DE102022110053A1 - Concrete double wall element as well as semi-finished product and supporting device for its production - Google Patents

Abstract

The invention relates to a support device (40) for the precise relative positioning of two concrete shells (2a, 2b) in the course of producing a concrete double wall element (1). The support device (40) comprises a fixing element (20) with a first end section (21) for embedding sections in the first concrete shell (2a) and an anchor element (30) for direct or indirect fastening of the support device (20) to the second concrete shell ( 2b) supporting pallet (5b). Fixing element (20) and anchor element (30) are advantageously detachably connected to one another. The fixing element (20) is provided with a detachable sleeve (23), which is embedded at least in sections in the first concrete shell (2a) during the production of the concrete double wall element (1).

Description

The invention relates to a support device for producing a concrete double wall element according to the preamble of claim 1. Furthermore, the invention relates to a semi-finished product produced using this support device and a concrete double wall element.

The production of precast concrete parts often takes place in two steps, which take place in spatially separate locations. First, so-called concrete double wall elements are produced in a precast concrete factory, which include a first shell and a second shell made of reinforced concrete. There is a cavity between the two shells, which can be provided with insulating materials if necessary. These double wall elements, prefabricated in the precast concrete factory, are transported to the construction site and fixed there in the desired end position. The cavity between the first and second shell is then filled with concrete.

The production of the double wall elements in the precast concrete factory typically takes place in several process steps using a so-called pallet circulation system. In a first step, a so-called first shell is produced and hardened in a drying chamber. Composite means and/or double wall spacers are concreted into this first shell, which are typically distributed over the entire wall element, act as spacers and define the wall thickness of the component in the later component. Once the first shell has hardened, it is turned 180° and placed on a layer of liquid concrete (fresh concrete), which forms the (still unhardened) second shell. The spacers or double wall spacers cast in concrete into the first shell rest on the lower formwork when the first shell is placed in the fresh concrete of the second shell. The assembly of the first and second shells is brought back into the drying chamber to harden the second shell. The concrete double wall element manufactured in this way is then removed from the pallet in a demoulding station.

When producing concrete double wall elements in the pallet circulation system, the concrete shells and concrete elements to be manufactured are stored on movable pallets that are moved to different work stations for the different work steps. This procedure enables very efficient production, but during the step of placing the first shell on the fresh concrete of the second shell, it poses the difficulty that the hardened first shell rests with its entire weight on the point-shaped spacers or double-wall spacers. While the process step of placing the first shell is machine-controlled and highly precise, the subsequent compaction process and in particular when transferring the pallet carrying the fresh concrete to a next work station can occur due to the braking and acceleration forces that occur in combination with the inertia of the first shell a displacement of the hardened first shell relative to the fresh concrete of the second shell. If such misalignments are noticed before the second shell of the double wall part has hardened, they can be corrected manually, although this involves a lot of effort. However, such misalignments are often only noticed when the walls are being assembled on the construction site. At this point, the misalignments can no longer be corrected but must be compensated for through increased assembly effort.

A method for avoiding or reducing the misalignment of the two concrete shells described above is in DE 10 2018 124 980 B3 described, the entire disclosure content of which is hereby incorporated into the present patent application. For the relative positioning of the two individual shells, a fixing device is used, the first end section of which is concreted into the first concrete shell together with the connecting means during the production of the first concrete shell. A second end section of the fixing device protrudes both laterally and vertically beyond the first concrete shell. An anchor element is or is attached to the end of this second end section. When the first concrete shell is turned and placed on the fresh concrete layer of the second concrete shell, this anchor element comes into engagement with the pallet carrying the fresh concrete layer and thereby connects the first concrete shell to this pallet in a non-displaceable manner. In this way it is ensured that no changes in position of the first concrete shell relative to the pallet can occur during the shaking of the first concrete shell and during the transport of the pallet into the hardening station or drying chamber.

After the double wall element has completely hardened, a part of the fixing device embedded in concrete that protrudes from the double wall element is separated, so that a stub of the fixing device remains in the double wall element. The fixing device is thus destroyed, so that a new fixing device is required to produce another double wall element. This is complex and causes additional material costs. There is therefore an interest in further developing the fixing device in such a way that the greatest possible reusability can be ensured.

The invention is based on the object that arises from the DE 10 2018 124 980 B3 to further develop the known fixing device in such a way that it can be reused with the least possible amount of material and work and used to produce different double wall elements. Furthermore, a concrete double wall element and a semi-finished product in the form of a specially designed individual shell are to be provided, which is manufactured using such an improved fixing device.

This task is solved by a support device with the features of independent claim 1. The task is further solved by a concrete double wall element with the features of independent claim 9 and a semi-finished product with the features of independent claim 13. The subclaims relate to advantageous developments and variants the invention.

The support device according to the invention, which is used for the precise relative positioning of two concrete shells in the course of producing a concrete double wall element, comprises a fixing element with a first end section which is embedded in the first concrete shell during the production/hardening thereof. The support device further comprises an anchor element with which the fixing element can be releasably attached to a pallet carrying the second concrete shell. In the course of placing the first concrete shell, which has been turned 180°, onto the fresh concrete layer of the second concrete shell, a firm connection is established between the two pallets carrying the concrete layers using a fixing element and anchor element. The fixing element and anchor element thus work together in such a way that they fix the first concrete shell relative to the pallet carrying the fresh concrete layer, so that there are no changes in position of the first concrete shell during the shaking of the first concrete shell and during the transport of the pallet into a hardening station or drying chamber the palette can occur more.

In order to ensure a high level of reusability of the support device, the first end section of the fixing element to be embedded in the first concrete shell is provided with a sleeve which is releasably attached to the end section of the fixing element. The sleeve is designed and arranged in such a way that when the fixing element is concreted into the first concrete shell, only this sleeve, but not the rest of the fixing element, comes into contact with the concrete. After the concrete shell has hardened, this sleeve is concreted into the concrete shell and therefore remains in the concrete shell. The fixing element can then be pulled out of the sleeve and is available for the production of further concrete shells after the manufacturing process of the concrete double wall element has been completed.

The sleeve is preferably made of a plastic and is provided with longitudinal and/or transverse ribs on its outside. The ribs stabilize the sleeve against deformations and ensure that the sleeve is well anchored in the first concrete shell.

In order to ensure during the hardening process of the first concrete shell that the fixing element or the sleeve attached to the fixing element is reliably concreted into the desired installation position, it is advantageous if the fixing element is detachably attached to one of the first in a support area (magnetically and/or mechanically). Concrete shell-bearing pallet can be attached. Advantageously, the fixing element has a permanent magnet in the support area, so that the fixing element can be fixed to the (metallic) pallet or a (metallic) formwork located on this pallet by means of magnetic force and held in the desired position relative to the pallet and the first concrete shell located thereon becomes.

Fixing element and anchor element can be firmly connected to one another. Advantageously, the fixing element and anchor element are separate elements that can be detachably connected to one another. In this case, the fixing element has a foot part in the area of which it can be attached to the anchor element. This foot part advantageously has the shape of a hemisphere, which enables the foot part to be easily clamped in the anchor element so that it cannot move. The connection is preferably made using a lockable plug connection.

The anchor element is attached to the pallet carrying the fresh concrete layer, preferably by means of an easily detachable connection, so that the anchor element can be detached from the pallet without much effort after completion of the double wall element and the pallet can be reused without leaving any residue from the fixing device. In particular, the anchor element can comprise a permanent magnet, which can be fixed to the (metallic) pallet by means of magnetic force and is removed without leaving any residue after the finished double wall element has been removed - for example when removing the formwork.

A semi-finished product according to the invention produced using such a support device comprises a flat concrete shell in which composite means are embedded in such a way that peaks of these composite means protrude from the concrete shell in a connecting direction. The semi-finished product further comprises, in an area near the edge, a sleeve embedded in the concrete shell for receiving a fixing element, which serves to fix the semi-finished product during a further processing step for producing a concrete double wall element.

The sleeve is embedded in an area near the edge and has an opening which is located on the inside of the concrete shell facing the tops of the composite means. The sleeve is preferably made of a plastic and is provided with stabilizing longitudinal and/or transverse ribs.

A concrete double wall element according to the invention produced using such a semi-finished product comprises two flat concrete shells, in which composite means are embedded in sections, which serves to connect and as a spacer of the concrete shells. A sleeve for receiving a fixing element is concreted into one of these concrete shells in an area near the edge. This sleeve is located in an area of the concrete shell near the edge and has an opening which is located on an inside facing the opposite concrete shell. The sleeve is preferably made of a plastic and is provided with stabilizing longitudinal and/or transverse ribs.

• 1 eine schematische Schnittdarstellung eines erfindungsgemäßen Beton-Doppelwandelements, das unter Verwendung einer in 2a - 2c gezeigten Stützvorrichtung hergestellt wurde;
• 2a, 2b schematische Darstellungen einer erfindungsgemäßen Stützvorrichtung mit Fixierelement und Ankerelement in getrenntem (2a) und verbundenem (2b) Zustand;
• 2c eine schematische perspektivische Darstellung des Ankerelements der 2a;
• 3a - 3e: Einzelschritte bei der Herstellung eines Doppelwandelements:
  • 3a eine schematische Schnittdarstellung einer ersten Betonschale auf einer Palette;
  • 3b eine schematische Schnittdarstellung eines durch Aushärten der gegossenen ersten Betonschale der 3a erzeugten Halbzeugs;
  • 3c eine schematische Schnittdarstellung des um 180° gewendeten ausgehärteten Halbzeugs der 3b über einer Schicht von Frischbeton;
  • 3d eine schematische Schnittdarstellung des auf der Frischbetonschicht abgelegten gewendeten Halbzeugs;
  • 3e eine schematische Schnittdarstellung des durch Aushärten des Frischbetons erzeugten Beton-Doppelwandelements.

Exemplary embodiments and variants of the invention are explained in more detail below with reference to the drawing. Show it:

• 1 a schematic sectional view of a concrete double wall element according to the invention, which is constructed using an in 2a - 2c the support device shown was made;
• 2a , 2 B schematic representations of a support device according to the invention with fixing element and anchor element in separate ( 2a) and connected ( 2 B) Condition;
• 2c a schematic perspective view of the anchor element 2a ;
• 3a - 3e : Individual steps in the production of a double wall element:
  • 3a a schematic sectional view of a first concrete shell on a pallet;
  • 3b a schematic sectional view of a hardening of the cast first concrete shell 3a produced semi-finished products;
  • 3c a schematic sectional view of the cured semi-finished product turned by 180° 3b over a layer of fresh concrete;
  • 3d a schematic sectional view of the turned semi-finished product placed on the fresh concrete layer;
  • 3e a schematic sectional view of the concrete double wall element created by hardening the fresh concrete.

1 shows a schematic representation of a concrete double wall element 1 with two flat shells 2a, 2b made of hardened concrete, which are connected by composite means 3 and fixed at a predetermined distance from one another with the help of double wall spacers 3 '. A cavity 15 is formed between the two concrete shells 2a, 2b, which is filled with liquid concrete in a later process step, not described in detail here, at a construction site, in particular on a construction site, to form a concrete wall.

A sleeve 23 made of plastic is embedded in the first concrete shell 2a of the concrete double wall element 1, which - as will be described in detail below - accommodates an in 2a and 2 B Support device 40 shown is used, which is used during the production of the concrete double wall element 1. The sleeve 23 is embedded in a region 11a of the concrete shell 2a near the edge in such a way that the outside 26 of the sleeve 23 is partially encased in concrete. The opening 26 'of the sleeve 23 faces the edge 12a of the concrete shell 2a, and the sleeve 23 protrudes obliquely from the inside 13a of the first concrete shell 2a facing the second concrete shell 2b.

2a and 2 B show schematic representations of the support device 40 with a fixing element 20 and an anchor element 30, which are detachably connected to one another. For this purpose, the fixing element 20 is provided with a foot part 25, which can be locked in the anchor element 30 so that it cannot be displaced. 2a shows fixing element 20 and anchor element 30 in a separated state, 2 B in a state in which fixing element 20 and anchor element 30 are connected and locked. 2c shows a perspective detailed view of the anchor element 30.

3a until 3e illustrate individual process steps of a process flow for producing the concrete double wall element 1 1 and as well as the use of the supporting device 40 used 2a , 2 B and 2c . The concrete double wall element 1 is manufactured with the help of pallets 5a, 5b, which successively pass through several stations of a production line (not shown in the figures). The displaceability of the pallets 5a, 5b during the production of the concrete double wall element 1 is in the 3a - 3e through Trans port rollers 8 indicated below the pallets 5a, 5b.

In a first process step, formwork elements 6a and double wall spacers 3 'are attached to the first pallet 5a. The entirety of the formwork elements 6a forms a formwork that encloses an interior space 7a to be filled with liquid concrete and corresponds to the outer and inner contours of the concrete double wall element 1 to be manufactured. Liquid concrete 10a (so-called fresh concrete) is poured into this interior 7a ( 3a) . Composite means 3, for example lattice girders, are inserted into the still unhardened liquid concrete 10a, which later, in the concrete double wall element 1 to be manufactured, connect the two concrete shells 2a, 2b to one another (see 1 ). Peaks 4 of these composite means 3 protrude upwards from the liquid concrete 10a.

Furthermore, the fixing element 20 is placed on the formwork 6a 2a shown supporting device 40 placed in such a way that a first end section 21 of the fixing element 20 - as well as the composite means 3 and the double wall spacers 3 ' - protrudes in sections into the fresh concrete 10a of the first concrete shell 2a. The first end section 21 is inserted at the end into a sleeve 23, and the end section 21 and the sleeve 23 are dimensioned in such a way that only areas of the sleeve 23, but not the rest of the first end section 21, are immersed in the fresh concrete 10a. The sleeve 23 is preferably made of a plastic and provided with longitudinal and/or transverse ribs 24 (see 2a) . On the one hand, these ribs 24 effect a mechanical stabilization of the sleeve 23, but on the other hand they also have the function of ensuring anchoring and thus ensuring that the sleeve 23 remains in the first concrete shell 2a after the fixing element 20 has been removed.

A second end section 22 of the fixing element 20, designed as a bent metal rod 29, projects both vertically (in an in 3a connection direction 14 shown as an arrow) as well as laterally (perpendicular to the connection direction 14) beyond the formwork 6a and has the foot part 25 at the end, which serves to fasten the fixing element 20 to the anchor element 30. For the temporary attachment of the fixing element 20 to the pallet 6a carrying the fresh concrete 10a, a permanent magnet 28 is also provided on the fixing element 20, which is located in a support area 27 of the fixing element 20 opposite the formwork 6a; In the present exemplary embodiment, the support area 27 is placed on the formwork 6a made of a magnetizable material (eg steel) and causes the fixing element to be held stably on the pallet 6a.

The one equipped in the manner described, in 3a Pallet 5a shown is now placed in a hardening station in which the liquid concrete 10a hardens to form a first concrete shell 2a (first shell). The fixing element 20 is held in the desired spatial position and orientation on the pallet 5a by the permanent magnet 28 during transport to the hardening station and during the hardening of the liquid concrete 10a. As the concrete hardens, the composite means 3, the double wall spacer 3' and the fixing element 20 are firmly concreted into the first shell 2a in the area of the sleeve 23.

In this way an in 3b shown semi-finished product 9 (intermediate product) for producing the concrete double wall element 1 1 created. The semi-finished product 9 comprises the hardened first shell 2a with the composite means 3 partially embedded in concrete, the tips 4 of which protrude from the concrete layer 2a in the connecting direction 14, the double wall spacers 3 'and the sleeve 23 of the fixing element 20 partially embedded in concrete.

Parallel to or subsequent to the production of the semi-finished product 9, formwork elements 6b are attached to a second pallet 5b, which also correspond to the outer and inner contours of the concrete double wall element 1 to be manufactured, but which are arranged inverted to the formwork 6a of the first pallet 5a. Furthermore, the anchor element 30 is plugged onto the foot part 25 of the fixing element 20 (see 2a) and connected with this (see 2 B) . The foot part 25 of the fixing element 20 is first inserted into a recess 33 provided for this purpose in the housing 31 of the anchor element 30 and pre-fixed there by a magnet 32 mounted in the anchor element 30. For the subsequent non-displacement fixing of the foot part 25, the anchor element 30 comprises a locking slide 34, which is in a locking direction 38 (ie in a direction perpendicular to the plane of the drawing in 2a , 2 B) is movably mounted relative to the housing 31 of the anchor element 30. The longitudinal guidance of the locking slide 34 relative to the housing 31 of the anchor element 30 is carried out by an extension 36 in the housing 31 of the anchor element 30, which engages in a groove or a slot 35 of the locking slide 34 and in this way a guided movement without unintentional detachment of the locking slide 34 causes (see 2c ). The groove or slot 35 runs slightly obliquely; As a result, during a translational movement of the locking carriage 34 in the closing direction 38, the foot part 25 of the fixing device 20 is pressed against the anchor element 30 and is thus locked in the anchor element 30. The mechanical locking of the fixing element 20 relative to the anchor element 30 via the The magnetic attraction also occurs through a displacement of the locking slide 34 along the closing direction 38, so that - due to a trapezoidal opening 37 in the locking slide 34 and the opposite hemispherical shape of the foot part 25 of the fixing element 20 - the foot part 25 is clamped in the anchor element 30 becomes.

Liquid concrete 10b is now poured into the interior 7b formed by the formwork elements 6b on the second pallet 5b, and the hardened first shell 2a located on the first pallet 5a is turned through 180 ° using a turning device (not shown in the figures), so that the tips 4 of the composite means 3 protrude downwards (see 3c ). Subsequently, the first shell 2a with the fixing element 20 held therein and the anchor element 30 attached to the fixing element 20 is placed in a precisely positioned position on the liquid concrete layer 10b of the second pallet 5b in a pre-calculated manner. The peaks 4 of the composite means 3 sink into the liquid concrete layer 10b (see 3d ), and the anchor element 30 comes into contact with the surface of the second pallet 5b. Since the second pallet 5b (at least in the fastening area of the anchor element 30) consists of a magnetizable material, usually steel, the anchor element 30 is magnetically attracted to the surface of the pallet 5b by means of the permanent magnet 32 and is therefore firmly connected to the second pallet 5b via magnetic force . Since the fixing element 20 is embedded in the first concrete shell 2a in the area of the sleeve 23 and the anchor element 30 is firmly attached to the second pallet 5b, the support device 40 thus fixes the first concrete shell 2a relative to the second pallet 5b.

The second pallet 5b with the liquid concrete layer 10b and the first shell 2b stored thereon is then brought into the hardening station. Due to the fixation of the first concrete shell 2b on the second pallet 5b by means of the support device 40, displacements of the first concrete shell 2b relative to the second pallet 5b are prevented during this transport. In the hardening station, the liquid concrete 10b poured into the interior 7b of the second pallet 5b is hardened to form a second concrete shell 2b (second shell). The first shell 2a and second shell 2b are now firmly connected to one another; displacements of the two shells 2a, 2b relative to one another are prevented by the composite means 3 embedded in concrete on both sides ( 3d ).

The locking carriage 34 of the anchor element 30 is then released so that the fixing element 20 can be pulled out of the anchor element 30. Now the finished concrete double wall element 1 is removed from the second pallet 5b (arrow 41), with the anchor element 30 initially remaining on the second pallet 5b and can be removed later (see 3e) . The fixing element 20 is then released from the sleeve 23 fixed in the first concrete shell 2a. The sleeve 23 remains in the concrete double wall element 1.

The anchor element 30 and the fixing element 20 can - after pushing a further sleeve 23 onto the first end section 21 of the fixing element 20 - be used to produce another concrete double wall element.

Reference symbol list

1

Concrete double wall element

2a, 2b

First, second concrete bowl

3

Composite means

3`

Double wall spacers

4

protruding areas of the composite means

5a, 5b

palette

6a, 6b

formwork

7a, 7b

Interior of the formwork

8th

Transport roller

9

Workpiece

10a, 10b

Liquid concrete

11a

Area near the edge of the first concrete shell

12a

Edge of the concrete bowl

13a

Inside of the concrete shell

14

connection direction

15

Cavity of the concrete double wall element

20

Fixing element

21

first end section of the fixing element

22

second end section of the fixing element

23

sleeve

24

Ribs

25

Foot part of the fixing element

26

Outside sleeve

26'

Opening of the sleeve

27

Support area

28

Permanent magnet in the support area

29

curved metal rod

30

anchor element

31

Housing anchor element

32

magnet

33

Recess in the housing - holder for fixing element

34

Locking carriage

35

Slot or groove in the locking slide

36

Extension on the housing

37

Trapezoidal recess in locking slide

38

Closing direction

40

Support device

41

removal direction

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102018124980 B3 [0005, 0007]

Claims (16)

Support device (40) for the precise relative positioning of two concrete shells (2a, 2b) in the course of producing a concrete double wall element (1), the support device (40) - a fixing element (20) with a first end section (21) for embedding in sections in the first concrete shell (2a) - and an anchor element (30) for direct or indirect attachment of the support device (20) to a pallet (5b) carrying the second concrete shell (2b), characterized in that the fixing element (20) has a detachable one at the end section (21) of the fixing element (20) has attached sleeve (23). Support device (40). Claim 1 , characterized in that the sleeve (23) consists at least in sections of a plastic. Support device (40). Claim 1 or 2 , characterized in that an outside (26) of the sleeve (23) is provided with ribs (24). Support device (40) according to one of the preceding claims, characterized in that the fixing element (20) comprises a support area (27) for direct or indirect support of the fixing element (20) on a pallet (5a) carrying the first concrete shell (2a). Support device (40). Claim 4 , characterized in that the fixing element (20) in the support area (27) has a permanent magnet (28), with the help of which the fixing element (20) can be fixed directly or indirectly to a pallet (5a) carrying the first concrete shell (2a). Support device (40) according to one of the preceding claims, characterized in that the fixing element (20) has a foot part (25) for releasable attachment to the anchor element (30). Support device (40). Claim 6 , characterized in that the fixing element (20) can be connected to the anchor element (30) by means of a lockable plug connection. Support device (40) according to one of the preceding claims, characterized in that the anchor element (30) comprises a permanent magnet (32), with the help of which the anchor element (30) can be attached directly or indirectly to the pallet (5b) carrying the second concrete shell (2b). can be fixed. Concrete double wall element (1) with two hardened, flat concrete shells (2a, 2b) and composite means (3), which are embedded in sections in the concrete shells (2a, 2b) and both for connecting and as spacers of the concrete shells (2a, 2b) serve, characterized in that the first concrete shell (2a) comprises a sleeve (23) embedded at least in sections in a region (11a) near the edge of this concrete shell (2a) for receiving a fixing element (20). Concrete double wall element (1). Claim 9 , characterized in that the sleeve (23) projects obliquely into the first concrete shell (2a) and is opened towards an inside (13a) of the first concrete shell (2a) facing the second concrete shell (2b). Concrete double wall element (1). Claim 9 or 10 , characterized in that the sleeve (23) consists at least in sections of a plastic. Concrete double wall element (1) according to one of the Claims 9 until 11 , characterized in that an outside (26) of the sleeve (23) is provided with ribs (24). Semi-finished product (9) for producing a concrete double wall element (1), the semi-finished product comprising a hardened, flat concrete shell (2a) and composite means (3) embedded in sections in this concrete shell (2a), with crests (4) of these composite means (3) protrude in a connecting direction (14) from an inside (13a) of the concrete shell (2a), characterized in that the semi-finished product (9) has a sleeve (23) embedded at least in sections in a region (11a) near the edge of the concrete shell (2a). Receiving a first end section (21) of a fixing element (20) for a support device (40). Semi-finished product (9). Claim 13 , characterized in that the sleeve (23) projects obliquely into the concrete shell (2a) and has an opening (25) which is located on the inside (13a) of the concrete shell (2a) facing the embedded composite means (3). Semi-finished product (9). Claim 13 or 14 , characterized in that the sleeve (23) consists at least in sections of a plastic. Semi-finished product (9) according to one of the Claims 13 until 15 , characterized in that a Outside (26) of the sleeve (23) is provided with ribs (24).

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