DE3932058A1 - Mfg. prefab, flat, ceiling and wall slabs - uses continuous slab mfr. of preset width, sizing, and reinforcement insertion into slab cavities - Google Patents

Abstract

The prefab. flat wall or roof slabs are mfd. as blocks (11) with transverse, parallel holes which extend from one side to the other. The blocks are fed, one at a time, to a station (3) where adhesive is applied to one face. The blocks are then pushed onto a table and are joined together by the adhesive. The block row then forms a structural element which is reinforced by feeding reinforcing elements (7) through the transverse holes, which are subsequently filled with mortar to hold the reinforcement in place. ADVANTAGE - Mechanisation facility, even for large slabs.

Description

The invention relates to a method of manufacture len prefabricated surface components in particular re for the production of ceilings, walls and the like chen, the surface components from dimensionally there are precisely specified individual components that with the insertion of glue or the like be lined up in that Cavities are aligned, at least in part wise inclusion of reinforcements.

One understands a surface component Wall or ceiling part in a rational way as Assembled structure to form the construction. Such components can he static functions fill or are at least partially as Ver clothing used in load-bearing structures. It should be noted that e.g. for the transport certain strengths of surface components are required to crack or damage avoid.

Known surface components become factory made on a flat worktop according to plan where e.g. Some stones together manually between individual rows of stones reinforced concrete ribs the load-bearing structure form.

In other processes, reinforced concrete parts are used compiled and anchored. At the construction site carriers are differentiated according to the system material spaced apart, single building  stones inserted and removed as an intermediate component concreted, this laying is done manually guided.

The disadvantage is that when using concrete a hardening time is required, whereby in Be large areas to manufacture or on agile heating causes great costs. The Work processes depend on the curing time. In addition, there is a high transport weight. In other known constructions, a individual building blocks inserted as intermediate components in the carrier sets. Elaborate formwork is no longer required however, this manual laying creates a is a lot of time, additional concreting required.

If concrete parts are used on the building, this results that due to the high density of concrete Transport weight. A common construction site crane does not meet these requirements, it arises Costs through the use of heavy lifting equipment. Other known constructions of surface construction elements have cavities in the reinforcements can be inserted, but are not special their measures taken around the individual rie gel to connect with each other. These elements are not to create a wall or ceiling suitable in this sense.

From DE-PS 32 30 078 is a prefabricated Wall component known in which the individual component ne glued together. This will a connection festival necessary for transport achieved, but can only be compared wise small-area components with sufficient Realize strength. In addition, this construction stone composite only suitable for wall construction.

With the aforementioned methods, manual work is considerable required.

Based on the previous state of tech nik the invention is based on the object Sheep manufacturing method fen which can be carried out largely by machine and also used to create large-scale components can be used both as wall and Ceiling elements are suitable.

The invention is there to solve this problem characterized in that the surface construction elements te with a given width almost endlessly by An joining the individual building blocks together the that a cut to length accordingly the dimension of the later surface component follows that subsequently the reinforcement in the hollow is inserted and that finally the Cavities having reinforcement elements by means of Grout or the like can be filled.

Such a surface component is by maschi Easy assembly of prefabricated single stones ne, which have corresponding cavities to manufacture. Individual modules are preferred assign using a quick-curing adhesive joined together according to the predetermined length machine cut and with another device with reinforcement in the corresponding cavities filled. The number of filled cavities with reinforcement is aimed according to the component span. Be further the cavities with the reinforcements using a Pressed in mortar, which is a positive Connection with the stones results in a reinforced self-supporting area construction created an element that is no longer load-bearing Constructions such as beams or the like required ma loads can also be absorbed.  

The above-mentioned procedure is by the special to carry out their process mechanically, considerable Time savings are the result, the costs ver wrestles.

The reinforcement is advantageously after the insertion into the cavities in the longitudinal direction tion biased, with a bias on off filling the cavities can replace, however the filling of an additional positive connection between reinforcement and stones.

The cavities can be filled with mortar, Glue, cement glue or any other Fasteners are made using the reinforcement without pretension, so-called limp, with can be connected to the stones. The advantage reinforcement with prestressing can be that compared to limp reinforcement less deflection, therefore one Crack formation z. B. is avoided with blankets.

Furthermore, the parts can be preloaded dispenses with a quick-curing adhesive will compress the individual stones with the reinforcement, this can result in a slow binding glue or mortar is used become a strand around the individual stones join together.

A further development of the invention provides that the individual surface components on the structure et wa be aligned, and that in forehead mutually facing, open on the front Cavities, grout or the like, if necessary reinforcement is also introduced. This is a quick and easy assembly of the Surface components possible. The connection will through special edge training, with reinforcement and mortar or the like filled out, form-fitting.  

A shift of the individual parts after the Er hardening of the mortar, concrete or the like is not possible.

A further development of the invention provides that when assembling the individual components by gluing ben and / or by filling with grout Preforming in the sense of a convex pre-curvature against the later direction of loading becomes. This creates the Components as ceiling parts a flat surface. The Deflection by the dead weight takes place in a about flush level.

Another embodiment provides that after Prestressing the reinforcement a positive Ver bond is preferably welded. Advantage of this weld at the end where the Be reinforcement protrudes over the surface component, that the reinforcement under prestress the individual stones compresses, a load capacity of the component is without final hardening of the mortar and / or of the adhesive at least for transport.

Instead of welding the reinforcement is one Bracing with other known clamping parts or Screwing possible, for example, the advantages are that no curing times are required the components can be used immediately.

Furthermore, the invention relates to a surface Component in particular for the production of ceilings, Walls and the like made of individual building blocks with cavities and reinforcement inside stands. Known components made of single stones the disadvantage that they are each in connection with Supporting elements, but without the edge formation one represent a meaningful connection to the next element, are trained.

To solve this problem, the present invention struck that at least part of the individual component  ne on their non-glued narrow sides have open, undercut grooves. Thereby there is a possibility that when merging of the surface components in these grooves on both sides reinforcements interfering with the impact, e.g. B. zigzag, insert and with grout to fill. The benefits of this undercut Grooves are that when joining the surface construction flat, ready-to-fill surfaces are created.

The connection of the plates is on their surface not visible. Reinforcements can be placed in these grooves be placed with the mortar both plates Connect non-positively. Such reinforcements are quickly insert the void without filling that a lot of time is involved.

Appropriately located at the ends of the Cavities of the individual building blocks undercut Er Extensions, so that od he like Ver at these points ties result. It will make it special prevents the grout with the coated Reinforcements in the cavity of the channels can be moved. These extensions are used in the manufacture of the Individual stones are taken into account.

The undercut are advantageous Longitudinal grooves in the individual modules both to one Narrow side as well as open to a flat side educated. This is the case with a ceiling element Possibility of laying supply lines or the like, filling with mortar as well as inserted reinforcements prevent ver push the panels in the joint area.

A further embodiment provides that the one cell block about a T-shaped cross section points and for the manufacture of a ceiling element serves and that inside the web transitions outward and upward open rear snow  slots are provided. Such preferably Partially circular grooves are used for non-positive Connection of the panels in the joint area; Reinforcements, Mortar or the like can be found there quickly and just type.

A further training provides that the undercut tten longitudinal groove has a cross section which is larger is as a semicircle, preferably a three-four corresponds to the circular area. This form is in the Manufacture of the individual components is easy to manufacture The connection of the mortar to the stone is guaranteed accomplishes.

Another advantage is that the individual stones Cavities open on the face to accommodate ver have supply lines or the like. These Cavities are not filled with mortar, as a result the weight of the surface component is reduced These continuous cavities can lead to additional lines are used. With ent speaking arrangement of the cavities is a heat Insulation of the component is given, as can for example with a corresponding arrangement of Cavities and connection with a heating system Channel system for the transmission of air serve as Ventilation heating is used. With this system is in the ceiling / wall area due to the heating or cooling the stones with appropriate air feed the space in the cavities of the components control temperature.

The inserted reinforcement is advantageous by appropriate coatings, preferably Galvanized, protected against corrosion. Such Coating prevents corrosion in places which the rust protection by the mortar does not guarantee is accomplished.

The individual components are expediently for Manufacture of ceiling and / or wall elements  Lime sandstone. These stones have dimensions exact areas on which to glue together which are particularly suitable.

It is advantageous that the individual stones are building blocks are with a through hole, which in particular to create a fireplace and that the Cavities for receiving reinforcement or the same laterally at a distance from the passage opening are arranged. The inner opening serves the intake of the smoke pipe, the diameter depends on the required chimney cross cut. The side cavities serve the Inclusion of reinforcements with those single stones formed into a floor-to-ceiling element will. Such elements can be manufactured in the factory will. With the use of single stones Lightweight concrete is an education to a strand, joint formation with mortar required. A glue with thin bed mortar can because of uneven surface of the individual stones not through leads. Reinforcement becomes after hardening of the mortar inserted into the cavities and with the individual stones connected to a component. The Reinforcement prevents the formation of cracks between the Single stones and brings them for transportation required strength.

Another embodiment provides that between the joints of the individual building blocks at which opening s for the reinforcements, flat iron or similar are inserted before joining, wel openings are connected to the reinforcement. Such flat bars can be used as fastenings for the Components on structures or the like ver be applied. Such flat iron can also be used turned on as a tensile connection of two components are used as so-called formwork blocks  Filled in concrete as basement walls or the like be used. The advantage of this design is that the concrete without joints as impermeable Wall can be made, the concrete strength can be about 15 cm and is made using components each about 7 cm thick as formwork stones delimited on both sides. Such elements as Formwork can be, for example, floor height and manufactured in the factory. The reinforcements form with the flat iron in the individual stone joints a tensile unit that absorbs the concrete pressure. The assembled individual stones are in this Senses the formlining that remains in the building costs for formwork etc. are saved. Additional embodiments of the invention are in the further subclaims. Next The invention is based on the drawings described in more detail. It shows:

Fig. 1 is a plant for the production of area elements,

Fig. 2 is a longitudinal section through a wall structure,

Fig. 3 is a ceiling cut-out in the joint region,

Fig. 4 + 5 shows a section in the joint area of a ceiling plate,

Fig. 6 + 7 shows a section in the joint area of a wall or ceiling plate,

Fig. 8 is a section along the reinforcement channels with their extensions,

Fig. 9, the connections of individual plates as a wall structure,

Fig. 10 with a camber roller shutter case,

Fig. 11 shows a connection in the wall and ceiling area,

Fig. 12 is a section in the panel joint region,

Fig. 13 wall, ceiling panels in the support,

Fig. 14 shows the section of a wall formwork with concrete,

Fig. 15 shows a chimney element.

Fig. 1 shows a system 100 for the production of surface components 1 , the machine consisting essentially of a table 2 , a press 3 for applying adhesive 4 , a device 5 Schneidvorrich, a reinforcement roller 6 with device 7 insertion device, a press B. for prestressing, a welding system 9 and a mortar press 10 be available. The individual building blocks 11 are provided with adhesive 4 and pressed against the existing stone strand 12, the excess adhesive 4 being pressed out and removed. The table 2 on which the stone strand 12 is made can be slightly curved to achieve a pre-curvature of the surface construction elements 1 . The stone strand 12 is pushed to the required length of the measuring device 13 by means of a press 14 and cut to length with the cutting device 5 . After the displacement of the component 1 in the direction of the reinforcement roller 6 , reinforcements 16 are inserted and cut to length in reinforcement channels 15 . The component 1 is pushed into the area of the press 8 for pretensioning. The reinforcement 16 is then welded to the counter plates 45 under tension so that the prestressing of the elements 1 is achieved. After the shift in the area of Mörtelzu guide 17 , the mortar 18 is pressed. Such a component 1 achieves high bending strength. Thus, these parts can be used as carrying parts. Because of the preferred use of quick-curing adhesive 4 , the surface component 1 reaches the required strength for transportation and installation after a short time.

Fig. 2 shows a longitudinal section through a wall structure 19 wherein the reinforcements 16 in the reinforcement channels 15 provided with mortar 18 are filled. The joint area 20 partially directly butted is additionally provided with an undercut cavity 21 which is filled with reinforcements 22 and mortar 18 . This creates a positive connection after hardening.

Fig. 3 shows a ceiling section 23 in the joint area. The elements 1 consisting of individual stones 11 joined together, which have cavities 24 , openings 15 , reinforcements 16 . Mortar 18 is inserted on both sides in undercut cavities 21 . Reinforcements 22 are inserted in the joint area 20 and filled with mortar 18 . Such a connection in the joint area 20 is form-fitting to avoid cracks and displacements.

Fig. 4 + 5 show a section in the joint area of a ceiling plate 27 with the undercut longitudinal groove 25 may have different sizes and shapes. The cavities 21 are filled after inserting the reinforcements 22 with mortar 18 from the upper open side 26 in the case of ceiling tiles 27 .

Fig. 6 + 7 show a section in the joint area 20 of a wall or ceiling panel 27, wherein the cut longitudinal grooves 25 can have different shapes. The cavities 21 are filled after the reinforcements 22 have been inserted with mortar 18 by being pressed in in the longitudinal direction of the grooves 25 . Such a connection is comparable to the tensile strength and shear strength of conventional walls in a half-stone bond, about half of the stone surface remains, as much as with a half-stone bond.

Fig. 8 shows a section along the reinforcement channels 43 with the extensions 28 in the shock area 35 of the individual stones 11th These extensions 28 serve the better connection of the individual stones 11 with the mortar 18 so that the reinforcements 16 in the reinforcement channels 44 are not displaceable bar.

Fig. 9 shows surface components 1 perspectively shown as a wall system. The element joint 20 has a cavity 21 into which a zigzag-shaped reinforcement 22 is inserted and pressed out with mortar 18 in order to achieve a connection of the elements 1 .

Fig. 10 shows a lintel with roller shutter box 28. The individual stones 11 are joined together, provided with reinforcements 16 and pressed out with mortar 18 . The cavity 29 serves to accommodate the roller shutter and is also formed as a lintel.

Fig. 11 shows a connection 31 in the wall, ceiling area. The reinforcements 16 protrude into the bearing 32 and are filled with concrete 33 . At the end of the ceiling part 23 , the bracing part 34 for prestressing the reinforcements 16 is shown. Fig. 12 shows the reinforcement 22 in the panel joint area 20 along the cavities 24th The individual stones 11 are connected in the joint area 20 with the zigzag reinforcement 22 and filled with mortar 18 . The reinforcement bars 16 absorb the tensile force in the component 1 , the connection to the individual stones 11 is created with mortar 18 ge.

Fig. 13 shows a perspective drawing areas component 1. The joint 35 of the individual stones 11 is formed with an adhesive 4 which hardens quickly. The element joint 20 is designed as a continuous, undercut groove 25 . The respective cavity 21 is provided with a zigzag reinforcement 22 . This cavity 21 is pressed out with mortar 18 . The undercut 25 of the cavity 21 is used for positive connection and prevents crack formation on the element joint.

Fig. 14 shows the section of a formwork wall 35 with concrete 33 , the components 1 being composed of individual stones 11 and pressed to increase the strength with reinforcing bars 16 in the cavities 15 with mortar 18 . The components 1 as two shells are formed together with the flat steels 36 in such a way that a continuous cavity 3 B is created between the components 1 and results in a wall 35 filled with concrete 33 . Is by way of advantage that the flat bars are inserted 36 in the joints 39 between the individual bricks 11 and are penetrated at holes 40 of the reinforcement 16 in order to achieve a corresponding fixed accuracy of the shuttering wall 35th After striving and aligning the lead-making cavity 38 is filled with concrete 33 , a wall with continuous concrete 33 without joints being created, which is an example of a water-impermeable wall in basement walls. A corresponding connection to the floor 41 can be carried out. The components 1 are used as formwork blocks in the wall structure 35 .

Fig. 15 shows a fireplace assembly 43. The individual stones 11 are joined together approximately in alignment. Reinforcements 16 run in the cavities 15 and are filled with mortar 18 or the like in order to obtain an assembled component 43 . Corresponding smoke pipes can be installed in the inner opening 42 . In this way, storey-high components 43 can be created at the factory.

Claims (15)

1. Process for the manufacture of prefabricated surface components, in particular for the production of ceilings, walls and the like, the surface components consisting of dimensionally precisely specified individual building blocks, which are optionally strung together with the addition of glue or the like so that be Sensitive cavities are aligned with one another, for at least partially receiving reinforcements, characterized in that the surface components with a predetermined width are produced virtually endlessly by joining the individual building blocks, that a cutting to length is then carried out in accordance with the dimension of the later surface component, that subsequently the reinforcement is inserted into the cavities and that the cavities having reinforcement elements are finally filled in by means of grout or the like. 2. The method according to claim 1 characterized net that the reinforcements after insertion in the cavities are prestressed in the longitudinal direction  the and that then the filling of the corresponding hollow chambers with grout or the like. 3. The method according to claim 1 or 2 thereby characterized that the individual surface Components next to each other on the building be aligned and that in forehead facing each other, open on the front cavities, grout or the like, if necessary, reinforcement is also introduced becomes. 4. The method according to one or more of the claims che 1 to 3, characterized in that at Joining the individual stones by gluing and or by filling in with grout or the like a preforming in the sense of ner convex curvature opposite to that later direction of loading is carried out. 5. The method according to one or more of the claims che 1 to 4, characterized in that the Reinforcement after insertion into the hollow spaces are prestressed and then by a positive connection, preferably Ver welding with counter plates. 6. Surface component especially for manufacturing of ceilings, walls and the like from individual building blocks with cavities and in them existing reinforcement is known records that at least part of the individual building blocks on their non-glued narrow egg  open-cut, undercut grooves sen. 7. surface component according to claim 6 thereby characterized in that at the ends of the hollow spaces of the individual blocks undercut Extensions are provided so that through the grout or the like positive connections at these points surrender. 8. surface component according to claim 6 or 7 characterized in that the undercut longitudinal grooves in the individual components a narrow side and / or a flat egg te open edge are provided. 9. Surface component after one or more of claims 6 to 8, that the individual block is approximately a T-shaped Has cross section and in particular for Production of a ceiling element serves and that on the inside at the web transitions outside and upside open rear undercut slots are provided. 10. Surface component after one or more of claims 6 to 9, that the undercut longitudinal groove a cross cut that is larger than half circle, preferably a three-quarter circle area corresponds. 11. Surface component after one or more of claims 6 to 10, that the individual blocks open on the front  Cavities for receiving supply lines lines or the like. 12. Surface component after one or more of claims 6 to 11, that the reinforcements inserted correspond to appropriate coatings, preferably galvanizing are protected against corrosion. 13. Surface component after one or more of claims 6 to 12, that the individual building blocks for the production of Ceiling and / or wall elements of sand-lime bricks are. 14. Surface component after one or more of claims 6 to 13, that the individual stones are building blocks with an inner Through opening are, in particular for Create a fireplace and serve that Cavities for receiving reinforcement or the like laterally at a distance from the through passage opening are arranged. 15. Surface component after one or more of claims 6 to 14, that between the joints of the individual building blocks which are openings for the reinforcements find flat iron or similar before Merge which are inserted at public not connected with the reinforcements.