EP0007852B1 - Production line for the making of concrete elements - Google Patents

Description

The invention relates to a chain for the production of concrete elements (unreinforced, reinforced or prestressed) such as piles, posts, in particular for power lines, slabs, beams, panels, curbs, comprising means for pouring concrete in molds and a liquid tank for transporting the concrete elements from the pouring means to the evacuation means, with the passage of these concrete elements through a hardening circuit.

A production line of this kind is known, in particular from the German patent application published before DOS examination No. 2,043,071. According to this request, the molds in which the material is poured, are immersed in the liquid of the tank so as to be carried, at least partially, by this liquid. The arms supporting the molds during their movement, are subjected to less significant forces, resulting in reduced deformations. Such a solution is advantageous in particular for molding elements having a relatively large mass. However, the solution proposed by this German patent application lacks flexibility, in particular when the type or shape of the products to be produced is called upon to change relatively frequently, with the need to change the molds.

German patent No. 477 368 provides for the use of floats, in a liquid tank, for transporting loads. However, this patent does not refer to a production line for concrete elements.

The FR patent application. No. 2 256 809 also illustrates the technological background of the invention and shows a complete chain for the manufacture of concrete elements.

The present invention aims, above all, to provide a production line, of concrete elements, of the kind defined in the preamble of claim 1, which is very flexible in use and which can be adapted easily and quickly. to different types or forms of products to be manufactured.

According to the invention, a chain for manufacturing concrete elements of the kind in question is characterized in that it comprises a chain of floats capable of being moved in the tank by supporting, in particular through the hardening circuit, the concrete elements which have just been removed from the mold, or the molds into which the concrete elements have been poured, these floats comprising means capable of modifying their balance by introducing inside or evacuating from the floats a liquid , in particular that of the tank, means being further provided for bringing the floats back to the concrete pouring means.

The advantages obtained thanks to this invention consist, essentially, in a great flexibility of use since the balance of the floats can be easily and quickly adapted to each type of product to be manufactured. In addition, when the concrete elements are demolded and placed on the floats, the number of molds used for the manufacture of the elements is reduced to a minimum, with maximum use of the mold (s). Mold changes, depending on the type of product to be manufactured, can be carried out simply and quickly, without the need to change the floats.

The means suitable for modifying the balance of the floats preferably comprise remote-controlled solenoid valves and means for admitting compressed gas into the float to expel the liquid.

The floats, for at least part of their displacement corresponding to the crossing of the hardening circuit, are advantageously immersed, with the concrete elements which they support, in the liquid of the tank, this liquid being in particular progressively heated along tank.

The invention consists, apart from the arrangements set out above, in certain other arrangements which will be more explicitly discussed below in connection with particular embodiments described in detail with reference to the attached drawings, but which do not are in no way limiting.

Figure 1 of these drawings is a schematic longitudinal section of a chain for the manufacture of concrete elements, with immediate release using a 180 ° tilting device, in which the movement of the floats is ensured by floating throughout the liquid tank, according to the invention.

FIG. 2 shows, on a larger scale, the means for pouring concrete and demolding the production line of FIG. 1.

Figure 3 is a schematic longitudinal section of a production line, with immediate release using a 90 ° tilting device, in which the movement of the floats is first carried out by floating during the gripping period concrete, and then by immersion in the tank liquid.

Figure 4 shows, on a larger scale, the concrete pouring and demolding means of the chain of Figure 2, suitable for the manufacture of electrical poles.

FIG. 5 is a schematic longitudinal section of an immediate demoulding production line, in which the elements, in unreinforced concrete, are placed directly on the floats, the latter describing, in the tank, a closed loop circuit in the vertical plane with floating in the forward direction and immersion in the liquid for the return.

Figure 6 is a cross section along 1-1, fig. 5.

FIG. 7 is a plan view with parts cut away of a production line in which the hardening of the concrete elements takes place in the molds, the movement of the floats taking place in a looped circuit in a horizontal plane, the tank with liquid having two adjacent compartments, the displacement being carried out by floating in a first compartment of the tank and by immersion in the liquid for the adjacent compartment.

Figure 8 is a cross section along 1-1, fig. 7.

Figure 9 is a cross section illustrating the mounting of the manufacturing line of Figures 7 and 8 in a floating hull of a boat.

Figure 10 is a perspective view, with part, cut, of a "float board" formed by an envelope filled with a material, in particular hydrophobic.

Figure 11 shows, similarly to Figure 10, a "float board" produced mainly using hollow profiles.

Figure 12 shows, similarly to Figure 10, a "float board" made mainly using a tube.

Figure 13, finally, is a cross section of a carrier-mold float produced using several tubes.

Referring to the drawings, we can see several types of production lines for a wide range of elements or products "p" in concrete, unreinforced, reinforced or prestressed.

Each production line for concrete elements comprises: means B for pouring and compacting the concrete in the molds or batteries of the molds D1, D2, D4; a circuit H for the hardening of the concrete elements which have just been molded and means K for the evacuation of the hardened elements.

According to the invention, the production line comprises a chain of floats formed either by float boards A1 (fig. 1 to 6 and 10 to 12) or by mold support floats A2 (fig. 7 to 9 and 13) suitable for being moved in a liquid tank E, generally a water tank or possibly an oil tank; this tank E may or may not be equipped with heating means R for accelerated hardening.

Means C, F, are provided for placing the concrete elements p, which have just been poured, on said floats A1, A2; these floats moving in the tank E transport the concrete elements p from the pouring means B to the discharge means K by passing the concrete elements through the hardening circuit H. The floats move head to head head and / or side by side.

Means, formed by handling means G (fig. 1, 3) or by the tank E itself (fig. 5 to 8) are provided to bring the floats A1, A2, to the concrete pouring means B.

The liquid tank E is arranged, according to the embodiments of Figures 1 and 3, such that the circuit followed by the floats A1 in this tank is an open circuit between the pouring means B and the discharge means K; the means for bringing the floats A1 back to the casting means B are constituted by handling means G such as overhead traveling cranes (fig. 1), cranes (fig. 3) or hoists.

According to the embodiment of Figures 7 and 8, the liquid tank is arranged so that the circuit followed by the floats A1, A2, is a looped or closed circuit passing through the pouring means B and the discharge means K, the means for bringing the floats back to the pouring means being constituted by a part of the tank E itself.

In the case of FIG. 5, the circuit is looped in a vertical plane; the tank E has a single compartment and the paths made by the floats in opposite directions are superimposed.

According to the embodiment of FIGS. 7 and 8, the circuit is looped in a horizontal plane and the tank E has two adjacent compartments as clearly visible in FIG. 8.

In the case of immediate demoulding of the concrete elements p, just after the concrete has been poured, the floats are constituted by "float boards" A1 (fig. 1 to 6 and 10 to 12). These floatboards can be arranged in the form of an envelope 1 (made of sheet metal, polyester, etc.) having the shape of a parallelepiped, envelope made waterproof by welding, or, in particular, by the injection of a hydrophobic material. and light 2 (fig. 10); according to a variant, these "float boards" A1 are produced using one or more friction elements (fig. 11 and 12) such as tubes, conduits, hollow profiles, etc. linked to a plate 4 for supporting the products or elements, by assembly pieces 5. The "float boards" A1 are provided on their ribs with guide pieces 6 (grooves, rollers, etc.) suitable for cooperating with rails 42 extending in the longitudinal direction of movement of the floats, on the walls of the tank E; buffer parts 7 are provided at the ends. of the boards A1 transverse to the direction of movement.

In certain cases, the two alternative embodiments illustrated in particular by FIGS. 10 and 11 can be combined.

In the case where the concrete elements p remain in the molds, during hardening, the floats are formed by mold support floats A2 (FIGS. 7 to 9 and 13); they include floating elements 3 and parts similar to those described above and designated by the same reference numerals 2, 5, 6 and 7; the floats A2 further comprise one or more working platforms 8, longitudinal or transverse; if necessary rollers 9 (fig. 8 and 9) can be provided below the flow ters A2. These floats are provided with mold supports 10 mounted on the float frame by means of support pieces 11, in particular elastic studs so that it is possible to vibrate the support 10 for compacting the concrete contained in the molds, filtering the vibrations towards the float frame. Advantageously, the vibration means V (FIG. 13), schematically represented, are arranged to be hooked, during the vibration, to the mold support 10; these vibration means V occupy a fixed position in the tank E while the floats A2 and therefore the supports 10 move in the longitudinal direction; receiving parts 13 (fig. 13) for example formed by U-shaped profiles are provided under the supports 10; during the step-by-step advancement of a float A2, the vibration means V are detached from the support 10 and rest by rotating rollers on the parts 13; it is understood that during the advance of a step equal to the length of a float A2, the vibration means V, kept fixed in the longitudinal direction of the tank E, in particular by a cable hooked to one end of the tank , pass below the immediately following float.

Advantageously, the volume of the floats A1, A2 is calculated, as a function of their weight and of the weight of the heaviest and lightest products to be manufactured, so as to ensure, during the immersion of the floats provided with the bare products, a force gravitational, obtained when the float is loaded with the heaviest products, the amplitude of which is equal to that of the ascending force obtained when the float is loaded with the lightest products; this ensures economical routing of the floats in the hardening circuit.

In other words, in the case of the heaviest products, Archimedes' thrust only partially compensates for the weight of the heaviest product and it undergoes a gravitational force oriented downwards; in the case of the lightest products, the buoyancy is greater than the weight of the product and this results in an ascending force.

The guide rails or slides 42 of the floats are thus subjected to reduced forces, in particular in the parts of the tank where the floats are completely submerged. Means, such as, for example remote-controlled N-valves, can be provided on the floats, to modify the balance of these floats by introducing, inside the floats, a liquid, in particular the liquid of the tank; these means also make it possible to evacuate the liquid from the floats, for example by admitting compressed gas into the float, in order to expel the liquid.

The means B for pouring and compacting the concrete (FIGS. 1 to 4) are conventional and include a distribution hopper, in particular provided with a drum 15 for adjusting the flow rate, with a finishing rule.

The demolding means and the means for placing the concrete elements p on the floats may include tilting means C arranged either to ensure a tilting at 180 ^° (fig. 1 and 2) or a tilting at 90 ° (fig. 3 and 4).

In the case of tilting 180 °, the tilting means comprise a frame C1 suitable for tilting 180 ° around an axis / 3 (fig.1 and 2). The frame C1 is provided with parts 17, in particular elastic, for supporting and fixing the molds D1. Means, such as a jack, are provided for controlling the tilting of the frame C1 around the axis 13. A device is, moreover, provided for clamping the "float boards" A1 against the molds D1; this device comprises bent lever arms 18, articulated at 18a and provided with two longitudinal contact pieces 19 suitable for pressing the boards A1 against the molds; the lever arms 18 are linked to a system of oscillating jacks 20 articulated on uprights 21 fixed on the frame C1; the joints 18a are also provided on the uprights 21.

In the case of a 90 ° tilting, the tilting means comprise a frame C2 (fig. 3 and 4) used in particular for the manufacture of elements of great length with cross section in the shape of a U or T. This frame C2 comprises a frame 22, capable of rotating about an axis of rotation 23; two jacks 24 are provided to control the tilting of the frame C2. A device is also provided for clamping the "float boards" A1 against the molds and for lowering these boards; this clamping and lowering device comprises a longitudinal support 25, guides 26 for the movements of this support 25, and two jacks 27 controlling these movements. For casting, the "float board" A1 is clamped in the frame, so as to form part of the mold, as visible in FIG. 4. After tilting of the frame C2 at 90 ° relative to the position of the figure 4, the loosening operation is carried out with the jacks 27, which causes a vertical downward movement of the support 25 and of the "float board" A1 in the tank E; at the same time, the immediate release took place, and the concrete elements p are supported by the board A1.

The molds or mold batteries D1 (FIGS. 1 and 2) comprise one or more shells 28, made of sheet metal, an assembly frame 29, provided with plates 30 for attaching the vibrators 31 and shims 32 bearing on the studs 17.

In the case of tilting at 90 ° (fig. 3 and 4) the mold D2 is constituted by a bottom 33, a wall 34 and the "float board" A1 itself, placed parallel to the wall 34; in some cases, removable shells 35 are fixed on the wall 34 and / or on the "float board" A1.

The tilting frame C1, C2 fitted with the molds and the concrete distribution and smoothing device are mounted on a metal frame common 36, with all the hydraulic and electrical connections so as to form an independent module or "pouring-demolding head", which can be transported and mounted within a very short time.

In the case of production lines where the hardening of the concrete elements takes place in the molds D4 (fig. 7 to 9 and 13), these molds are formed in the conventional way, independent or in batteries.

The water tank E (fig. 1 to 9) is arranged to ensure sealing and good thermal insulation. The heating means R of this tank, for the hardening circuit, differ according to the type of production lines.

For the type of production line in which the floats, supporting the concrete products, move by floating, so that the concrete products always remain above the level of the liquid, the volume of the tank located can be heated above the liquid using conventional means such as steam, or spray with hot water.

For the production lines in which the concrete elements are immersed in the tank liquid, during the passage of the hardening circuit H (fig. 3 to 8), heating means R of the tank liquid are provided, so as to ensure an increasing temperature of this liquid along the tank; these heating means can include a superheated water distribution installation provided with fittings, arranged along the tank, and provided with flow-adjusting solenoid valves, as a function of the desired temperature, in order to obtain the optimum curve for temperature. However, the heating of the liquid in the tank can be ensured by other means such as steam, electrical resistances or any other suitable heating means. In some cases, hot water from natural sources or industrial recovery can be used. By using for the recovery of cooled water a network parallel to that of supply and placed in the same channel, one obtains an increased economic efficiency.

Means F (fig. 1, 2 and 3) are provided to ensure the descent, immersion and exit of the float boards A1, provided with bare products. These means F comprise either mechanical elevators or float elevators 37, fitted with a sliding mechanism 38, guide pieces 39 for the float boards and two connectors, one 40 for filling the float elevator 37 with liquid and the other 41 for the evacuation of the liquid out of the float lift 37. The filling of this float lift 37 with liquid causes it to descend into the tank E, while the evacuation of the liquid from this lift, causes it to rise in the liquid of the tank.

The means of displacement of the floats A1 or A2 are constituted by pushing devices 43, in particular formed by synchronized jacks, ensuring a step-by-step advance of all the floats in abutment against each other. The floats are guided by the rails or slides 42 (see in particular fig. 2).

For the production lines in which the concrete elements are immersed in the liquid, use is made for the longitudinal and transverse displacements of the floats of conventional displacement means such as pushing devices with jacks described previously; for the vertical displacements of the floats intended to cause the immersion of these floats or their rise to the surface of the liquid, valves are used as explained previously to introduce or expel liquid from the floats.

The means K (fig. 1 to 9) for evacuating the concrete elements out of the chain can be confused, in certain cases (fig. 1 and 3) with the means G for returning the "float boards" A1 to the pouring means. These conventional means K (overhead traveling cranes, cranes, electro-hoists, etc.) are in particular provided with suction cup devices 44 (fig. 3, 5) or with electromagnet 45 (fig. 8, 9) for handling. steel reinforcements.

The production lines of the invention can be fixed or can be mounted in a hull 46 (fig. 9) of a boat in order to constitute a floating factory; this shell 46 is then equipped with a concrete buffer hopper, reinforcement workshops 47 for depositing materials 48 and other annexes.

In all cases, the curing can be natural, or accelerated by means of heating.

It will be noted that the means B for pouring the concrete, in the case of the production line in FIG. 5, are arranged to allow immediate release from the mold by placing the concrete elements directly on the floats A1.

The production lines according to the invention make it possible to produce good quality products, even if they are large, with reduced energy consumption. Indeed, the floats on which the concrete elements are placed during their hardening, are supported, by the liquid of the tank, over their entire surface; the deformations of the floats due to the load formed by the concrete elements are reduced during hardening which thus takes place under good conditions. This remains true, even if they are large elements such as electric poles whose length can reach ten meters or more.

The heat losses are reduced because the tank E can be thermally insulated in good condition, this tank communicating with the outside only at one or at its two ends, according to relatively small openings.

Claims (14)

1. Manufacturing line for the manufacture of (non-reinforced, reinforced or pre-stressed) concrete elements such piles, posts, especially for electric lines, slabs, beams, panels, curbs, comprising casting means (B) for casting concrete in moulds (D,, D₂, D₄) and a moat (E) filled with a liquid for transporting the concrete elements from the casting means to a removal, means (K) by passing the concrete elements through a hardening circuit, characterized by the fact that it comprises a chain of floats (A,, A_Z) adapted to be moved in the moat (E) by supporting, especially through the hardening circuit, the concrete elements (p) which have just been withdrawn from the moulds, or the moulds (D₄) in which the concrete elements have been cast, said floats comprising means adapted to modify their equilibrium by the introduction into or removal from the floats of a liquid, notably the liquid of the moat, means (G, E) being further provided to bring back the floats (A,, A₂) to the concrete casting means (B).

2. Manufacturing line for the manufacture of concrete elements according to claim 1 characterized by the fact that the means adapted to modify the equilibrium of the floats comprises remote controlled electrovalves and means for admitting compressed gas into the float to drive out the liquid.

3. Manufacturing line according to claim 1 or 2 characterized by the fact that the floats (A1, A_z), for at least a part of their movement, corresponding to the passage through the hardening circuit, are immersed with the concrete elements (p) that they support in the liquid of the moat, this liquid being notably progressively heated along the moat.

4. Manufacturing line according to any one of the preceding claims characterized by the fact that the concrete casting means (B) are arranged to ensure demoulding of the elements, immediately after their casting, and the floats are formed by "board-floats" (A,) on which the bar elements are deposited during the immediate unmoulding

5. Manufacturing line according to claim 4 characterized by the fact that the casting means are arranged so as to ensure the closing of the moulds by the "board-floats" (A₁) and they comprise means (C) for tilting the molds for the demoulding so that after tilting, the "board-floats" (A₁) are below the mou!ded elements, so as to support them, means being provided, in addition, to lower the board-floats into the water moat (E).

6. Manufacturing line according to claim 5 characterized by the fact that the tilting means comprise a tilting frame arranged to tilt to 180° and comprising a fixing frame for the moulds or batteries of moulds on elastic studs (17), a gripping device (18, 19, 20 and 21) for the "board-floats" (A₁) on the moulds after casting of the concrete into the moulds and means for tilting the whole to 180°, so that the "board-floats" (A,) support the bare elements after unmoulding.

7. Manufacturing line according to claim 5 characterized by the fact that the tilting means comprise a tilting frame (C_z) arranged to tilt to 90°, this frame comprising a framework (22) provided with axis of rotation (23), the tilting to 90° being actuated by jacks (24), and a device for gripping and lowering the "board-floats" (A,) is provided, this gripping device comprising notably a longitudinal support (25), guides (26) and two synchronized jacks (27), the assembly being such that during the casting of the concrete, the "board-float" (A,), if necessary provided with shells (35), is gripped on the frame by forming a part of the mould and after the tilting to 90°, by the operation of ungripping effected to the vertical, there is produced, at the same time, the unmoulding and the lowering of the "board-float" (A,) supporting the moulded products into the water moat.

8. Manufacturing line according to claim 7 notably for the manufacture of elements with a "I" or "T" cross-section, characterized by the fact that the mould is constituted by a bottom (33), by a vertical wall (34) and by the "board-float" (A,), itself arranged parallel facing said vertical wall and gripped on the bottom, dismountable shells (35) being notably fixable on the wall and/or on the "board-float".

9. Manufacturing line according to any one of claims 4 to 8 characterized by the fact that each "board-float" (A1) is arranged on the form of a fluid-tight casing (1), notably by the injection of a hydrophobic and light material (2) and/or by means of one or several float elements (3), connected to a tray support (4) for the bare products, said boards being provided with guide parts (6), buffers (7) and if necessary rollers.

10. Manufacturing line according to any one of claims 1 to 3 in which the concrete elements remain in the moulds during the hardening, characterized by the fact that the floats are formed by moulds-carrying floats (AzL on which are fixed the moulds (D₄), and these moulds-carrying floats move around a closed circuit so that the moulds pass not only through the hardening circuit but also through the various work stations (casting of the concrete, unmoulding, cleaning of the molds).

11. Manufacturing line according to claim 10 characterized by the fact that each carrier- mould float (A_z) comprises on the one hand float elements (3) and assembly parts, for guiding and contact, and on the other hand, at least one working platform (8) and support- moulds (10) provided with support and fixing parts, and possibly, with receiving parts (13) for the vibration means (V).

12. Manufacturing line according to claim 11 characterized by the fact that each carrier- mould float (A₂) comprises receiving parts (13), notably formed by U profiles, provided beneath the support (10) for the vibration means (V) and these vibration means (V) are arranged to be fastened, during the vibration, to the mould support (10) these vibration means having a fixed position in the tank (E) whereas the floats (A_z) are moved in the longitudinal direction, the above-said vibration means (V) being detached from the support (10) and resting, notably by rotary rollers, on the receiving parts (13) on the step-by-step advance of the float (A_z).

13. Manufacturing line according to any one of preceding claims characterized by the fact that it comprises means (F) for lowering, immersion and exit of the floats, these means comprising elevators, notably elevator floats provided with connectors, one for the filling of the elevator float with the liquid and the other for the evacuation of the liquid so as to cause the descent or the rise of the elevator-float.

14. Manufacturing line according to any one of preceding claims, characterized by the fact that it is mounted in a boat hull (46) so as to constitute a floating factory.

Images