Method and installation for forming a concrete element
The invention relates to the formation of a concrete element. This can take place in a wide variety of ways. The production of floor components or roof components in enclosed factory shuttering may be mentioned by way of example. According to yet another possibility the concrete element is formed in an existing framework, such as the opening between columns and beams present in an existing building.
In all of these cases the problem arises that the set concrete mix no longer fully abuts the framework because of the occurrence of shrinkage. This shrinkage is the consequence of the reduction in volume resulting from the chemical processes during setting and of a fall in temperature. As is known, concrete is a mixture that at least consists of aggregate, cement, sand and water. Hydration occurs during setting of this mixture, as a result of which the temperature in the mixture can rise to approximately 70 °C.
The water component of the concrete comprises water of crystallisation, water that is bound as a consequence of differences in electrostatic charge and free water. The free water from the mixture evaporates through it. Partly as a consequence of cooling of the mix, the concrete element shrinks somewhat compared with the formwork cavity.
The aim of the invention is to provide a method as described above for forming a concrete element, with which the formation of cracks, gaps and the like can be avoided. Said aim is achieved by a method for forming a concrete element comprising the following steps: the provision of a framework, such as a border or a frame and the like to define the periphery of the concrete element, closing off the frame and the like on both sides to form a formwork cavity, - provision of a feed for concrete mix, as well as a discharge for the air displaced when feeding in the concrete mix, completely filling the formwork cavity with concrete mix, applying an overpressure to the concrete mix, allowing the concrete mix to set whilst maintaining the oveφressure of the shuttering walls, removal of the shuttering walls. Various phenomena arise as a consequence of applying an overpressure to the mix. First of all the formwork cavity concerned is completely and reliably filled. Complete
filling is a primary requirement in order to obtain the desired result, but frequently is made more difficult by inadequate means of control. However, the degree of filling can be reliably determined by means of so-called risers in the discharge.
Furthermore, bulging of the shuttering walls occurs under the influence of the oveφressure in the mix. As a consequence these walls start to behave as a membrane. The shuttering walls are consequently able to follow the shrinkage of the mix to some extent by springing resiliently back into the flat state. As a result the mix initially remains under oveφressure, despite the shrinkage, and is pressed into those areas where there is a possible risk of cracking or cavity formation. It is true that the shrinkage that results in the shuttering walls springing back into shape takes place only after the mix has already acquired a plastic nature to some extent. A few crystalline compounds have already formed in this stage, but the degree of crystallisation is still so low that deformation of the mix under the influence of pressing by the shuttering walls is still possible. The best results are obtained if the oveφressure prevails in the entire formwork cavity. The method therefore also comprises applying an oveφressure to the concrete mix such that said oveφressure is at least 0.5 bar at the highest level of the concrete mix.
Complete filling of the formwork cavity can best be achieved by the use of flow concrete or self-levelling concrete. The durability of the concrete element obtained mainly depends on the quality of the outermost layer. This quality can be improved by attaching a fine-mesh fabric to that side of the shuttering walls that faces the formwork cavity and then introducing the concrete mix.
The fine-mesh fabric is permeable to water but not to the various components of the mix. As a result free discharge of water and air is possible, which is further improved by the oveφressure in the formwork cavity.
Water, air and vapour are able to escape through the discharge, but also through any small gaps which will virtually always be present in the joins between the shuttering walls and the frame. Minor leakage of this type is acceptable and does not have to lead to an excessive reduction in the oveφressure in the formwork cavity. After some time small openings of this type become clogged as a consequence of the minuscule particles of the mix which pass through.
Applying an oveφressure to the mix can take place in one or more stages, by means
of the pump for filling the formwork cavity, and optionally as a function of the pressure in the formwork cavity. As an alternative, the pressure can also be raised by means of, for example, a pneumatic accumulator that is connected to the feed line for the mix.
The invention also relates to shuttering for carrying out the method as described above, comprising a framework, such as a border or frame which defines the periphery of the formwork cavity, as well as two shuttering walls that can be joined to the sides of the framework, and a feed for concrete mix and discharge for displaced air provided in the framework and/or a shuttering wall.
The discharge is located in that part of the framework and/or at least one of the shuttering walls that is at the highest level, whilst the feed is located in that part of the framework and/or at least one of the shuttering walls that is at the lowest level.
In order to obtain as advantageous as possible a membrane behaviour as explained above, the shuttering can have to be modified somewhat. According to the invention this can be achieved by means of a shuttering where at least one of the shuttering walls is of relatively low rigidity, such that, as a consequence of membrane behaviour, this shuttering wall bulges outwards under the influence of applying an oveφressure to the concrete mix and the bulging decreases on shrinkage of the concrete mix as a consequence of the hydration and/or cooling thereof in order at least partially to counteract the decrease in pressure associated with shrinkage and in order to fill any shrinkage cavities arising as a consequence of the shrinkage.
The invention will be explained in more detail below with reference to a few illustrative embodiments shown in the figures.
Figure 1 shows an installation for forming a concrete element according to the invention. Figure 2 shows a second embodiment.
Figure 3 shows a possible application for installing a concrete element according to the invention.
The installation shown in Figure 1 for carrying out the method according to the invention comprises a shuttering 1 , consisting of a frame 2 as well as two shuttering walls 3, 4 adjoining the latter. At least one of the shuttering walls 3 has a connection point 5 to which a feed line 6 is connected. A mixture of aggregate, cement and water for forming a concrete element is fed via said line 6, under the control of the capacity regulator 7, by means of a concrete pump, which is not shown, to the formwork cavity in the shuttering 1.
The pressure under which said mix is fed can be read off by means of the manometer 8.
Risers or discharges 9, via which the air is able to escape from the formwork cavity, are located at the top of the frame 2. As soon as the mix appears in these risers 9 it is guaranteed that the entire formwork cavity has been filled with the concrete mix. The risers 9 are then closed off by means of the valves 20.
Reinforcement can optionally be accommodated in the shuttering 1 before the latter is closed.
The pumping action when feeding in the mix via the feed line 6 is continued until an oveφressure prevails in the entire mix in the formwork cavity. This pressure can optionally be measured by pressure gauges 10 fitted in the shuttering walls 3.
Preferably, the pressure is so controlled that an oveφressure of at least 0.5 bar prevails in the upper section of the formwork cavity. The pressure can, for example, reach values of 200 to 300 bar.
The shuttering walls 3, 4 bulge slightly outwards under the influence of this oveφressure. As the mix shrinks as a consequence of the setting thereof, the shuttering walls 3 are able to spring back to some extent as a consequence of their membrane behaviour. As this takes place the mix, which is still plastic, can be held continuously under pressure, such that any holes or gaps which form between the mix and the walls of the formwork cavity can be filled as they arise. In this way it can be ensured that the concrete element fills the entire formwork cavity even when it is set, as a result of which a precise product is guaranteed.
In the variant in Figure 2 it is shown that a pneumatic or hydraulic accumulator 13 can also have been connected to the feed line 6. The puφose of this pneumatic accumulator 13 is to guarantee a continuous oveφressure in the mix 12 during and after pumping of the latter.
The pressure build-up in the shuttering 1 can be influenced by suitable manipulation of the valves 18, 19 and 20. For instance, the shuttering 1 can be pressurised in one continuous pumping phase, after which the valve 18 is closed and the accumulator 13 ensures that the pressure is maintained. The pressure build-up can also take place in stages. In this case, the valve 19 is closed when a first pressure is achieved. The pumping action is then continued such that the pressure in the accumulator 13 rises. Valve 18 is then closed and valve 19 opened, such that a supplementary rise in pressure is obtained in the shuttering.
An example of a possible application of the method according to the invention is shown in Figure 3. The underground car park shown in this figure has a blinding 14 which is some distance below the parking level 15. Said parking level 15 is supported by the walls 16, as well as by the columns 17 which bear on the blinding 14. With a view to closing the open spaces between adjacent columns 17, the blinding 14 and the parking level 15, the shuttering walls 3, 4 can be erected in contact therewith.
By means of the method according to the invention the spaces between these columns 17 and the floors 14, 15 can reliably be completely filled with the mix, the concrete element thus obtained between said columns 17 and floors 14, 15 abutting completely, despite the shrinkage that takes place therein during setting.