CN110014505B

CN110014505B - Method for fastening a side wall element and side wall element

Info

Publication number: CN110014505B
Application number: CN201910013871.XA
Authority: CN
Inventors: 约尼·西尔卡; 保尔·哈伊胡斯特
Original assignee: Elematic Oy
Current assignee: Elematic Oy
Priority date: 2018-01-08
Filing date: 2019-01-08
Publication date: 2021-05-04
Anticipated expiration: 2039-01-08
Also published as: FI128708B; CN110014505A; FI20185014A1

Abstract

The invention relates to a method for fixing a detachable side wall unit (4), the side wall unit (4) comprising a mould surface (4a) in a horizontal mould for a concrete sandwich element (1, 8), which element comprises at least one insulation layer (1b, 8b), wherein the side wall unit (4) is fixed in the insulation layer (1b, 8b) of the concrete sandwich element (1, 8) to be cast. The invention also relates to such a side wall element (4).

Description

Method for fastening a side wall element and side wall element

Technical Field

The present invention relates to the moulding of precast concrete articles. More precisely, the invention relates to a method for detachably fixing a side wall element of a casting mold to form a casting mold, and to such a detachable side wall element.

Background

When manufacturing precast concrete articles, the articles are cast in a manufacturing plant with a mould, which may be a vertical mould (e.g. a set of vertical moulds) or a horizontal mould (e.g. a bench mould and a tilt mould). For assembling the mould, use is usually made of detachable side wall units which are attached to the mould surface, such as a horizontal or vertical surface, by means of magnets. The side walls or some of the side wall units of the casting mould may also be fixedly connected to the mould by bolts or welding or connected to the mould by hinges (typically at the edges of the mould surface).

When using a horizontal mould (such as a bench mould or an inclined mould), the manufacturing process starts by first building a mould on a horizontal casting table, which mould defines the dimensions of the article to be cast. Today this is usually done by building a mould on a metal tiltable casting table of a mould side wall unit, which is attached by means of magnets. When the mould defining the outer dimensions of the mould is completed, the areas delimited by the side wall elements, e.g. corresponding arrangements for windows, doors or other casting areas defining the cast product, are formed, respectively, in the interior of the mould, if necessary. Further, if necessary, various devices such as a cardboard provided with a surface retarder, which is disposed on the casting table when casting graphic concrete, are placed on the casting table in the mold for shaping the outer surface of the cast product or for forming a desired contour of the outer surface. In the final stage of the preparation of the mould, the necessary reinforcement is provided, and the concrete mixture is subsequently poured into the mould.

In order to pour the concrete mixture into the mould, a concrete mixture casting device is generally used which moves over the mould and feeds the concrete mixture to the casting mould. When an inclined or bench-top mould is used, this casting of the concrete mixture in the mould is carried out from a casting device placed above the casting table or brought above the casting table. When casting on a circulating mould line, the casting mould is usually brought to a vibration station provided with a casting device, in which the concrete mixture is poured into the mould.

When casting a concrete sandwich wall element comprising at least one layer of insulating material between two concrete layers, the casting of the concrete into the mould and the preparation and assembly of the horizontal mould table are performed in alternating stages. In a first stage, the reinforcement required for the first concrete layer is added to the bottom part of the mould and the concrete block is cast at the bottom of the mould against the surface of the mould table. This first casting forms the outer concrete surface layer of the concrete sandwich wall element. After the first layer has been cast, an insulating layer is formed on top of the first concrete layer in the mould. After the insulation is formed, the required reinforcement is formed on top of the insulation and a second concrete layer is cast on top of the insulation. The second concrete layer forms a load bearing structure of the concrete sandwich wall element.

In many concrete sandwich wall elements the last cast load carrying concrete layer is not of equal size to the first cast concrete layer and/or insulation layer, but is of smaller size. This makes the construction of moulds for such concrete sandwich elements a rather complicated manual work, which is not easily automated for the use of an assembly robot.

The situation is more complicated in case the load carrying layer of the concrete sandwich wall element comprises a reinforcement extending outside the formed concrete layer. This requires a special arrangement for the mould side wall units for allowing the reinforcement to pass through the surface in the mould that confines the concrete layer.

A known solution for a side wall unit for use in mould forming and casting such sandwich elements is disclosed in the publication DE 202015104489U 1. In this solution, the sidewall unit comprises a horizontally adjustable upper section, so that two separate horizontally displaced mould surfaces can be formed with the same sidewall unit.

Disclosure of Invention

The present invention provides a novel method of securing a side wall unit in the casting of a concrete sandwich element, wherein the side wall unit is secured in the insulation layer of the concrete sandwich element. This allows for easy fixation in the mould and less restricted placement of the side wall units, which can be implemented more easily with an assembly robot.

In the method of the invention, the fixing of the detachable side wall unit, which comprises the mould surface in the horizontal mould for the concrete sandwich element, which element comprises at least one insulating layer, is carried out via the insulating layer of the concrete sandwich element to be cast.

In an embodiment of the method of the invention, the fixation of the side walls to the insulating layer is performed by means of fixation means, which are an integral part of the side wall unit or a structural entity separate from the side wall unit.

In an embodiment of the method of the invention, the fixing of the sidewall units is performed via the top surface of the insulation layer with the orientation of the insulation layer in the horizontal mould.

In an embodiment of the method of the invention, the securing means of the sidewall unit are at least partially embedded in the insulating layer to obtain a securing effect on said sidewall unit.

The invention also provides a side wall unit for a mould for a concrete sandwich element, said element comprising at least one insulating layer, wherein the side wall unit comprises a mould surface and fixing means for detachably fixing the side wall unit to the insulating layer of the concrete sandwich element to be cast.

In an embodiment of the sidewall unit of the present invention, the fixation means may be an integral part of the sidewall unit or a structural entity separate from the sidewall unit.

In an embodiment of the side wall unit of the invention, the fixing means comprise a section embedded in the insulation layer of the concrete sandwich element for obtaining a fixing effect.

In an embodiment of the sidewall unit of the invention, the fixing means comprise means for applying a screwing action, which are screwed into the insulation for obtaining a fixing effect. Such a device comprises a section screwed within the layer of insulating material and suitable means for obtaining the screwing movement of said section screwed within the layer of insulating material.

In an embodiment of the sidewall unit of the invention, the mould surface comprises a slot for allowing a reinforcement to extend through the mould surface, the slot being provided with a flexible material for closing an area of the slot not covered by the reinforcement.

Drawings

Exemplary embodiments of the invention and their advantages are explained in more detail below in the sense of examples and with reference to the drawings, in which

Fig. 1 schematically shows the arrangement of a bench die according to the invention.

Fig. 2A and 2B schematically show an alternative sidewall unit fixing solution according to the invention.

Fig. 3A and 3B schematically show another alternative sidewall unit fixing solution according to the invention.

Fig. 4A and 4B schematically show one mold sidewall plate used in the solution of the present invention. And is

Fig. 5 schematically shows an example of a concrete sandwich wall element cast with the solution according to the invention.

Detailed Description

In fig. 1, an arrangement of a bench mold according to the invention for casting a concrete sandwich wall element 1 with a substantially horizontal bench mold is schematically shown. The concrete sandwich element 1 comprises an insulating layer 1b arranged between two

concrete layers

1a and 1 c. The insulating layer 1b is made of a sufficiently hard insulating material, such as polyurethane or Expanded Polystyrene (EPS) or similar types of insulating materials.

The mould in this solution comprises a horizontal mould surface 2, which horizontal mould surface 2 is formed by the upper metal surface of a substantially horizontal mould table, and

side wall units

3 and 4. The

side wall units

3 and 4 comprise mould side wall panels 3a and 4a and

support structures

3b and 4b, said mould side wall panels 3a and 4a defining a mould surface for the

concrete layers

1a and 1c of the concrete sandwich wall element 1. The

support structures

3b and 4b comprise removable fixing means 3c and 4c, said removable fixing means 3c and 4c being used to fix the

side wall units

3 and 4. The fixing means 3c of the side wall unit 3 for fixing the side wall unit to the mould surface 2 comprise a magnet, which in this embodiment is located within the support structure 3b and is an integral part of the side wall unit 3.

The fixing means 4c of the side wall unit 4 are in the form of a device for exerting a screwing action, which is screwed into the heat-insulating layer 1b for obtaining the desired fixing and supporting effect of the side wall unit 4. In the present embodiment, the fixing means 4c is an integral part of the side wall unit 4 and the fixing means 4c is operated by a rod extending upwardly from the upper surface of the support structure 4b, which allows the side wall unit to be fixed with the assembly robot.

In fig. 2A and 2B, an alternative embodiment of a fixing means of the sidewall unit 4 for fixing the sidewall unit 4 to the insulating layer 1B is schematically shown. Fig. 2A shows a side view of the side wall unit 4, and fig. 2B shows a bottom view of the fixing device 5.

In this embodiment the mould side wall panels 4a and the support structure 4b are fixed to the insulating layer of the concrete sandwich wall element via fixing means 5. The fixing device 5 includes a horizontal plate member 5a and a vertical plate-like protrusion 5b extending from a bottom surface of the horizontal plate member 5 a. The fixing means 5 are movable relative to the support structure 4b, i.e. they are moved inside the support structure 4b when the fixation of the side wall unit 4 is released or when the side wall unit is placed in its correct position before it is fixed in place, and they are moved outside the support structure for fixing the side wall unit. In order to obtain the fixing effect of the side wall unit 4, the fixing means 5 is pushed into the insulating layer 1b so that the vertical plate-like protrusions 5b are embedded in the insulating layer and the lower surface of the horizontal plate member 5a is substantially at the level of the surface of the insulating layer.

In the present embodiment, the fixing means 5 is an integral part of the sidewall unit 4, but the fixing means 5 may also be a separate part to which the remaining part of the sidewall unit 4 is detachably fixed. Such detachable fixing may be performed by a magnet, for example, when the horizontal plate member is made of metal.

Fig. 3A and 3B schematically show another alternative sidewall unit 4 fixing solution, which otherwise corresponds to the embodiment of fig. 2A and 2B, except that the plate-like projections 5B are replaced by a plurality of pins 5 c.

In the present invention, in order to obtain the fixing effect of the side wall unit 4 to the thermal insulation material layer, it is also possible to replace the vertical plate-like protrusions 5b or the pins 5c with other forms of suitable protrusions embedded in the thermal insulation material layer 1 b.

Fig. 4A and 4B schematically show one embodiment of a side wall panel 4A of the side wall unit of the invention. Fig. 4A shows a rear view of the side wall panel 4A, and fig. 4B shows a top view of the side wall panel.

The side wall plate 4a is provided with a groove which is filled by a two-piece section 6 of flexible material. These two-piece sections 6 of flexible material allow the stiffener 7 to extend through the side wall panel 4 a. The two

flexible material pieces

6a and 6b are arranged opposite each other in a vertical orientation in the slot of the side wall plate 4a such that: during assembly of the mould of the upper layer of the concrete sandwich element to be cast, the reinforcement 7 can be pushed between the two

flexible material pieces

6a and 6b from above. Due to the flexibility of the

flexible material pieces

6a and 6b, the areas above and below the reinforcement 7 are sufficiently sealed so that the concrete mass does not leak from the mould around the reinforcement 7.

In this embodiment, the two

flexible material pieces

6a and 6b are formed of a rubber profile comprising hollow sections, which enhances the flexibility of the pieces. Alternatively, the flexible material sections 6 may be formed by a single piece of flexible material, for example by them in a vertical direction. Alternatively, the flexible material section 6 may be made of other flexible but sufficiently stiff materials, such as expanded plastic, silicone or a combination of these.

Fig. 5 schematically shows an example of a concrete sandwich wall element 8 cast with the side wall plates shown in fig. 3A and 3B.

The concrete sandwich wall element 8 comprises an outer concrete shell 8a, an insulating layer 8b and an inner concrete shell 8c carrying the load. In this embodiment the inner concrete shell 8c covers a smaller area of the element 8 than the other two

layers

8a and 8b, and the inner concrete shell 8c is provided with a reinforcement 7 extending outwardly from the shell. These stiffeners 7 are used to connect adjacent wall elements 8 to each other or to other supporting structures of the building in both vertical and horizontal direction to provide a very strong building structure, especially in seismic areas.

The specific exemplary embodiments of the invention discussed above and illustrated in the drawings should not be construed as limiting. The above-described embodiments of the side wall unit of the invention can be modified and adapted in many obvious ways by a person skilled in the art within the scope of the appended claims. Therefore, the present invention is not limited to only the above-described embodiments.

Claims

1. A method for fixing a detachable side wall unit (4), which side wall unit (4) comprises a mould surface (4a) in a horizontal mould for a concrete sandwich element (1, 8) comprising at least one insulating layer (1b, 8b), characterized in that the side wall unit (4) is fixed in the insulating layer (1b, 8b) of the concrete sandwich element (1, 8) to be cast.

2. Method according to claim 1, wherein the fixing of the side wall unit (4) to the insulating layer (1b, 8b) is performed by means of fixing means (4c, 5), the fixing means (4c, 5) being an integral part of the side wall unit or being a separate structural entity from the side wall unit.

3. Method according to claim 2, wherein the fixing of the side wall unit (4) is carried out via the top surface of the insulation layer (1b, 8b) with the orientation of the insulation layer in the horizontal mould.

4. A method according to claim 2 or 3, wherein the fixing means (4c, 5) of the side wall element (4) are at least partially embedded in the insulating layer (1b, 8b) to obtain a fixing effect on the side wall element.

5. A side wall unit (4), which side wall unit (4) is intended for a mould for a concrete sandwich element (1, 8), which element comprises at least one insulating layer (1b, 8b), wherein the side wall unit comprises a mould surface (4a), characterized in that the side wall unit (4) comprises fixing means (4c, 5), which fixing means (4c, 5) are intended for detachably fixing the side wall unit to the insulating layer (1b, 8b) of the concrete sandwich element (1, 8) to be cast.

6. The sidewall unit (4) according to claim 5, wherein the fixing means (4c, 5) is an integral part of the sidewall unit (4) or a structural entity separate from the sidewall unit.

7. The side wall unit (4) according to claim 5 or 6, wherein the fixing means (4c, 5) comprise segments embedded in the insulation layer (1b, 8b) of the concrete sandwich element (1, 8) for obtaining a fixing effect.

8. The side wall unit (4) according to claim 5 or 6, wherein the fixing means comprise means for exerting a screwing action, which are screwed in the insulation layer (1b, 8b) for obtaining a fixing effect.

9. A sidewall unit (4) according to claim 5 or 6, wherein the securing means comprise a portion which is pushed at least partly into the insulating layer (1b, 8b) for obtaining a securing effect.

10. The side wall unit (4) according to claim 5 or 6, wherein the mould surface (4a) comprises a groove for allowing a reinforcement (7) to extend through the mould surface, the groove being provided with a flexible material (6), the flexible material (6) being used to close off an area of the groove not covered by the reinforcement.