CH442116A - Process for the continuous manufacture of molded construction elements in hardenable material, installation for carrying out this process and element obtained using this process - Google Patents

Description

Process for the continuous manufacture of molded construction elements in hardenable maure, installation for the implementation of this process and element obtained by means of this process The present invention relates to a process for the continuous manufacture of Building materials molded in hardenable material.

In the processes implemented so far, formwork frames of different types are used for walls, floors, sandwich units, etc., placed vertically or horizontally. These frames are usually filled by hand or sometimes by moving them on a conveyor below filling, leveling and compacting machines. The frames are made to standard dimensions and can only be adjusted with difficulty. By casting small-sized elements in these frames, space is lost. Because it is complicated to prepare a frame, to fix retaining bolts for the shuttering of windows and doors or other accessories, and to conform the profile for the end joint, no manufacturer can supply fully finished prefabricated elements. The shop drawings required for the preparation of forms, tooling and assembly of formwork for a particular molding are such that it is necessary to mold several hundred similar components from of the same formwork to make it economical.

It is also known to use truss or bed formwork to continuously cast floor slab elements which are then cut to length. This prockde West however not rational.

The mechanization of molding operations for construction elements of various types has led until now to the manufacture of standardized elements using formwork of various types, established with precision for given dimensions.

However, the architect is currently asking the manufacturer to provide him with elements of variable dimensions and shapes based on a certain module to allow the construction of different types of dwellings or buildings. The present invention aims, on the one hand, to remedy the drawbacks mentioned above, and on the other hand, to provide a solution to the problem posed by the architect to the manufacturer to enable him to pass from one type of element to another. in a simple way and without modifying the equipment or the installation used for this purpose.

The change from one type of molding to another, for example, for wall, floor, beam, column and roof elements, as well as for Sandwich elements for the construction of buildings with one or more floors , is carried out in a simple way and without additional work.

The method according to the invention is characterized in that formwork cores are arranged parallel and at a modular distance between them through a formwork frame for the formation of channels in the mass of cast material, instead reinforcing bars at least between said formwork cores, pouring said material in the frame between the formwork cores Over a thickness equal to the modular distance between the cores, and removing the formwork cores from the frame when the material has taken.

An installation for implementing the above process, which the invention also comprises, is characterized in that it comprises a formwork frame resting on a bottom and of which two parallel sides determine the length of the channels in the cast elements. ; these two sides having pairs of opposed openings to return the formwork cores parallel and separated by the modular distance, and means for modifying at will the surface of the formwork frame intended to receive the hardenable material.

The appended drawing represents, by way of example, a form of detailed execution of the installation which comprises the invention. fig. 1 is a perspective view of a shuttering frame forming part of the installation.

fig. 2 is a cross-section through two construction elements during manufacture.

fig. 3 is a section similar to FIG. 2 in another position of the 616ments.

fig. 4 is a partially sectioned perspective view of a building block.

fig. 5 is a cross-section through a Sandwich-type 616-ment.

fig. 6 is a section similar to fig. 5 of a variant.

fig. 7 is a sectional view similar to fig. 5 of another variant.

The detail of the installation is shown in fig. 1 relates to a formwork bed or frame comprising two U-shaped beams 1 arranged parallel on a flat bottom 2 with the branches of the U directed outwards. These beams 1 are pierced with openings 3 of generally hexagonal shape intended to receive formwork cores 4 of the type described in Swiss patent NO 437735, comprising two longitudinal shells a, b (fig. 6) that can be moved Tune with respect to the other in a formwork position where the aisles are spaced apart from each other by means of connecting rods c or in a close position edge to edge for formwork stripping. These formwork cores 4 will not be described in detail Gar they are not part of the invention.

The beams 1 form two sides of the formwork frame and have a dimension such that this frame makes it possible to obtain a modular thickness of the molded element, for example 15 cm. The openings 3 of the beams 1 are equally spaced by a modular distance of 15 cm. 0n could of course base the dimensions of the 616ments on another module whose value is 10-30 cm.

Means for modifying the surface of the shuttering frame as desired are shown in FIG. 1 by a frame 5 closed on its upper surface 6 and whose external dimensions correspond to the internal dimensions of a window. This frame 5 has, on two of its parallel sides, pairs of openings 7 for the passage of the formwork cores 4 passing through the frame.

In order to continuously manufacture construction elements in the form of concrete panels, for example, a frame as described is prepared over a considerable length enabling several panels to be formed at the same time. 0n then places reinforcement irons 8 between the cores 4 and irons 9 around Ges cores (see fig. 2, 3) according to the load conditions of the 61ements, in the first Gas, for example, where Ges elements RTI ID= "0002.0276" WI="11" HE="4" LX="733" LY="2131"> serve to form a floor slab or other particularly stressed construction. The concrete is then mechanically poured into the frame by means of a hopper (not shown) moving across the frame and receiving fresh concrete from a mixing station also not shown.

The concrete flows to conform to the shape of the frame 5 or any other means modifying the surface of the frame as will be described below, so that once the concrete has hardened and the formwork cores 4 have been removed from the frame, each element obtained is in the form of a panel crossed right through by channels 10 (Figs. 2, 3) jans households 1'e thickness of the panel. In the Gas of fig. 1, the panel obtained has a window opening, the dimensions of which correspond to Gelles of the frame 5, in order to form, for example, vertical columns. place reinforcing bars.

Instead of the frame 5 or in addition to it, an could arrange in the frame any other means to obtain in the molded elements openings of the desired shape and according to a determined arrangement. The described frame allows a great variety of manufacture and changes from one type of element to another are made quickly and without difficulty.

The fig. 2 and 3 show two building elements E, E' molded in the frame described above and whose formwork cores 4 have been eliminated leaving the channels 10 free. These channels 10 are spaced apart by a modular distance S and the thickness T of the elements E, E' is equal to this distance S. formwork on which it rests, is retained by means of bolts 12' distributed over the length of the pike 11 and screwed into a lower pike 12 also resting against the two formwork cores but on the other side of the these in relation to pike 11. By eliminating pike 11 and 12 after the concrete has set, an obtains two molded elements E, E' each presenting at one end a notch <B>13</B> respectively 14 with transverse bars 15 and 15' on standby. The notch 14 allows the junction between the panels E, E' and a perpendicular panel D whose end has on the edge an opening 16 coinciding with a channel 10 of this panel D. A connection is thus obtained in T.

fig. 4 shows in perspective a fragment of an F panel variant for a floor slab, for example, RTI ID="0002.0548" WI="7" HE="4" LX="1285" LY="1513"> in which the formwork cores were also eliminated before the invention of additional transverse irons 17 through side openings <B>18</B> communicating with the channels 10. These openings were obtained by arranging wooden pegs or in another material before pouring the concrete, pikes quo 1'on eliminates after setting. The longitudinal irons 19 are extended to reinforce the end of the slab. This end is molded into a block after having formed the channels at 20, so as to obtain a solid beam.

The building element partially shown in FIG. 5 is of the Sandwich type comprising panels G, G' similar to panels E, E', and on which a layer 21 of insulating material has been placed, for example, a foamed plastic material after having inserted irons 22 Jans 1st still soft concrete of panels G, G'. On this layer 21, there are Goulds panels H, H' of lower thickness Gar they are not stressed by a load but form an external coating. These panels H, H' are held to the panels G, G' by the irons 22. To f6aliser the ends of the panels G; G 'according to a desired profile, an arranged between Ges panels uri dldment M ferind by two metal profiles 26, 26 'provided with stiffening ribs R, R' 6 pousant the shape of the formwork core around which are arranged the profi16s 26, 26 ' . When the core is removed, the profiles 26, 26' can be compressed by the elasticity of an intermediate gasket 27 and removed. The ends of the panels H, H' are profiled by means of angle irons 23, 24 fixed by bolts 25 on the first profile 26. These angle irons have ribs to form corresponding recesses in the panels H, H' . The free space between the irons 23, 24 is closed by a wooden pike.

The panel G has at its end adjacent to the profile 26 a piece of wood 28 serving to form an opening communicating the channel 10 with the outside. This pike is removed after the concrete has set. The reinforcing bars have not been shown in this variant for reasons of clarity of the drawing. The panels H and H' are also cast on the same formwork frame as that of the elements G, G', but on which additional formwork means have been adapted. Element M could be placed anywhere on the formwork frame to limit a panel of any length.

fig. 6 shows how the deerite installation makes it possible to manufacture I-shaped elements. 32 respectively. These parts extend over the entire length of the cores between the beams 1 of the formwork frame of FIG. 1 and thus create longitudinal spaces dividing the panel into 616 N elements in a double T. The reinforcing bars are not included in this execution either.

In fig. 7 an has shown a building corner assembly formed of two sandwich panels similar to those in fig. 5. The adjacent extremities of these panels are profiled by means of formwork elements such as 1'616ment M of FIG. 5 and angles for the ends of the covering panels O, O'. These angle irons (not shown) have ribs to form grooves 33, 33' in the elements O, O' which, in the assembly, form a housing for a sealing gasket 34.

The insulating layer 35' of the panel O' comes into contact with the insulating layer 35 of the element O so that there is no solution of continuity in the insulation of the building. The reinforced panels P, P' have been molded as previously described and their end cells 36 respectively 37 are open on the outside of the panel at 38 respectively 39 to establish a closed space between the two panels P, P' in which are provided with reinforcing bars intended to be embedded in the concrete poured in this space. The openings 38, 39 are obtained as for the first panel G with the aid of a wooden pike such as that shown at 28 in FIG. 5.

A sealing gasket 40 is placed between the panels P, P'.

The process and installation described are very simple and RTI ID="0003.0277" WI="12" HE="4" LX="390" LY="2065"> can be used by unskilled labor for the manufacture of Brands honeycomb panels. This process makes it possible to divide the continuously molded elements into units of different lengths representing a multiple of a chosen Small Modulus. The ends profiled and provided with reinforcement irons are produced at the same time as the continuous molding. Such a process makes it possible to obtain a construction system based on a module without the need to repeat the design. Since the construction elements are manufactured continuously and in a row, that is to say adjacent to one another, the length defects are not added but are compensated from one element to another. <B>11</B> is therefore possible to work with very tight tolerances which is possible in the known installations only by producing extremely precise and expensive formwork. For the same reason thickness faults are uniform, and when two panels are joined, their surfaces are always level.

To pass from one type of element to another, an always uses the same formwork cores, which represents a significant simplification of the installation.

Claims (12)

CLAIMS I. Process for the continuous manufacture of structural elements molded in hardenable material, characterized in that, parallel to and at a modular distance between them, formwork cores are arranged through a formwork frame for the formation of channels in the mass of poured material, placing reinforcing bars between said formwork cores, pouring said material into the frame between the formwork cores over a thickness equal to the modular distance between the cores, and removing it from the frame formwork cores when the material has set. 1I. Installation for carrying out the process according to claim I, characterized in that it comprises a formwork frame resting on a bottom and of which two parallel sides determine the length of the channels in the cast elements, these two sides having pairs of opposed openings for receiving the formwork cores parallel and separated by the modular distance, and means for modifying at will the surface of the formwork frame intended to receive the hardenable material. 11I. Construction element obtained by the first process according to claim I. SUB-CLAIMS 1. Process according to claim I, characterized in that covering means are placed on a selected part of the surface of the frame so as to prevent the hardenable material from flowing into this Part. 2. Process according to claim 1, characterized in that the formwork cores are arranged at a modular distance of 10 to 30 cm and the hardenable material is poured over a thickness of the same module. 3. Proc6d6 according to claim I, characterized in that irons are inserted into the still soft cast material on which a layer of insulating material is placed, and a second layer of hardenable material is cast to obtain a Sandwich insulation element . 4. Procedure according to claim 1, characterized in that a cage of reinforcement irons is formed surrounding each formwork core and irons extending transversely relative to the formwork cores are attached to said Gage. 5. Process according to claim I, characterized in that transverse passages communicating with at least one channel of the element are formed by placing a filling material before casting the element. 6. Installation according to claim 11, characterized in that the means for modifying the surface of the frame at will comprise a frame whose exterior dimensions correspond to the interior dimensions of a window, this frame having on two sides parallel pairs of openings to receive formwork cores passing through the frame. 7. Installation according to claim 1I, characterized in that the means for modifying the surface of the frame at will comprise a covering piece extending between two formwork cores Over the entire length of these cores, and on one side of these, a second longitudinal pike also extending between these two formwork cores but on the other side of these, and means for fixing the two pieces between them. B. Installation according to claim 11, characterized in that the means for modifying the surface of the frame as desired comprise a Separation pike extending over the entire length of a formwork core On which it rests, the width of this pike being smaller than the core width. 9. Installation according to claim 11, characterized in that the means for modifying the surface of the frame as desired comprise a wedge-shaped pike, disposed laterally against the last core of the formwork of a row, -, 6th, of way to form an opening on the edge of the molded element, communicating with the channel formed by said formwork core. 10. Construction element according to claim III, characterized in that it consists of a reinforced concrete panel of modular thickness, comprising parallel channels crossing the element from side to side and separated by a modular distance equal to 1 ' modular thickness of the element. 11. Construction element according to claim III, of the Sandwich type, characterized in that it is formed of two reinforced concrete panels separated by a layer of insulating material. 12. Construction element according to claim III and sub-claim 10, characterized in that one end of the panel at least has a notch extending over the entire edge of the element and in which protrude irons on standby, this end being intended to be placed facing the corresponding indented end of an adjacent element for end-to-end fixing of the two elements.