Form, form manufacturing method, and form construction method

Abstract

Provided is a form with which a concrete wall having a large area is constructed, that does not require a separator, and that is lightweight.　A form (1) includes: a sheathing board connected body (5) in which a plurality of sheathing boards (4), each having a face plate (3) fixed to a surface on one side of a web plate (2), are provided side by side without gaps; and a plurality of truss beams (20) fixed to a surface on the other side of the sheathing board connected body (5) at intervals via battens (10). Each of the truss beams (20) has a truss structure (21) in which a plurality of truss members are connected, and the connected portions are pin-jointed.

Description

Formwork, formwork manufacturing method, and formwork construction method

[0001] The present invention relates to a formwork, a method for manufacturing a formwork, and a method for constructing a formwork.

[0002] Large-scale formwork construction is now becoming the mainstream method for construction of large concrete walls, such as bridge formwork construction (hivia) and seawall construction.

[0003] Conventional large-scale formwork construction methods use metal foam or wooden plywood as dam plates, and wide panel beams, shuttering, and other support materials for construction. However, construction using wide panel beams and shuttering has a height limit due to the performance of the materials. Specifically, when supported at both the top and bottom ends, the height limit is 3.6 m, and for heights exceeding this, it is necessary to connect opposing dam plates at an intermediate height with a separator.

[0004] However, installing separators can be difficult, and in some cases impossible, due to the recent improvements in earthquake resistance, which have led to overly dense reinforcement designs.

[0005] On the other hand, Patent Document 1 proposes a large-scale formwork device that does not require the installation of a separator. This large-scale formwork device 60 has a pair of formworks 61 arranged opposite each other, as shown in Figure 13. Each formwork 61 is equipped with a dam plate 62 and, on the side opposite the concrete pouring surface of the dam plate 62, an H-beam back pressure receiving member 64, which is connected via a number of crosspieces 63. Each formwork 61 is fixed by a lower end support portion 65 and an upper end support portion 66 that connect and support the lower and upper ends of the formworks 61.

[0006] With this large formwork device 60, even without installing separators between the opposing weir plates 62, the concrete pressure during concrete pouring is received by the highly rigid H-steel back pressure receiving member 64, making it possible to construct concrete walls without distortion or deformation.

[0007] Japanese Patent Application Publication No. 9-273302

[0008] However, the large-scale formwork device 60 disclosed in the above-mentioned Patent Document 1 has a problem in that it is very heavy and difficult to handle because it uses a back pressure receiving member 64 made of H-beam steel.

[0009] Therefore, an object of the present invention is to provide a lightweight formwork for constructing a large-area concrete wall without using a separator, a method for manufacturing the formwork, and a construction method using the formwork.

[0010] The present invention has been made in consideration of the above problems, and is characterized in that (1) it comprises a shear plate connecting body in which a plurality of shear plates each having a face plate fixed to one side of a nodal plate are arranged side by side without any gaps, and a plurality of truss beams arranged at intervals on the other side of the shear plate connecting body and subjected to back pressure from the shear plate connecting body, each truss beam having a truss structure in which a plurality of beam members are connected and the connecting points between them are pin-jointed, and the truss beam has protruding rod portions protruding from both ends of the truss structure, and the protruding rod portions protrude from both ends of the shear plate connecting body.

[0011] (2) In the above (1), a plurality of thick end members are arranged between the sheathing panel connector and the plurality of truss beams at intervals in a direction perpendicular to the plurality of truss beams.

[0012] (3) In the above (1) or (2), the dam plate is made of steel and is characterized in that it has a square frame body portion, a nodal plate having a reinforcing rib portion arranged within the frame body portion, and a face plate fixed to one side of the nodal plate.

[0013] (4) In the above (2), the truss beams are arranged in pairs at intervals on the upper surfaces of the plurality of thick end materials.

[0014] (5) A formwork construction method using the formwork described in (1) or (2) above, characterized in that it includes the steps of: positioning the formwork along an outer position of the concrete pouring area; connecting the upper ends of the truss beams arranged opposite each other; and supporting the lower ends of each truss beam on the concrete installation side.

[0015] According to the present invention, a sheathing plate connector, in which multiple sheathing plates are arranged side by side with no gaps, forms a single sheathing plate, making it possible to construct concrete walls of large area. The truss beam is formed much lighter than when the back support member is made of H-beam. Furthermore, because the concrete pressure during concrete pouring is supported by the extremely strong truss beam, concrete walls can be constructed without distortion or deformation even without installing separators between the sheathing plates. As described above, it is possible to provide a lightweight formwork, a method for manufacturing the formwork, and a construction method using the formwork for constructing large concrete walls without using separators.

[0016] The drawings show specific embodiments of the present invention according to the present disclosure, and include not only essential configurations of the invention but also optional and preferred embodiments. This embodiment shows a front view of a formwork. This embodiment shows a plan view of the formwork. This embodiment shows an exploded perspective view of the formwork. This embodiment shows (a) a plan view of a node plate, (b) a front view of the node plate, and (c) a side view of the node plate. This embodiment shows a plan view of a shear plate connector. This embodiment shows a plan view illustrating a formwork installation process. This embodiment shows a plan view illustrating installation of tie rods. This embodiment shows a plan view illustrating installation of steel members for ensuring formwork dimensions. This embodiment shows a plan view illustrating installation of embedded anchors. This embodiment shows (a) a cross-sectional view taken along line X(a)-X(a) in FIG. 9, and (b) an enlarged view of part X(b) in FIG. 10(a). 11(a) is a cross-sectional view of the XI(a)-XI(a) line in FIG. 9, and FIG. 11(b) is an enlarged view of the XI(b) portion in FIG. 11(a). 11(a) is a vertical cross-sectional view of a conventional large formwork device.

[0017] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings. In this embodiment, a description of already known technologies will be omitted. Furthermore, the following merely illustrates an apparatus and method for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to the following. The technical idea of ​​the present invention can be modified in various ways within the scope of the matters described in the claims. In particular, it should be noted that the drawings are schematic and may differ from the actual product.

[0018] (Formwork) As shown in FIGS. 1 to 4, the formwork 1 includes a dam board connecting body 5 formed by connecting a plurality of dam boards 4, a plurality of thick end members 10, and a plurality of truss beams 20.

[0019] Each of the dam panels 4 constituting the dam panel connecting body 5 is composed of a node panel 2 and a face panel 3 .

[0020] As shown in detail in Figure 4, the node plate 2 is made of a highly rigid material such as steel. The node plate 2 is composed of a rectangular frame portion 2a and reinforcing rib portions 2b arranged in a perpendicular direction within the frame portion 2a. A plurality of rib holes 2c are formed at intervals around the entire periphery of the side of the frame portion 2a. The reinforcing rib portions 2b divide the inside of the frame portion 2a, forming a plurality of rectangular spaces within the frame portion 2a. These rectangular spaces contribute to the weight reduction of the node plate 2. The dimensions of the node plate 2 are, for example, a width (B) of 600 mm, a length (L) of 1800 mm, and a thickness (t) of 55 mm.

[0021] The face plate 3 is fixed to one side of the joint plate 2 by driving steel screws (not shown) or concrete nails (not shown). The face plate 3 is made of a decorative concrete panel, a transparent acrylic plate, or the like. The type of face plate 3 is selected taking into consideration various situations. The face plate 3 has the same width and length as the joint plate 2, and a thickness of, for example, 12 mm.

[0022] The dimensions of the weir plate 4 are, for example, a width (B) of 600 mm, a length (L) of 1800 mm, and a thickness (t) of 67 mm. The thickness of a conventional metal form is, for example, 55 mm, and the thickness of the joint plate 2 is set to the same thickness. If an auxiliary weir plate with an outer diameter other than that of the weir plate connector 5 described below is required, a decorative concrete panel is installed by hammering it into the metal form with concrete nails. In other words, the auxiliary weir plate and the weir plate 4 are designed to have the same thickness.

[0023] The plurality of thick end members 10 are arranged on a sheathing plate connecting body 5 which is formed by arranging a plurality of sheathing plates 4 side by side without any gaps. The plurality of thick end members 10 are arranged at intervals on the other side surface of the sheathing plate connecting body 5, and each thick end member 10 is fixed to each sheathing plate 4.

[0024] The multiple truss beams 20 are arranged at intervals on the upper surfaces of the multiple thickened members 10, oriented in a direction perpendicular to the thickened members 10. Each truss beam 20 is fixed to each thickened member 10 and the sheathing board 4. Each truss beam 20 has a truss structure 21 in which the beam members are connected to each other and the connecting points are pin-jointed.

[0025] In this embodiment, the truss structure 21 is a Warren truss. The beam members that make up the Warren truss are upper chord members 21a, lower chord members 21b, and lattice members 21c, and the lattice members 21c form identical triangles that are lined up in a row between the upper chord members 21a and the lower chord members 21b.

[0026] The truss beam 20 has protruding rods 22, 23 extending from both ends of the lower chord 21b of the truss structure 21. These protruding rods 22, 23 at both ends protrude from both ends of the sheathing panel connector 5. An L-shaped angle 30, which is a truss connector member, is hung across the protruding rod 22, which is the upper part when the formwork 1 is installed. The L-shaped angle 30 is fixed to each truss beam 20.

[0027] The truss beams 20 are arranged in pairs, spaced apart on the top surfaces of the multiple thick end members 10. Square steel pipes 31, which serve as sway suppression members, pass through the truss structures 21 of all the truss beams 20, utilizing the triangular space formed by the upper chord members 21a, lower chord members 21b, and lattice members 21c. Each square steel pipe 31 is fastened to the truss structures 21 of all the truss beams 20 with fastening bands (not shown). The square steel pipes 31 stop the truss beams 20 from swaying or touching each other.

[0028] In this embodiment, the formwork 1 configured in this way has a square meter count per panel of, for example, 5.4 m x 4.8 m = 26 m ２ The construction will be as follows:

[0029] (Form Fabrication Procedure) Next, a description will be given of a fabrication procedure for the form 1. First, a face plate 3 is fixed to one side of each node plate 2 to fabricate a predetermined number of sheathing plates 4 (sheathing plate fabrication step).

[0030] Next, as shown in Fig. 4, a predetermined number of sheathing plates 4 are arranged side by side in both orthogonal directions with no gaps between them, with the other side facing up. In this embodiment, as shown in Fig. 5, three sheathing plates 4 are arranged side by side in both the longitudinal direction and the orthogonal direction. Then, adjacent sheathing plates 4 are connected with U-clips (not shown), bolts, and nuts (not shown) to produce a sheathing plate assembly 5 (sheathing plate assembly production process).

[0031] Next, a plurality of thickened materials 10 are arranged at intervals on the upper surface (the surface on the other side) of the sheathing board connecting body 5. Each of the arranged thickened materials 10 is fixed to each sheathing board 4 (thickened material fixing process).

[0032] Next, a plurality of truss beams 20 are arranged at intervals on the upper surfaces of the plurality of thickened materials in a direction perpendicular to the thickened materials 10. Each of the arranged truss beams 20 is fixed to the thickened materials 10 and the dam board 4, and the plurality of truss beams 20 are fixed to the dam board connector 5 via the plurality of thickened materials 10 (truss beam fixing process).

[0033] Finally, L-shaped angles 30 are placed across the upper surfaces of the protruding rod portions 22 of all truss beams 20, which will be the upper portions when the formwork 1 is installed. These L-shaped angles 30 are fixed to the protruding rod portions 22 of each truss beam 20. Furthermore, square steel pipes 31 are passed through the triangular spaces of the truss structures 21 of all truss beams 20, and the square steel pipes 31 are fastened to the truss structures 21 of all truss beams 20 with fastening bands (not shown), completing the process (auxiliary material fastening process). The square steel pipes 31 are removed during or after the formwork installation process described below.

[0034] (Formwork construction work (formwork erection work)) When constructing concrete columns for a bridge, the formwork construction work will be explained using an example in which the concrete pouring area S (shown in Figure 6) has a rectangular basic shape and an octagonal cross section with chamfered corners (see Figure 6).

[0035] As a work before the construction of the formwork, in the formwork production process described above, two sets of short-side formwork 1A are produced, each consisting of eleven truss beams 20 assembled in pairs. Two sets of long-side formwork 1B are produced, each consisting of thirteen truss beams 20 assembled in pairs. In addition, corner formwork (the auxiliary formwork described above) 1C is produced, each consisting of two truss beams 20 assembled in pairs. Triangular nodal plates 2A (shown in Figure 7) are added to the corner formwork 1C as nodal plates 2, and face panels 3 are attached to the corner portions.

[0036] Next, the formwork construction work (formwork erection method) will be described. First, the scaffolding for the reinforcing bar brackets is removed, the receiving metal fittings for the formwork 1A, 1B, and 1C are installed, and the main bodies are attached to the embedded anchors (construction preparation process).

[0037] Next, the formworks 1A, 1B, and 1C are moved to predetermined installation positions using a crane or the like and then suspended (formwork suspension step). The suspension by the crane is performed using dedicated suspension hardware (not shown).

[0038] Next, as shown in Figure 6, the formwork 1A, 1B, and 1C are placed around the periphery of the concrete pouring area S, so as to completely surround the concrete pouring area S (formwork installation process). Note that Figure 6 shows the intermediate process in which only the long side formwork 1B has been installed.

[0039] After the formwork has been installed, as shown in Figure 7, tie rods 40, which are truss connecting members, are stretched over the upper positions of the truss beams 20 arranged opposite each other in each of the formworks 1A, 1B, and 1C (tie rod installation process).

[0040] Next, as shown in Figure 8, a plurality of formwork dimension securing steel materials 41, which serve as width stoppers, are hung at intervals between the L-shaped angles 30 on the opposing long sides, and each of the hung formwork dimension securing steel materials 41 is fixed to each L-shaped angle 30 (steel material installation process).

[0041] Next, as shown in Figures 9 to 11, embedded anchors 43 are fixed to the upper and lower sides of the lower chord member 21b of each truss beam 20 of the formworks 1A, 1B, and 1C using truss bands 42 or the like (embedded anchor installation process). The truss bands 42 are attached to the upper side of the truss beam 20 by utilizing the lower chord member 21b of the truss structure 21. The truss bands 42 are attached to the lower side of the truss beam 20 by utilizing the protruding rod portions 23. As described below, inclined embedded anchors 43 are used.

[0042] Figure 12 shows the detailed installation state of the embedded anchor 43. The embedded anchor 43 is positioned so as not to interfere with the numerous distribution reinforcement bars 50 and column reinforcement bars 51 arranged in the concrete pouring area S. Here, as shown in Figure 12(a), when the distribution reinforcement bars 50 and column reinforcement bars 51 are densely arranged, the straight embedded anchor 43A needs to be installed in a position significantly shifted from its predetermined installation position to avoid interference with the column reinforcement bars 51, for example. Therefore, as shown in Figure 12(b), an embedded anchor 43 with an oblique angle (for example, about 15 degrees) is used for the embedded anchor 43A, and it is installed in a position slightly shifted from its predetermined installation position.

[0043] In more detail, when the installation positions of the embedded anchors 43, 43A are located at the center of the column reinforcement 51, as shown in Figure 12(a), with a straight embedded anchor 43A, interference cannot be avoided unless the installation position is shifted significantly, but as shown in Figure 12(b), interference can be avoided by simply shifting the installation position slightly by using a bent embedded anchor 43. The same is true when the installation positions of the embedded anchors 43, 43A are located near the center of the column reinforcement 51; the installation shift position can be made smaller with a bent embedded anchor 43 than with a straight embedded anchor 43A.

[0044] Finally, the concrete scaffolding is installed to complete the work (scaffolding installation process).

[0045] When constructing a concrete wall in which the height of the concrete pouring area S is higher than the height of the dam plate connectors 5 (for example, 5.4 m), the concrete pouring process is divided into multiple lots. That is, in the first lot process, concrete is poured to a height less than the height of the dam plate connectors 5 (for example, 5.4 m), and in the second lot process, the formwork 1 installed in the first lot process is removed and reinstalled at the next height position, where concrete is poured. This process is repeated up to the desired height of the concrete pouring area S.

[0046] (Fresh concrete pouring process) In the formwork 1 configured in this manner, when fresh concrete is poured into the concrete pouring area S during the concrete pouring process, the pressure of the fresh concrete acts on the sheathing plate connectors 5 until the fresh concrete hardens, and this concrete pressure is received by the multiple truss beams 20 via the multiple thick end members 10. Each truss beam 20 has a truss structure and is extremely strong, so all of the truss beams 20 can fully withstand the high concrete pressure that acts when constructing a large-area concrete wall.

[0047] (Effects of the embodiment) As described above, the formwork 1 of this embodiment comprises a sheathing panel connecting body 5 consisting of a plurality of sheathing panels 4 arranged side by side without any gaps, each having a face plate 3 fixed to one side of a node plate 2, and a plurality of truss beams 20 arranged at intervals on the other side of the sheathing panel connecting body 5 and receiving back pressure from the sheathing panel connecting body 5, and each truss beam 20 has a truss structure 21 in which a plurality of beam members 21a, 21b, 21c are connected and the connecting points between them are pin-jointed.

[0048] Therefore, the sheathing plate connector 5, in which multiple sheathing plates 4 are arranged side by side with no gaps, forms a single sheathing plate, resulting in a large-sized formwork 1, enabling the construction of large-area concrete walls. The truss beam 20 is constructed much lighter than in the conventional case where the back pressure-receiving member 64 is formed from H-shaped steel (see Figure 13). Furthermore, since the concrete pressure during concrete pouring is supported by multiple truss beams 20 with extremely high strength, a concrete wall can be constructed without distortion or deformation even without installing separators between the sheathing plates 4 arranged opposite each other. As described above, a lightweight formwork 1 can be provided for constructing large-area concrete walls without using separators. Furthermore, the light weight of the formwork 1 improves the handleability of the formwork 1 and shortens the construction cycle, etc.

[0049] Since the dam plate connector 5 is made by connecting multiple dam plates 4, assembly and disassembly work can be easily carried out near the concrete pouring site.

[0050] Between the sheathing plate connector 5 and the plurality of truss beams 20, a plurality of thickened members 10 are arranged at intervals in a direction perpendicular to the plurality of truss beams 20. Therefore, the concrete pressure during concrete pouring is received almost evenly by the plurality of thickened members 10, and the plurality of truss beams 20 can withstand the high concrete pressure acting when constructing a large-area concrete wall. Furthermore, since the surface force from the sheathing plate connector 5 is received by the plurality of thickened members 10 and the plurality of truss beams 20 arranged perpendicular to one another, the surface direction of the sheathing plate connector 5 can be made two-dimensionally flush with no distortion or steps, and the concrete wall surface can be made flush.

[0051] The dam plate 4 is made of steel and has a rectangular frame body 2a, a node plate 2 having a reinforcing rib portion 2b arranged within the frame body 2a, and a face plate 3 fixed to one side of the node plate 2.

[0052] Therefore, because the joint plate 2 is made of steel, it will not deform due to the pressure of the concrete when poured. Also, because the joint plate 2 is reinforced by the reinforcing rib portion 2b, it has higher rigidity than when the reinforcing rib portion 2b is not provided, and deformation due to the pressure of the concrete when poured can be reliably prevented.

[0053] The truss beam 20 has protruding rod portions 22 and 23 that protrude from both ends of the truss structure 21, and the protruding rod portions 22 and 23 protrude from both ends of the sheathing plate connector 5.

[0054] Therefore, the protruding rod portions 22, 23 can be used to fix the formwork 1 at the installation location, which improves the installation workability of the formwork 1 and shortens the construction cycle.

[0055] The truss beams 20 are arranged in pairs on the upper surfaces of the plurality of thick end members 10 at intervals.

[0056] Therefore, compared to when one truss beam 20 constitutes one set, the strength is higher, and the concrete pressure during concrete pouring can be reliably withstood without causing problems such as deformation of the sheathing plate 4. Note that one truss beam 20 may be used as one set, depending on the level of concrete pressure acting when constructing the concrete wall. Conversely, three or more truss beams 20 may be used as one set.

[0057] In this embodiment, the truss structure 21 of the truss beam 20 is a Warren truss type. The concrete pressure during concrete pouring acts as a distributed load on the truss structure 21, and the Warren truss naturally does not experience a bending moment in response to the distributed load, and only a uniform axial force acts on each lattice member 21c, resulting in high pressure resistance. However, the truss structure 21 of the truss beam 20 may be a truss structure other than a Warren truss.

[0058] As described above, the formwork manufacturing method of this embodiment includes the steps of fixing a face plate 3 to one side of each section plate 2 to manufacture a plurality of sheathing panels 4, arranging the plurality of sheathing panels 4 side by side without any gaps to manufacture a sheathing panel connector 5, fixing a plurality of thick-end materials 10 to the other side of the sheathing panel connector 5, and fixing a plurality of truss beams 20 at intervals to the upper surfaces of the plurality of thick-end materials 10 in a direction perpendicular to the thick-end materials 10, and fixing the plurality of truss beams 20 to the sheathing panel connector 5 via the plurality of thick-end materials 10.

[0059] Therefore, there are no advanced or complicated work processes that can only be performed by skilled workers, which allows for a shorter construction cycle.

[0060] As described above, the formwork construction method of this embodiment includes the steps of positioning the formwork 1 along the outer position of the concrete pouring area S, connecting the upper ends of the truss beams 20 arranged opposite each other, and supporting the lower ends of each truss beam 20 on the concrete installation side.

[0061] Therefore, there are no advanced or complicated work processes that can only be performed by skilled workers, which allows for a shorter construction cycle.

[0062] Although each embodiment has been described in detail above, it is not limited to a specific embodiment, and various modifications and changes are possible within the scope of the claims. It is also possible to combine all or a plurality of components of the above-described embodiments.

[0063] REFERENCE SIGNS LIST 1, 1A to 1C formwork 2 nodal plate 3 face plate 4 sheathing plate 5 sheathing plate connector 10 thick end material 20 truss beam 21 truss structure 21a upper chord material (beam material) 21b lower chord material (beam material) 21c lattice material (beam material) 22, 23 protruding rod portion

Claims

1. A formwork comprising: a shear plate connecting body in which a plurality of shear plates, each having a face plate fixed to one surface of a nodal plate, are arranged side by side without any gaps; and a plurality of truss beams arranged on the other surface of the shear plate connecting body and subjected to back pressure from the shear plate connecting body, wherein each of the truss beams has a truss structure in which a plurality of beam members are connected and their connecting points are joined by pins; and the truss beams have protruding rod portions protruding from both ends of the truss structure, and the protruding rod portions protrude from both ends of the shear plate connecting body.

2. A formwork as described in claim 1, characterized in that a plurality of thick end members are arranged between the sheathing panel connector and the plurality of truss beams, spaced apart in a direction perpendicular to the plurality of truss beams.

3. The formwork described in claim 1 or 2, characterized in that the dam plate is made of steel and has a square frame body, a nodal plate having a reinforcing rib portion arranged within the frame body, and the face plate fixed to one side of the nodal plate.

4. The formwork according to claim 2, characterized in that the truss beams are arranged in pairs at intervals on the upper surfaces of the plurality of thick end members.

5. A formwork construction method using the formwork described in claim 1 or 2, characterized by comprising the steps of: positioning the formwork along the outer position of a concrete pouring area; connecting the upper ends of the truss beams arranged opposite each other; and supporting the lower ends of each truss beam on the concrete installation side.

Images