DE102007040263B3 - Concrete floor component i.e. bending-resistant concrete floor component, producing method, involves arranging mold elements in gaps formed between frames, and casting concrete in mold cavities formed between mold elements - Google Patents

Abstract

The method involves applying reinforcement frames (2) for carrier elements (3b) on a base (1) such that the frames are aligned parallel to each other in a horizontal direction. Passage surfaces are arranged in a row of the frames. Mold cores (4a, 4b) are retracted into another horizontal direction through the passage surfaces where the latter horizontal direction runs transverse to the former horizontal direction. Mold elements (8) are arranged in gaps formed between the frames. A concrete is casted longitudinally to extend mold cavities formed between the mold elements. An independent claim is also included for a device for producing a concrete floor component, comprising a concrete shuttering plate.

Description

The The invention relates to a method and an apparatus for the production a concrete ceiling element.

From the EP 1 146 180 A1 is a method for producing a concrete ceiling element with rigid support elements known. Initially, the rigid support elements are produced by casting a reinforcing framework with concrete. Breakthroughs in the support element are formed by the retraction and subsequent extraction of mandrels. On a support elements produced in this way a concrete formwork panel is then cast. - The known method is relatively expensive. To produce the concrete ceiling element, the prefabricated support elements must be used in parallel alignment in a formwork. When casting the concrete formwork panel can lead to a misalignment of the support elements.

task the invention is to provide a method and a device, with which the disadvantages of the prior art are eliminated. In particular, it should provide a method for the fastest possible and efficient Manufacture of rigid concrete ceiling elements to be specified with where a unterjochungsfreie production of concrete ceilings is possible.

These The object is solved by the features of claims 1 and 13. Advantageous embodiments result from the features of claims 2 to 12 and 14 to 23.

According to the invention, a method for producing a concrete ceiling element is provided, in which a concrete formwork panel is provided with rigid support elements, with the following steps:
Providing a base suitable for producing the concrete shuttering panel,
Placing reinforcement frames for the support elements on the base, so that the reinforcement frames are aligned parallel to one another in a first horizontal direction and passage areas provided therein are aligned,
Retracting cores in a transversely to the first horizontal direction extending second horizontal direction through the passage areas,
Arranging of form elements in spaces formed between the Armierungsgerüsten and
Potting concrete in elongated mold cavities formed between the mold elements.

The proposed method easy and inexpensive carry out. It can be from a conventional one Base or a formwork table for producing a concrete formwork panel assumed become. On the pad are in deviation from the prior art Armierungsgerüste for the support elements placed in such a way that formed therein penetration areas in an escape are arranged so that mandrels through the pass-through surfaces can be driven. Between the Armierungsgerüsten Beyond that Form elements arranged. Subsequently, for the production of the Concrete ceiling element concrete in the formed between the mold elements elongated mold cavities cast. The poured concrete spreads over the base and forms the concrete formwork panel and the support elements. The procedure does not require a lot of time. It can be done relatively inexpensively.

advantageously, is a reinforcement for the concrete formwork panel before placing the Armierungsgerüste placed on the surface. This makes it possible to enter in one step Completely to produce reinforced concrete ceiling element.

To A further embodiment is prior to arranging the mold elements poured the concrete formwork panel. In particular, when providing a Reinforcement allows This is a particularly fast and even distribution of the concrete on the pad. The production of the concrete ceiling element can be accelerated again.

To In another embodiment, the mandrels of two are each other opposite Sides of the form retracted through the passage surfaces. This makes it possible in particular pulling the mandrels in opposite directions. That makes it easier demolding. This is especially true when they are different from each other opposite sides retracted form cores are arranged offset, so that two adjacent Form cores are pulled in each case in the opposite direction can.

It has proved to be useful that the form elements placed on the retracted mandrels become. The form elements can be lowered for example with a crane on the mandrels. Advantageously, the mold elements are so on the mandrels placed on the profile of the cores corresponding recesses on whose underside facing the pad form-fitting manner rest on the mold cores. This will both the form elements as well the mandrels in a proper arrangement gezwun gene. So becomes a simple way a particularly accurate production of concrete ceiling elements allows.

According to another embodiment excess concrete peeled off on a peel surface formed by an upper surface of the mold elements. Thus, the top of the support elements can be given a desired contour. In particular, the Abziehfläche may have arranged at regular intervals recesses. Such recesses can be used to insert a reinforcing grid.

To the Shaping cores are conveniently pulled and simultaneously shaken. If the mandrels on two opposite sides of the pad are arranged, pulling the mandrels takes place in opposite directions Directions under simultaneous shaking.

When It has proven to be particularly advantageous that during the Pulling the mandrels also removes the form elements from the base, preferably lifted. It uses the fact that the shaking motion The mold cores acting on the poured concrete and thus a Removing the mold elements easier. On a separate shaking the Moldings can be dispensed with in this case.

According to another aspect of the invention, an apparatus for producing a concrete ceiling element is provided in which a concrete formwork panel is provided with rigid support members, with
a substrate suitable for the production of the concrete shuttering panel,
in which at least one side of a device for retracting parallel aligned mandrels is provided in a plane parallel to the base plane and
wherein means are provided for arranging parallel aligned form elements transversely of the mandrels.

The proposed device allows a simplified and efficient production of rigid concrete ceiling elements. The proposed device is simple. She lets herself by simple extensions of conventional formwork tables for Realization of concrete formwork panels.

To an advantageous embodiment is on one side of the pad a first and on the opposite other side of the pad a second means of moving provided by cores. The mandrels are advantageously arranged so that in the retracted state in each case a mold core the first device adjacent to a mandrel of the second Device is arranged. As a result, each adjacent Form cores moved in opposite directions over the pad. advantages arise especially when pulling the mandrels. It comes here not to a deformation of the support elements.

Conveniently, the mandrels are mounted in a horizontal plane. Ie. they are at the same height above the Document.

To a further advantageous embodiment the mold elements are bar-shaped. They extend over the whole length the Armierungsgerüste. The form elements can on one of the pad facing bottom to the profile of the mold cores have corresponding recesses for engagement in the mandrels. The recesses can for example, V-shaped be educated. Furthermore, can the mold elements provided on a top side facing away from the mold at regular intervals Have recesses. Such recesses are used to manufacture of recesses in the support elements, which serve for the insertion of reinforcing bars.

To a particularly advantageous embodiment, the mold elements at its ends from the bottom extending extensions, so that thus a concrete ceiling element can be produced, in which the support elements over extending a side wall of the concrete shuttering panel addition. The supernatant the support elements is expediently 2 to 10 cm, preferably 3 to 8 cm.

To a further embodiment is a device for shaking the Form cores provided. This allows a relieved demolding. Furthermore, a device for automatic execution a pulling movement of the mold cores and a simultaneous movement, preferably lift-off, the form elements are provided. A simultaneous and automatically coordinated movement of the cores and the mold elements allows a particularly gentle demolding. An undesirable deformation, in particular the Support elements, is avoided.

To A further embodiment is a device for filling the along with the elongated spaces formed between the mold elements Concrete provided. With such a device, the entire for the production of the concrete ceiling element required concrete to be poured. But it is also possible with this device first the concrete formwork panel to pour and subsequently for the production of the carrier elements the gaps to shed with concrete.

Furthermore, means for removing excess concrete may be provided on a peel surface formed by the tops of the mold elements. Such a device he allows the introduction of predetermined contours in the top of the support elements.

following is an embodiment of Invention with reference to the drawing explained. It demonstrate:

1 a first side view of the device,

2 a second side view according to 1 .

3 a plan view of the device, wherein the reinforcement has been omitted and

4 a side view of a formula element.

In the in the 1 to 3 shown device is with 1 a pad or a formwork table for producing a concrete formwork panel 3a with cast-on support elements 3b designated. In the 1 and 2 are on the pad 1 Armierungsgerüste 2 for the support elements 3b supported. Lancet-shaped mandrels 4 , which preferably have a triangular profile, are on horizontally movable carriage 5 dissuaded. Each of the mandrels 4 is with a vibrating device 6 connected.

At the in 1 to 3 shown device are on one side of the pad 1 next to each other a variety of first cores 4a and on an opposite other side of the pad 1 a variety of second cores 4b intended. The first 4a and the second mandrels 4b are about the same length. Its length corresponds approximately to a width B of the pad 1 , The first 4a and the second mandrels 4b are staggered so that the first cores 4a in between the second cores 4b formed gaps are retractable. The offset corresponds to half the distance A between the first 4a or the second cores 4b ,

As in particular from 1 it can be seen that they are the first 4a and the second mandrels 4b receiving sled 5 via a circulating guided chain or the like. 7 kinematically connected with each other so that the first 4a and the second mandrels 4b are each movable in the opposite direction. These are the first cores 4a receiving the first sled 5a on an upper strand of the chain 7 and the second cores 4b receiving second carriage 5b on a lower strand of the chain 7 attached.

With the reference number 8th are bar-like design features called, which on a support frame 9 are attached. The scaffold 9 is by means of a crane 10 vertically movable. With 11 is one concerning the thesis 1 horizontally movable concrete feeding device called. This can be a conventional concrete feeder 11 for the production of concrete formwork panels 3a act.

In 4 is a form element 8th shown in detail. The form element 8th points to one of the underlay 1 facing underside U V-shaped recesses 12 on which to the shape of the cores 4a and 4b correspond. At one of the bottom U opposite top O are recesses 13 provided, which for producing corresponding recesses 13 in the carrier elements 3b serve. Such recesses 13 serve in the carrier elements 3b for receiving reinforcing bars. Furthermore, the form elements 8th at their Be tenwänden and at the top O a corrugation 14 on, which serves an intimate connection with an in-situ concrete layer aufzuschießenden on the concrete ceiling element. At the ends extending from the bottom U extensions 15 serve to a supernatant of the carrier elements to be produced 3b over a side wall of the concrete formwork panel 3a to realize. For the production of in 4 shown further recesses 16 can work in a similar way as the mandrels 4a and 4b be provided further mandrels.

The function of the device is as follows:
First, on the pad 1 in a conventional manner, a reinforcement for the concrete formwork panel 3a hung up. On the reinforcement are then in parallel arrangement and parallel to a longitudinal side of the pad 1 Armierungsgerüste 2 for the support elements 3b hung up. The armor scaffolding 2 are formed, for example, of one upper and two lower straps which are interconnected by V-shaped diagonals. The lower chords and the diagonals form triangular penetration areas. The armor scaffolding 2 so be on the pad 1 arranged that the passage areas are in alignment with the direction of movement of the mandrels 4a and 4b are located.

After a first process variant is after placing the reinforcement and Armierungsgerüste 2 on the pad 1 by means of the concrete feeder 11 First, the concrete formwork panel 3a cast. Subsequently, then by an opposite movement of the first 5a and second sled 5b the first 4a and the second mandrels 4b in a plane parallel to the surface 1 retracted. The mandrels reach through this 4a and 4b the pass-through surfaces of all parallel juxtaposed Armierungsgerüste 2 , Subsequently, by means of the crane 10 the form elements 8th into the between the Armierungsgerüste 2 lowered remaining spaces. The recesses grip 12 into the mold cores 4a and 4b one. Due to the positive connection between the recesses 12 and the profile of the mandrels 4a and 4b the mandrels are aligned 4a and 4b and the form elements 8th at right angles to each other. Subsequently, by means of the concrete feeder 11 Concrete in between the form elements 8th filled formed elongated spaces. Excess concrete is by means of a (not shown here) puller on the tops O form elements 8th deducted. As a result, the on the top O of the mold elements 8th formed surface contour on the surface O of the support elements 3b transfer.

After a second process variant, it is also possible after supporting the reinforcement and the Armierungsgerüste 2 first the first 4a and the second mandrels 4b over the pad 1 retract and then on the form elements 8th lower. Then then by means of the concrete feeder 11 Concrete in between the form elements 8th filled spaces are filled. In this case, the consistency of the concrete should be adjusted to ensure that all mold cavities are filled.

After casting and partial solidification of the concrete, the vibrators become 6 put into operation and the first 4a and the second mandrels 4b simultaneously in opposite directions from the pad 1 pulled away horizontally. The coupled into the partially solidified concrete ceiling element vibration is advantageously used simultaneously, including the mold elements 8th withdraw. In this way, without deformation of the concrete ceiling element quickly and easily removing the mandrels 4a and 4b as well as the form elements 8th respectively.

The proposed method allows on quick and easy way to produce rigid concrete ceiling elements. The proposed concrete ceiling elements can without the provision of a Unterjochung be used for the production of concrete ceilings. there can Spans of up to 8.50 m are bridged.

1

document

2

Armierungsgerüst

3a

Concrete formwork panel

3b

support element

4, 4a, 4b

Mandrel first mold core, second mold core

5, 5a, 5b

Carriage, first sleigh, second sleigh

6

shaker

7

Chain

8th

forming element

9

supporting framework

10

crane

11

Concrete feeder

12

recess

13

depression

14

curl

15

extension

16

Further recess

U

bottom

O

top

A

distance

B

width

Claims (23)

Method for producing a concrete ceiling element, in which a concrete formwork panel ( 3a ) with rigid support elements ( 3b ), comprising the following steps: providing one for producing the concrete formwork panel ( 3a ) suitable substrate ( 1 ), Placing of armor frameworks ( 2 ) for the support elements ( 3b ) on the base ( 1 ), so that the Armierungsgerüste ( 2 ) are aligned parallel to each other in a first horizontal direction and provided therein Durchgriffsflächen are aligned, retraction of mandrels ( 4a . 4b ) in a transversely to the first horizontal direction extending second horizontal direction through the Durchgriffsflächen, arranging form elements ( 8th ) in between the Armierungsgerüsten ( 2 ) and pouring concrete in between the mold elements ( 8th ) formed elongate mold cavities. Method according to claim 1, wherein prior to laying the reinforcing frameworks ( 2 ) a reinforcement for the concrete formwork panel ( 3a ) in the pad ( 1 ) is inserted. Method according to one of the preceding claims, wherein prior to arranging the molded elements ( 8th ) the concrete formwork panel ( 3a ) is poured. Method according to one of the preceding claims, wherein the mandrels ( 4a . 4b ) from two opposite sides of the pad ( 1 ) are retracted through the pass-through surfaces. Method according to one of the preceding claims, wherein first mandrels ( 4a ) in gaps between second cores ( 4b ) are moved. Method according to one of the preceding claims, wherein the shaped elements ( 8th ) on the one driven mandrels ( 4a . 4b ). Method according to one of the preceding claims, wherein the shaped elements ( 8th ) so on the mandrels ( 4a . 4b ), that the profile of the cores ( 4a . 4b ) corresponding recesses ( 12 ) at whose base ( 1 ) facing lower sides (U) positively on the mandrels ( 4a . 4b ) rest. Method according to one of the preceding claims, wherein excess concrete on a through a top (O) of the form elements ( 8th ) Abziehfläche is subtracted. Method according to one of the preceding claims, wherein the peeling surface is arranged at regular intervals recesses ( 13 ) having. Method according to one of the preceding claims, wherein for demolding the mandrels ( 4a . 4b ) and shaken at the same time. Method according to one of the preceding claims, wherein in the retracted state adjacent first ( 4a ) and second mandrels ( 4b ) are pulled in opposite directions. Method according to one of the preceding claims, wherein during the drawing of the mandrels ( 4a . 4b ) the form elements ( 8th ) from the base ( 1 ) are removed, preferably lifted. Device for producing a concrete ceiling element, in which a concrete formwork panel ( 3a ) with rigid support elements ( 3b ), with one for producing the concrete formwork panel ( 3a ) suitable substrate ( 1 ), on at least one side of a device for moving parallel aligned mandrels ( 4a . 4b ) in a parallel to the pad ( 1 ) extending level and wherein a device for arranging parallel aligned form elements ( 8th ) transversely to the cores ( 4a . 4b ) is provided. Device according to claim 13, wherein on one side of the support ( 1 ) a first ( 5a ) and on the opposite other side of the pad ( 1 ) a second device ( 5b ) for moving mandrels ( 4a . 4b ) is provided. Apparatus according to claim 13 or 14, wherein the mandrels ( 4a . 4b ) are mounted in a horizontal plane. Device according to one of claims 13 to 15, wherein the shaped elements ( 8th ) are formed bar-like. Device according to one of claims 13 to 16, wherein the shaped elements ( 8th ) on one of the substrates ( 1 ) facing the underside (U) to the profile of the mold cores ( 4a . 4b ) Corresponding recesses ( 12 ) for engagement in the mandrels ( 4a . 4b ) exhibit. Device according to one of claims 13 to 17, wherein the shaped elements ( 8th ) on one of the substrates ( 1 ) facing away from the top (O) provided at regular intervals recesses ( 13 ) exhibit. Device according to one of claims 13 to 18, wherein the shaped elements ( 8th ) extending at their ends from the bottom (U) extensions ( 15 ), so that carrier elements produced therewith ( 3b ) over a side wall of the concrete formwork panel ( 3a ). Device according to one of claims 13 to 19, wherein a device ( 6 ) for shaking the mandrels ( 4a . 4b ) is provided. Device according to one of claims 13 to 20, wherein a device for automatically performing a pulling movement of the mandrels ( 4a . 4b ) and a simultaneous movement, preferably lift-off, of the form elements ( 8th ) is provided. Device according to one of claims 13 to 21, wherein a device ( 11 ) for filling the between the form elements ( 8th ) formed elongated spaces is provided with concrete. Apparatus according to any one of claims 13 to 22, wherein means for extracting excess concrete on a through the tops (O) of the form elements ( 8th ) Abziehfläche is provided.