Abstract
There is provided: a novel roof panel that is easy to manufacture, is durable, and is capable of completely preventing rainwater ingress and easily draining rainwater; a roof using the roof panel; and a three-dimensional structure with the roof. A precast concrete roof panel 10 includes on its upper surface 14 an inclined main portion 16 that is inclined downward toward an edge.
Claims
1. A roof panel of precast concrete for a roof of a three-dimensional structure, comprising on its upper surface an inclined main portion that is inclined downward toward an edge.
2. The roof panel according to claim 1, wherein the upper surface has a rectangular shape in a planar view, and includes, in its center in a longitudinal direction, a ridge line that extends in a short direction, and the inclined main portion is inclined downward from the ridge line toward both side edges located on both sides in the longitudinal direction.
3. The roof panel according to claim 1, wherein the inclined main portion is inclined downward to an edge portion of the upper surface, and the edge portion includes a groove formed along a lower end edge of the inclined main portion.
4. The roof panel according to claim 3, wherein the groove includes a drain hole that penetrates vertically.
5. The roof panel according to claim 4, wherein the groove has a bottom surface that is inclined downward toward the drain hole.
6. The roof panel according to claim 1, wherein the upper surface includes a standing wall that stands upward along the edge.
7. The roof panel according to claim 1, wherein a threaded fastener is embedded to be exposed on a lower surface.
8. The roof panel according to claim 1, wherein a lower surface is horizontal.
9. The roof panel according to claim 1, wherein a lower surface is also inclined downward toward the edge along the inclined main portion on the upper surface.
10. A roof composed of a plurality of the roof panels according to claim 1 arranged in parallel, wherein adjacent two of the roof panels are arranged with a gap therebetween.
11. The roof according to claim 10, wherein a cover member is provided to straddle upper surfaces of edge portions of the two adjacent roof panels, the cover member extending along the respective edge portions.
12. The roof according to claim 11, wherein: the upper surface includes a standing wall that stands upward along the edge, and the cover member is provided to straddle the standing walls.
13. The roof according to claim 10, wherein; the inclined main portion is inclined downward to an edge portion of the upper surface, the edge portion includes a groove formed along a lower end edge of the inclined main portion, a waterproof tape is provided to straddle end parts of the grooves provided in the two adjacent roof panels, and the grooves of these two roof panels communicate with each other.
14. A three-dimensional structure comprising the roof according to claim 10, wherein the roof is supported by a single or a plurality of precast concrete side wall panels.
15. The three-dimensional structure according to claim 14, wherein a box-shaped fastening aid is embedded in an upper end surface of the side wall panel with an interior space exposed, and the fastening aid includes on its upper surface a through hole that penetrates vertically.
16. The three-dimensional structure according to claim 14, placed on a concrete foundation.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1: an exploded perspective view showing the overall construction of a preferred embodiment of a single-story three-dimensional structure using roof panels constructed in accordance with the present invention;
[0013] FIG. 2-1: views showing only the (outer) roof panel of the three-dimensional structure shown in FIG. 1;
[0014] FIG. 2-2: views showing only the (inner) roof panel of the three-dimensional structure shown in FIG. 1;
[0015] FIG. 3-1: views showing a modification of the (inner) roof panel constructed in accordance with the present invention;
[0016] FIG. 3-2: views showing a modification of the (inner) roof panel constructed in accordance with the present invention;
[0017] FIG. 4: views showing the structure of a threaded fastener embedded in the lower surface of the roof panel;
[0018] FIG. 5: a view showing the positional relationship between the roof panels and side wall panels of the three-dimensional structure shown in FIG. 1;
[0019] FIG. 6: a partially enlarged plan view showing a state in which the roof panels constructed in accordance with the present invention are arranged in parallel;
[0020] FIG. 7: an enlarged view of the A-A cross section in FIG. 6;
[0021] FIG. 8: views showing only a cover member;
[0022] FIG. 9: an enlarged view of the B-B cross section in FIG. 6;
[0023] FIG. 10: a view for explaining the fastening structure between the side wall panel, the roof panel and a foundation of the three-dimensional structure shown in FIG. 1;
[0024] FIG. 11: a view for explaining the fastening structure between adjacent two of the side wall panels of the three-dimensional structure shown in FIG. 1;
[0025] FIG. 12: a view showing only a fastening aid;
[0026] FIG. 13: a view showing the structure of a drainage pipe in the three-dimensional structure shown in FIG. 1; and
[0027] FIG. 14: a perspective view showing a process embodiment of a multistory three-dimensional structure using the roof panels constructed in accordance with the present invention.
MODE FOR CARRYING OUT THE INVENTION
[0028] Hereinafter, a description will be given in more detail of preferred embodiments of a roof panel constructed in accordance with the present invention, a roof composed of this roof panel, and a three-dimensional structure with this roof, with reference to the accompanying drawings.
[0029] As shown in FIG. 1, a three-dimensional structure denoted as a whole by reference numeral 2 includes a roof 4, a side wall 6, and a foundation 8.
[0030] Still referring to FIG. 1, the roof 4 is composed of a plurality of (i.e., four in the illustrated embodiment) precast concrete roof panels 10 arranged in parallel, and has a rectangular shape in a planer view. Regarding the four roof panels 10 arranged in parallel, two of the roof panels located at both ends in the longitudinal direction are referred to as outer roof panels 10a, and the remaining two roof panels are referred to as inner roof panels 10b. FIG. 2-1 (b) shows only the outer roof panel 10a, and FIG. 2-2 (b) shows only the inner roof panel 10b. As shown in the drawings, both of the roof panels 10 are reinforced with appropriate steel bars 12 inside. In each of FIGS. 2-1 and 2-2, (a) is a front view, (b) is a plan view, and (c) is a bottom view. In the following description, when the roof panel is simply denoted by reference numeral 10 without a or b, this roof panel 10 is meant to encompass both the outer roof panel 10a and the inner roof panel 10b. The same applies to the following description of components of the respective roof panels 10.
[0031] It is important for the roof panel 10 of the present invention that it includes on its upper surface 14 an inclined main portion 16 that is inclined downward toward an edge. Referring to FIGS. 2-1 (a) and (b), the upper surface 14a of the outer roof panel 10a as shown has a rectangular shape in a planer view, and includes in its center in the longitudinal direction a ridge line 18a that extends linearly in the short direction. The inclined main portion 16a is inclined downward from the ridge line 18a toward both side edges located on both sides in the longitudinal direction. (The side edge as used herein refers to an edge extending in the short direction at both ends of the outer roof panel 10a in the longitudinal direction, while an end edge to be used later refers to an edge extending in the longitudinal direction at both ends of the outer roof panel 10a in the short direction.) The inclined main portion 16a is inclined downward to side edge portions 20a of the upper surface 14a, and each of the side edge portions 20a includes a groove 22a that extends linearly in the short direction along the lower end edge of the inclined main portion 16a. In the center of the groove 22a in the longitudinal direction (i.e., in the center of the outer roof panel 10a in the short direction), a circular drain hole 24a is formed to penetrate vertically. The bottom surface of the groove 22a is inclined downward toward the drain hole 24a. On the outer side of the groove 22a, the side edge portion 20a also includes a side-edge standing wall 26a that stands upward along the side edge of the outer roof panel 10a. At one end edge of the upper surface 14a of the outer roof panel 10a, an outer end-edge standing wall 28a is formed to stand upward along the end edge of the outer roof panel 10a. The side-edge standing walls 26a and the outer end-edge standing wall 28a are connected to each other at corners of the upper surface 14a to form an approximately inverted U-shape in a planar view, and the upper surface of each of the standing walls is substantially horizontal. At the other end edge of the upper surface 14a, an inner end-edge standing wall 30a is formed to stand upward along the end edge of the outer roof panel 10a except the side edge portions 20a, that is, the inclined main portion 16a. The upper surface of the inner end-edge standing wall 30a is in parallel with the upper surface 14a and is at the same height as the upper surfaces of the side-edge standing wall 26a and the outer end-edge standing wall 28a in its center in the longitudinal direction. In the vicinity of the corners of the upper surface 14, a threaded fastener 32 that is used to lift the outer roof panel 10a is embedded with its upper surface exposed. The threaded fastener 32 will be described later.
[0032] Referring to FIGS. 2-1 (a) and (c), a lower surface 34a of the outer roof panel 10a as shown is substantially horizontal, and includes two rows of grooves, namely, a drainage 36a and a guide groove 38a, that are locally displaced upward. Each of the grooves includes portions that extend linearly in the short direction in both end parts of the outer roof panel 10a in the longitudinal direction, and a portion that extends linearly in the longitudinal direction in one end part of the outer roof panel 10a in the short direction, forming an inverted U-shape in a bottom view. The drainage 36a is located on the outer side of the guide groove 38a, and has a smaller groove width than the guide groove 38a. As described later, an upper end part of the side wall 6 is fitted into the guide groove 38a, and the threatened fastener 32 that is used to fasten the upper end part of the side wall 6 and the outer roof panel 10a together is embedded in the guide groove 38 with its lower surface exposed. A plurality of (i.e., five in the illustrated embodiment) the threatened fasteners 32 are embedded in the guide groove 38a at intervals. The threaded fastener 32 will be described later.
[0033] The inner roof panel 10b has almost the same configuration as the outer roof panel 10a. Thus, the following description is directed only to the difference of the inner roof panel 10b from the outer roof panel 10a, and the same components as those of the outer roof panel 10a are denoted by the same reference numerals with b and will not be described. For example, as can be understood from a comparison between FIGS. 2-2 (b) and 2-1 (b), in a planar view, the inner roof panel 10b has the same length in the longitudinal direction as the outer roof panel 10a, but is somewhat longer in the short direction than the outer roof panel 10a. Further, the outer end-edge standing wall (28a) is not formed on the upper surface 14b of the inner roof panel 10b. Instead, at both end edges of the upper surface 14b, inner end-edge standing walls 30b are formed to stand upward along the end edges of the inner roof panel 10b except the side edge portions 20b, that is, the inclined main portion 16b. Furthermore, the drainage 36b and the guide groove 38b on the lower surface 34b of the inner roof panel 10b are not formed in a U-shape, but extend linearly in the short direction in both end parts in the longitudinal direction.
[0034] FIG. 3-1 shows a modification of the roof panel, or more specifically the inner roof panel, constructed in accordance with the present invention. An inner roof panel denoted as a whole by reference numeral 10b is different from the inner roof panel 10b in that a lower surface 34b is not substantially horizontal. More specifically, the inner roof panel 10b is formed of a central wall portion 11b and an endless outer peripheral wall portion 13b extending perpendicularly downward from the peripheral edge of the central wall portion 11b. The central wall portion 11b is such that an upper surface 14b and the lower surface 34b are inclined downward in parallel from a ridge line 18 toward both side edges, and has a constant thickness in the longitudinal direction. The lower surface of the outer peripheral wall portion 13b is substantially horizontal. FIG. 3-2 shows a further modification of the inner roof panel. In an inner roof panel denoted as a whole by reference numeral 10b, a member 39 with a relatively low specific gravity, such as expanded polystyrene, is embedded as shown by the dashed line in the drawing. The member 39 is embedded along with the steel bars in the concrete. In the embodiment shown in FIG. 3-2, the member 39 is a rectangular panel, and a plurality of the members 39 are arranged in parallel at intervals in a planar view. By embedding the member 39, it becomes possible to reduce not only the use of a concrete material but also the weight of the roof panel. The same modification may also be applied to the outer roof panel.
[0035] Next, the threaded fastener 32 will be described with reference to FIG. 4. FIG. 4(a) is a cross-sectional view of a part of the roof panel 10 where the threaded fastener 32 is embedded in the lower surface 34, and FIG. 4(b) is a view of (a) as viewed from below. The threaded fastener 32 is a metal cylindrical member with an internal thread 40 formed on its inner periphery. The threaded fastener 32 is welded and fixed between the reinforcing steel bars 12, and is embedded along with the steel bars 12 in the concrete with its lower end surface exposed. As shown in FIG. 4(a), in the part where the threaded fastener 32 is fixed, an additional steel bar 42 is also provided locally so that the threaded fastener 32 is welded and fixed also thereto. The threaded fastener 32 may be provided also on the upper surface 14 of the roof panel 10 in a like manner. In such a case, the upper end surface of the threaded fastener 32 is exposed.
[0036] A plurality of the above-described roof panels 10 (i.e., the outer roof panels 10a and the inner roof panels 10b) are supported and fastened to each other from below by the side wall 6. FIG. 5 shows the positional relationship between the roof panels 10 and the side wall 6. The fastening structure between the roof panels 10 and the side wall 6 will be described later. As shown in FIG. 5, two of the roof panels 10 are arranged such that their end edges are adjacent to each other. The two roof panels 10 are arranged in parallel on the side wall 6 with a gap 44 provided therebetween. Referring to FIGS. 1, 6 and 7, a cover member 46 (as shown by the dash-dot-dot line in FIG. 6) is provided to straddle the upper surfaces of end edge portions of the two adjacent roof panels 10. The cover member 46 extends along the respective end edges. FIGS. 6 and 7 show the outer roof panel 10a and the inner roof panel 10b arranged adjacent to each other. The following description will be given only of this case, but the same applies to the case where the two inner roof panels 10b are arranged adjacent to each other. In the illustrated embodiment, the outer roof panel 10a and the inner roof panel 10b include the inner end-edge standing walls 30a and 30b, respectively, at their end edges, and the cover member 46 is provided to cover the entire inner end-edge standing walls 30a and 30b in the longitudinal direction (In the case of the two adjacent inner roof panels 10b, the cover member 46 is provided to straddle their inner end-edge standing walls 30b.)
[0037] The cover member 46 will be described with reference to FIGS. 6, 7 and 8. FIGS. 8(a), 8(b) and 8(c) are a front view, a bottom view, and a side view, respectively, of the cover member 46. The cover member 46 is also made of precast concrete, and includes a top panel wall 48 with an elongated rectangular shape in a planar view (bottom view) and an endless downward wall 50 extending perpendicularly downward from the outer peripheral edge of the top panel wall 48. The top panel wall 48 has a slightly inverted V-shape in a front view with the same inclination angle as the inclined main portion 16 of the roof panel 10. As shown in FIG. 8(c), the top panel wall 48 has an arc-like upper surface and a flat lower surface, and is constant in thickness in the longitudinal direction. As such, the downward wall 50 extends perpendicularly downward from the top panel wall 48 for a constant length, and the lower surface of the downward wall 50 is in parallel with the lower surface of the top panel wall 48. As shown in FIG. 7, when the cover member 46 is provided to straddle the inner end-edge standing walls 30a and 30b, the upper end parts of the inner end-edge standing walls 30a and 30b are received within the downward wall 50 such that the upper surfaces of the inner end-edge standing walls 30a and 30b abut the lower surface of the top panel wall 48, whereby the gap 44 between the inner end-edge standing walls 30a and 30b is covered with the cover member 46.
[0038] Referring to FIGS. 6 and 9, a waterproof tape 51 is provided to straddle end parts of the grooves 22 in the two adjacent roof panels 10 in the longitudinal direction. In a region of the side edge portion 20 where the waterproof tape 51 is to be provided, the upper surface 14 is somewhat cut before the waterproof tape 51 is provided. Then, after the provision of the waterproof tape 51, a waterproof mortar 53 is provided such that it is adjusted to the surrounding height. Thus, the grooves 22 of the two roof panels 10 communicate with each other.
[0039] As shown in FIG. 1, the side wall 6 has an approximately rectangular cylindrical shape and is formed of a combination of four precast concrete side wall panels 52. Two of the four side wall panels 52 that form the long sides of the side wall 6 are referred to as long-side side wall panels 52a, and the remaining two side wall panels 52 are referred to as short-side side wall panels 52b. The long-side side wall panel 52a is substantially flat, while the short-side side wall panel 52b is bent inward at 90 degrees in a planar view at its both ends. Thus, the long-side side wall panels 52a and the short-side side wall panels 52b can be connected to each other with their side end surfaces facing each other. The fastening structure between the side end surfaces of the long-side side wall panel 52a and the short-side side wall panel 52b will be described later. In the following description, when the side wall panel is simply denoted by reference numeral 52 without a or b, this side wall panel 52 is meant to encompass both the long-side side wall panel 52a and the short-side side wall panel 52b. The side wall panel 52 includes, as appropriate, a window or opening (like a doorway) 54 that penetrates the inner and outer surfaces of the panel 52. A lower end portion 56 of the side wall panel 52 has an increased thickness (board thickness), and includes on its lower surface a groove 58 that is displaced upward as shown in FIG. 10. The groove 58 extends continuously in the front-back direction in FIG. 10. The side wall panel 52 is also reinforced with appropriate steel bars 12 inside.
[0040] As shown in FIG. 1, the foundation 8 is formed by placing concrete on the ground. Although not shown in the drawing, the foundation 8 is also reinforced with steel bars inside so that it has sufficient load capacity for a concrete three-dimensional structure to be placed thereon. In the illustrated embodiment, the foundation 8 has a rectangular shape in a planar view, and includes on its upper surface an endless frame-like rising portion 60 that protrudes upward. The rising portion 60 corresponds to the side wall 6 in a planar view, and is fitted into the groove 58 of the side wall panel 52 as described later. The rising portion 60 includes a number of rebar anchors 62 that are provided at intervals to extend upward from the upper surface of the rising portion 60. Each of the anchors 62 is welded and fixed at its base end to the steel bars inside the foundation 8.
[0041] Next, a description will be given of the fastening structures between the panels and between the panels and the foundation 8, and of the assembly process of the three-dimensional structure 2. For fastening between the panels and between the panels and the foundation 8, a fastening aid 64 as shown in FIG. 12 is used. The fastening aid 64 is a box-shaped metal aid with an interior space 66 that is accessible from the outside. The fastening aid 64 further includes a small through hole 68 that communicates with the interior space 66. The fastening aid 64 shown in FIG. 12 is in the shape of a hollow cube with one open face and five closed faces. The small through hole 68 is formed in the center of one of the five closed faces. The small through holes 68 may be formed on two faces as described later. Referring to FIGS. 10 and 11, the fastening aid 64 is embedded in the side wall panel 52 in the following locations: an upper end part, a lower end part, and a vertically central part at either end of the panel 52 in the horizontal direction. The fastening aid 64 is welded and fixed to the steel bars 12 and embedded along with the steel bars 12 in the concrete with the interior space 66 exposed through the one open face. Thus, the interior space 66 of the fastener aid 64 is accessible from the outside of the side wall panel 52.
[0042] Still referring to FIGS. 10 and 11, the fastening aid 64 provided in the upper end part of the side wall panel 52 includes the small through holes 68 on two faces, one of which is exposed on the side end surface of the side wall panel 52 and the other of which is exposed on the upper end surface of the side wall panel 52. The fastening aid 64 provided in the vertically central part of the side wall panel 52 includes the small through hole 68 on only one face such that it is exposed on the side end surface of the side wall panel 52. The fastening aid 64 provided in the lower end part of the side wall panel 52 includes the small through holes 68 on two faces, one of which is exposed on the side end surface of the side wall panel 52 and the other of which is located on the lower side. The face with the lower-side small through hole 68 is connected with a sleeve 70 that surrounds the outer peripheral edge of the small through hole 68 and extends perpendicularly downward to communicate with the groove 58. The sleeve 70, which is also made of metal, is welded and fixed to the lower surface of the fastening aid 64, and is embedded along with the fastening aid 64 and the steel bars 12 in the concrete during production of the side wall panel 52.
[0043] Referring also to FIG. 1, when the three-dimensional structure 2 is to be constructed at a building site, the foundation 8 is initially formed at the building site. Then, the side wall panels 52 manufactured in advance in a factory are placed on the foundation 8, followed by the formation of the roof 4. For the placement of the side wall panels 52 on the foundation 8, a suitable lifting device, such as a crane, is used so that the side wall panels 52 are lifted, moved to a required position, and then lowered. The side wall panels 52 are lowered such that the anchors 62 extending upward from the upper surface of the foundation 8 are inserted into the sleeves 70 provided in the lower end portion 56, and that the rising portion 60 is fitted into the groove 58. When the side wall panels 52 are in place on the foundation 8, the upper end part of each of the anchors 62 passes through the sleeve 70 into the interior space 66 of the fastening aid 64. Then, an external thread is formed on the upper end part of the anchor 62, followed by the screwing of a nut 72 thereon, whereby the side wall panels 52 are fixed to the foundation 8. The external thread may be formed on the upper end part of the anchor 62 in advance. Adjacent two of the side wall panels 52 are fastened together as follows. As the fastening aids 64 of these two side wall panels 52 are adjacent to each other, a bolt 74 is inserted into the small through hole 68 formed in the fastening aid 64 of one of the side wall panels 52 and then into the small through hole 68 formed in the fastening aid 64 of the other side wall panel 52. Then, the nut 72 is screwed on the front end part of the bolt 74 in the interior space 66 of the fastening aid 64 of the other side wall panel 52. In this manner, the two adjacent side wall panels 52 are fastened together. Consequently, the side wall 6 is formed on the foundation 8.
[0044] Thereafter, the roof panels 10 manufactured in advance in a factory are placed on the side wall 6 to form the roof 4. For the placement of the roof panels 10 on the side wall 6, an appropriate lifting device, such as a crane, is also used. At this time, an appropriate lifting aid (not shown), such as an eye bolt, is attached to each of the threatened fasteners 32 on the upper surface 14 to help lift the roof panel 10. The roof panels 10 lifted by the lifting device are lowered to where the threaded fasteners 32 provided on the lower surface 34 are in alignment with the fastening aids 64 provided on the upper end parts of the side wall panels 52, thereby allowing the upper end parts of the side wall panels 52 to be fitted into the guide groove 38 formed on the lower surface 34. Afterwards, the bolts 74 are inserted from the small through holes 68 formed in the fastening aids 64 to be screwed into the threaded fasteners 32, whereby the roof panels 10 and the side wall panels 52 are fastened together.
[0045] The three-dimensional structure 2 constructed as described above preferably includes a spout 76 that is connected to the lower surface of the roof 4 to lead the water flowing into the drain hole 24 to the ground level, as shown in FIG. 13.
[0046] As above, the precast concrete roof panel constructed in accordance with the present invention, the roof composed of the roof panel, and the three-dimensional structure with the roof have been described in detail with reference to the accompanying drawings. However, the present invention is not limited to the above-described embodiments, and appropriate modifications and changes can be made without departing from the scope of the present invention. For example, the roof 4, which is composed of the four roof panels 10 arranged in parallel in the illustrated embodiment, may be composed of a single roof panel 10, if desired. Further, the number of the roof panels 10 arranged in parallel and the number of the side wall panels to form the side wall 6 for supporting the roof can be increased or decreased to increase or decrease the length of the three-dimensional structure 2. Furthermore, the precast concrete roof panel constructed in accordance with the present invention and the roof composed of the roof panel can be applied not only to a single-story three-dimensional structure but also to a multistory three-dimensional structure, as shown in FIG. 14.
EXPLANATIONS OF LETTERS OR NUMERALS
[0047] 2: Three-dimensional structure [0048] 4: Roof [0049] 6: Side wall [0050] 8: Foundation [0051] 10: Roof panel [0052] 14: Upper surface (of the roof panel) [0053] 16: Inclined main portion
