invention has been made in consideration of the above points, and an object of the present invention is to provide a manufacturing method for a masonry structure and a masonry structure that can be constructed in a simple process and that can provide a reinforcing effect to the wall surface.

[0006] One form of the present invention is a method for manufacturing a masonry structure, which includes a step of forming a reinforcing coating layer on a wall surface of a masonry wall in which a plurality of masonry members are arranged vertically and horizontally, and the step of forming the reinforcing coating layer includes applying a paint containing a fibrous material whose length is longer than the distance between any first masonry member among the plurality of masonry members and a second masonry member adjacent to the first masonry member to the wall surface.

[0007] In the step of forming the reinforcing coating layer, the paint in which the fiber material having a length of 3 mm or more and 20 mm or less is dispersed may be applied to the wall surface.

[0008] The method may further include the step of preparing a masonry wall, wherein the step of preparing the masonry wall includes placing the plurality of masonry members without providing a filler material between the first masonry member and the second masonry member.

[0009] One form of the masonry structure of the present invention comprises a masonry wall in which a plurality of masonry members are arranged vertically and horizontally, and a reinforcing coating layer formed on the wall surface of the masonry wall, wherein the reinforcing coating layer is a layer of paint containing a fibrous material that is longer than the distance between any first masonry member among the plurality of masonry members and a second masonry member adjacent to the first masonry member.

[0010] The length of the fiber material may be 3 mm or more and 20 mm or less.

[0011] The method for manufacturing a masonry structure of the present invention includes the steps of forming a masonry wall by stacking layers formed by supplying material from a moving material supply unit or by irradiating light onto selected areas, and forming a reinforcing coating layer on a wall surface of the masonry wall, wherein the step of forming the reinforcing coating layer includes applying paint containing a fibrous material of 3 mm or more and 20 mm or less to the wall surface.

[0012] The present invention provides a method for manufacturing a masonry structure and a masonry structure that can be constructed using simple steps and that can provide a reinforcing effect to a wall. The reinforcing effect of the wall may be used to obtain a wall that is stronger than a normal wall, or may be used to obtain a wall that is as strong as a normal wall by reviewing the overall wall configuration based on the reinforcing effect.

[0013] Fig. 6 is a perspective view showing a masonry structure according to one embodiment of the present invention. Fig. 7 is a front view of a masonry wall constituting the masonry structure of Fig. 1. Fig. 8 is a diagram for explaining the cross-sectional shapes of a reinforcing coating layer and a masonry wall. Fig. 9 is a flowchart showing an example of a process for manufacturing a masonry structure. Fig. 10 is a graph showing the results of a simulation. Fig. 11 is a schematic diagram for explaining the conditions for the simulation of Fig. 6. Fig. 12 is a cross-sectional view schematically showing a modified example of the masonry structure of the present invention.

[0014] Fig. 1 is a perspective view showing a masonry structure according to one embodiment of the present invention. Fig. 2 is a front view of a masonry wall constituting the masonry structure of Fig. 1. In Fig. 1, a part of the reinforcing coating layer is shown cut away. Note that the up-down direction in each drawing of this application corresponds to the vertical direction, and the left-right direction corresponds to the horizontal direction.

[0015] As shown in Fig. 1, the masonry structure S100 of this embodiment includes a masonry wall 10 and a reinforcing coating layer 20. The masonry structure S100 is used as an interior or exterior wall of a building, for example.

[0016] The masonry wall 10 includes masonry materials 11 and filler material 15. In the example of FIG. 1, the masonry materials 11 have a rectangular parallelepiped outer shape. For example, the masonry materials 11 are blocks without through holes. Specifically, the masonry materials 11 are blocks made of, for example, lightweight aerated concrete (AAC). In the masonry structure S100, multiple masonry materials 11 are arranged vertically and horizontally. For example, the multiple masonry materials 11 are stacked in a grid pattern, known as a "pot masonry" method. The present invention can also be applied to masonry construction using fired bricks, concrete blocks, etc.

[0017] The masonry materials 11 may be blocks with through holes formed therein. The masonry materials 11 may be stacked in a so-called horse-stacking manner, in which the position of the masonry material 11 in a given row is offset horizontally from the position of the masonry material 11 in the row above or below that row.

[0018] The density of the masonry material 11 is, for example, 0.3 g / cm ３ 1.5g / cm or more ３ The masonry material 11 does not have to have such a relatively low density. The density of the masonry material 11 is, for example, 1.5 g / cm ３ It may be more than that.

[0019] The plurality of masonry materials 11 are arranged with a predetermined gap between them. In Fig. 2, one of the plurality of masonry materials 11 is shown as a first masonry material 11-1, and the masonry material 11 arranged above it is shown as a second masonry material 11-2.

[0020] A gap Sa1 is provided between the first masonry material 11-1 and the second masonry material 11-2, and the distance d1 of this gap is, for example, several millimeters (e.g., 2 mm) or more and several tens of millimeters (e.g., 15 mm) or less. A gap Sa2 is provided between the first masonry material 11-1 and the masonry material 11 horizontally adjacent to the first masonry material 11-1, and the distance d2 of this gap is, for example, several millimeters or more and several tens of millimeters or less, as described above. The distances d1 and d2 may be the same length or different lengths, but in this embodiment, they are the same length as an example.

[0021] Distances d1 and d2 are, for example, the arithmetic mean values ​​of the lengths between the sides of one masonry material 11 and the sides of the other masonry material 11 measured at 10 arbitrary locations based on an image of the masonry wall 10 taken from the front. To determine distance d1, the vertical length between the side of one masonry material 11 and the side of the other vertically adjacent masonry material 11 is measured at 10 arbitrary locations. In the case of the so-called "imo-tsumi" method, distance d1 is measured within a region of vertical overlap between vertically adjacent masonry materials 11 (the region where the side of one masonry material 11 faces the side of the other masonry material 11), within a region of approximately four-fifths of the horizontal area (left-right direction in the plane of FIG. 2 ) centered on the center of the overlapping portion. In the case of the so-called horse-stacking method, measurements are taken in the area where two vertically adjacent masonry materials 11 overlap in the vertical direction, within an area of ​​approximately four-fifths of the horizontal direction (left to right on the paper in Figure 2) with the center of the overlapping area as the center (the horizontal ends of the masonry materials 11 are excluded from the measurement points).

[0022] Furthermore, when determining distance d2, the horizontal length between the side of one masonry material 11 and the side of the other horizontally adjacent masonry material 11 is measured at any 10 points. The measurement points for distance d2 are in the area where horizontally adjacent masonry materials 11 overlap in the horizontal direction, and are measured within an area that is approximately four-fifths of the vertical direction (up and down in the plane of FIG. 2 ) with the center of the overlapping area as the center (the vertical ends of the masonry materials 11 are excluded from the measurement points).

[0023] In this embodiment, since filler material 15 is provided, the distance between the masonry materials (e.g., distance d1 and / or distance d2) is, for example, several mm or more; however, if filler material 15 is not provided, the distance between the masonry materials may be, for example, less than several mm (e.g., 2 mm) (e.g., 1 mm or less), or the masonry materials may be closely packed together so that distance d1 and distance d2 are 0 mm.

[0024] Alternatively, by appropriately adjusting the amount of filler 15 used, the distance between the masonry materials (e.g., distance d1 and / or distance d2) can be set to less than a few millimeters (e.g., 2 mm) (e.g., 1 mm or less), or the masonry materials can be closely spaced to 0 mm.

[0025] In the masonry wall 10, it is preferable that the average distance between the masonry elements (e.g., distance d1 and / or distance d2) be the predetermined length as described above in at least one section of the wall surface (e.g., a section consisting of an arbitrary masonry element A and multiple masonry elements B arranged horizontally or vertically adjacent to the masonry element A, or a section consisting of an arbitrary masonry element A, multiple masonry elements B arranged horizontally or vertically adjacent to the masonry element A, and multiple masonry elements C arranged horizontally or vertically adjacent to the masonry element B), and it is also preferable that the average distance between the masonry elements (e.g., distance d1 and / or distance d2) be the predetermined length as described above. If the predetermined length as described above is realized in at least one section of the wall surface, a reinforcing effect can be obtained, and if the predetermined length as described above is realized as an average throughout the wall, an even higher reinforcing effect can be obtained.

[0026] The filler 15 is a material provided between adjacent masonry blocks 11. The filler 15 is, for example, mortar. The mortar may be any type, such as cement mortar, mud mortar, or lime mortar, and as an example, cement mortar may be used. Cement mortar is a mixture of cement and sand in a predetermined ratio, and is applied in a paste state between the masonry blocks.

[0027] The material of the reinforcing coating layer may be used as the filler 15. In one example, the filler 15 may not be used.

[0028] 3 is a diagram illustrating the cross-sectional shape of the reinforcing coating layer and the masonry wall. The reinforcing coating layer 20 is a layer formed on the wall surface of the masonry wall 10. Specifically, the reinforcing coating layer 20 is formed in a state where it is firmly attached to the wall surface of the masonry wall 10. The reinforcing coating layer 20 may be formed on both sides or one side of the masonry wall 10, but in this embodiment, it is formed on one side. The reinforcing coating layer 20 may be formed on only a portion of the wall surface of the masonry wall 10, or may be formed on the entire surface, but in this embodiment, it is formed on the entire surface.

[0029] 3, the reinforcing coating layer 20 is formed by, for example, a paint in which a fiber material 22 is dispersed in a resin material 21. Specifically, the reinforcing coating layer 20 is formed by, for example, curing the resin material 21 that is in a slurry state and contains the fiber material 22. In the following description, the reference numerals of the respective components will generally be omitted.

[0030] (Regarding specific fibers) The reinforcing coating layer preferably contains fibers having a predetermined length (hereinafter referred to as "specific length"). Hereinafter, fibers having the specific length are referred to as specific fibers. In this specification, the length of the fiber material means the actual length.

[0031] The specific length is preferably 1 mm or more, more preferably 3 mm or more, even more preferably 6 mm or more, and particularly preferably 13 mm or more, in view of the superior reinforcing effect achieved by the reinforcing coating layer.

[0032] The specific length is preferably 50 mm or less, more preferably 20 mm or less, and even more preferably 16 mm or less, from the viewpoint of workability (hereinafter simply referred to as "workability") when applying a paint containing the specific fiber (hereinafter referred to as "this paint") to form a reinforcing coating layer.

[0033] The type of the specific fiber may be the same as the type of fiber that can be used as the fiber material. The specific fiber is preferably an inorganic fiber (such as glass fiber) because it has better weather resistance and reinforcing effect.

[0034] The content of the specific fiber relative to the total mass of the reinforcing coating layer is preferably 0.1 mass% or more, more preferably 0.3 mass% or more, even more preferably 0.5 mass% or more, even more preferably 1.0 mass% or more, and particularly preferably 2.0 mass% or more, in terms of a better reinforcing effect.

[0035] The content of the specific fiber relative to the total mass of the reinforcing coating layer is preferably 75 mass% or less, more preferably 65 mass% or less, even more preferably 55 mass% or less, and particularly preferably 20 mass% or less, from the viewpoint of better workability.

[0036] The content of the specific fiber relative to the total mass of the present paint is preferably 0.1 mass% or more, more preferably 0.3 mass% or more, even more preferably 0.5 mass% or more, and even more preferably 1.0 mass% or more, in terms of a more excellent reinforcing effect.

[0037] The content of the specific fiber relative to the total mass of the present coating material is preferably 60 mass% or less, more preferably 50 mass% or less, even more preferably 40 mass% or less, and particularly preferably 18 mass% or less, from the viewpoint of better application properties.

[0038] The content of the specific fiber relative to the total mass of the fiber material contained in the reinforcing coating layer or the present paint is preferably 50% by mass or more, more preferably 75% by mass or more, even more preferably 92% by mass or more, and particularly preferably 99% by mass or more, from the viewpoint of a good balance between reinforcing effect and workability. The upper limit is not particularly limited, and is 100% by mass.

[0039] (Measurement of specific fiber content) When determining the content of the fiber material and specific fiber contained in the present paint, an appropriate method may be used taking into consideration the composition and properties of the present paint. In particular, when the present paint is composed of a resin material, a solvent, and a fiber material (including specific fiber) that is an inorganic fiber (preferably glass fiber), the content of the fiber material and specific fiber contained in the present paint can be determined, for example, by carrying out the procedures (A) and (B) shown below.

[0040] (A) An organic solvent compatible with the resin material is added to the paint to reduce viscosity, and the resulting mixture is filtered. The filtered residue is thoroughly washed with the organic solvent and then dried, and the resulting dried material is taken as the fiber material contained in the paint. The mass of the resulting dried material (fiber material) is taken as the content of fiber material in the paint.

[0041] (B) The dried material (fiber material) obtained in (A) above is observed under a magnifying glass or microscope and separated based on the length of the fibers to obtain specific fibers (fiber material having a specific length). The mass of the obtained specific fibers is taken as the content of the specific fibers contained in the paint.

[0042] In addition, when the present paint contains a solid material (such as a filler) different from the fibrous material, an additional step may be added in which the dried material obtained in (A) above is re-dispersed in an appropriate liquid and then centrifuged to separate the solid material from the fibrous material. The content of the fibrous material and specific fiber contained in the present paint may be determined by an appropriate method depending on the composition of the present paint.

[0043] The content of the fibrous material and the specific fiber contained in the reinforcing coating layer can be measured by any appropriate method taking into consideration the composition and characteristics of the reinforcing coating layer. In particular, when the reinforcing coating layer is composed of a resin material and a fibrous material (including the specific fiber) that is an inorganic fiber (preferably glass fiber), the content of the fibrous material and the specific fiber contained in the reinforcing coating layer can be determined, for example, by carrying out the following procedures (a) and (b).

[0044] (a) An organic solvent capable of dissolving a resin material is added to the reinforcing coating layer, and the resulting mixture is filtered. The resulting residue is thoroughly washed with the organic solvent and then dried. The dried product is taken as the fiber material contained in the reinforcing coating layer. The mass of the resulting dried product (fiber material) is taken as the content of the fiber material contained in the reinforcing coating layer.

[0045] (b) The dried product (fiber material) obtained in (a) is observed under a magnifying glass or microscope and separated based on the fiber length to obtain specific fibers (fiber material having a specific length). The mass of the obtained specific fibers is defined as the content of the specific fibers contained in the reinforcing coating layer.

[0046] If there is no organic solvent capable of dissolving the resin material contained in the reinforcing coating layer, the reinforcing coating layer may be heat-treated in air to remove the resin material, thereby obtaining a dried product (fiber material). The conditions for the heat treatment may be determined appropriately depending on the properties of the resin component and the fiber material, etc., but for example, heating at 400°C for 10 hours in an air atmosphere may be considered.

[0047] If the reinforcing coating layer contains a solid material (such as a filler) other than the fibrous material, the content of the fibrous material and the specific fiber contained in the reinforcing coating layer can be determined by an appropriate method depending on the composition of the reinforcing coating layer, such as by adding a step of redispersing the dried material (the dried material obtained in (a) above or the dried material obtained by the heat treatment above) in an appropriate liquid and then centrifuging it to separate the solid material from the fibrous material.

[0048] Referring again to Figure 3, the resin material 21 may be a so-called elastic paint, the coating surface of which exhibits a single layer of rubber-like properties. For example, an acrylic paint containing a cross-linked acrylic emulsion as a main component is preferred as the resin material 21. The content of the resin material 21 is preferably, for example, 80 to 99.5 mass% with respect to the total mass of the reinforcing coating layer 20. The reinforcing coating layer 20 is formed so as to adhere closely to the wall surface, thereby increasing at least one of the rigidity, strength, and deformability of the masonry structure S100.

[0049] Note that urethane paint may be used instead of acrylic paint as the resin material 21. Also, a part (preferably a majority by mass) or all of the resin contained in the fiber-reinforced resin that can constitute the reinforcing coating layer 20 is preferably an elastic resin, and is preferably an acrylic resin, a silicone resin, an acrylic silicone resin, a urethane resin, or a natural resin (latex paint).

[0050] The fibrous material 22 may be inorganic fibers (such as glass fibers, carbon fibers, or boron fibers) or organic fibers (such as aramid fibers or plant fibers), with inorganic fibers being preferred. In this embodiment, glass fibers are used as an example. The average diameter of the fibrous material 22 is, for example, 0.5 μm or more and 20 μm or less. Mixing the fibrous material 22 into an acrylic paint can produce a slurry in which the fibrous material 22 is suspended in the resin material. The weight ratio of the fibrous material 22 to the paint is, for example, 1% to 40%. The glass fiber may be, for example, glass fiber chopped strands cut to a predetermined length, from which a sizing agent (e.g., an adhesive polymer such as PVA or methyl cellulose) has been removed with an organic solvent such as toluene or styrene. The fibrous material 22 may be surface-treated to adjust its adhesion to the resin. The content of the fibrous material 22 is preferably 0.75 to 4 mass% of the total mass of the reinforcing coating layer 20. The fibrous material 22 is not limited to one type, and multiple types of fibrous materials may be included.

[0051] (Relationship between the length of the fiber material and the distance between the masonry members) The inventors have found that when the length L of the fiber material 22 in Fig. 3 is longer than the distance d1 between the masonry members, the reinforcing effect achieved by providing the reinforcing coating layer 20 on the masonry wall 10 can be effectively obtained. Note that, although the following mainly describes the relationship between the distance d1 between the masonry members in the vertical direction and the length L of the fiber material 22, the length L of the fiber material 22 may also be longer than the distance d2 between the masonry members in the horizontal direction.

[0052] The length L of the fibrous material 22 is not limited to a specific dimension as long as it is longer than the distance d1 and / or the distance d2 between the masonry members. In the paint of this embodiment, the fibrous material acts like a spring in the resin, for example, and if the adhesion between the fibrous material and the resin is good, it is expected that the rigidity and / or strength of the resin around the fibrous material will be improved.

[0053] For example, if the distance d1 between the masonry members is 5 mm, the length L of the fibrous material 22 may be greater than 5 mm. For example, the length L of the fibrous material 22 is preferably at least 10% longer than the lengths of the distances d1 and d2, and more preferably at least 20% longer than the lengths of the distances d1 and d2. Furthermore, the specific length is preferably longer than the distances d1 and / or d2, more preferably at least 10% longer than the distances d1 and / or d2, and even more preferably at least 20% longer than the distances d1 and / or d2.

[0054] The length L may refer to the length of the longest fiber among the fibers contained in the fibrous material 22, or may be a weighted average (length-average fiber length) value of the fiber lengths of the fibrous material 22. The weighted average value of the fiber lengths of the fibrous material 22 can be measured by analyzing a micrograph (or a photograph at a sufficiently high magnification) with an image analyzer.

[0055] As an example, the weighted average fiber length of the fibrous material 22 may be the weighted average fiber length of 50 randomly selected fibrous materials. The "50 fibrous materials" may be fibrous materials contained in a paint for forming a reinforcing coating layer, or fibrous materials contained in a reinforcing coating layer formed on the surface of a masonry wall. The fibrous material contained in the paint may be obtained, for example, by the above-described procedure (A). If necessary, a step of separating the solid material from the fibrous material may be added to the procedure (A). The fibrous material contained in the coating layer may be obtained, for example, by the above-described procedure (a). If necessary, instead of the procedure (a), a method of heating the coating layer in air to extract the fibrous material may be performed, or a step of separating the solid material from the fibrous material may be added.

[0056] The fiber material thus obtained from the paint or coating layer may be redispersed in an appropriate solvent, the resulting mixture spread on a clean glass plate, and a microscopic photograph (or a photograph at a sufficiently high magnification) of the group of fiber materials dispersed on the glass plate may be obtained. The photograph may then be analyzed using an image analyzer (software) to determine the weighted average fiber length (actual length) of 50 randomly selected fiber materials.

[0057] (Application of the Reinforcing Coating Layer) The paint forming the reinforcing coating layer 20 is applied to the masonry wall 10 using, for example, a roller, trowel, brush, or spray, and adheres to the wall surface. Specifically, the reinforcing coating layer 20 is formed by applying a paint containing glass fibers suspended in the paint and curing it. When the paint is, for example, a cross-linked acrylic emulsion, the paint forms a single layer that adheres firmly to the wall regardless of the surface morphology of the masonry wall 10.

[0058] The paint may be applied to the primer layer after the primer material has been applied to the masonry wall 10 and dried. The reinforcing coating layer 20 does not need to be a single layer, but may be formed by stacking multiple layers with different properties. The reinforcing coating layer 20 may not be formed directly on the wall surface of the masonry wall 10, but may be formed via a layer of mortar or the like. The reinforcing coating layer 20 may be hardened by drying, by using a hardener, or by using both drying and a hardener.

[0059] (Masonry Structure Manufacturing) Figure 4 is a flowchart showing an example of a process for manufacturing a masonry structure. In step S1, a worker prepares a masonry wall 10. For example, the worker repeatedly places masonry materials 11 and applies mortar, which is a filler material 15, to form a masonry wall 10 in which a plurality of masonry materials 11 are stacked. Note that, while an example in which the same worker performs steps S1 to S3 is shown here, the present invention is not limited to this, and the worker may perform steps S2 and S3 on a pre-formed masonry wall 10.

[0060] Next, in step S2, the worker applies the paint of the reinforcing coating layer 20 to the wall surface of the masonry wall 10. As described above, the worker applies the paint in which the fiber material 22 is dispersed in the resin material 21 to the wall surface using a roller, trowel, brush, sprayer, or the like.

[0061] Next, in step S3, the worker cures the applied paint. When forming multiple reinforcing coating layers, paint for forming another reinforcing coating layer may be applied before the reinforcing coating layer is completely dried.

[0062] The reinforcing coating layer 20 is formed by steps S2 and S3, and the masonry structure S100 reinforced by the reinforcing coating layer 20 is manufactured by the above series of manufacturing methods.

[0063] In step S1 of preparing the masonry wall, the plurality of masonry members 11 may be arranged without providing filler material 15. For example, a masonry wall may be formed without providing filler material 15 between vertically adjacent masonry members, a masonry wall may be formed without providing filler material 15 between horizontally adjacent masonry members, or a masonry wall may be formed without providing filler material 15 between both vertically adjacent masonry members and horizontally adjacent masonry members.

[0064] (Effects of this embodiment) According to the masonry structure S100 of this embodiment as described above, the reinforcing coating layer 20 is formed by applying paint containing a fiber material 22 that is longer than the distances d1 and d2 between the masonry materials to the wall surface of the masonry wall 10 and then hardening it, so that the reinforced masonry structure S100 can be manufactured in a simple process.

[0065] The reinforcing coating layer 20 of the masonry structure S100 has a high reinforcing effect by itself compared to paint that does not contain the fiber material 22, so even if the rigidity of the masonry wall 10 is insufficient, the final masonry structure S100 reinforced with the reinforcing coating layer 20 has sufficient rigidity. In addition, the formation of the reinforcing coating layer 20 can be expected to have the effect of improving the strength of the masonry structure S100.

[0066] Furthermore, the configuration of this embodiment is advantageous in reducing the overall weight of the building compared to existing buildings using masonry walls, and therefore the overall design of the building can be reconsidered, which can reduce the materials and costs used in building the building and reduce carbon dioxide emissions.

[0067] 2, the masonry material 11 above the first masonry material 11-1 is described as the second masonry material 11-2, but the relationship between the first masonry material and the second masonry material in the present invention does not necessarily have to be vertically adjacent as described above, and may be horizontally adjacent. In other words, the phrase "the fiber material is longer than the distance between the first masonry material and the second masonry material adjacent to the first masonry material" also includes the case where the length of the fiber material is longer than the horizontal distance between the masonry materials.

[0068] The inventors conducted a simulation to verify the relationship between the fiber length relative to the distance between masonry members and the effect of improving stiffness. Figures 5 and 6 are graphs showing the results of the simulation. Figure 5 is a semi-logarithmic graph, with the horizontal axis representing the fiber content (%) and the vertical axis representing the degree of increase in stiffness. Figure 6 is also a semi-logarithmic graph, with the horizontal axis representing the distance between masonry members (mm) and the vertical axis representing the degree of increase in stiffness. Note that Figures 5 and 6 relate to initial stiffness.

[0069] The purpose of this simulation is to verify the effect on the rigidity of the resin when the length of the fiber material is changed, and the effect when the length of the fiber material / distance between masonry members is changed. The simulation conditions are as follows: - Analysis method: Finite element method (FEM) - The resin was modeled with a standard FEM model using elastic two-dimensional constant strain triangular elements. - The fiber material was modeled with a standard FEM model using one-dimensional axial elements. - Young's modulus of fiber material (glass fiber) = 100,000 MPa - Poisson's ratio of fiber material (glass fiber) = 0.2 - Young's modulus of resin = 1 MPa

[0070] One of the parameters that influences the results is the ratio of the Young's modulus of the resin to that of the glass fiber, which was set to 1:100,000 in this analysis. The fiber material was assumed to be present at random positions within the resin. Furthermore, because it is difficult to conduct experiments to obtain the nonlinear load-slip behavior of the fiber within the resin, the boundaries between the fiber material and the resin, and between the fiber material, the resin, and the masonry material were fixed.

[0071] The increase rate is given by the following formula: Increase rate = (stiffness of coating layer with fiber) / (stiffness of coating layer without fiber) = (applied load / displacement of coating layer with fiber) / (applied load / displacement of coating layer without fiber).

[0072] The simulation shown in Figure 5 examined the tensile strength of a material containing dispersed fiber material in resin. Specifically, the tensile strength was examined when the fiber content (%) was varied for materials containing 3 mm, 6 mm, and 13 mm fiber material. As shown in Figure 5, it was confirmed that the tensile strength of the 3 mm fiber material increased with increasing fiber content. For the 6 mm fiber material, the tensile strength increased effectively up to a fiber content of approximately 4%, and for the 13 mm fiber material, the tensile strength also increased significantly with increasing fiber content.

[0073] In the simulation shown in Figure 6, the tensile strength of a structure in which a coating containing 3 mm, 6 mm, and 13 mm of fiber material was applied to the wall surface was examined. Specifically, as shown in Figure 7, the tensile strength (tensile force was applied in the vertical direction in the figure) of a structure in which a reinforcing coating layer containing fiber material was applied to the wall surface of two masonry blocks placed above and below a specified distance was examined. The fiber material content was 4%, and the distance between the masonry blocks was changed from 1 mm to 30 mm.

[0074] As shown in Figure 6, regardless of whether the fiber material is 3 mm, 6 mm, or 13 mm, in areas where the fiber material is longer than the distance between the masonry members, the "increase in rigidity" exceeds "5" (an effect exceeding the effect of the increase in rigidity due to the reinforcing coating layer itself can be confirmed). Therefore, it was confirmed that the effect of increasing the rigidity of the masonry structure can be obtained by forming a reinforcing coating layer using paint containing fiber material longer than the distance between the masonry members.

[0075] Of these, the 3mm fiber material, when the fiber material was longer than the distance between the masonry members (see the area to the left of line a), was confirmed to have an effect of increasing rigidity, although not as much as the 6mm and 13mm fiber materials, due to the configuration in which a reinforcing coating layer was formed using paint containing fiber material longer than the distance between the masonry members. Furthermore, the 6mm fiber material, when the fiber material was longer than the distance between the masonry members (see the area to the left of line b), exhibited a better stiffness-increasing effect than the 3mm fiber material. Similarly, the 13mm fiber material, when the fiber material was longer than the distance between the masonry members (see the area to the left of line c), exhibited a better stiffness-increasing effect than the 3mm fiber material.

[0076] From the above simulation results, it was confirmed that in a configuration in which a reinforcing coating layer is formed using paint containing fiber material longer than the distance between the masonry members, it is more preferable for the lower limit of the fiber material to be 3 mm or more, particularly 6 mm or more, in order to effectively reinforce the structure.

[0077] The results in Figures 5 and 6 are relative values ​​compared to resin without fiber material, not absolute values, and therefore similar trends are expected even if the thickness of the coating layer is different.

[0078] (Modification) Fig. 8 is a cross-sectional view schematically showing a modification of the masonry structure of the present invention. The up-down direction in Fig. 8 corresponds to the vertical direction, as an example. In the above-described embodiment, an example in which the reinforcing coating layer 20 is formed on the masonry wall 10 formed by stacking a plurality of masonry materials 11 has been described, but the present invention is not limited to this.

[0079] The masonry structure in FIG. 8 includes a masonry wall 110 and a reinforcing coating layer 120. The masonry wall 110 is, for example, a wall additively manufactured using a 3D printer. The masonry wall 110 only needs to have a surface (wall surface) on which the reinforcing coating layer 120 can be formed (particularly when the masonry wall 110 is manufactured using a 3D printer). The masonry wall 110 may be a structure that forms part or all of a wall or other component in a building or construction, or may be part or all of a component other than a wall, such as a bridge pier, monument, furniture, or ornament. The masonry wall 110 has multiple layers 111. Additive manufacturing using a 3D printer may be performed using any of a material extrusion method, a material jetting method, a liquid vat photopolymerization method, or a powder bed fusion method.

[0080] Layer 111 may be formed, for example, by discharging material from a moving nozzle of a 3D printer. Alternatively, if the material is photocurable, layer 111 may be formed by irradiating selected areas of an uncured layer with light. The material of layer 111 may be any material that can be discharged by a 3D printer, such as mortar. The material of layer 111 may also be cement, concrete, resin, or the like.

[0081] 8, no other material is interposed between a layer 111 and another layer 111 adjacent thereto in the vertical direction. However, in one embodiment of the present invention, another material may be interposed between the layers 111. The thickness da of the layer 111 is, for example, 1 mm or more and less than 200 mm, and specifically, for example, 15 mm or more and less than 50 mm.

[0082] The reinforcing coating layer 120 is a reinforcing layer formed on the wall surface of the masonry wall 110. The material of the reinforcing coating layer 120 is the same as that of the reinforcing coating layer 20 described above. The reinforcing coating layer 120 may be opaque or transparent.

[0083] In a masonry wall 110 formed by stacking multiple layers 111 as in the configuration of Figure 8, depending on the material and the manufacturing process using a 3D printer, the bond strength between the layers 111 (or, if an intervening material exists between adjacent layers 111, the bond strength between the layer 111 and the intervening material) may be reduced. Therefore, in the example of Figure 8, the masonry structure can be reinforced by providing a reinforcing coating layer 120 containing a fiber material.

[0084] 8, the length of the fiber material contained in the reinforcing coating layer 120 is, for example, 3 mm or more and 20 mm or less. For example, the length of the fiber material is preferably 1.5% or more of the thickness da of the layer 111 (for example, 3 mm or more for a layer 111 having a thickness of 200 mm) because this provides a good reinforcing effect.

[0085] The method for manufacturing the masonry structure of FIG. 8 includes the steps of stacking layers 111 formed by supplying material from a moving material supply (e.g., a nozzle of a 3D printer) to form a masonry wall 110, and forming a reinforcing coating layer 120 on the wall surface of the masonry wall 110.

[0086] In this way, according to a masonry structure comprising a masonry wall 110 formed by additive manufacturing and a reinforcing coating layer 120 formed on the wall surface, the masonry wall 110 is effectively reinforced by the reinforcing coating layer 120, thereby improving the strength and rigidity of the masonry wall.

[0087] Note that the "movement" in the above-mentioned "moving material supply unit" may refer to a change in position relative to the masonry wall to be formed. In other words, the material supply unit is considered to be moving not only when the material supply unit itself moves, but also when the material supply unit itself is fixed and the base (stage) on which the masonry wall is to be formed moves. In addition, a step of smoothing the surface of the masonry wall 110 (such as smoothing out surface irregularities) may be performed between the step of forming the masonry wall 110 and the step of forming the reinforcing coating layer 120 on the wall surface of the masonry wall 110.

[0088] The length of the fiber material when layered using a 3D printer is not limited to the above, and may be 1 mm or more and 20 mm or less.

[0089] The present invention has been described above using embodiments, but the technical scope of the present invention is not limited to the scope described in the above embodiments, and various modifications and changes are possible within the scope of the gist of the present invention. For example, all or part of the device can be configured by functionally or physically distributing or integrating in any unit. Furthermore, new embodiments resulting from any combination of multiple embodiments are also included in the embodiments of the present invention. The effects of the new embodiments resulting from the combination also have the effects of the original embodiments.

[0090] 10, 110 Masonry wall 11, 111 Masonry material 11-1 First masonry material 11-2 Second masonry material 15 Filler material 20, 120 Reinforcing coating layer 21 Resin material 22 Fiber material S100 Masonry structure

Claims

1. A method for manufacturing a masonry structure, comprising the step of forming a reinforcing coating layer on a wall surface of a masonry wall having a plurality of masonry members arranged vertically and horizontally, wherein the step of forming the reinforcing coating layer includes applying to the wall surface a paint containing a fibrous material whose length is longer than the distance between any first masonry member of the plurality of masonry members and a second masonry member adjacent to the first masonry member.

2. The method for manufacturing a masonry structure according to claim 1, wherein in the step of forming a reinforcing coating layer, the paint in which the fiber material having a length of 3 mm or more and 20 mm or less is dispersed is applied to the wall surface.

3. The method for manufacturing a masonry structure according to claim 1 or 2, further comprising the step of preparing a masonry wall, wherein in the step of preparing the masonry wall, the plurality of masonry members are arranged without providing a filler material between the first masonry member and the second masonry member.

4. A masonry structure comprising: a masonry wall in which a plurality of masonry members are arranged vertically and horizontally; and a reinforcing coating layer formed on a wall surface of the masonry wall, wherein the reinforcing coating layer is a layer of paint containing a fibrous material that is longer than the distance between any first masonry member among the plurality of masonry members and a second masonry member adjacent to the first masonry member.

5. The masonry structure according to claim 4, wherein the length of the fibrous material is between 3 mm and 20 mm.

6. A method for manufacturing a masonry structure, comprising: forming a masonry wall by stacking layers formed by supplying material from a moving material supply unit or by irradiating selected areas with light; and forming a reinforcing coating layer on a wall surface of the masonry wall, wherein the step of forming the reinforcing coating layer includes applying paint containing a fibrous material having a size of 3 mm or more and 20 mm or less to the wall surface.

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