EP0085366B1 - Method of and device for manufacturing three-dimensional cells from solidifying building material - Google Patents

Description

The invention relates to a method for manufacturing room cells according to the preamble of claim 1.

The method according to the invention can be applied to solidifying materials which, e.g. Glass fiber or needle-reinforced concrete already contains its reinforcement when poured into the form space of a formwork or after the insertion of a reinforcement cage and is shaken in the process. According to the invention, room-sized structures are produced, which either form larger buildings with several other room cells according to the room cell construction or set up individually, for. B. can be used as prefabricated garages. This prefabricated construction enables the production of the room cells according to the invention in large quantities with a high degree of mechanization and rationalization in mostly room cell formworks that can be heated for the rapid hardening of the solidifying building material and which are then often part of a production line. After completion, the room cells are generally five-sided buildings. The method according to the invention enables the production of such room cells with all five wall or ceiling and floor panes in a monolithic design, but can also be applied to room cells in which one or more panes are missing or such as e.g. the base plate is prefabricated and then often kept ready on rolling pallets.

On the one hand, the manufacture of such room cells has to make do with as little manual work as possible in order to take advantage of the side construction. On the other hand, the room cell production must also reduce the subsequent completion work to the inevitable dimension by making the visible surfaces in the formwork as smooth as possible and therefore level.

It is known (DE-AS 24 62 352) to pour the liquid building material into the open top space of a room cell side wall. The building material rises in the subsequent molding space of the room cell floor and fills it up to about half. For this purpose, the space cell formwork must be pivoted about the longitudinal edge common to the two mold spaces in such a way that the mold space floor of the space cell floor encloses an angle of approximately 20 ° with the horizontal. In this process, the mold cavity opening of the longitudinal wall inclined against the vertical, through which the building material has been poured in, must first be closed. The formwork is then tilted again and so far that the bottom of the still empty mold space for the other longitudinal wall lies flat and above. This molding space fills the molding space of the room cell floor, which is only partially filled in the 20 ° position, before it is covered with the liquid building material itself.

The first step of this process has the advantage that when the building material is poured into the mold spaces which are closed on all sides, the mold floors and walls are only vertical or only inclined against the horizontal. As a result, the formation of air pockets and water pockets in the hardened building material can be largely avoided in a simple manner, so that the space cell panes produced in the closed mold rooms only have visible formwork surfaces that are smooth. However, it is disadvantageous that the liquid building material must be carefully removed in the second process step in the open mold space of the longitudinal wall of the room cell after the formwork has been filled in order to achieve a smooth visible surface there as well. That means a lot of work. The level of rationalization that can be achieved is already unusually low due to the multi-stage filling and hardening process.

DE-A-28 45 106 describes a method and a formwork for producing monolithic reinforced concrete room cells, in which the formwork is tilted by 90 ° and the top, outer, horizontal formwork surface is missing. The liquid concrete is poured into this formwork and the unshielded end face is removed. After the concrete has hardened sufficiently, the room cell including the formwork is tilted back to the starting position. After hardening, the finished room cell is released.

The necessity that the uppermost, outer formwork surface is missing, because the concrete is poured in here, results in a room cell that does not have smooth formwork walls everywhere. Another disadvantage of this method is that both the empty and the formwork filled with concrete have to be tilted by a large arc angle. These weights are structurally difficult to master. In addition, the degree of rationalization of this process is still low, since the outer end face must be removed in a further operation.

The invention has for its object to carry out a method of the latter type in such a way that a higher degree of rationalization is achieved and a spatial cell is created which only has visible formwork surfaces.

This object is achieved with the features of claim 1.

In the method according to the invention, the liquid building material is filled into the formwork, which is closed on all sides, via a special system which can have one or more pouring or pumping channels and one or more risers depending on the arrangement of the shape and design of the space cell. This saves the work previously required for smoothing and / or removing the liquid building material, which results when filling through the open mold space. In the method according to the invention, the filling of the mold is therefore also carried out in one operation carried out; The resulting hydrostatic pressure of the liquid building material cannot drive the filling out of the mold, which is closed on all sides, so that a further process step is saved. The risers allow the air that cannot be accessed due to the inclination of the room cell to escape before the liquid building material emerges and indicates the filling of the mold spaces.

bzw. gekippt werden, sich um

sie Ausgangsstellung für das Füllen zu bringe_';The filling of exclusively vertical and / or slightly inclined mold spaces takes place either in a known manner from above, preferably by on or near the edge oriented upwards due to the inclination of the room cell and its formwork due to the gravity and the hydrostatic pressure of the liquid building material, can also be carried out by increasing the pressure at or near the downward-facing edge of the room cell, e.g. using a concrete pump. Formwork according to the invention can be carried out more easily and can be better controlled structurally, because it only clings to one

or tilted around

to bring them to the starting position for filling _' ;

Advantageous embodiments of the invention are given in the subclaims.

The last-mentioned advantage of the invention is preferably ensured in that the mold is inclined in preparation for filling by about 20-25 ° relative to the horizontal, so that the mold spaces for incident space cell panes are limited by walls with this slope.

Such an inclination is not only due to the effect of avoiding air pockets and water pockets in the material of the room cell that has been attributed to it; at the same time, it reflects the inclination of an inclined plane on which the room cell cannot slip off its base with the friction coefficients customary for concrete. An embodiment of the method according to the invention makes use of this, according to which the floor cell is brought out of the formwork resting on a pallet at rest in the inclination predetermined by the orientation of the room cell transverse or longitudinal edge and is pivoted with it into the horizontal position for curing . The advantage is that the usual pallets can be used and special measures for locking the room cell on the pallet need not be taken.

This inclination is used in a further embodiment of the method according to the invention to support demoulding with forces which result from the weight component of the space cell falling in the inclination. The hardened space cell is transported out of the formwork in the direction of incidence over the space cell edge arranged downwards in the form of the formwork. The utilization of the weight component of the room cell falling in the direction of removal from the formwork then facilitates the removal of the finished room cell from the inner formwork, in particular when the formwork can be removed over a transverse edge of the room cell.

Several devices suitable for carrying out the method according to the invention are described below for better understanding of the invention with reference to the figures in the drawing.

• Fig. 1 in einer Seitenansicht eine Schalung für Stahlbetonfertiggaragen gemäß der Erfindung,
• Fig. 2 einen Schnitt längs der Linie 11-11 der Fig. 1,
• Fig. 3 einen Schnitt längs der Linie 111-111 der Fig. 1,
• Fig. 4 eine abgeänderte Ausführungsform einer Schalung für Stahlbetonfertiggaragen gemäß der Erfindung in der Stellung für das Eingießen des Baustoffes,
• Fig. 5 den Gegenstand der Fig. 4 nach dem Entschalen und
• Fig. 6 in Fig. 4 entsprechender Darstellung eine weitere Ausführungsform der erfindungsgemäßen Schalung.

Show it

• 1 is a side view of a formwork for prefabricated reinforced concrete garages according to the invention,
• 2 shows a section along the line 11-11 of FIG. 1,
• 3 shows a section along the line 111-111 of FIG. 1,
• 4 shows a modified embodiment of a formwork for prefabricated reinforced concrete garages according to the invention in the position for pouring in the building material,
• Fig. 5 shows the subject of Fig. 4 after demoulding and
• Fig. 6 in Fig. 4 corresponding representation of a further embodiment of the formwork according to the invention.

In the embodiment according to FIGS. 1 to 3, a track 3 is laid on an inclined plane 1 with an inclination angle of approximately 20 ° relative to the horizontal 2. It leads to a scaffold 6 erected on the inclined plane and enables the transport of roller pallets 16 along the inclined plane 1. The scaffold 6 carries an only schematically represented internal formwork 7, which according to the exemplary embodiment shown is rigid, but also for loading and unloading Stripping can have movable formwork parts. Short-stroke cylinders 8 are connected to a frame 9, which closes the mold space 12, which is delimited on the inside by the formwork 7 and on the outside by an outer formwork 14, on its end face 11.

The outer formwork of the mold space 12 for the room cell floor 15 is a roller pallet 16 of conventional design, which has a supporting frame and trolleys 17, 18 which run on the track 3. The molding space for the end wall 19 of the space cell, generally designated 20, is delimited by an external control panel 21. This formwork panel is articulated via a joint 22 with a vertical joint axis to an outer formwork panel 23 and can be demolded via a lever 24 with a hydraulic thrust piston transmission 25 from the shift position shown in solid lines. The double arrow 26 indicates the pivoting direction, a position of the formwork panel 21 being indicated in dash-dotted lines at 27, which position is assumed after the formwork has been removed. The formwork panel 23 corresponds to the formwork panel 28 that is parallel to it. The formwork panels 23 and 28 are mounted in steel frames 29, 30, which in turn can be moved with trolleys 31, 32, 33, 34 on rails 35, 36 in the direction of the double arrows 37, 38. The Double tracks 35, 36 run perpendicular to the direction of track 3, the rails of which are shown at 39 and 40 in FIG. 2. The formwork walls 23, 28 delimit the mold spaces for the longitudinal walls 41, 42 of the room cell, which is thus a room body closed on five sides except for the front end opening. The fifth side is formed by the ceiling 43, which is shut off to the outside with a two-part ceiling formwork 44, 45. Each slab formwork part 44, 45 can be moved via a lever gear 46, 47 in accordance with the double arrows 48, 49 with the aid of thrust piston gears 50, 51 into the descaling position shown in broken lines and in the switching position shown in solid lines.

On the front side 53, the roller pallet 16 carries a coupling 54 for the connecting cable 56 of a winch 57, which is fastened behind the frame 6 at the head of the inclined plane 1.

In the embodiment according to FIG. 1, at a distance corresponding approximately to the space cell length, there is a swivel platform 71 below the inner formwork 7, which has a swivel joint 72 with a swivel axis oriented transversely to the track 3. The underside 73 of the stage 71 opposite the joint 72 carries a bracket 74 for connecting a triple cylinder 75 which can be actuated hydraulically. The cylinder end is housed at 76 in a lined recess 77 in the hall floor. The cylinder, including its piston rod 78, can therefore be drawn in below the floor height indicated at 79.

• In der nicht dargestellten Ausgangsstellung steht die Rollpalette 16 auf dem ebenen Teil 59 des Gleises 3. Sie trägt einen Bewehrungskorb, der später auf der über dem Gleis 3 befindlichen Inncnschalung 7 ausgerichtet wird. Dazu wird die Rollpalette 16 mit Hilfe der Winde 57 auf die Kippbühne 71 gezogen, nach unten geschwenkt und in die Schalungsstellung verbracht, in der sie mit dem Gerüst 6 verriegelt ist. Die Außenschalung wird angefahren, und damit ist die Schalung für das Eingießen des erstarrenden Baustoffes - hier von Beton - vorbereitet.

The formwork works in the following way:

• In the initial position, not shown, the roller pallet 16 stands on the flat part 59 of the track 3. It carries a reinforcement cage which is later aligned on the inner formwork 7 located above the track 3. For this purpose, the roller pallet 16 is pulled onto the tilting platform 71 with the aid of the winch 57, pivoted downward and brought into the formwork position in which it is locked with the frame 6. The outer formwork is started up, and the formwork is thus prepared for pouring the solidifying building material - here of concrete.

Then the shape consisting of the different shape spaces for the described space cell panes is closed on all sides. The lower transverse edge 60 assigned to the end wall 19 is oriented downward, resulting in only a flat inclination of the longitudinal walls of the room cells, the ceiling and the floor corresponding to the inclination of the inclined plane 1, while the transverse wall 19 is inclined slightly at the same angle to the vertical . All mold floors and walls are thus inclined, i.e. none of these parts are horizontal.

The liquid building material is introduced into the mold via a pouring or pumping system, generally designated 62. For this purpose, a nozzle 64 for connecting a concrete line 65 is provided on the upper cross member 10a of the frame 10. In addition, a flexible hose 66 is connected to a corresponding opening in the cross member of the frame 10 for ventilation. Parts of the concrete remain in the socket 64 and in the hose 66, namely a sprue in the socket 64 and a riser in the hose 66.

The liquid concrete is poured into the mold, which fills from the edge 60 and on which further risers can be provided as required to prevent air from being trapped.

• Zunächst werden die Deckenschalungen 44 und 45 in die in Fig. 2 ersichtliche Stellung nach oben geschwenkt. Dann wird die Rückwandschalung 21 mit Hilfe des Schubkolbengetriebes 25 in die strichpunktierte Stellung 27 verbracht. Hierauf werden die beiden Außenschalwände 23 und 28 abgefahren. Damit ist das Entschalen der Außenschalung abgeschlossen.

After the concrete has been poured in, it is first allowed to harden. This can be accelerated by rapid hardening, which is known and for which the formwork walls are heated with steam, for example. As soon as the room cell has reached the strength required for the formwork removal, this process is carried out as follows:

• First, the slab formwork 44 and 45 are pivoted upwards into the position shown in FIG. 2. Then the rear wall formwork 21 is brought into the dash-dotted position 27 with the aid of the thrust piston gear 25. The two outer formwork walls 23 and 28 are then moved down. The formwork removal of the external formwork is now complete.

By actuating the thrust piston gear 8, the frame 10 is actuated in relation to the inner formwork 7 in the direction of the inclination of the inclined plane 1. At the same time the winch 57 is lowered so that the room cell 20 is stripped from the inner formwork 7. The weight component of the room cell 20 falling into level 1 helps here. The disconnected room cell 20 is moved onto the track section of the downwardly inclined tilting platform, which then pivots upward, so that the parts assume their position shown in FIG. 1. As a result of the inclination of the inclined plane 1, self-locking occurs between the room cell 20 and the pallet 16, so that the room cell need not be fastened to the pallet 16.

The formwork shown in FIGS. 1 to 3 can be part of a production line which enables the finished spatial cells 20 to be transported transversely to the inclined plane 1.

In contrast to the illustration in FIG. 3, the slab formwork 80 of the embodiment according to FIGS. 4 and 5 is formed in one piece and is therefore only operated with thrust piston drives 81 via angle levers 82 which are arranged on one side of the room cell formwork. In contrast, the risers 66 and the inlets 65 are arranged on the opposite side of the room cell at the highest longitudinal cell edge 83. The formwork can be pivoted with the help of the thrust piston mechanism 75 about the joint 72 running parallel to the track 3 in this embodiment in such a way that the longitudinal edge 84 of the room cell between the room cell floor 15 and the Room cell longitudinal wall 42 is oriented downwards. As a result, the floor, ceiling and longitudinal wall panels of the room cell assume a slightly inclined position, which can correspond to that of FIG. 1, while the room cell end wall is vertical. 4, the liquid building material is also introduced in a falling manner. For this purpose, the parts are first brought into the switch position shown in FIG. 4. Since the entire formwork is accommodated on the stage 71 in this embodiment, it is brought into the pivoting position 70 shown in FIG. 4 by extending the piston rod 78 and the cylinder from the thrust piston transmission 70.

To remove the formwork, the thrust piston mechanism 75 is retracted, the ceiling formwork is removed, as is the end wall formwork not shown in the exemplary embodiment according to FIGS. 4 and 5, and the side wall formwork 23, 28 are moved down. Then the room cell 20 can be pulled off the inner formwork and is in its horizontal position.

In the exemplary embodiment according to FIG. 6, the stage 90 rests on a supporting frame, which in turn is braced in guides 91 of a seesaw 112 which are curved in circles. The guides 91 are held at a distance with the aid of traverses 92, 93, 94, 95 and 96 and 97. On at least one guide 91 there is a ring gear 98 with which the pinion 99 of a geared motor 100 meshes. The guides are supported in rollers 101, 102, 103, 104, which are arranged distributed over the lower part of the circumference of the guides 91 and are mounted in a pit 105 under a hallway 106 on a common frame 107 and brackets 108, 109, 110, 111.

The rails 40, 39 of the track 3 are laid on the stage 90. However, the roller pallet 16 also carries the rails 35, 36 for the scaffolding 29, 30 of the outer formwork 23, 28, which close off the formwork spaces for the longitudinal walls 41, 42 of the room cells. The ceiling formwork 80 is designed as in the exemplary embodiment according to FIG. 4.

In the position shown, either the room cell is hardened to the extent that it can be disconnected, or the parts are prepared for casting the room cell.

In the latter case, the space cell is tilted by means of the geared motor 100 by pivoting the guides 91 into a position which corresponds to the position of the stage 71 according to FIG. 4. The liquid concrete is introduced via the pouring system, which is not shown in FIG. 6, but possibly corresponds to FIG. 4. The room cell can then be pivoted back into its position shown in FIG. 6 in order to bring about the hardening of the concrete in this position up to the strength of the formwork.

In a departure from the exemplary embodiments shown, in which the liquid concrete is poured into the closed form on all sides, the building material can also be pumped up, preferably at the edge of the room cell at the bottom. The pumping system required for this differs essentially only from the gate system 62 in that the riser and gate are further apart.

In a further deviation from the illustrated embodiments, it is also possible to finish casting the room cell with prefabricated panes. Thus, the prefabrication of the floor 15 comes into consideration, which can be introduced into the formwork together with the rolling pallet 16 in a manner known per se. The method according to the invention therefore also has the advantage that the already existing and tried and tested formwork systems can be used according to the invention in a modified form by adding a swivel platform according to the type of FIG. 4 and a ceiling formwork, insofar as this is not already available . It is only necessary to move the formwork into the slight inclination to the horizontal by rotating it about the longitudinal or transverse axis of the room cells.

Claims (8)

1. A method of manufacturing three-dimensional cells (20) from solidifying building material and from a reinforcing unit assembled as occasion arises in a basket, particularly ferroconcrete prefabricated garages between an outer and an inner casing (14), wherein fluid building material is introduced into, and allowed to pre- harden in, the shuttered-off molding spaces (12), which are joined together and which face at least the wall and roof-panels of the three-dimensional cell (20), in a position deviating from the horizontal position of the three-dimensional cell, before the fluid building material hardens fully in the horizontal position of the three-dimensional cell, characterised in that the casing (14) is inclined slightly, up to 25°, to the horizontal plane by means of a rotation about an axis parallel to a lower longitudinal or transverse edge (60,84) of the three-dimensional cell (20), and that the fluid building material is introduced, downwardly or upwardly,into the casing (14), which is closed on all sides, by means of a pipe (65) by way of a pouring or pumping system (62).

2. A method according to claim 1, characterised in that the fluid building material is introduced into the casing (14) inclined by 20 to 25° to the horizontal.

3. A method according to claim 1 or 2, characterised in that the three-dimensional cell (20) with its floor (15) resting on a pallet (16) is transported, with its transverse or longitudinal edges (60,84) inclined downwardly, out of the casing (14) and is pivoted into the horizontal position for full hardening with the aid of the pallet (16).

4. A method according to any one of claims 1 to 3, characterised in that the pre-hardened three-dimensional cell (20) is removed in the direction of inclination over the downwardly facing edge (60) of the casing (14).

5. A device for carrying out the method according to any one of claims 1 to 4, in a casing (14) which forms a closed molding space, and which can be tipped about an axis parallel to a transverse or longitudinal edge (60,84) of the three-dimensional cell and which can be pivoted back into its horizontal position for the uncasing of the three-dimensional cell (20), characterised by a pouring-in or pumping system (62) with one or more feeders (64) and risers (66) on or immediately adjacent to a casing (14) inclined slightly, by up to 25°, to the horizontal at the topmost or lowermost horizontal edge of the three-dimensional cell (11,83,84).

6. A device according to claim 5, characterised in that the casing (14) is arranged on an inclined plane (1), and for rolling pallets (16) operating in conjunction with the casing (14) there is provided a tipping platform which pivots a rolling pallet (16) into the inclination of the casing (14) or which shifts the rolling pallet (16) loaded with a pre-hardened three-dimensional cell (20) into the horizontal position for full hardening.

7. A device according to claim 5, characterised in that the casing (14) is fitted pivotably.

8. A device according to claim 5, characterised by a tipper (112) which operates in conjunction with a casing (14) fitted on an inclined plane and which picks up rolling pallets (16).

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