EP2580036B1 - System und verfahren zur herstellung von bodenfertigteilelementen aus beton - Google Patents

System und verfahren zur herstellung von bodenfertigteilelementen aus beton Download PDF

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Publication number
EP2580036B1
EP2580036B1 EP11726227.9A EP11726227A EP2580036B1 EP 2580036 B1 EP2580036 B1 EP 2580036B1 EP 11726227 A EP11726227 A EP 11726227A EP 2580036 B1 EP2580036 B1 EP 2580036B1
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EP
European Patent Office
Prior art keywords
mould
forming
concrete
slab
beams
Prior art date
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Application number
EP11726227.9A
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English (en)
French (fr)
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EP2580036A1 (de
Inventor
Gerardus Cornelis Maria Van Der Zanden
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Kanaalbreedplaat Holding Bv
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Kanaalbreedplaat Holding BV
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Publication of EP2580036A1 publication Critical patent/EP2580036A1/de
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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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
    • B28B7/0082—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with surfaces for moulding parallel grooves or ribs
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
    • B28B7/164—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes for plates, panels, or similar sheet- or disc-shaped articles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/48—Special adaptations of floors for incorporating ducts, e.g. for heating or ventilating

Definitions

  • the invention relates to a system for forming concrete prefab floor elements.
  • the invention further relates to a method for forming such elements.
  • Concrete wall elements are known to be moulded in moulds.
  • Such moulds comprise a first and second mould part, which when closed against each other form a mould cavity.
  • a pouring opening is provided at an upper side of the mould for pouring concrete into the mould cavity and letting air out of the mould cavity at the same time.
  • the first and second part comprise side walls which are vertical and parallel, defining an interspace as the mould cavity.
  • the upper side of the mould forms the pouring opening. This means that this end will be rough and the dimensions in the vertical direction are unspecified, in the sense that the dimensions are not stable. Different elements can thus have different heights.
  • Concrete floor elements are commonly moulded in horizontal position, for example in a carousel system.
  • a lower part is placed on a transport element, where after end pieces of metal are placed between fixed upper and lower side profiles, defining a square mould cavity part with a flat bottom.
  • the end pieces can be placed in the mould by robots, but still will have a relative high imprecision in their relative positions, for example ⁇ 27 mm.
  • the floor element is then formed by pouring concrete into the cavity and let it set. Due to the pouring from the open upper side and the imprecision of the position of the end pieces only the side facing the bottom surface of the mould and the opposite sides of the element formed against the fixed side profiles will be both relatively smooth and define dimensional stability. This means that one face of the element and the two opposite length sides of the floor element will be well defined, whereas the length can vary between elements, as can the thickness of the floor element.
  • DE2253706 discloses a forming device for forming concrete, prefab elements, which aims and combining advantages of flat forming and vertical forming methods.
  • the device comprises a mould with a lower mould part and an upper mould part, as well as foil providing means for lining the mould prior to molding the elements, including an aeration and de-aeration device.
  • the mould is held in a horizontal position during forcing of the concrete into the mould cavity, a slab forming portion at the top of the mould and a profile forming portion facing down.
  • the mould is vibrated after filling, and slowly brought into an upright position, at the same time forcing the concrete further into the mould cavity by using a piston, compensating for the repacking of the concrete.
  • This forming device is complicated in construction and use, is expensive and stationary.
  • An object of the present invention is to provide an alternative system and method for forming concrete prefab floor elements. Another object can be to provide a system and/or method for forming prefab floor elements which are more form and dimensional stable. A still other object of the present invention can be to provide a method and/or system for forming concrete prefab floor elements that need relatively little or substantially no finishing after setting of the concrete.
  • a mould according to this description can be designed for concrete floor elements which have at least one slab and at least one beam extending along said slab in a length direction.
  • the mould can comprise at least a first part and a second part, which can close against each other for forming a mould cavity.
  • the first mould part has a bottom surface for forming a first side of the slab, which preferably is substantially flat.
  • the second mould part has a top side with a beam forming profile for forming at least part of the at least one beam.
  • the mould is supported by a support structure, such that the bottom surface extends at an acute angle ⁇ to a horizontal plane and the length direction is substantially horizontal.
  • At least one opening is provided at a level at or above the at least one beam forming profile, forming a filling and/or aeration opening.
  • a series of moulds can comprise at least two moulds in the series which differ in the number of beams and/or the distance between at least two beams. They preferably have at least the same length in the length direction, and wherein elements formed in the different moulds are connectable to each other by sides parallel to the length direction.
  • a method for forming a prefab concrete floor element which comprises a slab and at least one beam extending along said slab in a length direction, can comprise placing a mould for forming such elements with beam forming parts extending with said length direction horizontally. Concrete is poured into the mould for forming said element, forcing air from the mould upward, out of the mould.
  • the mould according to the invention supported by a support structure, is angled at an acute angle relative to a horizontal plane, at least during pouring of the concrete, such that an upper part of each beam forming part of the mould slopes at least partly upward towards a slab forming part of the mould.
  • slabs and beams In this description reference is made to slabs and beams.
  • the floor elements comprising slabs and beams are made integrally by mould forming.
  • the slabs and beams are therefore parts of the same, integral element.
  • beams or a slab could be placed in a mould as inserts, forming the other of the slab and beams against the insert or inserts in the mould.
  • a mould according to the present disclosure preferably has a substantially reusable configuration.
  • the mould can also be made of disposable material.
  • a mould according to the present invention is set at the indicated acute angle during the pouring of the element forming material, especially concrete into the mould cavity through an opening, such that it can flow into and fill the mould cavity. In embodiments this can be done primarily by gravity, for forming the element. In other embodiments the material can be forced into the mould from an opening near a lower end of the mould.
  • a filling device is or can be used that extends above said opening, or the material can be brought to the said opening through appropriate feeding means connected to the opening, which can be referred to as a filling device extending above said opening too, even though part of the device can be positioned differently, for example next to the mould or well spaced apart from the mould.
  • a slab forming portion of the mould is at a side facing at least partly downward, beam forming portions at a side facing at least partly upward. Air inside the mould cavity will therefore rise at least partly into said beam forming portions, to be driven out by the material filled into the cavity.
  • the material will advantageously flow at least along the wall of the slab forming portion, without significant interference of the beam forming portions, because of the acute angle.
  • the mould in step a can be formed by integral first and second mould parts.
  • at least one of the mould parts, especially the part comprising the one or more beam forming portions can be made from modules.
  • the mould in embodiment in step b can be filled through at least one opening at the top of the mould cavity, wherein preferably the material flows along a bottom of the slab forming part of the mould cavity, towards the lower part of the mould cavity, to fill the cavity.
  • the at least one opening at the top can in such embodiments be both filling opening and aeration opening for letting air escape from the mould cavity, at least during filling.
  • the material can be inserted into the mould cavity through an opening near the lower side of the mould cavity.
  • the material is fed into the mould cavity such that each beam forming portion is filled substantially evenly over its entire length.
  • each beam forming portion Preferably of each beam forming portion an upper wall part slopes up towards the slab forming portion, such that when the beam forming portion is filled with the material, air will flow along said upper surface, which forms a side face of a beam, into the slab forming portion to be driven out.
  • pouring of concrete can be understood as but is not limited to gravity feeding and/or force feeding of concrete into the mould.
  • a floor element 1 comprising a slab 2, four parallel beams 3 extending in a length direction L1 on a top side 4 of the slab 2.
  • the slab 2 is in this example substantially square, having a length L and a width W.
  • a first beam 3A and a second beam 3B extend along longitudinal sides 5A, 5B of the slab 2.
  • two cross beams 7A, 7B are provided, between the ends of the beams 3A, B, connecting these beams 3A, B.
  • the third longitudinal beams 3C extends in between the first and second beam 3A, 3B and are connected at opposite ends to the cross beams 7A, B.
  • a series of first openings 8 is provided in the first and second longitudinal beams 3A, B, such that two elements 1 can be placed side by side and be connected to each other by connecting means (not shown) extending through said openings 8, for example but not limited to nuts and bolts, screws, chemical anchors, rivets and the like known connecting means.
  • a second series of openings 9 can be provided, extending through the first, second and third longitudinal beams 3A, B, C, wherein preferably openings 9 in adjacent beams 3 are in line with each other, such that long elements (not shown) such as but not limited to pipes, hoses, lines and the like can easily be fed through said openings 9, in a direction substantially cross to the longitudinal direction L1 of the beams 3.
  • the openings 9 can be larger than the openings 8.
  • the openings 9 can have a lower side substantially flush with the top side 4 of the slab 2.
  • the cross beams 7 are preferably without openings 8 or 9.
  • a beam 3 especially an outer first or second beam 3A, B, and the slab 2, with a side 5 of the slab 2.
  • the openings 8 and 9 can extend substantially parallel to each other across the beam 3.
  • the beam 3 has a height H above the top side 4 of the slab 2.
  • the slab 2 has a thickness t between the top side 4 and the opposite lower or bottom side 10.
  • the bottom side 10 can during use for example form a ceiling of a space SB below the floor element 1 or of a crawl space.
  • the beam 3 has, in this example, a substantially flat top side 11 and two opposite side surfaces 12, 13, which slope at an angle ⁇ relative to the top surface 4 of the slab 2.
  • the top surface 4 of the slab 2 extends, during use, substantially horizontally, meaning that in these embodiments the top surface can for practical purposes be referred to as a horizontal surface.
  • an element 1 could be positioned at an angle, having the surface 4 sloping in one or two directions.
  • the angle ⁇ can be the same for both or all sloping surfaces 12, 13 of the same or all beams 3.
  • the edge 5 of the slab 2 is defined substantially by a substantially straight, flat side surface 14, extending substantially perpendicular to the top surface 4.
  • the sloping surface 12 of the beam is connected to the sloping side surface 12 of the beam, in this embodiment directly, that is without an intervening part of the top surface or beam.
  • a stripe-dotted line 15 shows schematically a connecting element extending through openings 8 in line with each other for connecting the elements 1, 1A.
  • the beam 3 can have a substantially trapezoid cross section, wherein the top surface 11 has a width W1 and the base, near the top surface 4 of the slab 2 has a width W2.
  • the longitudinal outer beams 3A, B can have a cross sectional area A1 which is smaller than the corresponding cross sectional area A2 of the beam or beams 3C in between.
  • the area's A1, A2 can be chosen such that when two outer beams 3 of two adjacent elements 1, 1A are properly connected by the connecting means 15, the load capacity of two joined beams 3A, B of such elements 1, 1A is about the same as the load capacity of the or any of the intermediate beams 3C.
  • This can for example be achieved by the widths W1, W2 of the outer beams 3A, B being about half the widths W1, W2 of the or any intermediate beam(s) 3C.
  • a top floor element or elements 17 can be placed on the top surfaces 11 of the beams, for forming a floor 18 and for closing off the pockets 16. Openings 19 can be provided in the top floor elements 17 for feeding utility lines into or from the pockets 16 from or to a space 20 above the floor 18. Similarly openings 21 can be provided in the slab 2 for feeding utility lines into or from the pockets 16 from or to a space SB below the slab 2.
  • Isolating material 23, especially but not limited to acoustically isolating elements such as rubber, elastomeric, plastic and/or foam strips can be placed between the beams 3, 7 and the top floor elements 17.
  • a partial cross section of an element 1 is shown, in an alternative embodiment, in which a beam 3C is shown on the slab 2.
  • the beam 3C has a stepped top surface 11, such that on two opposite, longitudinal sides a shoulder 24 is formed on which an edge of the top floor element 17 can be placed.
  • This will allow a smaller overall height Ht of the element 1 with top floor elements 17, whereas about the same load capacity can be obtained with similar width beams 3 as in an embodiment of fig. 1A .
  • a series of top floor elements 17 is provided, allowing access to individual pockets 16 more easily.
  • Isolating elements 23 are provided between top floor elements 17 and shoulders 24.
  • longitudinal first and second beams 3A, B and cross beams 7A, B could be provided with a stepped upper surface 11, at the side facing the adjacent pocket 16, as schematically indicated in fig. 1B by the vertical line 14A.
  • Fig. 1C shows part of an element 1, showing a cross beam 7 and slab 2.
  • an edge portion 26 is made of a material different from the concrete from which the slab and beams are formed.
  • the material of the edge portion 26 can for example be softer and/or more brittle than the concrete.
  • a wall element 27, for example but not limited to a prefab concrete element or a brick wall, can be placed on top of the top surface 11 of the cross beam 7, as for example schematically shown in fig. 1C in broken lines.
  • the edge portion 26 allows easy access into said wall element 27, easier than when part of the concrete of the beam has to be removed, for example for cables or pipes, as schematically indicated by striped line 22.
  • an edge of a beam 3, 7 or a slab 2 can be made of the same or similar material, for the same or similar purpose. Openings such as 8, 9, 19, 21 can also be made by providing such material in a position in which an opening could be advantageous, such that during use the opening can easily be created by removing part or all of said material.
  • An element 1 can be made of concrete, preferably compacted concrete.
  • the element 1 can be made of self compacting concrete, foaming concrete or the like. Self compacting concrete will easily allow forming the element in a substantially closed mould cavity, as will be described here below.
  • a mould 30 for forming a floor element 1, such as for example but not necessarily limited to embodiments as disclosed here before.
  • the mould 30 comprises a first part 31 and a second part 32 and is placed on a support structure 50.
  • the support structure can for example be part of a carousel system for in a (semi) continuous process forming floor elements 1.
  • the first mould part 31 is placed with a bottom part against an upstanding part 51 of the support structure 50, and can be resting on a lower part 52 of said structure 50.
  • the moulds can circulate through different stages of casting the elements 1.
  • a mould 30 is shown for a floor element 1 having four longitudinal beams 3: two outer beams 3A, B near opposite longitudinal sides 5 and two intermediate beams 3C in between.
  • the mould 30 can have at least two parts 31, 32.
  • Fig 7 shows inter alia a part of the mould 30 for forming a cross beam 7 at opposite ends 6 of the element 1.
  • cross beam 7 forming elements can be left out, for casting elements 1 without such cross beams 7.
  • the mould 30 is designed for casting the floor element 1 with a side edge 5B facing down, wherein the longitudinal direction L1 of the beams 5 is substantially horizontal.
  • the horizontal plane Hp is indicated, whereas vertical planes obviously extend perpendicular to said horizontal plane.
  • the first mould part 31 has a bottom forming part or surface 37 for forming a bottom side 10 of the element 1, especially of the slab 2.
  • the second mould part 32 in this embodiment has a profiling 38 for forming the longitudinal beams 3A - C and the top surface 4 of the slab 2 in between the longitudinal beams 3 and the cross beams 7, if available.
  • the bottom surface 37 can be profiled, for example ribbed or can have another pattern in relief, for example as decoration, for fitting wall elements, guides and the like, and/or for strengthening the element 1.
  • Still an actual or virtual main plane P of the said surface 37 can be defined by for example the opposite side edges or end edges of the slab 2 to be formed.
  • the bottom surface 37 or plane P encloses an angle ⁇ with a horizontal plane or surface Hp.
  • the angle ⁇ can be acute.
  • the angle ⁇ can be between 60° and 120°.
  • the angle ⁇ can be between 60° and 90°, preferably between 75° and 89°, more preferably between 80° and 89°.
  • the angle ⁇ can be about 82.5°.
  • the profiling 38 comprises parts 39 for forming a sloping side of a beam 3, especially at a side of the beams 3 facing upward.
  • parts 39 are provided on both sides of a space for forming a beam 3, such that a cross section of the beam defining an area A1, A2 is substantially symmetric about a plane P1 perpendicular to the bottom surface 37 or plane P.
  • the part 39 for forming a sloping side of a beam 3 facing upward, when in the position in the mould as shown, includes an angle 6 with the horizontal surface or plane Hp.
  • the angle 6 is such that the side 39A of the part 39 facing the bottom surface 37 is positioned at a level higher than the opposite side 39B of said part 39, at least over a part of the length of said part 39, preferably over substantially its entire length L2. This means that any air inside the beam 3 forming space 40 can escape easily when filling a mould cavity 41 formed between the first and second mould part 31, 32.
  • the angle 6 preferably is such that ⁇ ⁇ 90° - ⁇ .
  • the bottom surface 37 is preferably tilted from a vertical position backward, such that the bottom surface 37 is exposed upward, as for example shown in fig. 2 . As can be seen in fig. 2 for each of the upper parts 39 for forming the beams 3 the angle 6 is about the same. The angle 6 can however be different for different beams of an element 1 and/or for different sides of the beams.
  • an opening 43 is provided, for example extending along a part, most or substantially all of the length L1 of the beam forming space 40 adjacent said side 42.
  • a side edge surface 14 of an element 1 forming portion 44 of the mould 30 is connected to the bottom surface 37, extending at substantially right angles to the bottom surface 37 or plane P. Due to the angles ⁇ and ⁇ the opening 43 will be substantially at the highest level of the mould cavity 41, thus preventing the entrapment of air when filling the mould cavity 41.
  • the mould 30 can rest on a carrier 50 with which the mould 30 can be moved through a factory or plant for manufacturing the elements 1.
  • a possible lay out of such plant 70 is schematically shown in fig. 8 , by way of example only. This will be discussed further on.
  • a filling device 80 is shown, schematically, for bringing the material, especially concrete into the mould cavity.
  • the device 80 is connected to the opening 43, such that material can flow into the mould cavity through the opening 43 which can thus perform the function of filling opening as well as aeration opening.
  • Aeration opening has to be understood as meaning that air can enter and/or leave the mould cavity through said opening.
  • the device 80 is connected to the opening 43A near a lower side of the mould 30. Initially the filling device 80 is connected to the cavity through an opening 43, 43A, the cavity or at least a part thereof adjacent the opening 43, 43A being substantially empty, i.e. free of the filling material such as concrete.
  • FIG. 3 schematically different steps in filling the mould cavity 41 are shown.
  • First the lowest longitudinal space 40 is filled, pushing air upward in the mould cavity, to the first level F1.
  • the material can then easily fill the mould cavity upward, towards the second and third spaces 40 for forming the intermediate longitudinal beams 3C.
  • the material will gradually fill the space 40 from the lower level F2 to the upper level F3, pushing again the air from the space 40 upward.
  • the filling opening 43 is substantially the highest point. Therefore air will escape there from easily.
  • Fig. 4 schematically shows assembling a mould 30, in which first a first mould part 31 is placed on a carrier 50, such that the back of the bottom forming surface 37 rests against a first carrier surface 51, angled relative to the vertical plane and the horizontal plane Hp.
  • the side of the longitudinal beam 5B forming part can rest on a bottom part 52 of the carrier or can be suspended just above it.
  • sides 53 can be provided to the first mould part 31, defining the overall length L1 of the element 1 to be formed.
  • One or both of the sides 53 can be formed by elements such ass but not limited to beams or profiled plate elements which can be attached to the mould 30, the carrier 50 or both, such that they form at least part of a wall of the mould cavity, especially part of or entirely the spaces 54 for forming a cross beam 7.
  • the sides 53 can be integral parts of one or both of the mould parts 31, 32.
  • inserts 55 can be provided in and/or on the mould 30 or mould cavity 41, for example for forming the openings 8, 9 and/or for forming openings 21 and/or 19, or for providing parts made of different materials, such as but not limited to the elements 26.
  • inserts 55 can be elements that can be removed from the element 1 after casting, or can be elements that remain in the element 1 after casting and can for example provide an area for fastening, an area for easy access of the pockets 16 and/or walls 27, reinforcements such as metal or plastic rods, wickerwork or the same, as known for reinforcing concrete.
  • the second mould part 32 can be placed against and/or over the first part 31, in order to close the mould and form the mould cavity 41 with spaces 40, 54. Then concrete or another settable and/or curable constructional material can be poured into the mould cavity 41, filling the cavity 41 with spaces 40 and 53, forming the element 1. After setting and/or curing the mould 30 can be opened and the element can be removed from the mould 30. The mould 30 can then be reused.
  • Fig. 5 shows three embodiments of a mould 30A, suitable for forming elements 1.
  • These moulds 30A are similar to the moulds 30 as described here before, using the same or similar reference signs, for forming elements 1B similar to the elements 1, 1A described before.
  • elements 1B with different widths W 2 , W 3 and W 4 can be made, whereas the elements 1B can have the same or different lengths L 1 .
  • One or more of the elements 1B made with the moulds 30A as disclosed in fig. 5 can for example be used with elements 1, 1A made in the mould of fig. 2 - 4 and/or as discussed with reference to fig.
  • the length L 1 of the elements 1, 1A, 1B defining the width of the floor, for example starting with an element 1 in a position remote from either longitudinal end of the floor, wherein at the longitudinal end or ends, or somewhere else in the floor at least one element 1B can be used, made with a mould 30A according to fig. 5 , when the length of the floor is not equal to N times the width W 1 of an elements of fig. 1 - 4 or at least the floor cannot be formed with such elements 1 entirely, N being a real number.
  • the moulds 30A can be such that an element 1B formed therewith has at least two longitudinal beams 3A, 3B.
  • the parts of the element are shown in the mould as if the mould has been filled with such element formed therein.
  • the distance D1 between these beams, measure heart-to-hart, can be similar to the distance D1 between two adjacent beams 3 of an element 1 of fig. 1 - 4 , or N*D1, wherein N is a natural, real number, or can be different, for example larger.
  • three moulds 30A are shown, respectively having, left to right in the drawing:
  • the moulds 30A can generally have a construction similar to that of fig. 2 - 4 .
  • the first ad second mould parts 31, 32 for forming these moulds 30A can have fixed dimensions.
  • a mould 30, 30A is disclosed schematically, which is especially but not exclusively suitable for forming moulds 30A having varying widths W.
  • three moulds 30A are shown, similar to the embodiments of fig. 5 , by way of example only.
  • a first mould part 31A is used, having a flat bottom forming surface 37A and having a first part 56 for forming a first longitudinal beam 3A, which will be the same for each mould 30A.
  • This first part 56 can be an integral part of the first mould part 31A or can be a separate part.
  • a second part 57 comprising a forming part 58 for forming the other longitudinal beam 3B and comprising the filling opening 43.
  • a cover part 59 extends, in use substantially parallel to the bottom forming surface 37A.
  • the cover part 59 has a height Z, measured in the direction of the width W of the element, i.e. substantially perpendicular to the length L of the beams 3, which can be chosen based on the desired total width W of the element to be formed.
  • a series of such second parts 57 can be provided, varying in said height Z, or the cover part 58 can be made such that said height Z can be adjusted, for example telescopically or by adding segments to a minimal sized cover part 58.
  • a third part 60 can be provided, having a forming part 61 for forming an intermediate longitudinal beam 3C and a cover part 62 for forming the slab 2 between two adjacent longitudinal beams 3.
  • the cover part 62 can have a height Z 1 such that when connected to a similar part 60 or to a first part 56 the distance D1 between two forming parts 56, 58 for two longitudinal beams 3A, B, C is as desired and preferably as discussed before.
  • the distance D1 shall preferably be larger than the height of the cover part 58 of the second part 57.
  • a first and second part 56, 57 and preferable one or two third parts 60 different elements 1, 1A, 1B can be provided, differing in overall widths W. It shall be clear that the parts 56, 57, 60 can be connected to each other and/or to the further mould parts 31, 53 that a substantially closed mould cavity 41 is obtained, except at least for the filling opening 43. In fig. 6 the different parts are shown separated from each other for clarity purpose only.
  • fig. 8 schematically the lay out of a moulding process and/or assembly is shown.
  • Such system and process are known and for example described by De Hoop Pekso, The Netherlands, and as shown on their website www.dehoop-pekso.nl.
  • floor elements and wall elements are manufactured in a horizontal orientation.
  • the elements 1 are preferably manufactured in a position in which the longitudinal beams extend substantially horizontally and the slabs 2 have an angled position relative to the horizontal positions. This saves space and makes handling of the elements 1, moulds and filling and manufacturing equipment more easily possible.
  • a process of fig. 8 also known as a carrousel process comprises basically the steps of cleaning a mould 30, 30A or parts thereof in a first station 71. Then the side elements 53 can be placed in a second station 72, defining the length of the elements 1, which is normally done after a plotter has been used for plotting the positions of for example inserts 55, the desired width W of the element 1, 1B to be formed, the number and positions of the longitudinal beams 3 and the like. In a third station 73 inserts can be provided. In a fourth station 74 the mould parts can be oiled, waxed or greased, or otherwise be provided with a release agent. Then in a fifth station 75 the reinforcements can be provided on the relevant part of the mould. Then in a sixth station 76 the or each second mould part 32 or the first 56, second 57 and when desired third parts 59 for forming the cover of the mould cavity can be placed, in the appropriate order. Thus the mould 30, 30A is ready for forming the element.
  • a seventh station 77 the material is poured or injected into the mould cavity 41, using a filling device 80, for example from the opening 43 at the top of the mould 30, 30A filling the cavity 41 up, including the spaces 40, 54.
  • a self compacting material such as self compacting concrete is used for these elements 1, 1A, 1B. This can have the advantage that for example vibrating the moulds is not necessary, whereas a complete filling of the mould cavity 41 can easily be obtained.
  • An element 1, 1A, 1b formed shall have the right density.
  • the material can be chosen such that it slightly foams or at least slightly expands during setting and/or curing, in order to prevent undesired voids in the material.
  • the moulds 30, 30A are placed in or moved through an eight station 78, comprising or formed by a dryer, to allow the material to cure and/or set at least sufficiently for the element to be form stable. Then in a ninth station 79 the moulds 30, 30A are opened and the element 1,, 1A, 1B can be removed from the mould, substantially ready for use. The mould parts are returned to storage and/or the first station for reuse.
  • the floor elements are manufactured horizontally, with the ceiling forming side facing down.
  • the reinforcements are placed such that they extend above the upper surface of the elements.
  • the beams can be moulded integrally with the slab, preferably fully enclosing the reinforcements if available. Therefore the process is uncomplicated and provides for beams suitable for carrying the cover elements.
  • the beams further strengthen the elements 1 and provide for the pockets in between the beams.
  • the openings 8, 9 are preferably provided at or close to a neutral line of the element.
  • the mould can be brought and held in the angled position during the entire process of preparing the mould and forming the elements therein.
  • the mould can be moved between different angled positions during the process.
  • the mould can be in a substantially horizontal opposition, such that the back surface 37 of the mould is substantially horizontal or at least at a shallow angle relative to the horizontal plane Hp, during for example cleaning, mounting inserts 55 and/or end portions 53, and/or during plotting and or during closure and/or assembly of the mould, whereas for example during filling of the mould 30 the mould is brought in the acute angled position, in which the back surface 37 extends at said acute angle, as discussed before.
  • the filling and/or aeration opening 43 can be closed, for example by a lid or valve, the mould can be brought back to a substantially horizontal position after filling too.
  • Fig. 9 schematically shows a mould 30 mounted on tracks 60 by rollers 61, such that the mould can be moved along the tracks 60 in any suitable way.
  • the tracks can extend through part of or, preferably, the entire plant 70, such that the moulds 30 can pass through the different stations, guided by the tracks 60.
  • the tracks can be bent such that the moulds 30 are forced into different positions in and/or between different stations 71 - 79.
  • the position of the tracks can be amended in one or more of the stations, for example in order to amend the angled position of the moulds in the relevant station.
  • FIG. 10 schematically part of a further embodiment of a mould 30 is shown, in which the material of which the elements 1 are to be made can be injected into the mould cavity 41, for example using a pump 81 and a valve 63 near a lower side of the mould 30, as part of a filling device 80.
  • the valve 63 can for example be provided in the first part 31 of the mould 30, for example in the bottom surface 37 thereof.
  • the valve can for example be but is not limited to a butterfly valve.
  • Valves for use in apparatus for forwarding settable and/or curable materials such as concrete are well known in the art.
  • the material can be forced into the mould cavity from a point of entry spaced apart from the opening 43, which can then be used as an aeration opening only and can be relatively small compared to the size when the opening 43 is also used as a filling opening.
  • a pouring mark 82 is shown, on a sloping side surface of a beam 3A.
  • the mark 82 can for example extend over substantially the full length L of the element 1 and can be an imprint of a filling and/or aeration opening 43.
  • the shape and size can be different, depending on inter alia the opening 43 used.
  • a different number of beams can be provided, whereas at least one of the outer longitudinal beams and/or the cross beams can be provided spaced apart from a longitudinal or transverse side edge respectively.
  • the beams can have different cross shapes, sections or lengths, and can be placed differently then all parallel.
  • one or more of the beams could be diagonal or at least could enclose an angle different from 90 degrees with the transverse edges of the element.
  • one or both of the transverse edges and/or longitudinal edges could slope or be other than straight.
  • the element can for example be trapezoid, triangular, curved at a side or otherwise different from rectangular.
  • the openings 8 and/or 9 could be omitted in some or all of the beams.
  • the carrier can be different, for example having perpendicular supporting surfaces or otherwise angled surfaces or only one supporting surface to which at least one of the mould parts 31, 32 is directly mounted.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)

Claims (18)

  1. System, umfassend eine Trägerstruktur (50) und eine Form (30) für Beton-Bodenelemente (1), welche zumindest eine Platte (2) und zumindest einen Träger (3), welcher sich entlang der Platte (2) in einer Längenrichtung (L1) erstreckt, umfassen, wobei die Form (30) zumindest ein erstes Teil (31) und ein zweites Teil (32) umfasst, welche zum Bilden eines Formhohlraums gegeneinander schließen können, wobei das erste Formteil (31) eine untere Oberfläche (37) aufweist, welche vorzugsweise im Wesentlichen eben ist, zum Bilden einer ersten Seite von der Platte (2), und wobei das zweite Formteil (32) eine Oberseite aufweist mit einem trägerbildenden Profil (38) zum Bilden zumindest eines Teils von dem zumindest einen Träger (3), wobei die Trägerstruktur (50) konfiguriert ist, um die Form (30) zu positionieren, zumindest während des Gießens des Betons, wobei sich die untere Oberfläche (37) in einem spitzen Winkel (α) zu einer horizontalen Ebene (Hp) erstreckt, so dass ein oberer Teil (39) von jedem trägerbildenden Profil (38) von der Form (30) zumindest teilweise nach oben in Richtung zu dem ersten Formteil (31) geneigt ist, und wobei die Längenrichtung (L1) im Wesentlichen horizontal ist, und wobei zumindest eine Öffnung (43) vorgesehen ist, welche eine Füll- und/oder Belüftungsöffnung bildet,
    dadurch gekennzeichnet, dass die Trägerstruktur (50) weiterhin konfiguriert ist, um die Form (30) zumindest während des Gießens des Betons zu positionieren, so dass das obere Teil (39) von jedem trägerbildenden Profil (38) der Form (30) zumindest teilweise nach oben in Richtung zu der Trägerstruktur (50) geneigt ist, an welcher das erste Formteil (31) platziert ist.
  2. System gemäß Anspruch 1, wobei das zumindest eine trägerbildende Profil (38) ein Teil zum Bilden einer Seite von dem zumindest einen Träger (3), welcher in der Form (30) nach oben zeigt, umfasst, wobei das Teil eine Hauptebene (39) aufweist, welche einen Winkel (β) mit der horizontalen Ebene (Hp) einschließt, so dass eine Seite von der Ebene (39) nahe dem ersten Teil (41) von der Form (30) zumindest teilweise höher liegt als das gegenüberliegende Ende.
  3. System gemäß Anspruch 1 oder 2, wobei der spitze Winkel α zwischen 60° und 90° beträgt, vorzugsweise zwischen 75 und 89°, und noch bevorzugter zwischen 80 und 89°.
  4. System gemäß Anspruch 2 und 3, wobei der Winkel β gleich oder größer ist als 90° minus dem spitzen Winkel α (β ≥ 90° - α).
  5. System gemäß irgendeinem der vorhergehenden Ansprüche, wobei die zumindest eine Öffnung (43) nahe eines oberen Endes von dem Formhohlraum vorgesehen ist.
  6. System gemäß irgendeinem der vorhergehenden Ansprüche, wobei das zumindest eine trägerbildende Profil (38) nahe dem oberen Ende von dem Formhohlraum vorgesehen ist, wobei die zumindest eine Öffnung (43) in einer oberen Oberfläche (39) von dem formbildenden Profil (38) vorgesehen ist.
  7. System gemäß Anspruch 6, wobei eine Seite von dem plattenbildenden Abschnitt (31) von der Form (30), welche im Wesentlichen nach oben gerichtet ist, sich auf einem Niveau unterhalb der zumindest eine Öffnung (43) erstreckt.
  8. System gemäß irgendeinem der vorhergehenden Ansprüche, wobei die Form (30) zumindest zwei, vorzugsweise zumindest drei trägerbildende Profile (38) umfasst, welche sich im Wesentlichen parallel zueinander erstrecken.
  9. System gemäß irgendeinem der vorhergehenden Ansprüche, wobei zumindest das zweite Formteil (32) eine Anzahl von Modulen umfasst.
  10. System gemäß irgendeinem der vorhergehenden Ansprüche, welches eine Reihe von Formen umfasst, wobei jede Form gemäß irgendeinem der vorhergehenden Ansprüche ist, wobei zumindest zwei von den Formen (30) in der Reihe in der Anzahl von Trägern (3) und/oder im Abstand zwischen zumindest zwei Trägern (3) unterschiedlich sind, wobei sie vorzugsweise zumindest die gleiche Länge in der Längenrichtung (L1) aufweisen, und wobei Elemente von den unterschiedlichen Formen (30) miteinander über Seiten parallel zu der Längenrichtung verbindbar sind.
  11. System gemäß irgendeinem der vorhergehenden Ansprüche, weiterhin eine Füllvorrichtung (80) zum Befüllen der Form (30) zumindest teilweise durch die zumindest eine Füllöffnung umfassend, wobei zumindest eine Belüftungsöffnung an einem im Wesentlichen höchstem Niveau des Formhohlraums vorgesehen ist.
  12. System gemäß Anspruch 11, wobei zumindest ein Teil von dem Formhohlraum angrenzend zu der zumindest einen Öffnung leer ist, um durch die Füllvorrichtung befüllt zu werden, wobei das Teil vorzugsweise zumindest ein trägerbildendes Profil (38) und einen Teil von einem angrenzenden plattenbildenden Abschnitt umfasst.
  13. System gemäß irgendeinem der Ansprüche 10 - 12, wobei die Formen (30) von modularem Aufbau sind, wobei zumindest zwei von den Formen (30) in der Reihe sich in der Anzahl von Trägern (3) und/oder im Abstand zwischen zumindest zwei Trägern (3) unterscheiden durch Aufweisen einer unterschiedlichen Anzahl von Modulen, welche jeweils zumindest ein trägerbildendes Profil (38) umfassen.
  14. Verfahren zum Bilden eines vorgefertigten Betonbodenelements (1), welches eine Platte (2) und zumindest einen Träger (3) umfasst, welche sich entlang der Platte (2) in einer Längenrichtung (L1) erstreckt, unter Verwendung eines Systems, welches eine Trägerstruktur (50) und eine Form (30) gemäß Anspruch 1 umfasst, die Schritte umfassend:
    - Anordnen der Form (30) zum Bilden solcher Elemente (1) auf der Trägerstruktur (50) in einer Orientierung, so dass:
    - trägerbildende Profile (38) sich in der Längenrichtung (L1) im Wesentlichen horizontal erstrecken; und
    - die Form (30) in einem spitzen Winkel (α) relativ zu einer horizontalen Ebene (Hp) abgewinkelt ist, zumindest während des Gießens des Betons, so dass ein oberes Teil (39) von dem trägerbildenden Profil (38) von der Form (30) zumindest teilweise nach oben in Richtung zu einem plattenbildenden Teil von der Form (30) geneigt ist; und
    - Gießen von Beton in die Form (30) hinein zum Bilden des Elements (1), wodurch Luft aus der Form nach oben aus der Form (30) heraus gedrängt wird.
  15. Verfahren gemäß Anspruch 14, wobei eine Reihe von Formen (30) in einem Karussellsystem angeordnet ist.
  16. Verfahren gemäß Anspruch 14 oder 15, wobei das Bodenelement (1) aus Beton hergestellt ist, vorzugsweise aus selbstverdichtendem Beton, wobei Querbalken vorgesehen werden können, und wobei vorzugsweise zumindest ein Kantenabschnitt von der Platte (2) und/oder von den Trägern (3) aus einem Material hergestellt ist/sind, welches weicher und/oder spröder ist als der Beton.
  17. Verfahren gemäß Anspruch 14, wobei der plattenbildende Teil von der Form (30) zumindest teilweise während des Gießens des Betons nach unten zeigt, und wobei sich die trägerbildenden Teile an einer Seite erstrecken, welche zumindest teilweise nach oben zeigt.
  18. Verfahren gemäß irgendeinem der Ansprüche 14 - 17, wobei der Beton in den Formhohlraum gegossen wird, so dass er den Hohlraum im Wesentlichen in einer Richtung von unten nach oben füllt, wobei der Beton:
    - in den Formhohlraum (41) durch eine Öffnung (43) an einer oberen Seite von dem Hohlraum (41) gegossen wird, so dass der Beton im Wesentlichen entlang einer Wand von dem plattenbildenden Abschnitt (31) hinunter in den Formhohlraum (41) fließt, oder
    - in den Hohlraum (41) durch eine Öffnung (43) an einem unteren Teil von dem Formhohlraum (41) gegossen wird, wobei die Luft in dem Formhohlraum (41) durch den Beton nach oben gedrängt wird, wobei die Öffnung (43) vorzugsweise in einer Wand von dem plattenbildenden Teil vorgesehen ist.
EP11726227.9A 2010-06-09 2011-06-09 System und verfahren zur herstellung von bodenfertigteilelementen aus beton Active EP2580036B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL2004864A NL2004864C2 (en) 2010-06-09 2010-06-09 Moulds and methods for forming prefab concrete floor elements and prefab elements.
PCT/NL2011/050420 WO2011155841A1 (en) 2010-06-09 2011-06-09 Moulds and methods for forming prefab concrete floor elements and prefab elements

Publications (2)

Publication Number Publication Date
EP2580036A1 EP2580036A1 (de) 2013-04-17
EP2580036B1 true EP2580036B1 (de) 2019-12-04

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NL (1) NL2004864C2 (de)
WO (1) WO2011155841A1 (de)

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Publication number Priority date Publication date Assignee Title
AT514035B1 (de) * 2013-03-13 2016-03-15 Waagner Biro Stahlbau Ag Verfahren zur Herstellung eines flächenartigen Elements mit von einer ebenen Oberfläche abweichender Oberfläche, Formteil zur Herstellung sowie flächenartiges Element
CN114599843A (zh) * 2019-09-06 2022-06-07 Cpc公司 混凝土顶板、混凝土顶板件和制造混凝土顶板和混凝土顶板件的方法
CN114800790B (zh) * 2022-04-15 2024-03-22 东岳机械股份有限公司 一种蒸压加气混凝土设备模箱摩擦轮及摩擦梁定位工装

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Publication number Priority date Publication date Assignee Title
FR1422473A (fr) * 1965-01-12 1965-12-24 élément polyvalent, en béton armé, pour construction industrialisée
DE2253706A1 (de) * 1972-11-02 1974-05-16 Stetter Gmbh Verfahren und maschine zur herstellung von betonbauelementen
EP0818287B1 (de) * 1995-12-01 2002-10-09 Vicente Solana Gomez Formwerkzeug für vorgefertigte betonplatten
WO2006056073A1 (en) * 2004-11-26 2006-06-01 Nick Di Lorenzo Concrete panel construction system and method of making panels

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Title
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NL2004864C2 (en) 2011-12-13
EP2580036A1 (de) 2013-04-17

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