Patent Application
20090127427
The present invention relates to a substrate for interior and exterior materials and a form panel used for concrete formwork in construction work, and a form construction method including installation of the substrate for interior and exterior materials.
In a construction method using a concrete form, after casting concrete into a concrete building framework and removing a form therefrom, a substrate material is assembled with a wood frame on the concrete casting surface, and interior and exterior materials are secured thereon by nailing. Alternatively, light-gauge steel is assembled, and then interior and exterior materials are secured thereon with screws. Alternatively, an adhesive is applied in balls, and then interior and exterior materials are directly secured by pressure bonding or other method.
In addition, when thermal insulation work is performed, concrete is casted while a thermal insulation board comprised of foamed synthetic resin is nailed in advance onto an inner surface of a sheathing. Then, after curing the concrete, by removing only plywood, a thermal insulation concrete wall is formed. Afterward, a substrate material for interior and exterior materials is assembled, so that the interior and exterior materials are attached thereto.
As described above, in the concrete formwork, after casting concrete, securing work to secure interior and exterior members is required. In recent years, a sheathing is used as a substrate for interior and exterior materials as a rational method. In this construction method, a foamed plastic thermal insulation board, in which a foamed plastic thermal insulation material is adhered to a wood wool board or a new building material board, is used as a sheathing of a concrete form, which can be also used as a substrate for interior and exterior materials. After casting concrete, without removing the sheathing, finishing of the interior and exterior materials is done on a surface thereof. Since the thermal insulation board is used as the sheathing in this construction method, thermal insulation work can be also performed at the same time.
The above method, however, has the following problems. The sheathing used in formwork is required to have enough rigidity and strength against deformation, breakage, and so on. Because of a low strength of the panel itself, the foamed plastic thermal insulation material that composes the sheathing has to have a larger thickness or has to be adhered and integrated with another composite board, so that financial burden is larger. In addition, for actual construction, there are also many issues regarding carrying members in a construction site for the formwork, labor cost, transportation cost, and storage of materials, etc.
These problems are aroused since the sheathing that requires a strength is used as the substrate. However, it is still desired to maintain an advantage of forming the interior and exterior substrate on the concrete framework at the time of casting concrete in view of rationalizing the work steps.
In view of the problems described above, an object of the invention is to achieve a construction method, in which a sheathing is not used as interior and exterior substrates, and a substrate member for interior and exterior materials is separated from the sheathing and is formed on the concrete framework after casting concrete.
In order to attain the objects described above, according to the present invention, a form panel 1 doubling as a substrate for interior and exterior materials has the following configuration.
A sheathing surface of a concrete form panel has a plurality of longitudinal grooves having a rectangular cross-section, so as to provide rigidity as a sheathing of the concrete form panel. For a material to compose the form, a material having high rigidity is used in view of strength, deflection, a spacing between horizontal lumbers, and so on. In addition, substrate members in a square bar shape for interior and exterior materials are fitted in the longitudinal grooves. Here, the square bar shape includes a hollow shape, for example, C-form steel. The substrate for interior and exterior materials also works as a reinforcing material against a side pressure upon casting concrete and a vertical lumber. More specifically, in order to increase the strength and rigidity of the form panel, the longitudinal grooves having a rectangular cross-section are formed in the surface thereof. The substrate members in a square bar shape for interior and exterior materials are fitted in the longitudinal grooves. Then, the substrate members are secured from a backside of the longitudinal grooves with screws. Accordingly, the substrate members for interior and exterior materials are integrated thereto as a reinforcing material against a concrete side pressure.
The substrate member for interior and exterior materials may have an anchoring section in a surface exposed from the sheathing. Therefore, the anchoring section of the substrate member for interior and exterior materials is surely secured onto the concrete framework after casting concrete, thereby preventing the substrate members from peeling off.
Screw holes may be formed in bottoms of the longitudinal grooves of the concrete form panel at arbitrary intervals for securing the substrate members in a square bar shape for interior and exterior materials, so as to increase efficiency of the work. Here, it is preferred that the substrate members in a square bar shape for interior and exterior materials have a certain range of rigidity that enables securing nails, screws, and so on, or have female screws formed therein in advance. A separator holes may be formed in the longitudinal grooves, and the substrate members for interior and exterior materials may have a separator hole at a corresponding position.
As a construction method, when no thermal insulation work is performed, the substrate members for interior and exterior materials are fitted in the plurality of longitudinal grooves in a center part of the sheathing of the concrete form. Then, the substrate members for interior and exterior materials are secured with nails, screws or the like, so as to form the form panel doubling as the substrate for interior and exterior materials. The panel is assembled into a specified shape at a construction site and casting concrete therein, so that the concrete framework is molded. Thereafter, dissembling the form and releasing the fastening between the substrate members for interior and exterior materials and a plastic board by removing screws and so on, and the form panel is removed while leaving the substrate members for interior and exterior materials in the concrete framework. Thereafter, using the remaining substrate members for interior and exterior materials as a foundation, interior and exterior work is performed.
Where thermal insulation work is performed, the substrate members for interior and exterior materials made of C-form steel are fitted in the longitudinal grooves formed in the sheath surface of the form panel, so that the form panel doubling as the substrate for interior and exterior materials is formed. Then, a heat insulation board is attached to the concrete casting surface, and the form panel doubling as the substrate for interior and exterior materials is secured on the backside thereof. Thereafter, a separator is secured such that the separator pierces the substrate members for interior and exterior materials and the thermal insulation board from the backside of the form panel doubling as the substrate for interior and exterior materials, so that the separator is embedded in the concrete framework. Then, concrete is cast to mold the concrete framework. After curing concrete, while leaving the thermal insulation board and the substrate members for interior and exterior materials therein, the form panel is removed. Thereafter, a fastening member is inserted into the substrate members for interior and exterior materials, and the interior and exterior members are attached thereto.
Here, when there is unevenness on the wall surface, etc. after curing concrete, it is possible to adjust the unevenness by loosening nuts engaged with the separator that secures the substrate members for interior and exterior materials and inserting an intervening material, such as packing, between the thermal insulation board and the substrate members for interior and exterior materials.
According to the present invention, with the above-described configuration, by fitting the substrate members in a square bar shape for interior and exterior materials in the plurality of longitudinal grooves having a rectangular cross-section provided on the center part of the sheathing, it is not necessary to use a conventional vertical lumbers in the formwork, thereby reducing transportation, assembling, and dissembling works. In addition, a complicated work of attaching the substrate members for interior and exterior materials can be also omitted, and steps in a work contents between the formwork and the work of attaching substrate members for interior and exterior materials can be rationalized, so that the steps can be shortened, and the cost can be significantly reduced.
In addition, when the thermal insulation board is secured, the substrate members for interior and exterior materials and the thermal insulation board can be surely secured and integrated to the concrete via the separator.
Furthermore, since a space as a hallow layer is generated between the substrate members for interior and exterior materials, the space can have effects of a ventilation layer to prevent dew condensation and have sound insulation, and also can be used as a space for piping and wiring.
Form panel doubling as a substrate for interior and exterior materials
Hereunder, the first embodiment of the present invention will be explained.
A plastic board that composes a form has a shape shown in
In the next step, the form panel 1 doubling as a substrate for interior and exterior materials is carried and constructed in the site. Then, a separator C, a form tie, and so on are attached to the form panel 1 doubling as substrate for interior and exterior materials as shown in
According to the form construction method of the invention, since the construction work from the formwork to the installation of the substrate for interior and exterior materials can be done consistently as described above, the work steps can be significantly simplified.
With the form panel 1 doubling as a substrate for interior and exterior materials, an interior material and an exterior material can be finished at the same time. In addition, for the formwork as shown in
Hereunder, the second embodiment of the invention will be described.
A form panel 5 has a shape shown in
In the form panel 5 according to the embodiment shown in
Then, as shown in
According to the form panel 6 of the invention, the outer form 9, the stiffeners 10, and the reinforcing stiffeners 11 as the longitudinal grooves 8 are mounted on the heat insulation board 2 and the substrate member 7 for interior and exterior materials. Accordingly, through the their synergetic effects, the form panel 6 can increase a bending strength of the sheathing, and can be also used as a vertical lumber. Accordingly, by fastening the separators C, on which a horizontal lumber E is arranged, with form ties H, it becomes durable against the side pressure from the concrete G.
In addition, the form panel 6 has a configuration so as to be used on the both sides of the concrete casting surface. Furthermore, depending on a use, any type of conventional form board P can be additionally used on one side.
Furthermore, for materials of the form panel 6, the substrate member 7 for interior and exterior materials, and the fastening receiving material 12, steel and plastic are preferred. The materials and shapes can be arbitrary as long as they satisfy suitable criteria for simplification of the construction, possible frequency for recycling, reduction of weight, etc. Furthermore, as far as the strength of the form panel 6 is sufficient, concrete can be cast without engaging the substrate member 7 for interior and exterior materials in the longitudinal grooves 8 as shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2005-192780 | Jun 2005 | JP | national |
| 2005-318813 | Oct 2005 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2006/311112 | 6/2/2006 | WO | 00 | 11/29/2007 |
