JP5826699B2 - Building block, wall structure using the same, and method of forming wall structure - Google Patents

Description

  The present invention relates to a building block, and more particularly to a building block made of foamed resin and a method for forming a wall structure using the same.

The wall separating the residential site and the road is usually constructed by stacking concrete blocks and, in some cases, passing reinforcing bars through the concrete blocks. Concrete blocks are standardized in dimensions, are available in a variety of quality, and can be procured inexpensively and in large quantities.
However, concrete blocks are heavy with a weight of about 100 kg per square meter when building a wall, and the work of stacking blocks is a heavy labor coupled with the aging of workers.
Also, in areas where the 2011 Great East Japan Earthquake shook strongly or where liquefaction occurred, even if a reinforcing bar was passed through a concrete block, the reinforcing bar could not support the weight of the block, the wall was tilted, There was damage such as falling down.
In order to solve the problem caused by such a heavy concrete block, it has been proposed to reduce the weight of the block by using a foamed plastic material as a part of the block material (see Patent Document 1). If a lightweight block is used, the stacking operation can be performed quickly, and the collapse and damage of the wall structure due to the weight of the block itself can be reduced. In addition, even if the wall structure collapses, there is an advantage that it is light in weight and therefore less likely to damage people and surrounding structures.

JP-A-9-158392

However, simply replacing a part or all of a concrete block with a lightweight resin does not provide sufficient strength for a block cage assembled with the resin, and it does not meet the recent requirements for earthquake resistance.
Accordingly, an object of the present invention is to provide a lightweight building block capable of quickly constructing a wall structure excellent in earthquake resistance and a method for forming a wall structure using the same.

In order to solve the above-mentioned problems, the inventors have made the block made of foamed resin to reduce the weight, and after passing a reinforcing bar through the cavity in the block, the mortar is poured into the cavity to solidify the wall structure. I came up with the idea of improving the strength. The present invention has been completed by adding various improvements to the foamed resin block premised on pouring mortar into the cavity.
That is, the means for solving the above problems are as follows.

  It is a building block used by stacking a plurality in the vertical direction, and is disposed between a pair of plate-like members made of foamed resin opposed to each other with a predetermined interval, and the pair of plate-like members A foamed resin beam member, and the beam member is arranged so as to connect the inner surfaces of the pair of plate members and to form a series of spaces on the inner surface side of the pair of plate members, The lower surface of the beam member is inclined upward from the center toward both side surfaces, and the upper and lower portions of the plate-like member are connected to each other so as to connect the adjacent blocks in the vertical direction. It is a building block in which a structure is formed.

  In the building block, the ridge line on the lower surface of the beam member is an arc; the upper surface of the beam member is inclined downward from the center toward both side surfaces; the ridge line on the upper surface of the beam member It is circular arc shape; The space | interval of a pair of said plate-shaped member arrange | positioned facing is 50-100 mm; The hard surface layer which consists of a polymer cement composition is formed on the outer surface of the said plate-shaped member It is preferable that a net-like member is embedded in the hard surface layer.

  According to the present invention, a plurality of the building blocks are stacked in the vertical direction by fitting the concavo-convex structure with each other, and the reinforcing bars erected on the foundation are arranged in the space; and There is provided a method of forming a wall structure, comprising: pouring mortar into the space and solidifying the mortar.

  ADVANTAGE OF THE INVENTION According to this invention, the lightweight building block which can construct rapidly the wall structure excellent in earthquake resistance, and the formation method of a wall structure using the same are provided.

The perspective view which shows one Embodiment of the building block of this invention. The right view which looked at the building block of FIG. 1 from the A direction. C-C 'sectional drawing in FIG. The top view which looked at the building block of FIG. 1 from the B direction. The perspective view which shows another embodiment of the building block of this invention. The perspective view which shows another embodiment of the building block of this invention. The perspective view which shows another embodiment of the building block of this invention. The schematic diagram which shows the process in which the building block of this invention is piled up and down and a wall structure is formed. The schematic diagram which shows the foundation for forming a wall structure.

Next, the form for implementing this invention is demonstrated concretely.
1-4 is a figure which shows one Embodiment of the building block of this invention, FIG. 1 is a perspective view, FIG. 2 is the side view seen from the A direction of FIG. 1, FIG. 3 is CC of FIG. FIG. 4 is a plan view seen from the direction B in FIG.
As shown in FIG. 4, the building block 1 of this embodiment includes a pair of foamed resin plate-like members 2 and 2 ′ and plate-like members 2 and 2 that are disposed to face each other with a predetermined interval T <b> 3. It is comprised from the foamed resin beam member 3 arrange | positioned between '.

As shown in FIGS. 2 and 4, the beam member 3 is disposed so as to connect the inner surfaces 25, 25 ′ of the pair of plate-like members 2, 2 ′.
Further, the beam member 3 does not form a space isolated from the other in the space 4 between the pair of plate-like members 2 and 2 ′ when a plurality of building blocks are stacked to form a wall structure. Need to be placed in. FIG. 8 shows a process of forming the wall structure 100 by stacking the building blocks 1 of this embodiment on the base 70. When such a wall is formed, the beam member 3 and a pair of plate-like members are shown. The space 4 formed by 2 and 2 'needs to be a continuous series of spaces as shown in FIG.

Since the building block of the present invention is made of foamed resin and is in close contact with the adjacent block when the wall structure is formed, the airtightness of the space formed inside the wall structure is higher than that of the wall formed of the concrete block. Remarkably high. For this reason, when the mortar 60 is poured into the space inside the wall, it is difficult to fill the mortar without gaps and to smoothly exhaust the mortar. When the space separated by the beam member 3 is formed, a space that is not filled with the mortar 60 is generated when the mortar 60 is poured into the space 4 formed on the inner surface side of the pair of plate-like members 2 and 2 ′. When the wall structure is formed, a desired strength may not be obtained. Therefore, by making the space 4 a series of spaces, exhaust can be performed smoothly when the mortar 60 is poured, and the mortar 60 can be filled quickly.
Further, if the width of the beam member 3 is the same as the width W of the building block 1, the mortar 60 is prevented from flowing into the space 4 when the wall structure 100 is constructed. It is preferable to make it smaller.

  Further, as shown in FIGS. 3 and 8, the beam member 3 is configured such that the lower surface 32 is inclined upward from the center toward both side surfaces. In the case of forming a wall structure, as shown in FIG. 8, after a plurality of building blocks are stacked on the base 70, the space 4 on the inner surface side of the pair of plate-like members 2 and 2 ′ is opened from the upper opening. Pour in mortar 60. Then, the mortar 60 first forms a horizontal plane on the base 70 by gravity. Further, when the mortar 60 is poured, the horizontal plane gradually rises and comes into contact with the lower surface 32 of the beam member 3, but in the block of the present invention, the lower surface 32 of the beam member 3 is inclined upward from the center toward both side surfaces. Therefore, the mortar 60 rises smoothly along the lower surface 32, and the mortar 60 can be filled quickly without generating bubbles. Moreover, since the mortar can be filled and hardened without gaps, a wall structure having sufficient strength can be formed even if the block is made of foamed resin. In addition, the center which is the lowest point of the lower surface 32 may not be located equidistant from both ends of the beam member 3.

  In addition, the upper and lower portions of the plate-like members 2 and 2 ′ of the building block of the present invention are provided with an uneven structure for fitting the blocks adjacent to each other in the vertical direction. The building blocks of the present invention are used by stacking a plurality in the vertical direction in order to form a wall structure, but the upper and lower blocks are displaced when the blocks are stacked in the vertical direction due to the uneven structure. And the strength of the formed wall structure can be increased. Moreover, since the upper and lower blocks are brought into close contact with each other by fitting the upper and lower blocks, the mortar 60 filled in the space 4 can be prevented from leaking from the gap between the blocks.

As an example of the concavo-convex structure, as shown in FIG. 1, the ridges 11 formed at the corners of the upper surface 21 of the plate-like member 2 and the corners of the lower surface 22 of the plate-like member 2 so as to be fitted thereto. The notch 12 provided in the part is mentioned.
The concavo-convex structure may be provided on only one of the pair of plate-like members 2 and 2 ′, but in order to securely fit the blocks in the vertical direction, as shown in FIG. It is preferable to provide both.
Furthermore, as shown in the enlarged view in the upper right of FIG. 2, a ridge 13 that runs in the longitudinal direction of the plate member is provided on the inner wall of the ridge 11, and the longitudinal direction of the plate member is formed in the notch 12 so as to correspond to this. By providing the groove running in the vertical direction, it is possible to more reliably fit the vertical blocks.

  The size of the building block of the present invention is not particularly limited. However, if it is small, the labor for assembling and forming the wall structure increases, and if it is too large, it may be difficult to carry or handle during wall structure formation. As an example, the width W is 200 to 2000 mm, the height H of the main body portion excluding the concavo-convex structure is 100 to 1000 mm, and the depth T is in the range of 100 to 300 mm. JIS standard concrete blocks that form the wall structure are widely used. When this is replaced, the width W is 400 mm or double 800 mm, and the height H of the main body excluding the uneven structure is 200 mm or less. The double 400 mm and the depth T may be 120 to 150 mm.

  When the wall structure 100 is formed by filling the building block of the present invention with mortar, both side surfaces of the wall structure 100 need to be sealed. In order to seal both side surfaces of the wall structure 100, a building block 1 'having a side wall 10 on one side as shown in FIG. In the case of forming a wall structure with a narrow lateral width, a wall structure may be formed by assembling a building block 1 ″ having side walls 10 and 10 ′ on both sides in the vertical direction as shown in FIG. .

  As described above, the lower surface 32 of the beam member 3 needs to be inclined upward from the central portion toward both side surfaces. However, when the ridgeline is an arc shape, the filling of the mortar 60 can be performed without delay. Further, it is more preferable since the generation of bubbles is small.

  In addition, as shown in FIG. 3, the beam member 3 preferably has an upper surface 31 inclined downward from the central portion toward both side surfaces. When the upper surface 31 has such a shape, even when the mortar 60 poured from the top when forming the wall structure hits the upper surface 31, the mortar 60 can fall down without any delay, and the mortar 60 is filled. This is preferable because there is no remaining space left. Specifically, it is more preferable that the ridge line of the upper surface 31 has an arc shape.

When the wall structure is formed by stacking the building blocks of the present invention in the vertical direction, the cross-sectional area of the beam member 3 (shown by hatching in FIG. 3) is plate-like in order to make the wall structure sufficiently strong. It is preferably 20% or more, more preferably 30% or more, relative to the area (H × W) when the member 2 is viewed from the front.
If there is a thin portion in the vertical direction of the beam member 3, it may be damaged by an impact when the mortar is poured, so it is preferable not to make a thin portion in the vertical direction.

  The number of beam members 3 per building block of the present invention may be one or plural. The installation location of the beam member 3 is not particularly limited, but it is preferable that the beam member 3 is disposed so as not to collide with a reinforcing bar that is passed through when the wall structure is formed.

  If the predetermined distance between the pair of plate-like members 2 and 2 ′ of the building block of the present invention shown as T3 in FIG. 4 is narrow, it may be difficult to pour the mortar 60. It is preferably 50 mm or more, more preferably 60 mm or more because it is easy to come into contact with a reinforcing bar that passes through when forming the wall structure. On the other hand, if the width is too large, the amount of mortar 60 necessary for filling the space between the plate-like members 2 and 2 'increases, and the weight of the formed wall structure becomes too heavy. , 80 mm or less is more preferable.

  The composition of the foamed resin is not particularly limited, and an appropriate one may be used in consideration of strength, cost, weight, and the like. Examples of the raw material resin for the foamed resin include polyurethane, polystyrene, polyethylene, polypropylene, phenol resin, polyvinyl chloride, urea resin, and the like. In order to increase the strength of the building block of the present invention, a high density foamed resin such as high density foamed polystyrene or high density foamed urethane may be used. The composition of the foamed resin constituting the plate-like member 2 and the foamed resin constituting the beam member 3 may be the same or different.

  In order to increase the strength of the building block of the present invention, a hard surface layer 40 made of a polymer cement composition may be formed on the outer surface 23 of the plate-like member 2 as shown in FIG. Since the plate-like member 2 of the building block of the present invention is made of foamed resin, it may be dented or cracked when subjected to a strong impact, but by providing the hard surface layer 40 on the outer surface 23, the building block and the The wall structure formed from building blocks can be protected. Moreover, the hard surface layer 40 has an effect which protects the plate-shaped member 2 from the ultraviolet rays and acid rain of the sun, and lengthens the service life of the building block and the wall structure. Furthermore, it is also excellent as a basis for applying decorative tiles to the surfaces of building blocks and wall structures and for applying exterior coating materials.

  The polymer cement is a cement whose properties such as mechanical properties and chemical resistance are modified by the addition of a polymer, and various properties can be obtained from the market. For this reason, what is necessary is just to use an appropriate thing according to a use or a desired function. In order to improve the adhesion between the outer surface 23 of the plate-like member and the polymer cement composition, it is preferable to apply a primer to the outer surface 23 before applying the polymer cement composition.

  Further, as shown on the right side of FIG. 7, a net member 41 may be embedded in the hard surface layer 40. Thereby, when the outer surface 23 of the plate-like member 2 receives an impact, the mesh-like member 41 can disperse and mitigate the impact. Examples of the material of the net member 41 include metals such as copper and stainless steel, plastics such as nylon and polypropylene, plant fibers such as cotton and hemp, and inorganic fibers such as glass fibers and carbon fibers.

  Moreover, you may form a groove | channel or mesh shape in the outer surface 23 of the plate-shaped member of the building block of this invention. For example, by providing a vertical stripe groove on the outer surface 23 and applying a stone-like exterior coating material thereon, the appearance of the wall structure can be made high-class. The building block subjected to such surface processing can be used in place of the concrete decorative block.

The manufacturing method of the building block of the present invention is not particularly limited, and the plate-like members 2 and 2 ′ and the beam member 3 may be manufactured separately, and may be bonded and combined, but from the viewpoint of manufacturing efficiency, It is preferable to perform integral molding. Examples of the molding method include extrusion molding and a method of foaming a resin in a mold.
When the building block of the present invention is manufactured with polystyrene foam, its weight is about 1/80 compared with a normal concrete block, and even when a hard surface layer is formed on the outer surface shown in FIG. Is less than 1/40 of normal concrete blocks. For this reason, when forming a wall structure using the building block of this invention, it is not necessary to use heavy machinery, such as a crane, and a block can be piled up rapidly only by human power.

  Next, the method for forming the wall structure of the present invention will be described. FIG. 8 is a schematic diagram showing a process of forming the wall structure by stacking the building blocks of the present invention in the vertical direction, and FIG. 9 is a schematic diagram showing a base for forming the wall structure of the present invention. Since the building block of the present invention is made of foamed resin and is not strong against the pressure pushed from the outside, the building block of the present invention is installed on the concrete base 70 rather than directly on the ground. It is preferable to do. Specifically, it is preferable that the building blocks 1 are stacked in a vertical direction on a concrete base 70 on which vertical reinforcing bars 50 are erected as shown in FIG. At this time, the longitudinal reinforcing bars 50 are passed through the space 4 in the building block 1 so as not to collide with the inner surfaces of the plate-like members 2 and 2 ′ and the beam member 3, and the plate-like members of the building block 1 The concavo-convex structure formed in the upper part and the lower part is fitted to each other, and the blocks adjacent in the vertical direction are joined together. In addition, a mortar layer may be provided between the base 70 and the building block 1 on the base, and the direction and inclination of the building block 1 may be finely adjusted.

  The blocks in the vertical direction and the horizontal direction are preferably in close contact with each other. However, since the mortar has high viscosity, the mortar does not flow out if the gap is about 1 to 2 mm. An adhesive may be used to bring the blocks into close contact. Moreover, in order to further improve the strength of the wall structure 100 to be formed, as shown in FIG. 8, horizontal reinforcing bars 51 may be provided between building blocks adjacent in the vertical direction. As a block at both ends of the wall structure 100, a building block 1 'having a side wall 10 shown in FIG. 5 on one side is used.

  When the arrangement of the building blocks and the reinforcing bars is completed, the mortar 60 is poured into the space 4 from the opening formed at the upper end of the wall structure. By filling the space 4 with the mortar 60, it is possible to fix the building block of the present invention, the reinforcing bars, and the base, and to strengthen the formed wall structure 100. As shown in FIG. 8, the mortar 60 poured into the space 4 first accumulates on the bottom base 70 by gravity and gradually rises. In the building block of the present invention, since the lower surface 32 of the beam member 3 is inclined upward from the center toward both side surfaces, the space 4 can be filled with the mortar 60 without any delay.

Once the mortar 60 has been filled to the top of the stacked building block, the surface is leveled with a trowel or the like and then dried. Further, a decorative tile or the like may be fitted on the upper surface 80 of the wall structure 100 as necessary. As for the building block of embodiment shown by FIG. 1 and FIGS. 5-7, when the side 24 and the side wall 10 of the plate-shaped member 2 are both planes and comprise a wall, the blocks on either side are a surface and a surface. Contact. Then, since a narrow gap is generated between the surfaces, water can be removed from the mortar poured into the space 4 by capillary action, and drying of the mortar can be promoted.
The wall structure 100 thus formed is lighter than a wall structure constructed by stacking concrete blocks, and is excellent in earthquake resistance and wind resistance. In addition, depending on the scale, the period required for construction is about 0.5 days for the wall around the entrance of the house to be completed and mortar filling is completed, and about 1 day for drying the mortar. The wall can be formed in a short time.

When forming a wall structure with a high height, it is one step until the mortar is poured and dried after stacking one stage of the building block of the present invention, and another tiered building block is poured and dried by pouring mortar. Although the process may be repeated, it is preferable to pour the mortar after stacking the building blocks to the top as described above because the construction period can be shortened.
Alternatively, the wall structure may be constructed by assembling the block of the present invention in the vertical direction in advance in a factory and carrying it into a construction site.

  After the formation of the wall structure 100, it is preferable that the appearance of the wall structure 100 can be improved and that the weather resistance of the wall structure 100 can be improved by applying a tile or the like to the surface or applying an exterior coating material.

  EXAMPLES Next, although an Example is given and this invention is demonstrated further more concretely, these Examples are only the illustrations of this invention, and do not intend limiting of this invention. In the following description, the term “parts” simply refers to parts by mass.

[Example 1]
A polystyrene building block having the shape shown in FIGS. 1 and 5 was produced by foaming polystyrene in the mold. The width W of the building block is 800 mm, the height H is 200 mm, the height H ′ of the concavo-convex structure is 10 mm, the depth T2 of the plate-like members 2 and 2 ′ and the side wall 10 is 40 mm, and the depth T4 of the concavo-convex structure is 10 mm. The interval T3 between the pair of plate-like members was set to 70 mm.
Further, two beam members 3 having the shape shown in FIG. 3 and having a minor axis height of 140 mm and a width of 260 mm were provided. The weight of the building block having the shape shown in FIG. 1 was 370 g, and the weight of the building block having the shape of FIG. 5 was 385 g.

  After applying a primer (Kikusui Primer Super E, manufactured by Kikusui Chemical Industry Co., Ltd.) to both outer surfaces of the building block plate members, 16 mesh cut on the same size as the pair of plate members 2 and 2 ' The polypropylene mesh is placed, and the polymer cement composition (Kikusui Chemical Co., Ltd. Kikusui Filler) is applied on it to a thickness of about 1 mm. Block was manufactured. Hereinafter, the building block according to the first aspect and the building block according to the second aspect will be referred to, respectively. The weight of the building block of the first aspect was 740 g, and the weight of the building block of the second aspect was 770 g.

  As shown in FIG. 9, the building blocks of the second mode are fitted to both ends of a base 70 having a width of 4 m and a depth of 150 mm, and the three rows of building blocks of the first mode are fitted between the concavo-convex structures. And stacked two layers at a time. In addition, the base 70 has a total of ten vertical reinforcing bars 50 each having a height of 1 m and a diameter of 10 mm arranged every 400 mm. These vertical reinforcing bars 50 are the plate-like members 2 and 2 'of the building block. The building blocks were stacked so as not to come into contact with the inner surface and the beam member 3. Next, a reinforcing bar having a length of 3.8 m and a diameter of 10 mm was disposed on the upper part of the building block to form a horizontal bar 51, and an intersection with the vertical bar 50 was fixed with a wire. Further, after the building blocks were stacked in two stages, the horizontal reinforcing bars 51 were arranged on the upper part of the building blocks as in the first two stages. After that, each building block was stacked two more levels to build a wall with a height of 1.2m and a width of 4m.

  Next, the mortar composition was poured into the space 4 from the opening at the upper end of the wall to the top of the wall structure, and the upper part was flattened with a trowel and then dried for one day to form the wall structure 100. Thereafter, decorative tiles were affixed to the surface of the wall structure 100 without any gaps to complete the wall.

  ADVANTAGE OF THE INVENTION According to this invention, the lightweight building block which can construct rapidly the wall structure excellent in earthquake resistance, and the formation method of a wall structure using the same are provided. The building block of the present invention is lightweight and easy to carry, and can be easily stacked when forming a wall structure. Moreover, since the weight of itself is light, even if it receives an earthquake or a strong wind when forming a wall structure, it is less likely to be damaged due to its own weight. Furthermore, since the building block of the present invention is lighter than a concrete block, it can be easily transported and constructed with a wall structure, and can quickly perform disaster recovery work due to an earthquake or land subsidence. Further, even if the wall structure collapses, it is lightweight and therefore rarely damages people and surrounding structures.

1, 1 ', 1 "building block 2, 2' plate-like member 3 beam member 4 space 10, 10 'side wall 11 ridge 12 notch 13 notch 13 ridge 21 upper surface 22 of plate-like member The lower surface 23 of the member The outer surface 24 of the plate-shaped member The side surfaces 25 and 25 'of the plate-shaped member The inner surface 31 of the plate-shaped member The upper surface of the beam member
32 Lower surface 40 of beam member Hard surface layer 41 Reticulated member 50 Longitudinal reinforcing bar 51 Horizontal reinforcing bar 60 Mortar 70 Base 80 Upper surface of wall structure 100 Wall structure H Height of building block H 'Height of uneven structure T Building block Depth T2 Depth T3 of plate-like member Interval T4 between a pair of plate-like members Depth of concavo-convex structure W Width of building block

Claims (8)

A building block made of foamed resin used to form a wall structure by filling a series of spaces on the inner surface side and forming a wall structure, a plurality of which are used stacked at least in the vertical direction,
A pair of plate-like members made of foamed resin disposed opposite to each other;
A foamed resin beam member disposed between the pair of plate members so as to connect the inner surfaces of the pair of plate members; and
The pair of plate-like members are arranged to face each other with an interval of 50 to 100 mm,
A concave-convex structure is formed at the upper and lower corners of the plate-like member so that the blocks adjacent to each other in the vertical direction can be joined to each other. A ridge formed by including the notch formed by including the other corner,
The beam members are arranged on the inner surface side of the pair of plate-like members so as to form a continuous series of spaces for pouring the mortar after the plurality are stacked, The cross-sectional shape is an arc shape convex downward, and the cross-sectional area is 20% or more with respect to the area of the plate-like member,
Further , the pair of plate members and the beam member are building blocks formed by bonding or integral molding of members. The beam member is provided with a plurality, within the width of 200～2000Mm, within the height of the portion except for the relief structure of 100 to 1000 mm, in claim 1 depth Ru der range of 100~300mm The building block described.   The building block according to claim 1, wherein an upper surface of the beam member is inclined downward from the center toward both side surfaces.   The building block according to claim 3, wherein the ridge line on the upper surface of the beam member is arcuate.   The building block according to any one of claims 1 to 4, wherein a hard surface layer made of a polymer cement composition is formed on an outer surface of the plate-like member.   The building block according to claim 5, wherein a net-like member is embedded in the hard surface layer. A foundation with reinforcing bars standing on its upper surface,
A plurality of building blocks according to any one of claims 1 to 6 stacked in a vertical direction on the foundation;
Solidified mortar for fixing the building blocks to each other,
The plurality of building blocks, wherein the concavo-convex structure is mutually fitted, and the mortar filled with the reinforcing bars of the base disposed in the space is solidified. Construction. A process of stacking a plurality of building blocks according to any one of claims 1 to 6 in a vertical direction and arranging reinforcing bars erected on a foundation in the space;
Pouring mortar into the space and solidifying the mortar.

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