EP0036313A1 - Manufacturing process for concrete roof tiles - Google Patents
Manufacturing process for concrete roof tiles Download PDFInfo
- Publication number
- EP0036313A1 EP0036313A1 EP81301068A EP81301068A EP0036313A1 EP 0036313 A1 EP0036313 A1 EP 0036313A1 EP 81301068 A EP81301068 A EP 81301068A EP 81301068 A EP81301068 A EP 81301068A EP 0036313 A1 EP0036313 A1 EP 0036313A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- tiles
- tile
- uncured
- curing
- mix
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000004567 concrete Substances 0.000 title claims abstract description 30
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 238000000034 method Methods 0.000 claims abstract description 33
- 239000007787 solid Substances 0.000 claims abstract description 19
- 239000000203 mixture Substances 0.000 claims abstract description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000012856 packing Methods 0.000 claims abstract description 5
- 238000003825 pressing Methods 0.000 claims abstract description 5
- 230000015572 biosynthetic process Effects 0.000 claims description 6
- 230000000295 complement effect Effects 0.000 claims description 3
- 238000003860 storage Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 238000000605 extraction Methods 0.000 description 3
- 239000004568 cement Substances 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000009432 framing Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
- B28B5/02—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/04—Discharging the shaped articles
Definitions
- the present invention relates to a process for manufacturing concrete roof tiles.
- a process for manufacturing concrete roof tiles without the use of curing moulds comprising the steps of metering concrete mix into a tile mould, applying pressure to the mix in the mould both to form an uncured tile having a thin, non-planar shape which nevertheless permits packing of the tiles to form a substantially solid block of tiles, and also to dewater and deaerate the mix and give an uncured tile containing the water required for hydraulic curing, removing the uncured tile from the mould, and loading the tile into a support frame; the steps being repeated, and the loading being carried out with the repitition of the steps, so as to form a virtually solid block of uncured tiles on the support frame; and curing the tiles, or allowing the tiles to cure, while in the form of the solid block.
- This invention is particularly directed to improvement upon the processes, already in existence, for manufacturing thin concrete roof tiles. It can totally eliminate the need for curing pallets in the curing or hardening processes.
- the tiles usually have exactly complementary upper and lower surfaces, thus permitting their being stacked face-to- face whilst still fresh, optionally separated by a fine film of paper or other products, to form a solid block of concrete without gaps, which, once enclosed in a support-case or frame of the same shape as the outside part of the concrete blocks, permit that this can withstand the following transportation and curing processes without the tiles within suffering any damage.
- the tiles Once the protecting support-case has been removed, the tiles remain in a block during all the following stages of stacking in the yard and transportation to the building site.
- the principle objective of this invention is the improvement in the existing systems of mass-production of concrete tiles.
- Figure 1 is a diagram of a conventional tile making process.
- the proposed invention seeks essentially to reduce radically these costs, basing itself on the substitution for the above described stages of the previous manufacturing process, of a system of solid block formation and continuous curing chamber; the only auxiliary equipment being the support-cases, as illustrated in Figure 2.
- Figure 2 is a diagram of tile making process of the invention.
- Figure 3 is an example of the process of the invention.
- Figure 4 is an example of a press employed in the present invention.
- Figure 4 can be seen a rotating press of 5 stages, in which four tiles are produced in parallel simultaneously.
- FIGS 5 to 8 illustrate solid blocks formed during the process of the invention.
- This invention offers very important advantages over the conventional systems of concrete roof tile production already in existence. These are listed below.
- the present invention is further illustrated by the following non-limiting example.
- Figures 9 to 12 show a tile made by the process of the invention
- Figure 12 illustrates the steps in the process of the invention.
- a wet concrete mix was prepared using 1 part by weight of cement, 2 parts by weight of sand (mesh size:on 2 mm, pass 3 mm) and sufficient water to give a plastic consistency.
- the mix was then metered into 4 lower moulds arranged in side-by-side relationship across a conveyor belt.
- the 4 moulds formed part of a continuous array of moulds extending the length of the belt. This metering and the subsequent stages are shown illustratively in Figure 12, with each part of Figure 12 showing a stage through which each mould passes on the belt.
- the 4 moulds under consideration left the metering station and reached a pre-forming station, where an upper forming mould was applied to each lower mould to shape the wet concrete mix to give a.preformed tile having the shape shown in Figures 9 to 11.
- the preformed tile was slightly undersize.
- the moulds were then advanced to a surface treatment station, where a pigmented coating of a semi-dry concrete mix containing fine sand, cement and other additives was applied to the tiles through an overhead sieving device. Thereafter with advancement to a pressing and dewatering station a high pressure of between 50 and 120 kg/cm 2 , usually 80 kg/cm 2 , was applied to the preformed tiles in the moulds. In this manner air and excess water was expressed from the tiles, and drained off through filter openings provided for this purpose.
- the belt was then advanced to a demoulding station, where a vacuum-assisted lifting head with a shape complementary to the top of the tile served to remove the tiles from the four moulds and transfer them to a support frame.
- the support frame comprised a base and a rear wall at right angles, with the base being supported such that the top of the rear wall was inclined rearwardly at an angle of about 10° to the vertical.
- the support frame When the support frame was full, it was transferred to a curing chamber and the tiles cured for 2 to 6 h, say 4 h, at about 50 0 C and at about saturation lumidity. Thereafter the tiles were unloaded from the support frame, moved to the factory yard, left about a month for curing to complete and were then ready for transportation as the block, Each cured tile was about 42 cm long, about 33 cm in breadth, and about 1. 2 cm in depth.
Landscapes
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Finishing Walls (AREA)
- Panels For Use In Building Construction (AREA)
Abstract
Description
- The present invention relates to a process for manufacturing concrete roof tiles.
- According to the present invention there is provided a process for manufacturing concrete roof tiles without the use of curing moulds, the process comprising the steps of metering concrete mix into a tile mould, applying pressure to the mix in the mould both to form an uncured tile having a thin, non-planar shape which nevertheless permits packing of the tiles to form a substantially solid block of tiles, and also to dewater and deaerate the mix and give an uncured tile containing the water required for hydraulic curing, removing the uncured tile from the mould, and loading the tile into a support frame; the steps being repeated, and the loading being carried out with the repitition of the steps, so as to form a virtually solid block of uncured tiles on the support frame; and curing the tiles, or allowing the tiles to cure, while in the form of the solid block.
- It is by the formation of the solid block of uncured tiles that it becomes possible to dispense with curing moulds and yet process the thin, non-planar, uncured (and necessarily wet) tiles.
- This invention is particularly directed to improvement upon the processes, already in existence, for manufacturing thin concrete roof tiles. It can totally eliminate the need for curing pallets in the curing or hardening processes.
- This is achieved by a process of pressure and extraction of air and water, which leaves the fresh tiles already with a minimum of mechanical resistance. The tiles usually have exactly complementary upper and lower surfaces, thus permitting their being stacked face-to- face whilst still fresh, optionally separated by a fine film of paper or other products, to form a solid block of concrete without gaps, which, once enclosed in a support-case or frame of the same shape as the outside part of the concrete blocks, permit that this can withstand the following transportation and curing processes without the tiles within suffering any damage. Once the protecting support-case has been removed, the tiles remain in a block during all the following stages of stacking in the yard and transportation to the building site.
- Thus, the principle objective of this invention is the improvement in the existing systems of mass-production of concrete tiles.
- At the present, concrete roof tiles are manufactured by tile making machines using pressure or extrusion and the fresh concrete mass is left on individual moulds or pallets, usually of aluminium, where it remains until after hardening, to be later de-palleted and packed. Given the great speed and the great volume of production, it is necessary to store the fresh tiles during the curing process in racks, which are usually mobile, and to transport these racks to curing chambers in which they remain a minimum of eight hours. Later the racks are taken from the curing chamber to an unloading station, the moulds and tiles passing finally through a de-palletting station and through a packing station. A diagram illustrates this conventional tile making process: -
- Figure 1 is a diagram of a conventional tile making process.
- In Figure 1,
- T- tile making machine from which the fresh tiles come out on their moulds/pallets.
- A - fresh tiles are loaded on the racks
- B - racks are conveyed to the curing chambers/tunnels (C)
- C - curing chambers
- D - racks are removed from curing chambers
- E - tiles on their moulds are taken off the racks
- F - cured tiles are removed from moulds/de-palletted (moulds are returned to 1)
- G - cured tiles are packed
- P - packed tiles are conveyed to storage yard
- This process requires moulds and racks which with the auxiliary equipment, namely automatic systems of rack loading, conveyance systems for the racks, curing chambers, systems for transporting racks of already hardened tiles, de-palletting systems, and systems for packing the tiles, represents a large investment. It also implies large personnel, maintenance and amortization costs.
- The proposed invention, object of this patent, seeks essentially to reduce radically these costs, basing itself on the substitution for the above described stages of the previous manufacturing process, of a system of solid block formation and continuous curing chamber; the only auxiliary equipment being the support-cases, as illustrated in Figure 2.
- Figure 2 is a diagram of tile making process of the invention.
- In Figure 2,
- T - tile machine, out of which comes the fresh tiles
- A - solid blocks are formed in the support-cases
- B - these undergo a short curing process in a continuous curing chamber
- P - cured blocks pass to the storage yard, the empty support-cases returning to phase A to be filled again.
- To be able to understand better this manufacturing process, an example is illustrated in Figure 3.
- Figure 3 is an example of the process of the invention.
- In Figure 3,
- 1 and 1' - concrete mixer
- T - conveyor belts of already mixed concrete
- 2 - lineal press of various stages
- 3 - vacuum extractor
- 4 - formation of solid block
- 5 - continuous curing tunnel
- 6 - hardened solid blocks ready to go to the storage yard (P)
- If the support-cases are non-disposable they return to stage 4.
- Figure 4 is an example of a press employed in the present invention.
- In Figure 4 can be seen a rotating press of 5 stages, in which four tiles are produced in parallel simultaneously.
-
- 1 - extraction by vacuum of freshly pressed tile
- 2 - loading of concrete
- 3 - pre-pressing process
- 4 - pressure and extraction of water and air
- 5 - de-framing/de-palletting process by elevation
- The results of the formation of the blocks can be seen in the following diagrams, where
- Figures 5 to 8 illustrate solid blocks formed during the process of the invention.
- Figure 5 ------- block of concrete roof tiles with small spaces between tiles, a five-sided support-case in horizontal position.
- Figure 6 ------- support-case made of sheets of rubber which are compressing laterally, encasing a solid block of ridge tiles, in a three- sided support-case which is vertical.
- Figure 7 ------- seen from above, a block of concrete roof tiles with lower horizontal support, side ends closed.
- Figure 8 ------- horizontal block of tiles with three sides closed.
- This invention offers very important advantages over the conventional systems of concrete roof tile production already in existence. These are listed below.
-
- a Drastic reductions in the cost of auxiliary elements and automatic systems - so much so that the costs of a factory's investment can be reduced to approx. one third.
- b The running of a factory is possible by four people per shift; for the concrete mixer, the tile machine, the block formation and the transportation of the blocks to the storage yard.
- c Reduction of maintenance costs
- d Great versatility in patterns of tiles, curing moulds not being necessary.
- e Possibility of producing coloured tiles in which the colour- through concrete is a superficial layer, or the possibility of producing multi-layer tiles having one or more coloured layers.
- f Possibility of reinforcing the tiles with steel wire netting between various layers of pressed concrete, and thus of making tiles of greater length or width.
- We believe that this new method has great possibilities and can revolutionize the concrete roof tile industry - an industry established more than fifty years ago, and of which hundreds of factories exist all over the world, with annual productions of approximately 10 million tiles per factory, ie. 300 million pesetas per annum, per factory.
- The process has been described here in its purest form. Nevertheless, variations are possible.
- For instance, the following possibilities exist
- i of there being small spaces between the tiles, as for example in the lateral assemblies of roof tiles, without invalidating the "solid block" concept.
- ii of not placing a separating film between each tile when working with certain concretes
- iii of the separating film having a certain consistency and thickness so as to absorb small differences between one tile and the next
- iv of the support-case, or of some of its sides, being of paper, plastic, or some other disposable material
- v of not having to use even the curing chamber, stacking the fresh blocks directly in the storage yard.
- The present invention is further illustrated by the following non-limiting example.
- In the example reference is made to Figures 9 to 12, Figures 9 to 11 show a tile made by the process of the invention, and Figure 12 illustrates the steps in the process of the invention.
- A wet concrete mix was prepared using 1 part by weight of cement, 2 parts by weight of sand (mesh size:on 2 mm, pass 3 mm) and sufficient water to give a plastic consistency. The mix was then metered into 4 lower moulds arranged in side-by-side relationship across a conveyor belt. The 4 moulds formed part of a continuous array of moulds extending the length of the belt. This metering and the subsequent stages are shown illustratively in Figure 12, with each part of Figure 12 showing a stage through which each mould passes on the belt.
- With advancement of the conveyor belt, the 4 moulds under consideration left the metering station and reached a pre-forming station, where an upper forming mould was applied to each lower mould to shape the wet concrete mix to give a.preformed tile having the shape shown in Figures 9 to 11. In order to allow for subsequent expansion, the preformed tile was slightly undersize.
- The moulds were then advanced to a surface treatment station, where a pigmented coating of a semi-dry concrete mix containing fine sand, cement and other additives was applied to the tiles through an overhead sieving device. Thereafter with advancement to a pressing and dewatering station a high pressure of between 50 and 120 kg/cm2, usually 80 kg/cm2, was applied to the preformed tiles in the moulds. In this manner air and excess water was expressed from the tiles, and drained off through filter openings provided for this purpose.
- The belt was then advanced to a demoulding station, where a vacuum-assisted lifting head with a shape complementary to the top of the tile served to remove the tiles from the four moulds and transfer them to a support frame. The support frame comprised a base and a rear wall at right angles, with the base being supported such that the top of the rear wall was inclined rearwardly at an angle of about 10° to the vertical.
- The process of making the 4 preformed, uncured concrete tiles took about 6 seconds, and was repeated continuously. As the tiles were produced they were loaded onto the support frame to give 4 virtually solid blocks of tiles, each tile resting with a lower edge on the base and leaning at 10° to the vertical against previously loaded tiles.
- When the support frame was full, it was transferred to a curing chamber and the tiles cured for 2 to 6 h, say 4 h, at about 500C and at about saturation lumidity. Thereafter the tiles were unloaded from the support frame, moved to the factory yard, left about a month for curing to complete and were then ready for transportation as the block, Each cured tile was about 42 cm long, about 33 cm in breadth, and about 1. 2 cm in depth.
Claims (8)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AT81301068T ATE6916T1 (en) | 1980-03-13 | 1981-03-13 | PROCESS FOR PRODUCTION OF CONCRETE ROOF TILES. |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
ES489519 | 1980-03-13 | ||
ES489519A ES8100622A1 (en) | 1980-03-13 | 1980-03-13 | Manufacturing process for concrete roof tiles. |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0036313A1 true EP0036313A1 (en) | 1981-09-23 |
EP0036313B1 EP0036313B1 (en) | 1984-04-04 |
Family
ID=8480027
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP81301068A Expired EP0036313B1 (en) | 1980-03-13 | 1981-03-13 | Manufacturing process for concrete roof tiles |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0036313B1 (en) |
AT (1) | ATE6916T1 (en) |
DE (1) | DE3162922D1 (en) |
ES (1) | ES8100622A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0249197A1 (en) * | 1986-06-10 | 1987-12-16 | Disco Abrasive Systems, Ltd. | Cutter |
EP0338272A1 (en) * | 1988-04-18 | 1989-10-25 | Rieter-Werke Händle Kg | Pressed roofing tile |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE21814C (en) * | F. SCHMIDT in Chrosczina per Oppeln | Innovations in the process for the production of hollow structures (roof turrets), which is protected under No. 9868, etc. | ||
US2173107A (en) * | 1937-08-09 | 1939-09-19 | Robert E Gould | Making ceramic articles |
DE806952C (en) * | 1948-10-02 | 1951-06-21 | Erwin Bross Dipl Ing | Method of stacking and drying flat concrete parts |
US2601105A (en) * | 1949-08-16 | 1952-06-17 | Russell P Dunmire | Ceramic product and method of making same |
DE843466C (en) * | 1948-10-02 | 1952-07-10 | Kurt Milde | Flat brick and process for its manufacture |
FR1142846A (en) * | 1956-03-09 | 1957-09-23 | Manufacturing process of tiles on dies and tiles obtained by its implementation | |
US4158533A (en) * | 1975-06-27 | 1979-06-19 | Longinotti S.P.A. | Apparatus for producing and stripping pressed cement tiles with superimposition of a plurality of stripped tiles |
-
1980
- 1980-03-13 ES ES489519A patent/ES8100622A1/en not_active Expired
-
1981
- 1981-03-13 DE DE8181301068T patent/DE3162922D1/en not_active Expired
- 1981-03-13 EP EP81301068A patent/EP0036313B1/en not_active Expired
- 1981-03-13 AT AT81301068T patent/ATE6916T1/en not_active IP Right Cessation
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE21814C (en) * | F. SCHMIDT in Chrosczina per Oppeln | Innovations in the process for the production of hollow structures (roof turrets), which is protected under No. 9868, etc. | ||
US2173107A (en) * | 1937-08-09 | 1939-09-19 | Robert E Gould | Making ceramic articles |
DE806952C (en) * | 1948-10-02 | 1951-06-21 | Erwin Bross Dipl Ing | Method of stacking and drying flat concrete parts |
DE843466C (en) * | 1948-10-02 | 1952-07-10 | Kurt Milde | Flat brick and process for its manufacture |
US2601105A (en) * | 1949-08-16 | 1952-06-17 | Russell P Dunmire | Ceramic product and method of making same |
FR1142846A (en) * | 1956-03-09 | 1957-09-23 | Manufacturing process of tiles on dies and tiles obtained by its implementation | |
US4158533A (en) * | 1975-06-27 | 1979-06-19 | Longinotti S.P.A. | Apparatus for producing and stripping pressed cement tiles with superimposition of a plurality of stripped tiles |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0249197A1 (en) * | 1986-06-10 | 1987-12-16 | Disco Abrasive Systems, Ltd. | Cutter |
US4872289A (en) * | 1986-06-10 | 1989-10-10 | Disco Abrasive Systems, Ltd. | Cutter |
EP0338272A1 (en) * | 1988-04-18 | 1989-10-25 | Rieter-Werke Händle Kg | Pressed roofing tile |
Also Published As
Publication number | Publication date |
---|---|
EP0036313B1 (en) | 1984-04-04 |
DE3162922D1 (en) | 1984-05-10 |
ATE6916T1 (en) | 1984-04-15 |
ES489519A0 (en) | 1980-11-01 |
ES8100622A1 (en) | 1980-11-01 |
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