DE102006039085A1 - Method for manufacturing stone cuboid, involves applying of washing lacquer on all inner surfaces of stone coming in contact with mortar, and transversal iron removes transport loops for cleaning visible cuboid surfaces - Google Patents

Abstract

The method involves applying of washing lacquer (surface retarder for washed-out concrete) on all inner surfaces of stone in any mold (1.1) of geometry coming in contact with mortar, in a shake-proof stable mold, filled on a transport base. A transversal iron and laying aids removes fastened, fixed transport loops on the transport base for cleaning visible cuboid surfaces and their mortar joints, so that afterwards a stationary transfer takes place after reaching statically required insert stability, without transport base, with distant transport loops and corrosion proof disconnecting point. The stone packages are compressed in layers by shaking and with a liquid prefabricated mortar are flooded as bonding agents. The enclosed air is suppressed in the spacing and after hardening the molded stone cuboid at reinforcement steel mesh pre-inserted in the mold. An independent claim is also included for a device for manufacturing stone cuboid.

Description

Summary

The The present invention relates to a method and an apparatus of construction, for the production of cuboid bodies of stones and mortar. in this connection be on a vibrating table, in a form stones with mortar combined as a binder and so condensed that the cavities with mortar filled out are. After setting the mortar the cuboids on transport floors made of steel taken from the mold and on the surfaces of the visible fronts cleaned and structured by grouting so that the natural shapes of the stone surfaces clearly emerge. After an intermediate storage for further solidification the pieces of stonework become transport loops made of steel used at the place of work. After laying the stone block The transport loops are separated and their Tennstellen against corrosion influences protected.

State of the art

Piece of stone ashlar Made of rubble or pebbles, have long been under the name "gabion" known. One uses they for the production of retaining walls, Noise barriers, facades, Rigols, in road construction and to the shore fortification.

As the name suggests, the stones are caged (Gabbione = big cages) made of steel. The cages are shaped by the use of steel braids that Architecturally usable building elements in the form of stone blocks different sizes arise. The cuboids are placed on each other at the construction site and form then walls without mortar, their static load mainly determined by the steel mesh cages becomes. The stone bodies thus produced are only of which they enveloping Steel braid held together. This has the disadvantages of being relatively unstable body arise, which lacks the inner support and that the steel at injury the surface finish, by the effects of weather loses strength. Furthermore, their specific weight essentially only by the stones enclosed in the cages certainly. These disadvantages can lead to incalculable risks of accidents. Other disadvantages exist in that water pass through the stone parcels unhindered at almost every point can and at a later Dismantling the cuboid break apart.

Furthermore are known concrete blocks, which are also factory-made in forms are poured and after the setting of the concrete, if necessary also superficial (for example, washing, sandblasting, etc.) your application is but mainly limited on the use as floor coverings or wall plates. Become retaining walls or supporting columns Made of concrete, so the size of the components is usually too a manufacture on site lead. Furthermore, production in forms is only recommended if a mold can be used many times, as their production costs on a variety of structures be transferred if the production is to be economical.

inventive tasks

The to be solved Tasks thus existed in the stone-block squares to be produced in the factory (e.g., gabion blocks called) a higher one Strength, higher Load capacity, longer Lifespan, targeted water drainage and multiple forms too give. The shapes of the stone cuboid are said to be different geometric body shapes can accept. Your visible surfaces should be easy to clean, although they are made with quick-setting ready-mixed mortars. The Piece of stone ashlar should the merits have a quarrystone masonry and overcome the disadvantages of a cage masonry.

solution the tasks

The present invention proceeds in the solution that means suitable charger portable Stone cuboid, with most varied stones, factory-like in different, preferably made of steel molds, on vibrating tables, together with a cement mortar compacted as a binder and after setting the liquid-fed binder (Green strength), to superficial Post-processing, taken on a transport floor the forms and a surface cleaning place supplied become. After the surface cleaning and grouting - preferably be carried out by hand the stone block cuboid to obtain the final Strength, fed to a temporary storage space before use.

The Transport loops are inserted in the Steinstückquader, with transverse iron and structural steel mats associated laying aids made of structural steel, according to the laying at the construction site are separated, the separation point protected against corrosion becomes. The integration of the structural steels used in the Steinstückquaderblock has the advantage of less corrosion by protecting the surface finish.

The binder cement mortar has the properties: impermeability, high frost and Taumittelwiderstand and high strength successful setting on.

to solution the tasks of the invention are the basics of the texture of grain and surface textures the pieces of stone used, the flow and bonding properties of the binders, the static strength of the Stone pieces, the Binders and the resulting Steinstückquader required. Of the One of ordinary skill in the art of making standard stone packages is only through, over his expertise (production of steel baskets and backfilling with Steinstücken) beyond capabilities (such as determination of pot life, void-free body flooding, statics and precast concrete production) a solution reach the task.

Description of the manufacturing process and his device

The stones for making a Steinstückquader are preferably freed from unwanted Unterkornfraktionen. Thereafter, they are a standing on a vibrating table, made of steel plates, separable in parts, open-top form fed (Fig. 1.1 ). The shape has preferably the dimensions length: about 2 m, width: about 1 m, height: about 1 m. To obtain the required static strength, the approximately 20 mm thick walls with additional ribs (Fig. 2.1 ) strengthened. The mold is hinged (Fig. 1.2 ) and plug-in closures (Fig. 1.3 ) and consists of the following transportable individual elements: a bottom (Fig. 2.2 ), on which the mold rests, an inserted transport floor (Fig. 2.3 ), the side walls (Fig. 1.4 ) and end walls (Fig. 1.5 ). The side walls preferably have openings for drainage (Fig. 1.6 ), through which water displaced due to vibration can escape.

By way of example, the mold is placed on the electrically operated vibrating table (FIG. 2.4 ), secured against displacement and in the unfolded state, the transport tray is used for the Steinstückquader. On the side walls of the mold, as well as the surface of the transport tray is preferably a high-quality washcoat (surface retarder for washed concrete products) applied coated in the longitudinal and transverse directions. It prevents the binding of the binder on the walls and on the floor. On the transport floor spacers (Fig. 2.5 ) - these are bottom rails with a minimum concrete cover of approx. 5 cm - laid to accommodate the structural steel mesh (eg Q 257 A) (Fig. 1.8 ). Thereafter, the laying aids made of structural steel (Fig. 2.6 ) with curved loops (Fig. 1.7 ) and an additional transverse iron (Fig. 2.7 ) hung in the Baustahlgewebe. The laying aids are integrated into the Steinstückquader and are not visible from the outside. In the next operation, the first layer stones (Fig. 2.8 ) with a height of about 25 cm and the visible surfaces of the stone block are corrected by hand in position and shape, adjusted and shaken as a first layer. The next step is to apply cement mortar (Fig. 2.9 ) with the properties: impermeable to water, resistant to frost and thawing, filled in fair-faced concrete production up to the top of the first stone layer (about 25 cm). Thereafter, the vibrating table (Fig. 2.4 ) until the mortar spread evenly throughout all cavities and filled them. When the mortar has reached the height of the stone layer, the processes are repeated until the mold is filled and the mortar covers the upper layer of stone (Fig. 2.10 ). After obtaining the green strength of the Steinstückquaders a wheel loader lifts the Steinstückquader with the transport floor from the previously opened on the buckles and hinges form and brings him to the washplace. Here, the visible surfaces of Steinstückquaders are preferably washed off by hand with water so that the surfaces and joints of a fair-faced brickwork are clearly visible and the mortar joints are visually appealing. If this operation is completed, the Steinstückquader is fed to a temporary storage for further solidification. After reaching the intended static strength, the Steinstückquader is transported to the loops of the laying aids, without the reusable transport floor to the installation site. After he has taken his firm, assigned to him space, the loops of the laying aids are separated and their separation point is sealed to protect against corrosion.

Claims (8)

Process for the production of Steinstückquadern (gabion blocks), characterized in that pieces of stone in forms of any Geomtrie so after application of washcoat (surface retarder for washed concrete) on all coming into contact with mortar inner surfaces, in a vibration resistant stable form, filled on a transport tray, in layers the stone packages are compacted by shaking and flooded with a liquid ready-mixed mortar as a binder, the air contained in the spaces is displaced and fixed after setting the resulting stone cuboid, to the - previously inserted in the form of construction steel mats, cross irons and installation aids - fixed Transport loops is removed on the transport floor, for cleaning the visible square surfaces and their mortar joints, so that then a fixed installation after reaching the static required operational strength, without transport floor, with distant Transportc run and corrosion-protected separation points can be done. A method according to claim 1 characterized gekenn draws that the used stones were broken. Method according to claim 1, characterized that the Stones were mechanically processed. Method according to claims 1 and 3, characterized that the Have stones of any shape and size. Process according to claims 1-4, characterized that the used ready-mixed mortar has short-term setting properties. Device according to claim 1, characterized in that that the Shapes can be designed to produce any desired geometry of the stone block / gabion blocks is. Device according to claims 1-6, characterized that she from the parts vibrating table, vibration control, Mold with four movable walls and eyebolts, water outlet, Hinges, plug-in closures, Feed conveyor for bricks, Feed conveyor for mortar, Transport floor, Spacers, reinforcing steel mats, cross irons and laying aids with transport loops consists. Device according to claim 1, characterized that the coming in contact with the binder inner surfaces the mold and the transport base with wash or other release agent to be sealed.