JP2024110028A - Fences and fence construction methods - Google Patents

Abstract

To provide a fence using foamed resin panels that can be easily constructed in a short time without using reinforcing bars, and a construction method for said fence.
[Solution] This fence and fence construction method uses lightweight foamed resin panels and posts made of synthetic resin as the main components. This makes it easier to transport and construct the materials, and reduces the burden on workers. In addition, because the components are lightweight, the fence can be constructed in a shorter time than before. Furthermore, the foamed resin panels are fixed to the posts by small gravel filled in the post holes. This eliminates the need for the hardening time that was previously required with mortar, and the construction period can be shortened accordingly. Furthermore, the small gravel is only compacted and not fixed in place. Therefore, when the fence collapses or is removed, the small gravel flows out of the post holes, reducing the weight of the fence itself. This reduces the risk of collapse. Furthermore, removal work can be performed easily.
[Selected figure] Figure 2

Description

The present invention relates to a fence using foamed resin panels and a method for constructing such a fence.

In recent years, there have been reports of concrete walls collapsing during earthquakes, causing casualties and traffic disruptions. For this reason, proposals have been made to create walls made of foamed resin (expanded polystyrene), which is much lighter than concrete walls, such as the one described in Patent Document 1 below.

JP 2022-142010 A

Here, in the conventional foamed resin fence described in [Patent Document 1], post holes are formed vertically in the foamed resin panel that forms the main body of the fence, and reinforcing bars erected in the foundation are passed through these post holes to form a fence. Mortar, concrete, etc. are then filled into the post holes with the reinforcing bars inserted, and the foamed resin panel is fixed in place to form the fence. However, the reinforcing bars and the mortar used to fix the reinforcing bars are heavy, and in addition to requiring strength to transport the materials, there are problems in that the weight of the fence itself increases, reducing the benefits of a foamed resin fence. In addition, there are problems with the mortar cracking due to vibration and impact, and the reinforcing bars rusting and deteriorating when in contact with moisture.

The present invention was made in consideration of the above circumstances, and aims to provide a fence using foamed resin panels that can be easily constructed in a short time without using reinforcing bars, and a construction method for this fence.

The present invention relates to
(1) The above problem is solved by providing a fence 80 having foamed resin panels 30a, 30b having post holes 32 penetrating vertically, a synthetic resin post 40 inserted into the post hole 32 and fixed at one end to the foundation 1, small gravel 42 filled into the post hole 32 to fix the foamed resin panels 30a, 30b to the post 40, and a mortar layer 60 formed on the surface of the foamed resin panels 30a, 30b.
(2) The above problem is solved by providing the fence 80 described in (1) above, which is characterized in that the small gravel 42 is made of rubble.
(3) The above problem is solved by providing the fence 80 described in (1) above, characterized in that the foam resin panels 30a, 30b have real tongue and groove joints 34a, 34a' or grooved joints 34b, 34b' on their sides, and are connected horizontally by the real tongue and groove joints 34a, 34a' or grooved joints 34b, 34b'.
(4) A method for constructing a fence using foam resin panels 30a, 30b, comprising the steps of:
The foam resin panels 30a, 30b are provided with support holes 32 extending vertically therethrough,
The above problem is solved by providing a fence construction method comprising: a post fixing step S104 of erecting synthetic resin posts 40 on a foundation 1; a panel installation step S106 of passing the posts 40 through the post holes 32 of the foamed resin panels 30a, 30b and connecting the foamed resin panels 30a, 30b horizontally to form a fence; a panel fixing step S108 of filling the post holes 32 with small gravel 42 and compacting it to fix the foamed resin panels 30a, 30b to the posts 40; and a mortar layer forming step S130 of forming a mortar layer 60 on the surface of the foamed resin panels 30a, 30b.
(5) A method for constructing a fence using foam resin panels 30a, 30b, comprising the steps of:
The foam resin panels 30a, 30b have a support hole 32 passing through in the vertical direction and have joints 34b, 34b' on the sides.
The above problem is solved by providing a fence construction method comprising: a base mortar step S202 of forming a base mortar layer 50 in which a mesh member 52 is embedded on the surface of the foamed resin panels 30a, 30b; a panel installation step S208 of passing synthetic resin supports 40 through the support holes 32 of the foamed resin panels 30a, 30b and fixing the lower ends of the supports 40 to the foundation 1 and further connecting the grooved joints 34b, 34b' laterally to form the foamed resin panels 30a, 30b into a fence shape; a panel fixing step S108 of filling the support holes 32 with small gravel 42 and compacting it to fix the foamed resin panels 30a, 30b to the supports 40; and a finishing mortar step S222 of forming a finishing mortar layer 54 on the base mortar layer 50.

The fence and fence construction method of the present invention use lightweight foamed resin panels and synthetic resin posts as the main components. This makes it easier to transport and construct the materials, and reduces the burden on workers. In addition, because the components are lightweight, the fence can be constructed in a shorter time than before. Furthermore, the foamed resin panels are fixed to the posts by small gravel filled in the post holes. This eliminates the need for the hardening time that was previously required with mortar, and therefore shortens the construction period. Furthermore, the small gravel is only compacted and is not fixed in place. Therefore, when the fence collapses or is removed, the small gravel flows out of the post holes, reducing the weight of the fence itself. This reduces the risk of collapse. In addition, removal work can be performed easily.

FIG. 2 is a perspective view of a foam resin panel for a fence according to the present invention. FIG. 1 is a schematic cross-sectional view of a fence according to the present invention. FIG. 1 is a diagram illustrating a first construction method for a fence according to the present invention. FIG. 1 is a diagram illustrating a first construction method for a fence according to the present invention. FIG. 1 is a diagram illustrating a first construction method for a fence according to the present invention. FIG. 1 is a diagram illustrating a first construction method for a fence according to the present invention. FIG. 11 is a diagram illustrating a second construction method for a fence according to the present invention. FIG. 11 is a diagram illustrating a second construction method for a fence according to the present invention. FIG. 11 is a diagram illustrating a second construction method for a fence according to the present invention. FIG. 11 is a diagram illustrating a second construction method for a fence according to the present invention. 1 is a process flowchart of a wall construction method according to the present invention.

The embodiment of the fence 80 and the fence construction method according to the present invention will be described with reference to the drawings. Here, FIG. 1 is a perspective view of the foamed resin panels 30a and 30b, which are the main components of the fence 80 according to the present invention. First, the foamed resin panels 30a and 30b used in the present invention are made by foaming synthetic resin and forming it into a plate shape, and it is preferable to use polystyrene foam (EPS: bead method expanded polystyrene). However, in some cases, well-known foamed resins such as foamed polyethylene and foamed polypropylene may be used. When using polystyrene foam for the foamed resin panels 30a and 30b, it is acceptable to use foamed polystyrene with a foaming ratio of about 50 to 60 times for general containers and cushioning materials, but it is preferable to use foamed polystyrene with a high density and high strength of about 30 to 50 times. In addition, there is no particular limitation on the dimensions of the foamed resin panels 30a and 30b, but for example, when constructing a fence 80 with a height of 2 m, it is preferable to use foamed resin panels 30a and 30b with a width of 1 mm and a height of 2 m arranged horizontally. Additionally, the wall 80 may be constructed by stacking multiple low-height foam resin panels 30a, 30b.

The foamed resin panels 30a and 30b are provided with support holes 32 that penetrate vertically (heightwise) from the top to the bottom. The diameter of the support hole 32 is larger than the diameter of the support 40 described below, and is a diameter that allows a sufficient gap for small gravel 42 to be inserted between the support 40 and the inner surface of the support hole 32 when the support 40 is inserted. With this condition satisfied, the diameter of the support hole 32 is preferably about half to one third of the thickness of the foamed resin panels 30a and 30b. For example, when the thickness of the foamed resin panels 30a and 30b is 12 cm, the diameter of the support hole 32 is preferably about 3 cm to 6 cm. In addition, it is most preferable to form two support holes 32 on the left and right of the foamed resin panels 30a and 30b, but if the foamed resin panels 30a and 30b are long in the horizontal direction, the number of support holes 32 may be increased appropriately to three, four, or five. Furthermore, the foamed resin panels 30a, 30b may have an arc-shaped, wavy, or uneven upper surface to give the panels a decorative appearance. Decorative through-holes may also be formed in the walls of the foamed resin panels 30a, 30b. However, if through-holes are formed in the walls, they should be designed so that they do not intersect with the support holes 32.

Furthermore, it is preferable that the sides of the foamed resin panels 30a and 30b have a joint shape. It is particularly preferable that the joints to be formed are real tongue and groove joints or lap joints, which are easy to form. Here, FIG. 1(a) shows a first foamed resin panel 30a with real tongue and groove joints 34a and 34a' on the sides, and FIG. 1(b) shows a second foamed resin panel 30b with lap joints 34b and 34b' on the sides. In the real tongue and groove joints 34a and 34a' shown in FIG. 1(a), a convex portion (reference number 34a in the drawing) is formed on one side, and a concave portion (reference number 34a' in the drawing) is formed on the other side, and the convex portion (34a) of the adjacent foamed resin panels 30a is inserted into the concave portion (34a') to connect the foamed resin panels 30a in the horizontal direction. In addition, in the joints 34b and 34b' shown in FIG. 1(b), notches (34b and 34b' in the drawing) that are point-symmetrical are formed on both sides of the foamed resin panel 30b, and the joints 34b and 34b' of adjacent foamed resin panels 30b are combined to connect and connect the foamed resin panels 30b in the horizontal direction. The support holes 32 and the joints may be formed by integral molding when the foamed resin panels 30a and 30b are produced, or may be formed by performing machining such as drilling and cutting on the (plate-shaped) foamed resin panel after molding.

Next, the structure of the fence 80 according to the present invention will be described using the schematic cross-sectional view of the post hole 32 in Figure 2. First, the fence 80 according to the present invention has the foamed resin panels 30a, 30b mentioned above, a synthetic resin post 40 inserted into the post hole 32 and fixed at one end to the foundation 1, small gravel 42 filled into the post hole 32 to fix the foamed resin panels 30a, 30b and the post 40, and a mortar layer 60 formed on the surface of the foamed resin panels 30a, 30b.

The posts 40 used in the present invention are made of synthetic resin, and it is particularly preferable to use synthetic fibers hardened into a rod shape with a synthetic resin adhesive. Among these, it is most preferable to use aramid fibers as the synthetic fibers, which are tied into a rod shape with a braided cord and hardened with an epoxy resin adhesive as the synthetic resin adhesive. Such posts 40 have a higher tensile strength than conventional reinforcing bars and do not deteriorate due to rust. Furthermore, the synthetic resin posts 40 are much lighter than the reinforcing bars used in the past, which can reduce the burden on workers when transporting materials and during construction. In addition, the total weight of the fence 80 is reduced, improving safety in the event of collapse and reducing the burden on workers when removing the fence.

The small gravel 42 used in the present invention is filled between the posts 40 and the post holes 32 and compacted to secure the foamed resin panels 30a, 30b to the posts 40. There are no particular restrictions on the material, and any material can be used, such as crushed natural stone, recycled glass, ceramics, etc. In terms of size, the gravel should be one that fits between the posts 40 and the post holes 32 and has an outer diameter of approximately 2 to 3 cm or less. It is most preferable to use so-called 'billi' stones, which are 1 cm or less in size. In addition to being suitable for the present invention in terms of size, this 'billi' stone is extremely inexpensive compared to stones made of other materials, which allows for a reduction in the material costs involved in the present invention.

The mortar layer 60 of the present invention is preferably composed of a base mortar layer 50 applied to the surface of the foamed resin panels 30a, 30b, and a finish mortar layer 54 applied to the base mortar layer 50. The base mortar layer 50 and the finish mortar layer 54 are preferably made of elastic mortar. Here, elastic mortar is a mortar component to which 0.1 wt% to 10 wt% of a resin component such as a re-emulsified powder resin has been added, which gives the mortar a certain degree of flexibility after hardening and can suppress the occurrence of cracks due to bending, etc. Furthermore, the elastic mortar used in the present invention may be appropriately mixed with short fibers in addition to the resin component. The elastic mortar used in the base mortar layer 50 and the finish mortar layer 54 may be the same, or the mixture may be changed to suit each application.

Furthermore, it is preferable to embed a mesh member 52 within the base mortar layer 50. This mesh member 52 can be any well-known mesh member that is embedded in mortar walls and the like to increase their strength. In particular, it is preferable to use a lattice-shaped mesh of several millimeters square, mainly made of glass fibers that have been treated to be resistant to alkali.

Next, a method for constructing a fence 80 according to the present invention will be described. Figures 3 to 6 are diagrams for explaining a first construction method for a fence 80 using a first foamed resin panel 30a, and Figure 11(a) is a process flow chart. Note that in the first construction method, there are no particular limitations on the presence or absence or type of joints in the foamed resin panel, but here, an explanation will be given using a foamed resin panel 30a with real joints 34a, 34a' on the sides as an example.

In the first fence construction method according to the present invention, first, as shown in FIG. 3(a), a support 40 is erected and fixed to a foundation 1 that has been constructed by a known method (support fixing step S104). The support 40 may be erected and fixed at the same time as the foundation 1 is poured, or a hole may be drilled in the hardened foundation 1, the support 40 may be inserted, and then fixed with mortar or a known adhesive. The length of the above-ground portion of the support 40 is approximately equal to or slightly shorter than the height dimension of the foamed resin panel 30a. The position at which the support 40 is erected corresponds to the support hole 32 in the foamed resin panel 30a.

Next, as shown in FIG. 3(b), the support holes 32 of the foam resin panel 30a are passed through the erected support 40, and the side joints 34a, 34a' are connected to the joints 34a, 34a' of the adjacent foam resin panel 30a. This causes the foam resin panels 30a to be arranged horizontally to form a wall shape (panel installation step S106 of the first construction method).

Next, small gravel 42 is filled into the gap between the support 40 and the support hole 32 while applying appropriate vibrations using a well-known industrial vibration device. This causes the small gravel 42 to be compacted and filled into the support hole 32, and the foamed resin panel 30a and the support 40 are fixed together via the small gravel 42, as shown in FIG. 4 (panel fixing process S108).

Next, a mortar layer 60 is formed on the surface of the foamed resin panel 30a (mortar layer formation step S130). The mortar layer 60 is preferably formed as follows. First, as shown in FIG. 5(a), elastic mortar that will become the base mortar layer 50 is applied to the surface of the foamed resin panel 30a. Next, as shown in FIG. 5(b), the surface of this elastic mortar layer is covered with a mesh member 52. Next, elastic mortar is applied again on top of this mesh member 52, and the mesh member 52 is laid down. This forms the base mortar layer 50 with the mesh member 52 laid down, as shown in FIG. 6(a) (base mortar step S120 of the first construction method).

Next, a finishing mortar is applied to the surface of the base mortar layer 50 to form the finishing mortar layer 54 (finishing mortar step S122 of the first construction method). The finishing mortar layer 54 may be formed by spraying mortar. As a result, as shown in FIG. 6(b), a mortar layer 60 consisting of the base mortar layer 50 and the finishing mortar layer 54 is formed, and the fence 80 according to the present invention is completed. Furthermore, tiles, decorative blocks, natural stones, bricks, plaster, and other well-known wall materials may be bonded, processed, coated, patterned, painted, etc. on the finishing mortar layer 54 as appropriate.

Next, a second construction method for the fence 80 according to the present invention will be described. Here, Figs. 7 to 10 are diagrams for explaining the second construction method, and Fig. 11(b) is a process flow chart. In the second construction method, a base mortar layer 50 is formed on the front and back surfaces of the foamed resin panel in advance, and the wall 80 is constructed by installing this on-site. This increases the weight of the foamed resin panel by the amount of the base mortar layer 50. Therefore, in the second construction method, it is preferable to use a foamed resin panel 30b with half joints 34b, 34b' on the sides, which are easier to connect than real joints 34a, 34a'.

First, in the second construction method, as shown in FIG. 7(a), elastic mortar is applied to the front and back surfaces of the foamed resin panel 30b to form the base mortar layer 50. At this time, elastic mortar is not applied to the joints 34b, 34b' and the top and bottom surfaces where the post holes 32 are open. Next, as shown in FIG. 7(b), the elastic mortar layer on the front and back surfaces is covered with a mesh member 52. Next, elastic mortar is applied again from above the mesh member 52, and the mesh member 52 is laid down. As a result, the base mortar layer 50 with the mesh member 52 laid down is formed as shown in FIG. 7(c) (base mortar step S202 of the second construction method). This base mortar step S202 can be performed not only on-site but also in a factory, so it is not affected by weather, and since the foamed resin panel 30b can be laid down to perform the work, the burden on the worker can be significantly reduced.

Next, the foamed resin panel 30b on which the base mortar layer 50 has been formed is transported to the site, and the support 40 is passed through the support hole 32 of the foamed resin panel 30b, and the lower end of the support 40 is fixed to the foundation 1. In parallel with this, the joints 34b, 34b' of the foamed resin panel 30b are connected to the joints 34b, 34b' of the adjacent foamed resin panel 30b to form a wall (panel installation step S208 of the second construction method). There is no particular restriction on the order of the work in the panel installation step S208, but in the second construction method, since the base mortar layer 50 has already been formed on the foamed resin panel 30b, the panel itself is heavier than in the first construction method. Therefore, it is preferable to perform the steps shown below, for example, without lifting the foamed resin panel 30b high, as this reduces the workload.

First, holes are drilled in the foundation 1 to set up the support 40. Next, the foamed resin panel 30b on which the base mortar layer 50 has been formed is placed on the foundation 1, and the support 40 is passed through the support hole 32 as shown in FIG. 7(d). Then, the foamed resin panel 30b is shifted or raised to a degree that allows work to be performed, and the lower end of the support 40 is inserted into the support fixing hole provided in the foundation 1 and fixed with mortar or the like. Next, the foamed resin panel 30b is slid, etc., to connect the joints 34b, 34b' of the foamed resin panel 30b to the joints 34b, 34b' of the adjacent foamed resin panel 30b. These operations are then repeated to arrange the foamed resin panel 30b in a wall-like shape.

Next, as in the first construction method, small gravel 42 is filled into the gap between the support 40 and the support hole 32 while applying appropriate vibrations using a well-known industrial vibration device. This causes the small gravel 42 to be compacted and filled in the support hole 32, and the foamed resin panel 30a and the support 40 are fixed together via the small gravel 42, as shown in FIG. 8 (panel fixing process S108).

Next, a finishing mortar layer 54 is formed on the base mortar layer 50 of the foamed resin panel 30b (finishing mortar step S222 of the second construction method). It is preferable to form this finishing mortar layer 54 as follows. First, as shown in FIG. 9(a), elastic mortar that will become the finishing mortar layer 54 is applied to the base mortar layer 50 and the upper surface of the foamed resin panel 30b. Next, as shown in FIG. 9(b), a mesh member 52 is placed over the upper surface of the foamed resin panel 30b and the connection portion of the foamed resin panel 30b. Next, while this mesh member 52 is placed face down, elastic mortar is applied again to the entire foamed resin panel 30b. As a result, the finishing mortar layer 54 is formed as shown in FIG. 10. As a result, a mortar layer 60 consisting of the base mortar layer 50 and the finishing mortar layer 54 is formed, and the fence 80 according to the present invention is completed. As with the first construction method, tiles, decorative blocks, natural stone, bricks, plaster, and other well-known wall materials may be bonded, processed, coated, patterned, painted, etc. onto the finishing mortar layer 54 as appropriate.

As described above, the fence 80 and fence construction method of the present invention use lightweight foam resin panels 30a, 30b and synthetic resin supports 40 as the main components. This makes it easier to transport materials and construct, and reduces the burden on workers. In addition, because the components are lightweight, the fence can be constructed in a shorter time than before. Furthermore, even people with weak strength, such as women or the elderly, can carry out the work.

The foamed resin panels 30a, 30b are fixed to the posts 40 by small gravel 42 filled in the post holes 32. This eliminates the need for the hardening time that was previously required with mortar, and the construction period can be shortened accordingly. The small gravel 42 is only compacted and is not fixed with mortar or adhesives. Therefore, if the fence 80 of the present invention collapses due to a disaster or the like, the small gravel 42 will flow out from the post holes 32 to the outside, reducing the weight of the fence 80 itself. This reduces the risk of collapse. In addition, removal work can be performed more easily than with conventional fences because the small gravel 42 flows out and reduces the weight.

In particular, with the second construction method according to the present invention, the process up to the formation of the base mortar layer 50 can be carried out in a factory, etc. This allows the construction period on-site to be significantly shortened.

The configuration, design, shape, dimensions, and other aspects of the fence 80, foam resin panels 30a, 30b, etc. shown in this example are merely examples and are not limited to the above examples, and the present invention can be modified and implemented without departing from the scope of the invention. The fence construction method according to the present invention is merely examples and is not limited to the above examples, and the work procedures and process order can be modified and implemented without departing from the scope of the invention, such as by inserting necessary processes.

1. Basics
30a, 30b Foam resin panels
32 Post hole
34a, 34a' Real jointer
34b, 34b' Half-cut joint
40 Support
42 Small gravel
50 Base mortar layer
52 Mesh member
54 Finishing mortar layer
60 Mortar layer
80 Fence
S104 Pillar fixing process
S106, S208 Panel installation process
S108 Panel fixing process
S120, S202 Base mortar process
S122, S222 Finishing mortar process
S130 Mortar layer formation process

Claims (5)

A foam resin panel having a support hole extending vertically therethrough;
A synthetic resin support that is inserted into the support hole and has one end fixed to the foundation;
Small gravel filled in the support hole to fix the foam panel and the support;
and a mortar layer formed on the surface of the foam resin panel. The fence according to claim 1, characterized in that fine gravel is used. The fence according to claim 1, characterized in that the foam resin panels have a regular joint or a joint on the sides, and are connected horizontally by the regular joint or the joint. A method for constructing a fence using foam resin panels, comprising the steps of:
The foam resin panel has a support hole extending vertically therethrough,
a post fixing process for erecting a synthetic resin post on the foundation;
a panel installation process in which the support posts are passed through the support holes of the foam resin panels and the foam resin panels are connected in a horizontal direction to form a wall;
a panel fixing process for filling the support hole with small gravel and compacting it to fix the foamed resin panel to the support;
A fence construction method comprising: a mortar layer forming step of forming a mortar layer on the surface of the foamed resin panel. A method for constructing a fence using foam resin panels, comprising the steps of:
The foam resin panel has a support hole penetrating in the vertical direction and has a half-joint on the side,
a base mortar step of forming a base mortar layer having a mesh member embedded on a surface of the foam resin panel;
A panel installation process in which a synthetic resin support is inserted through the support hole of the foamed resin panel, the lower end of the support is fixed to a foundation, and the joints are connected laterally to form the foamed resin panel into a wall shape;
a panel fixing process for filling the support hole with small gravel and compacting it to fix the foamed resin panel to the support;
A fence construction method comprising: a finishing mortar process for forming a finishing mortar layer on the base mortar layer.

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