SUPPORT MEMBER, CONCRETE PLACING FORM, AND METHOD FOR CONSTRUCTING CONCRETE STRUCTURE

Abstract

Embodiments provide reusable support member capable of facilitating assembly and disassembly of a form, and a concrete placing form. A reusable support member supports outer side surfaces of concrete panels providing cavity as predetermined space for placing concrete includes horizontal rails with a length according to width of the panels, vertical rails with length according to height of the panels, and bolt and nut structures for locking the panels into inner direction of the cavity by penetrating intersections in which respectively parallel the horizontal and vertical rails are combined in lattice shape. Either of the horizontal and vertical rails relating to the intersections, include recesses capable of fitting in opposing rails by receiving a width and a part or all of a thickness of opposing rails. The rails are configured by channel steel or metal material with equivalent shape, and the rails contact the outer side surfaces at equal intervals.

Description

RELATED APPLICATIONS

This application, filed under 35 U.S.C. § 371, is a U.S. national phase application of and based on PCT/JP2016/072133, filed Jul. 28, 2016, which claims priority of Japanese Patent Application No. 2015-152122 filed Jul. 31, 2015 is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

Present invention relates to a support member, a concrete placing form, and a method for constructing concrete structure, in more detail, present invention relates to a support member for supporting form panels arranged to face each other by surrounding a set of reinforcing steels or steel frame, a concrete placing form using the support member, and a method for constructing concrete structure for constructing a reinforced concrete structure or a steel framed reinforced concrete structure (hereinafter, simply referred to as “concrete structure”) by placing concrete in concrete placing space (hereinafter, referred to as “cavity”) formed by the concrete placing form. This application is based upon and claims the benefit of priority from the Japanese Patent Application No. 2015-152122 filed in Japan on Jul. 31, 2015, which is incorporated by reference herein.

Description of Related Art

A conventional forming method of concrete structure generally comprises: a reinforcement arranging step for combining reinforcing steels; a form assembling step for arranging form panels to face each other with predetermined spacing by surrounding arranged reinforcement; a concrete placing step for pouring concrete into cavity formed between form panels, and each concrete skeleton part such as a pillar, a beam, or a slab is formed via a step for disassembling form panels after predetermined curing period has passed. In conventional method, an operation to disassemble assembled form panels and to convey them from construction site is performed, when forming each concrete skeleton part, as the above, and it required a labor, and also, it required days for disassembling operation and a space for temporarily storing form panels and assembling members, and else.

In addition, in a conventional forming method of concrete structure, an assembling step of mounting member for mounting an interior material such as an interior board such as a frame material or a stud to the concrete skeleton part is performed. In addition, in conventional method, a mounting step of interior material is performed after coping with heat insulation, sound insulation, damp proofing, and else by laying heat insulating and damp proofing body such as heat insulating and damp proofing board, or the like accordingly to a surface of the bare concrete skeleton. Therefore, in conventional method, because of heat insulating and damp proofing body and performance of its installation step, there was an increase in cost and time.

As a method for resolving the problem of the above conventional forming method of concrete structure, this applicant proposed a method for forming concrete structure by using form panels made of foamed synthetic resin, and by leaving these form panels on surfaces of the concrete skeleton part to be formed (refer to Patent Literature 1). According to this method for forming concrete structure, a step for disassembling form panels will not be necessary, and also, the form panels made of foamed synthetic resin integrated on surfaces of the concrete skeleton part will exert function of heat insulating and damp proofing body.

A concrete placing form described in Patent Literature 1 is configured by combining a pair of form panels made of foamed synthetic resin to be able to adjust spacing between the form panels facing each other by a connection mechanism. The connection mechanism of the concrete placing form is configured by a pair of arms (webs) combined in X-shape by coupling at a center, and a pair of plates forming connection strips for connecting ends of each arm by respectively combined to outer side surface of the form panels. The assembly of the concrete placing form is performed to suitably set spacing of the form panels facing each other by rotatably coupling a pair of arms at the center, and by connecting the ends of the arms with mounting strips of the plates penetrating the form panels to adjust connecting position.

• Patent Literature 1: JP 4169159 B

SUMMARY OF THE INVENTION

However, in the concrete placing form having the above various features, there is a room for improvement at least about support member (base plate), from a point of view of reducing construction cost significantly by reduction of cost of members and by shortening of construction period. The present invention is configured considering this problem, and a purpose of the present invention is to provide a support member capable of assembling and disassembling a form easily, and a concrete placing form or a method for constructing concrete structure using the support member. As a result, there is a purpose to reduce construction cost significantly by reducing cost of members and by shortening construction period. Further, the support member relating to the present invention is also having a purpose to generalize to be usable for all form panels such as normal form by plywood or the like, EPS form, rock cell form, and else only by changing its size.

The present invention is configured for such purposes and the invention described in claim 1 is a reusable support member for supporting outer side surfaces (12a) of concrete panels (12) providing cavity (20) as predetermined space for placing concrete, comprising: a plurality of horizontal rails (71) with a length according to width (w) of the concrete panels (12); a plurality of vertical rails (72) with length according to height (v) of the concrete panels (12); and bolt and nut structures (60) for locking the concrete panels (12) into inner direction of the cavity (20) by penetrating intersections (73) in which respectively parallel the plurality of horizontal rails (71) and the plurality of vertical rails (72) are combined in lattice shape, wherein, in at least either of the horizontal rails (71) and the vertical rails (72) relating to the intersections (73), recesses (R) capable of fitting in opposing rails by receiving a width (P) and a part or all of a thickness (Q) of opposing rails are arranged, the horizontal rails (71) and the vertical rails (72) are configured by channel steel or metal material with equivalent shape, and the horizontal rails (71) and the vertical rails (72) combined in the lattice shape contact the outer side surfaces (12a) of the concrete panels (12) at equal intervals respectively.

In addition, the invention described in claim 2 is a concrete placing form (100) fixed by a reusable support member for supporting concrete panels (12) providing cavity (20) as predetermined space for placing concrete, the support member comprises: a plurality of horizontal rails (71) with a length according to width (w) of the concrete panels (12); a plurality of vertical rails (72) with length according to height (v) of the concrete panels (12); bolt and nut structures (60) for locking the concrete panels (12) into inner direction of the cavity (20) by penetrating intersections (73) in which respectively parallel the plurality of horizontal rails (71) and the plurality of vertical rails (72) are combined in lattice shape; form fixing rods (40) penetrating mounting holes (13) and (74) drilled in the concrete panels (12), the horizontal rails (71) and the vertical rails (72) by aligning to the intersections (73); and skeleton side form fixing members (50) for supporting the concrete panels (12) to outer direction from inside of the cavity (20) by being locked at predetermined position of the form fixing rods (40), wherein, in at least either of the horizontal rails (71) and the vertical rails (72) relating to the intersections (73), recesses (R) capable of fitting in opposing rails by receiving a width (P) and a part or all of a thickness (Q) of opposing rails are arranged, the horizontal rails (71) and the vertical rails (72) are formed by channel steel or metal material with equivalent shape, the horizontal rails (71) and the vertical rails (72) combined in the lattice shape contact the outer side surfaces (12a) of the concrete panels (12) at equal intervals respectively, the skeleton side form fixing members (50), one of the concrete panels (12), the horizontal rails (71) and the vertical rails (72) are formed to be arranged in this order from a center (0) of longitudinal direction of the form fixing rods (40) to one end (41) of the form fixing rods (40), and the bolt and nut structures (60) are formed at least at one end (41) of the form fixing rods (40).

In addition, the invention described in claim 3 is the concrete placing form according to claim 2, wherein the concrete panels (12) are formed by suitably connecting unit panels (10) in same or similar shape in which adjacent peripheral edges (11) can be fitted to each other by a contour forming protrusions and recesses.

In addition, the invention described in claim 4 is the concrete placing form according to claim 2 or 3, wherein a structure from the center (0) of longitudinal direction of the form fixing rods (40) to one end (41) of the form fixing rods (40) is symmetrical with a structure from the center (0) of longitudinal direction of the form fixing rods (40) to other end (42) of the form fixing rods (40).

In addition, the invention described in claim 5 is the concrete placing form according to claim 2 or 3, wherein the unit panels (10) are formed by closed cell type foamed synthetic resin.

In addition, the invention described in claim 6 is the concrete placing form according to claim 2 or 3, wherein fitting parts (9) are formed in the peripheral edges (11) of the unit panels (10), and the unit panels (10) are arranged by combining many unit panels (10) in up and down and in left and right by abutting the peripheral edges (11) and fitting the opposing fitting parts (9), and the fitting parts (9) are configured by inner fitting parts (6) and outer fitting parts (7) alternately forming fitting protrusions (4) and fitting recesses (5) with opening size (H) approximately equal to the fitting protrusions (4) over entire region of longitudinal direction (Z) of the unit panels (10), respectively in inner region (2) and outer region (3) sectioned in thickness (G) direction of the unit panels (10), and also, the fitting protrusions (4) and the fitting recesses (5) of the inner fitting parts (6) and the outer fitting parts (7) are formed in opposed positions by shifting for one pitch.

In addition, the invention described in claim 7 is a method for constructing concrete structure by reusing a support member for supporting outer side surfaces (12a) of concrete panels (12) providing cavity (20) as predetermined space for placing concrete, the support member comprises: a plurality of horizontal rails (71) with a length according to width (w) of the concrete panels (12); a plurality of vertical rails (72) with length according to height (v) of the concrete panels (12); and bolt and nut structures (60) for locking the concrete panels (12) into inner direction of the cavity (20) by penetrating intersections (73) in which respectively parallel the plurality of horizontal rails (71) and the plurality of vertical rails (72) are combined in lattice shape, wherein, in at least either of the horizontal rails (71) and the vertical rails (72) relating to the intersections (73), recesses (R) capable of fitting in opposing rails by receiving a width (P) and a part or all of a thickness (Q) of opposing rails are arranged, the horizontal rails (71) and the vertical rails (72) are formed by channel steel or metal material with equivalent shape, and the horizontal rails (71) and the vertical rails (72) combined in the lattice shape contact the outer side surfaces (12a) of the concrete panels (12) at equal intervals respectively.

In addition, the invention described in claim 8 is a method for constructing concrete structure by using a concrete placing form (100) fixed by a reusable support member for supporting concrete panels (12) providing cavity (20) as predetermined space for placing concrete, the support member comprises: a plurality of horizontal rails (71) with a length according to width (w) of the concrete panels (12); a plurality of vertical rails (72) with length according to height (v) of the concrete panels (12); bolt and nut structures (60) for locking the concrete panels (12) into inner direction of the cavity (20) by penetrating intersections (73) in which respectively parallel the plurality of horizontal rails (71) and the plurality of vertical rails (72) are combined in lattice shape, form fixing rods (40) penetrating mounting holes (13) and (74) drilled in the concrete panels (12), the horizontal rails (71) and the vertical rails (72) by aligning to the intersections (73); and skeleton side form fixing members (50) for supporting the concrete panels (12) to outer direction from inside of the cavity (20) by being locked at predetermined position of the form fixing rods (40), wherein, in at least either of the horizontal rails (71) and the vertical rails (72) relating to the intersections (73), recesses (R) capable of fitting in opposing rails by receiving a width (P) and a part or all of a thickness (Q) of opposing rails are arranged, the horizontal rails (71) and the vertical rails (72) are formed by channel steel or metal material with equivalent shape, and the horizontal rails (71) and the vertical rails (72) combined in the lattice shape contact the outer side surfaces (12a) of the concrete panels (12) at equal intervals respectively, the skeleton side form fixing members (50), one of the concrete panels (12), the horizontal rails (71) and the vertical rails (72) are formed to be arranged in this order from a center (0) of longitudinal direction of the form fixing rods (40) to one end (41) of the form fixing rods (40), and the bolt and nut structures (60) are formed at least at one end (41) of the form fixing rods (40).

In addition, the invention described in claim 9 is the method for constructing concrete structure according to claim 7 or 8, wherein the concrete panels (12) become a part of a building without being disassembled and removed even after concrete placed in the cavity (20) is solidified.

According to the present invention, it is possible to provide a support member capable of facilitating assembly and disassembly of a form, and a concrete placing form or a method for constructing a concrete structure using the support member. As a result, it is possible to reduce construction cost significantly by reducing cost of members and by shortening construction period. In addition, the support member relating to the present invention can achieve a purpose to generalize to be usable for all form panels such as normal form by plywood or the like, EPS form, rock cell form, and else only by changing its size.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially perspective view for explaining schematically about a support member (hereinafter, referred to as “the support member”) relating to embodiments of the present invention, a concrete placing form (hereinafter, referred to as “the form”) and a method for constructing a concrete structure (hereinafter, referred to as “the method”) using the support member.

FIG. 2 is a side sectional view for explaining the form of FIG. 1 in more detail.

FIG. 3 is a projection view of a unit panel composing the concrete panel, which may be adopted in the form of FIGS. 1 and 2, and FIG. 3A is a top view, FIG. 3B is a sectional view along line F-F, FIG. 3C is a front view, FIG. 3D is a bottom view, and FIG. 3E is a side view.

FIG. 4 is a perspective view of a state that the unit panels of FIG. 3 are aligned and connected in up and down.

FIG. 5 is a view illustrating the adoptable support member and a bolt and nut structure for fixing the support member in the form of FIGS. 1 and 2 adopting the unit panel of FIG. 3, and FIG. 5A is a front view, and FIG. 5B is a sectional view of a type combining a collar.

FIG. 6 is a view illustrating the bolt and nut structure as FIG. 5, and FIG. 6C is a sectional view of a nut locking type using three nuts, FIG. 6D is a sectional view of a nut locking type using four nuts, and FIG. 6E is a sectional view of a type combining a nut with prescribed thickness.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, explaining about embodiments of the present invention by referring to the drawings. FIG. 1 is a partially perspective view for explaining schematically about a support member relating to embodiments of the present invention, a concrete placing form (the form) and a method for constructing a concrete structure (the method) using the support member. As illustrated in FIG. 1, the support member used in the form 100 composes a main part of reusable panel fixing means for supporting outer side surfaces 12a of concrete panels 12 providing cavity 20 as predetermined space for placing concrete. In addition, in the nature of the concrete placing form, same or different shape of concrete placing form may be extendingly provided in left and right direction of FIG. 1, or a structure for blocking a section may be provided, but due to explanation and space reasons, exposed sections are depicted in left and right of FIG. 1.

This support member is configured by combining horizontal rails 71 and vertical rails 72, which were respectively arranged in parallel, in lattice shape, and supports the outer side surfaces 12a of the concrete panels 12 evenly at equal intervals, by planes including the combination of the rails 71, 72 in lattice shape. In addition, holes are drilled to penetrate intersections 73 of the rails 71, 72 combined in lattice shape, and the concrete panels 12 are locked to inner direction of the cavity 20 by bolt and nut structures 60 and else arranged at form fixing rods 40 penetrating the holes of the intersections 73. In addition, details of an example of horizontal rails 71 and vertical rails 72 composed by channel steel or metal material with equivalent shape, and details of the bolt and nut structures 60 and else are described in the following descriptions using FIGS. 5 and 6.

The horizontal rails 71 are having a length according to width W of the concrete panels 12. Similarly, vertical rails 72 are having a length according to height V of the concrete panels 12. In addition, the horizontal rails 71 and vertical rails 72 are not necessarily continuing as one, in order to secure a length according to the width W and the height V respectively. In other words, the horizontal rails 71 with optional length and the vertical rails 72 with optional length may be configured to compose the support member by arranging a number of the horizontal rails and the vertical rails enough to cover whole surface of the wall to secure a length according to the width W and the height V respectively. A necessary numbers of the horizontal rails 71 and the vertical rails 72 are used to cover an area of the concrete panels according to its area. In addition, in at least either of the horizontal rails 71 and the vertical rails 72 relating to the intersections 73, recesses (R) capable of fitting in opposing rails by receiving a width (P) and a part or all of a thickness (Q) of opposing rails are arranged. Therefore, not only the horizontal rails 71 mounted at first, but also the vertical rails 72 mounted later are able to support the concrete panels 12 evenly without rising from the outer side surfaces 12a of the concrete panels 12.

FIG. 2 is a side sectional view for explaining the form 100 of FIG. 1 in more detail. As illustrated in FIG. 2, in the form 100, a pair of concrete panels 12 are fixed by panel fixing means in a state that the concrete panels 12 are faced to each other with predetermined spacing X, in between which a core of a skeleton in the concrete structure, for example a wall core Y is arranged. The cavity 20 is formed by this spacing X.

In other words, in the form 100, from a center O of longitudinal direction of the form fixing rods 40 toward both ends 41, 42 thereof, skeleton side form fixing members 50, the concrete panels 12, a plurality of horizontal rails 71, and a plurality of vertical rails 72 combined with these horizontal rails in lattice shape are arranged in this order. The structure arranged as the above is locked by the bolt and nut structures 60 in combination with the form fixing rods 40 to maintain the prescribed position relation, and the cavity 20 is formed. In this cavity 20, side ends not illustrated in upper and lower ends of FIG. 2 are blocked by plate materials such as fragments of the concrete panels 12, in order not to leak concrete to be placed. In addition, at the core of the skeleton of the concrete structure, such as the wall core Y, reinforcing steels 1 (not illustrated in FIG. 1) are put together in length and breadth, and configured to increase a strength of the concrete structure.

The support member, in which a plurality of horizontal rails 71 and a plurality of vertical rails 72 are combined in lattice shape, contacts the outer side surfaces 12a of the concrete panels 12 and supports the concrete panels 12 to a direction of the wall core Y of the cavity 20. The form fixing rods 40 penetrate mounting holes 13, 74 respectively drilled in the concrete panels 12, the horizontal rails 71 and the vertical rails 72. About a material of the concrete panels 12 forming the form 100, unit panels 10 are adopted and explained in the following description using FIGS. 3 and 4, but it is only an example. Therefore, the support member, the form 100 and the method using the support member can be applied not only by adopting a normal form by plywood or the like, but also by adopting all form panels in other shape such as EPS form, rock cell form, and else.

The skeleton side form fixing members 50 support the concrete panels 12 to outer (wall surface) direction from inside (for example, the wall core Y) of the cavity 20 by being locked to predetermined position of the form fixing rods 40. In addition, as an example of the bolt and nut structures 60, it is preferable to arrange the bolt and nut structures 60 at both ends 41, 42 of the form fixing rods 40. In other words, a combination of male screws 61 (FIGS. 5 and 6) formed spirally at both ends 41, 42 of the form fixing rods 40 and the bolt and nut structures 60 capable of fitting spirally to these male screws 61 is preferable. In addition, as the bolt and nut structures 60, it is fine as long as at least one of both ends 41, 42 of the form fixing rods 40 can be screwed, the other end may be locked by a locking means different from the bolt and nut structure.

In the form 100 exemplified in FIG. 2, the structure from a center O of the form fixing rods 40 to one end 41 and the structure from the center O of the form fixing rods 40 to other end 42 are a pair of structures with complete symmetry formed by the skeleton side form fixing members 50, the concrete panels 12, the horizontal rails 71, the vertical rails 72, and the bolt and nut structures 60. In other words, when forming a simple wall part in the concrete structure, the form 100 will mostly be a pair of completely symmetrical structures with the wall core Y as a center, but it is not limited as such. That is, the form 100 may be formed to correspond to complicated shapes of each concrete skeleton part of a pillar, a beam, a slab, a base or a curved part composing the skeleton of the concrete structure, so it is not limited to a symmetrical shape as the form 100 exemplified in FIG. 2.

[Contour of Unit Panel]

FIG. 3 is a projection view of a unit panel composing the concrete panel, which may be adopted in the form of FIGS. 1 and 2, and FIG. 3A is a top view, FIG. 3B is a sectional view along line F-F, FIG. 3C is a front view, FIG. 3D is a bottom view, and FIG. 3E is a side view. FIG. 4 is a perspective view of a state that the unit panels of FIG. 3 are aligned and connected in up and down. As illustrated in FIGS. 3 and 4, peripheral edges 11 of a unit panel 10 are sectioned to an inner region 2 and an outer region 3 each being ½ with respect to a thickness G, and fitting parts 9 are integrally formed in these inner region 2 and outer region 3. The fitting parts 9 comprise inner fitting parts 6 formed at the inner region 2 and outer fitting parts 7 formed at the outer region 3. The inner fitting parts 6 comprise a plurality of inner fitting protrusions 4a and a plurality of inner fitting recesses 5a. Similarly, the outer fitting parts 7 comprise a plurality of outer fitting protrusions 4b and a plurality of outer fitting recesses 5b.

As illustrated in FIG. 4, in the unit panels 10, the fitting parts 9 relatively fitted at long sides of the peripheral edges 11 to be abutted are formed. As illustrated in FIG. 4, the concrete panel 12 is composed by connecting identical or similar unit panels 10 for necessary numbers (refer to FIG. 1). In other words, the unit panels 10 configure the form 100 by arranging the concrete panels 12 formed in wide area by combining a number of unit panels 10 in up and down and in left and right by abutting the peripheral edges 11 facing each other. In the unit panels 10, the adjacent fitting parts 9 are able to be fitted to each other like jigsaw puzzle by the contour forming protrusions and recesses. However, in jigsaw puzzle, it is necessary to endeavor to find a match with appropriate shape to fit adjacently, but the unit panels 10 used in the form 100 are having identical shape based on unified specification, so it is not necessary to endeavor to find a match.

In the form 100, the unit panels 10 with identical shape based on unified specification are connected such that, for example, long sides of approximate rectangle will be adjacent to each other or that short sides of approximate rectangle will be adjacent to each other. Among the peripheral edges 11, especially in a connection 11a in which the fitting parts 9 formed by the contour forming protrusions and recesses are connected to be adjacent to each other, it is possible to connect by fitting securely. In other words, in the fitting parts 9 formed at long sides of the peripheral edge 11 in each of a plurality of unit panels 10, the protrusion 4 (including 4a and 4b) is fitted closely to the recess 5 (including 5a and 5b) of the match, and the recess 5 is fitted closely to the protrusion 4 of the match. Therefore, the connection 11a is strong, and prevents occurrence of a gap which generates a leakage of concrete, and also, forms a plane outer side surfaces without generating a step difference.

Hereinafter, explaining in more detail about the fitting parts to be fitted relatively. The fitting part 9 is configured by a number of inner fitting protrusions 4a and a number of inner fitting recesses 5a formed adjacently in longitudinal direction Z in the inner region 2 of the peripheral edge 11, and a number of outer fitting protrusions 4b and a number of outer fitting recesses 5b formed adjacently in longitudinal direction Z in the outer region 3 of the peripheral edge 11. In addition, the fitting part 9 is configured by forming the inner fitting protrusions 4a and the inner fitting recesses 5a alternately over entire region of longitudinal direction Z of the inner region 2 of the peripheral edge 11, and also, by forming the outer fitting protrusions 4b and the outer fitting recesses 5b alternately over entire region of longitudinal direction Z of the outer region 3 of the peripheral edge 11.

In addition, in the fitting part 9, the inner fitting protrusions 4a and the inner fitting recesses 5a and the outer fitting protrusions 4b and the outer fitting recesses 5b are formed with approximately equivalent size of protrusion and size of recess. Further, in the fitting part 9, the outer fitting protrusions 4b are positioned opposing to the inner fitting recesses 5a, and also, the outer fitting recesses 4a are positioned opposing to the inner fitting protrusions 5b, by forming a row of the inner fitting protrusions 4a and the inner fitting recesses 5a to be shifted for one pitch with respect to a row of the outer fitting protrusions 4b and the outer fitting recesses 5b. In addition, in the fitting part 9, in upper side and lower side of the peripheral edge 11 of the unit panel 10, a row of the inner fitting protrusions 4a and the inner fitting recesses 5a is formed to be shifted for one pitch with respect to a row of the outer fitting protrusions 4b and the outer fitting recesses 5b. In addition, as mentioned above, in two rows of the inner fitting part 6 and the outer fitting part 7, protrusions and recesses will be shifted for one pitch, which means a shape in which two rectangular waves with identical cycles are located side by side in antiphase.

In addition, in a method for constructing concrete structure relating to embodiment of the present invention, the concrete panels 12 may be used as a part of wall surface structure of a building without disassembling and removing the concrete panels 12 even after concrete of the cavity 20 has been solidified, and it can be applied to a method known as rock cell board (RCB) external heat insulation method. In this case, the unit panels 10 composing the concrete panels 12 are preferably formed by closed cell type foamed synthetic resin, and so-called EPS form can be adopted.

In addition, by integrating the concrete panels 12 (unit panels 10) with surfaces of concrete skeleton, it is having an effect that a step for disassembling the concrete panels 12 will be unnecessary. Further, by the concrete panels 12 integrated with the concrete skeleton, it is possible to form the concrete structure with improved heat insulation, sound insulation, high air tightness, fire resistance, durability or seismic resistance, and also, with significant shortening of construction period.

[Detail of Bolt and Nut Structure or the Like]

Hereinafter, explaining about an example of horizontal rails 71 and vertical rails 72 composed by channel steel or metal material with equivalent shape, and four examples of a bolt and nut structure 60 or the like, using FIGS. 5 and 6. FIG. 5 is a view illustrating the adoptable support member and the bolt and nut structure for fixing the support member in the form of FIGS. 1 and 2 adopting the unit panel of FIG. 3, and FIG. 5A is a front view, and FIG. 5B is a sectional view of a type combining a collar. FIG. 6 is a view illustrating the bolt and nut structure as FIG. 5, and FIG. 6C is a sectional view of a nut locking type using three nuts, FIG. 6D is a sectional view of a nut locking type using four nuts, and FIG. 6E is a sectional view of a type combining a nut with prescribed thickness.

In addition, about the horizontal rails 71 and the vertical rails 72, according to following [Contour and material of horizontal rail and vertical rail], between example 1 illustrated in FIGS. 1 and 2 and example 2 illustrated in FIGS. 5 and 6, respective thickness Q and shape of recess R differ a little, but they are having identical effect, and also, it should not cause any misunderstanding, so they are explained with identical reference numbers.

As illustrated in FIGS. 5 and 6, the horizontal rails 71 and the vertical rails 72 composing the support member are preferably configured by channel steel or metal material with equivalent shape having rigidity enough for fixing the concrete panels 12 against weight of placed concrete. The horizontal rails 71 and the vertical rails 72 are respectively having a length according to width W and height V of the concrete panel 12, the support member assembled by selectively adopting from the stored rails having specified lengths with several phases are disassembled by loosening the bolt and nut structure 60 every time after its role has been played, and collected intact to be used repeatedly.

In the horizontal rail 71 and the vertical rail 72, a mounting hole 74 is drilled to penetrate an intersection 73 in which the horizontal rail 71 and the vertical rail 72 are combined in lattice shape, and the concrete panel 12 is locked to inner direction of the cavity 20 by the bolt and nut structure 60 or the like arranged at a form fixing rod 40 penetrating the hole of the intersection 73. In the form fixing rod 40, a skeleton side form fixing member 50 is fixed at a position being close to a center for predetermined length from one end 41 of the form fixing rod 40, and its flange 51 is abutted on inner side surface 12b of the concrete panel 12 to restrict a position of the concrete panel 12 by supporting the concrete panel 12 in outer direction of the cavity 20. As a result, the spacing X forming the cavity 20 is maintained.

In addition, as explained using FIGS. 1 and 2, in the form 100, the skeleton side form fixing members 50, the concrete panel 12, the horizontal rails 71, and the vertical rails 72 are respectively arranged in this order symmetrically from a center O of longitudinal direction of the form fixing rod 40 toward both ends 41, 42. As such, in the form 100, the structure from the center O of the form fixing rod 40 to one end 41 and the structure from the center O of the form fixing rod 40 to other end 42 are symmetrical mostly, so by explaining about the one end 41 (left side of FIG. 2) of the form fixing rod 40 in detail, it can be assumed that the other end 42 (right side of FIG. 2) is also explained. However, as explained in the above, the present invention is not limited to symmetrical shape as the form 100 exemplified in FIG. 2.

In addition, in both of the horizontal rail 71 and the vertical rail 72 relating to the intersection 73, a recess R capable of fitting in opposing rail respectively by receiving entire width P and a half of thickness Q of opposing rail is arranged. Therefore, not only the horizontal rail 71 mounted at first, but also the vertical rail 72 mounted later are able to support the concrete panel 12 evenly without rising from the outer side surface 12a of the concrete panel 12. In addition, in the form 100, the horizontal rail 71 is mounted at first, and then, the vertical rail 72 is mounted, and they are fastened by the bolt and nut structure 60, but oppositely, it may be configured to mount the vertical rail 72 at first, and to mount the horizontal rail 71 later.

As illustrated in FIG. 5B, in the form fixing rod 40, the skeleton side form fixing member 50 is fixed at a position being close to a center for predetermined length from the one end 41 of the form fixing rod 40. The form fixing rod 40 is inserted into the mounting hole 13 of the concrete panel 12, and one end 41 of the form fixing rod 40 is protruded from the outer side surface 12a of the concrete panel 12 for a length longer than the thickness Q of the rail, such that the flange 51 of the skeleton side form fixing member 50 will be abutted to the inner side surface 12b of the concrete panel 12.

The horizontal rail 71 is mounted such that the protruding one end 41 of the form fixing rod 40 will be inserted into a mounting hole 74 of the horizontal rail 71. A horizontal rail locking nut 62 is tightened lightly at the protruding one end 41 of the form fixing rod 40 in which male screw 61 is spirally arranged, and the horizontal rail 71 is mounted over the outer side surface 12a of the concrete panel 12. At the protruding one end 41 of the form fixing rod 40, the vertical rail 72 is mounted over the horizontal rail 71, after a vertical rail back supporting collar 63 is fitted. A mutual position relation in thickness direction of the horizontal rail 71 and the vertical rail 72 is defined by a height of the vertical rail back supporting collar 63. As a result, the intersection 73 of the horizontal rail 71 and the vertical rail 72 is joined rigidly.

Hereinafter, explaining only about each difference of a nut locking type using three nuts of FIG. 6C, a nut locking type using four nuts of FIG. 6D, and a type combining a nut with prescribed thickness of FIG. 6E, with respect to a type combining a collar of FIG. 5B. In the nut locking type using three nuts illustrated in FIG. 6C, instead of the vertical rail back supporting collar 63 in the type combining the collar of FIG. 5B, a vertical rail back locking nut 65 is used, and a mutual position relation of the horizontal rail 71 and the vertical rail 72 is defined by difference of fastening position between the horizontal rail locking nut 62 and the vertical rail back locking nut 65. Therefore, three nuts will be used in total.

In the nut locking type using four nuts illustrated in FIG. 6D, before mounting the horizontal rail 71, only the concrete panel 12 is mounted to the form fixing rod 40 and fixed by a panel temporary locking nut 66. This panel temporary locking nut 66 is fastened such that the panel temporary locking nut 66 will be housed in a panel temporary locking nut housing hole 12c opening at the outer side surface 12a of the concrete panel 12 by expanding diameter of the mounting hole 13. Then, after mounting the horizontal rail 71 and fastening it by the horizontal rail locking nut 62, its assembly manner is same as the nut locking type using three nuts of FIG. 6C. In addition, a mutual position relation of the horizontal rail 71 and the vertical rail 72 is defined by difference of fastening position between the horizontal rail locking nut 62 and the vertical rail back locking nut 65. Therefore, four nuts will be used in total.

In the type combining the nut with prescribed thickness of FIG. 6E, a mutual position relation of the horizontal rail 71 and the vertical rail 72 is defined only by dedicated extremely thick nut 67 having thickness corresponding to the difference of fastening position between the horizontal rail locking nut 62 and the vertical rail back locking nut 65, instead of the horizontal rail locking nut 62 and the vertical rail back locking nut 65 in the nut locking type using four nuts of FIG. 6D, Therefore, three nuts will be used in total, and as one of which the dedicated extremely thick nut 67 will be used.

[Contour and Material of Horizontal Rail and Vertical Rail]

The material of the horizontal rail 71 and the vertical rail 72 is preferably wood, synthetic resin, iron, stainless material, aluminum or the like, and especially, it is preferably stainless material with high mechanical strength and high rust prevention. As such, the horizontal rail 71 and the vertical rail 72 are configured in a shape similar to a simple member such as sheet metal and compose the support member that can be used repeatedly. The support member bolted by combining the horizontal rails 71 and the vertical rails 72 in lattice shape, and the form 100 and the method using the support member are easy to assemble and disassemble. As a result, it is possible to reduce construction cost significantly by reducing cost of members and shortening construction period.

Size of contour of the horizontal rail 71 and the vertical rail 72 is formed such that, for example, a width P of the rail composed of channel steel is approximately 150 mm, and a thickness Q of the rail (approximately equal to depth of groove+thickness of steel) is approximately 30 to 60 mm. In addition, the recess R of the intersection 73 is arranged at least at any of the horizontal rail 71 and the vertical rail 72 to be able to be fitted in opposing rail by respectively receiving a width P and a part or all of thickness Q of opposing rail.

In example 1 illustrated in FIGS. 1 and 2, the horizontal rails 71 with length W, width P approximately 150 mm and thickness Q approximately 30 mm, and the vertical rails 72 with length V, width P approximately 150 mm and thickness Q approximately 60 mm, are used. In the vertical rails 72, at positions facing the opposing horizontal rails 71 in intersections 73 thereof, recesses R with width approximately 170 mm and thickness approximately 30 mm are arranged. The horizontal rails 71 with width P approximately 150 mm and thickness Q approximately 30 mm are fitted and received in the recesses R arranged only at the vertical rails 72, and fastened by the bolt and nut structures 60.

In addition, in example 2 illustrated in FIGS. 5 and 6, the recess R with width P approximately 170 mm and thickness Q approximately 30 mm is arranged respectively at the horizontal rail 71 with suitable length, width P approximately 150 mm and thickness Q approximately 60 mm, and the vertical rail 72 with identical shape as the horizontal rail 71, at positions facing each other in the intersection 73 of the horizontal rail 71 and the vertical rail 72. In addition, it goes without saying that the horizontal rail 71 and the vertical rail 72 are not limited to specification of such size of contour, and they may be formed by suitable specification according to specification of concrete skeleton, formed part, or other conditions, and in some cases, the rails processed by cutting, machining or the like with respect to standardized goods are used.

[Material of Unit Panel or the Like]

In addition, the form 100 is formed to a rectangular panel body by the unit panels 10 made of foamed synthetic resin material, for example foamed polyethylene resin. Size of contour of the unit panel 10 is formed, for example as length of approximately 1820 mm, width of approximately 467 mm, and thickness of approximately 50 (10 to 60) mm. In addition, it goes without saying that the unit panel 10 is not limited to specification of such size of contour, and it may be formed by suitable specification according to specification of concrete skeleton, formed part, or other conditions, and in some cases, the unit panel processed by cutting, machining or the like with respect to standardized goods is used.

The unit panel 10 may use foamed synthetic resin material, for example foamed styrene resin, foamed polyethylene resin or foamed polyurethane resin or the like, as raw material. In the assembled form 100, concrete is placed in the cavity 20. When placed concrete is drying, as raw material of the unit panel 10 is the foamed synthetic resin material, concrete will be penetrated into the unit panels 10 and solidified to integrate the unit panels 10 and the concrete skeleton rigidly. By using the above raw material to the unit panel 10, it is possible to process the unit panel 10 easily, and handling of the unit panels 10 such as transport and mounting is easy as it is lightweight, and also, by integrating the unit panels 10 on surfaces of the concrete skeleton, it is possible to exert characteristics of the above heat insulation or the like.

By the form 100, a step for disassembling the concrete panels 12 will be unnecessary, and by the concrete panels 12 integrated with the concrete skeleton, it is possible to form the concrete structure with improved heat insulation, sound insulation, high air tightness, fire resistance, durability or seismic resistance, and also, with significant shortening of construction period

In addition, it is not illustrated, but when placing concrete to form relatively wide wall surface using the form 100, until concrete is solidified, diagonal crosspieces are used accordingly for preventing wall surface from collapsing, from outside of the horizontal rails 71 and the vertical rails 72 in lattice shape against deforming stress, which bends or falls vertical surface of the wall, and expansion stress in a direction that the cavity 20 will be expanded. As a result, the form 100 endures weight of placed concrete and maintains its shape.

On the other hand, when placing concrete to form relatively narrow wall surface using the form 100, it is verified that the form 100 will endure weight of placed concrete and maintain its shape, even without rigidly fixing the outside of the horizontal rails 71 and the vertical rails 72 in lattice shape by diagonal crosspieces or the like. The reason for the above is that, when forming narrow wall surface by the form 100, weight of concrete placed in the cavity 20 is also light, and strength against its expansion stress is secured only by the horizontal rails 71 and the vertical rails 72 in lattice shape.

In other words, a risk of destruction or deformation of the form 100 to expanding direction is low, even without rigidly fixing by the diagonal crosspieces. Therefore, it is sufficient if there is unillustrated diagonal crosspieces against stress slightly in a direction to fall down concrete wall. Especially, when building the concrete structure in which the relatively narrow wall surface is extending orthogonally in plain view with respect to large wall surface by the form 100, it is verified that it is not necessary to take countermeasures against a falling direction to the form 100 for forming the narrow concrete wall surface.

As explained in the above, according to the support member, the concrete placing form, and the method for constructing concrete structure relating to the present invention, by using the support member (horizontal rail, vertical rail, bolt and nut structure and else) which can be used repeatedly and composed in similar shape by simple members, assembly and disassembly of the form is easy. As a result, it is possible to reduce construction cost significantly by reducing cost of members and shortening construction period. In addition, the support member relating to the present invention can achieve a purpose to generalize to be usable for all form panels such as normal form by plywood or the like, EPS form, rock cell form, and else only by changing its size.

GLOSSARY OF DRAWING REFERENCES

• 1 Reinforcing steels
• 2 Inner region
• 3 Outer region
• 4 Fitting protrusion
• 4a Inner fitting protrusion
• 4b Outer fitting protrusion
• 5 Fitting recess
• 5a Inner fitting recess
• 5b Outer fitting recess
• 6 Inner fitting part
• 7 Outer fitting part
• 9 Fitting part
• 10 Unit panel
• 11 Peripheral edge
• 11a Connection
• 12 Concrete panel
• 12a Outer side surface
• 12b Inner side surface
• 12c Panel temporary locking nut housing hole
• 13, 74 Mounting hole
• 20 Cavity
• 40 Form fixing rod
• 41, 42 End (of form fixing rod 40)
• 50 Skeleton side form fixing member
• 51 Flange
• 60 Bolt and nut structure (locking means)
• 61 Male screw
• 62 Horizontal rail locking nut
• 63 Vertical rail back supporting collar
• 64 Vertical rail locking nut
• 65 Vertical rail back locking nut
• 66 Panel temporary locking nut
• 67 Dedicated extremely thick nut
• 70 Pillar type supporting rail
• 71 Horizontal rail
• 72 Vertical rail
• 73 Intersection
• 100 Concrete placing form (the form)
• G Thickness (of unit panel 10)
• H Size of opening (of fitting recess 5)
• O Center (in longitudinal direction of form fixing rod 40)
• P Width of rail
• Q Thickness of rail
• R Recess (of intersection 73)
• V Height (of concrete panel 12)
• W Width (of concrete panel 12)
• X Spacing
• Y Wall core (of cavity 20)
• Z Longitudinal direction (of unit panel 10)

Claims

1. A reusable support member for supporting outer side surfaces of concrete panels providing cavity as predetermined space for placing concrete, comprising:

a plurality of horizontal rails with a length according to width of the concrete panels;

a plurality of vertical rails with length according to height of the concrete panels; and

bolt and nut structures for locking the concrete panels into inner direction of the cavity by penetrating intersections in which respectively parallel the plurality of horizontal rails and the plurality of vertical rails are combined in lattice shape,

wherein, in at least either of the horizontal rails and the vertical rails relating to the intersections, recesses capable of fitting in opposing rails by receiving a width and a part or all of a thickness of opposing rails are arranged,

the horizontal rails and the vertical rails are configured by channel steel or metal material with equivalent shape, and the intersections are joined by the bolt and nut structures for defining mutual position relation of the horizontal rails and the vertical rails by a plurality of nuts, and also, the horizontal rails and the vertical rails contact the outer side surfaces of the concrete panels at equal intervals respectively.

2. A concrete placing form fixed by a reusable support member for supporting concrete panels providing cavity as predetermined space for placing concrete, wherein the reusable support member comprises:

a plurality of horizontal rails with a length according to width of the concrete panels;

a plurality of vertical rails with length according to height of the concrete panels;

bolt and nut structures for locking the concrete panels into inner direction of the cavity by penetrating intersections in which respectively parallel the plurality of horizontal rails and the plurality of vertical rails are combined in lattice shape;

form fixing rods penetrating mounting holes drilled in the concrete panels, the horizontal rails and the vertical rails by aligning to the intersections; and

skeleton side form fixing members for supporting the concrete panels to outer direction from inside of the cavity by being locked at predetermined position of the form fixing rods,

wherein, in at least either of the horizontal rails and the vertical rails relating to the intersections, recesses capable of fitting in opposing rails by receiving a width and a part or all of a thickness of opposing rails are arranged, the horizontal rails and the vertical rails are formed by channel steel or metal material with equivalent shape, and the intersections are joined by the bolt and nut structures for defining mutual position relation of the horizontal rails and the vertical rails by a plurality of nuts, and also, the horizontal rails and the vertical rails contact the outer side surfaces of the concrete panels at equal intervals respectively, the skeleton side form fixing members, one of the concrete panels, the horizontal rails and the vertical rails are formed to be arranged in this order from a center of longitudinal direction of the form fixing rods to one end of the form fixing rods, and the bolt and nut structures are formed at least at one end of the form fixing rods.

3. The concrete placing form according to claim 2, wherein the concrete panels are formed by suitably connecting unit panels in same or similar shape in which adjacent peripheral edges can be fitted to each other by a contour forming protrusions and recesses.

4. The concrete placing form according to claim 2, wherein a structure from the center of longitudinal direction of the form fixing rods to one end of the form fixing rods is symmetrical with a structure from the center of longitudinal direction of the form fixing rods to other end of the form fixing rods.

5. The concrete placing form according to claim 3, wherein the unit panels are formed by closed cell type foamed synthetic resin.

6. The concrete placing form according to claim 3, wherein fitting parts are formed in the peripheral edges of the unit panels, and the unit panels are arranged by combining many unit panels in up and down and in left and right by abutting the peripheral edges and fitting the opposing fitting parts, and the fitting parts are configured by inner fitting parts and outer fitting parts alternately forming fitting protrusions and fitting recesses with opening size approximately equal to the fitting protrusions over entire region of longitudinal direction of the unit panels, respectively in inner region and outer region sectioned in thickness direction of the unit panels, and also, the fitting protrusions and the fitting recesses of the inner fitting parts and the outer fitting parts are formed in opposed positions by shifting for one pitch.

7. A method for constructing concrete structure by reusing a support member for supporting outer side surfaces of concrete panels providing cavity as predetermined space for placing concrete, wherein the support member comprises:

a plurality of horizontal rails with a length according to width of the concrete panels;

a plurality of vertical rails with length according to height of the concrete panels; and

bolt and nut structures for locking the concrete panels into inner direction of the cavity by penetrating intersections in which respectively parallel the plurality of horizontal rails and the plurality of vertical rails are combined in lattice shape, wherein, in at least either of the horizontal rails and the vertical rails relating to the intersections, recesses capable of fitting in opposing rails by receiving a width and a part or all of a thickness of opposing rails are arranged,

the horizontal rails and the vertical rails are formed by channel steel or metal material with equivalent shape, and the intersections are joined by the bolt and nut structures for defining mutual position relation of the horizontal rails and the vertical rails by a plurality of nuts, and also, the horizontal rails and the vertical rails contact the outer side surfaces of the concrete panels at equal intervals respectively.

8. A method for constructing concrete structure by using a concrete placing form fixed by a reusable support member for supporting concrete panels providing cavity as predetermined space for placing concrete, wherein the reusable support member comprises:

a plurality of horizontal rails with a length according to width of the concrete panels;

a plurality of vertical rails with length according to height of the concrete panels;

bolt and nut structures for locking the concrete panels into inner direction of the cavity by penetrating intersections in which respectively parallel the plurality of horizontal rails and the plurality of vertical rails are combined in lattice shape,

form fixing rods penetrating mounting holes drilled in the concrete panels, the horizontal rails and the vertical rails by aligning to the intersections; and

skeleton side form fixing members for supporting the concrete panels to outer direction from inside of the cavity by being locked at predetermined position of the form fixing rods, wherein, in at least either of the horizontal rails and the vertical rails relating to the intersections, recesses capable of fitting in opposing rails by receiving a width and a part or all of a thickness of opposing rails are arranged, the horizontal rails and the vertical rails are formed by channel steel or metal material with equivalent shape, and the intersections are joined by the bolt and nut structures for defining mutual position relation of the horizontal rails and the vertical rails by a plurality of nuts, and also, the horizontal rails and the vertical rails contact the outer side surfaces of the concrete panels at equal intervals respectively, the skeleton side form fixing members, one of the concrete panels, the horizontal rails and the vertical rails are formed to be arranged in this order from a center of longitudinal direction of the form fixing rods to one end of the form fixing rods, and the bolt and nut structures are formed at least at one end of the form fixing rods.

9. The method for constructing concrete structure according to claim 7, wherein the concrete panels become a part of a building without being disassembled and removed even after concrete placed in the cavity is solidified.

10. The method for constructing concrete structure according to claim 8, wherein the concrete panels become a part of a building without being disassembled and removed even after concrete placed in the cavity is solidified.

11. The concrete placing form according to claim 3, wherein a structure from the center of longitudinal direction of the form fixing rods to one end of the form fixing rods is symmetrical with a structure from the center of longitudinal direction of the form fixing rods to other end of the form fixing rods.