EP0197844B1 - Installation and process for manufacturing reinforced-concrete elements, in particular prestressed concrete sections - Google Patents

Abstract

An installation for manufacturing reinforced concrete elements, in particular prestressed concrete slabs or pre-slabs, by means of a bench including a manufacturing area of predetermined shape, together with a molding apparatus. Memory means (46) are provided for storing building data relating to the elements to be manufactured and concerning at least the geometry thereof, together with tracing means (48) for marking on the manufacturing area (16) the locations of at least some of the walls placed thereon and constituting portions of the molding apparatus.

Description

The present invention relates to an installation for manufacturing reinforced concrete elements, in particular slabs or pre-stressed concrete slabs.

It relates in particular to such an installation which comprises a bench comprising a manufacturing area of predetermined shape, as well as a molding apparatus capable of defining a set of molds whose base is formed by the manufacturing area and whose vertical contours are defined by walls attached to the manufacturing area.

According to French Patents Nos. 72 31148 and 79 07427 (published respectively under Nos. 2 152 604 and 2 421 040) in the name of the Applicant, installations of this type are already known which are used in particular for the manufacture of elongated building elements, such as beams, beams, posts, piles, etc. These known installations can also be used for the manufacture of building elements in the form of a plate, such as slabs or slabs.

The slabs are surface elements of reinforced or prestressed concrete, of small thickness, acting as lost formwork, which is used in particular for the manufacture of floors. A pre-slab being placed in its final location within a building, it then receives a layer of concrete which, after hardening, forms with this pre-slab a resistant slab of greater thickness.

At present, the production of pre-slabs consists either of a fairground prefabrication, that is to say on site, of reinforced concrete plates, or of a pre-production of pre-stressed concrete pre-slabs in the factory.

In the first case, we overcome the contingencies of the road gauge, but the performances and possibilities of rationalization of the production remain limited.

In the second case, large-sized elements can be produced, in particular elements at least 2.50 meters wide, making it possible to cross large spans.

Although such factory production theoretically lends itself to automatic industrial production, it is faced, in practice, with particular problems.

Such problems arise from the fact that each pre-slab constitutes a specific element which differs from the others in particular by its dimensions, by its frames and by the inserts and reservations which it must include.

This problem is all the more difficult to solve since the manufacturing area of an installation usually extends over a length of several tens of meters, for example 100 meters, and over a width which is generally between 2, 50 meters and 3 meters.

It is therefore necessary, before pouring the concrete, to delimit with precision on the manufacturing area the locations of the slabs for the subsequent installation of the mold assemblies, and this with the least possible loss of space on the area Manufacturing.

One of the aims of the invention is to improve the manufacture of elements of reinforced or prestressed concrete, in particular slabs or pre-slabs of prestressed concrete, by automating as much as possible the various manufacturing operations, in particular the tracing operations.

• une unité de traitement comportant des moyens de mémoire propres à recevoir, à travers une ligne de transmission, une pluralité de fichiers contenant des informations relatives aux éléments à fabriquer et concernant au moins la géométrie de ceux-ci, chaque fichier concernant un groupe d'éléments que l'on peut fabriquer ensemble avec un bon remplissage de la forme prédéterminée de l'aire de fabrication; et
• des moyens de traçage pilotés par l'unité de traitement pour matérialiser sur l'aire de fabrication les emplacements d'une partie au moins des parois rapportées de façon à définir complètement chaque moule en correspondance des informations stockées en mémoire à son sujet.

According to a first aspect, the invention relates to an installation for the manufacture of reinforced concrete elements, in particular slabs or pre-stressed concrete slabs using a bench comprising a manufacturing area of predetermined shape, as well as d a molding device capable of defining a set of molds the base of which is formed by the manufacturing area and the vertical contours of which are defined by walls attached to said manufacturing area, characterized in that it comprises:

• a processing unit comprising memory means suitable for receiving, via a transmission line, a plurality of files containing information relating to the elements to be manufactured and relating at least to the geometry thereof, each file relating to a group of elements that can be made together with a good filling of the predetermined shape of the manufacturing area; and
• tracing means controlled by the processing unit to materialize on the manufacturing area the locations of at least part of the attached walls so as to completely define each mold in correspondence with the information stored in memory on it.

According to another arrangement of the invention, the set of molds comprises, in combination, edge rules constituting the external longitudinal walls of the molds, as well as intermediate rules and combs suitable for being disposed respectively in the longitudinal direction and the transverse direction of the bench on the locations materialized by the tracing means.

According to yet another arrangement of the invention, the molding apparatus further comprises means of distribution-vibration of the concrete in the molds, which are controlled from the processing unit.

According to another arrangement of the invention, the installation comprises, for making the notching of the fresh concrete distributed by the concrete distribution-vibration means, a notching carriage movable along the bench and comprising a transverse beam, adjustable in height , on which depend a multiplicity of flexible teeth which come to bear on a transverse bed base.

According to another arrangement of the invention, the installation comprises, in order to section the prestressing reinforcements, between the elements obtained after hardening of the concrete, an automatic chainsaw with a disc movable transversely relative to a self-propelled carriage movable along the bench .

The installation of the invention also lends itself the manufacture of prestressed concrete elements with an insulating plate on the underside.

In a first variant, the invention comprises means for maintaining on the bottom of the manufacturing area longitudinal stapling profiles suitable for later use for fixing the insulating plate by means of staples passing through the thickness of the plate and coming to anchor in the profiles.

In a second variant, the tracing means are operative for tracing on a table, located in the extension of the manufacturing bench, the contour of an insulating plate and for then placing on the insulating plate deposited on the table along this contour, a sticks in selected places.

According to another aspect, the invention relates to a process for the manufacture of reinforced concrete elements, in particular slabs or pre-stressed concrete slabs using a bench comprising a manufacturing area of predetermined shape, as well as d '' a molding apparatus suitable for defining a set of molds the base of which is formed by the manufacturing area and the contours of which are defined by walls attached to said manufacturing area, characterized in that it comprises the operations consisting in store in memory, through a transmission line, a plurality of files containing information relating to the elements to be manufactured and relating at least to the geometry thereof, each file relating to a group of elements which can be manufactured together with good filling of the predetermined shape of the manufacturing area; to be carried out on the manufacturing area, as a function of one at a time of said files, plots materializing the locations of at least part of the reported walls so as to completely define each mold in correspondence with the information stored in its memory topic; to set up the vertical contours of the molds; and pouring the concrete into the mold assembly.

For the manufacture of elements with prestressing reinforcements, the tracing operation can be carried out either before the installation of the reinforcements, or preferably after their installation and their tensioning.

The method also provides, after the concrete has hardened and the tension in the reinforcements has been relaxed, to project the reinforcements into the gaps between the concrete elements, which makes it possible to remove the manufactured elements from the bench and store them for use. later.

• la figure 1 est une vue en coupe longitudinale du banc d'une installation selon l'invention;
• la figure 2 est une vue de dessus du banc de la figure 1;
• la figure 3 est un diagramme illustrant la commande des moyens de traçage et des moyens de répartition-vibration du béton à partir d'une unité de traitement;
• la figure 4 est une vue de face de l'organe de traçage de 1, l'installation;
• la figure 5 montre des exemples de tracés effectués sur l'aire de fabrication de l'installation;
• la figure 6 est une vue en coupe d'une règle de rive faisant partie de l'ensemble de moules;
• la figure 7 est une vue en coupe montrant une règle de rive dotée d'une rehausse;
• la figure 8 est une vue latérale montrant une cale de serrage bloquant la rehausse de la règle de rive de la figure 7;
• la figure 9 est une vue en coupe montrant une règle intermédiaire faisant partie de l'ensemble de moulage et dotée d'une rehausse amovible;
• la figure 10 est une vue partielle en coupe d'une presse de maintien de règle intermédiaire;
• la figure 11 est une vue de dessus d'un peigne faisant partie de l'ensemble de moules;
• la figure 12 estunevue en coupe transversale du peigne de la figure Il;
• la figure 13 est une vue partielle en coupe d'un peigne maintenu par d'autres moyens de blocage;
• la figure 14 est une vue de face d'une benne de répartition-vibration du béton;
• la figure 15 est une vue latérale de la benne de la figure 14;
• la figure 16 est une vue latérale d'un chariot de crantage;
• la figure 17 est une vue de face d'un chariot équipé d'une scie pour tronçonner les armatures;
• la figure 18 est une vue de dessus montrant les organes de détection-réception du chariot de la figure 17;
• la figure 19 montre schématiquement des organes de recalage de la scie de la figure 17;
• la figure 20 montre la mise en place d'un profilé d'agrafage sur l'aire de fabrication;
• la figure 21 montre la mise en place d'une plaque d'isolant en sous-face d'une prédalle dans laquelle est noyé au moins un profilé d'agrafage selon la figure 20;
• la figure 22 est une vue de face d'un poste d'agrafage de l'installation;
• la figure 23 est une vue de côté du poste d'agrafage de la figure 11;
• la figure 24 est un détail de la figure 22; et
• la figure 25 est un détail de la figure 23.

In the description which follows, given solely by way of example, reference is made to the appended drawings, in which.

• Figure 1 is a longitudinal sectional view of the bench of an installation according to the invention;
• Figure 2 is a top view of the bench of Figure 1;
• FIG. 3 is a diagram illustrating the control of the tracing means and of the distribution-vibration means of the concrete from a treatment unit;
• Figure 4 is a front view of the tracing member of 1, the installation;
• FIG. 5 shows examples of plots made on the manufacturing area of the installation;
• Figure 6 is a sectional view of an edge rule forming part of the mold assembly;
• Figure 7 is a sectional view showing a bank rule with a riser;
• Figure 8 is a side view showing a clamp blocking the raising of the edge rule of Figure 7;
• Figure 9 is a sectional view showing an intermediate rule forming part of the molding assembly and provided with a removable riser;
• Figure 10 is a partial sectional view of an intermediate rule holding press;
• Figure 11 is a top view of a comb forming part of the mold assembly;
• Figure 12 is a cross-sectional view of the comb of Figure II;
• Figure 13 is a partial sectional view of a comb held by other locking means;
• Figure 14 is a front view of a concrete distribution-vibration bucket;
• Figure 15 is a side view of the bucket of Figure 14;
• Figure 16 is a side view of a notching carriage;
• Figure 17 is a front view of a carriage equipped with a saw for cutting the frames;
• Figure 18 is a top view showing the detection-reception members of the carriage of Figure 17;
• FIG. 19 schematically shows adjustment members of the saw in FIG. 17;
• Figure 20 shows the establishment of a stapling profile on the manufacturing area;
• Figure 21 shows the establishment of an insulating plate on the underside of a pre-slab in which is embedded at least one stapling profile according to Figure 20;
• Figure 22 is a front view of a stapling station of the installation;
• Figure 23 is a side view of the stapling station of Figure 11;
• Figure 24 is a detail of Figure 22; and
• FIG. 25 is a detail of FIG. 23.

The body of the bench shown in FIGS. 1 and 2 comprises, at its ends, two buried solid masses in reinforced concrete 10 and 12 as well as stop massifs 10, and 10 _Z. Between these two blocks extends a ribbed slab 14 which supports the manufacturing area 16 and which compensates for the compression forces generated by the tension of the prestressing reinforcements and used for the manufacture of the construction elements.

The manufacturing area 16 includes a deck formed by a set of thick metal plates which rests on a series of profiles 18 in 1 which extend parallel to each other and transversely to the length of the bench. These sections rest on the ribbed slab 14 by means of elastic studs (not shown).

The manufacturing area 16 defines a flat and horizontal surface of rectangular shape, the length of which can be of the order of 100 meters and the width of between 2.50 meters and 3 meters.

Below the sheets forming the manufacturing area 16 is provided a heating device making it possible to accelerate the setting of the concrete after casting on the manufacturing area. In the example shown, it is a steam heating comprising an inlet 20 and two outlets 22 for condensate discharge (lost steam).

The bench in Figures 1 and 2 also includes means for tensioning and / or releasing prestressing reinforcements. In a pit 24 provided behind the buried block 10 are arranged vertical metal profiles 26 which come to bear on a transverse profile 28. Two jacks 30 for tensioning are articulated on the one hand to the profiles 26 and, on the other hand, to a traction trimmer 32.

At the other end of the bench, a sealed anchoring device 34 is installed vertically in a pit 36 formed behind the block 12. The device 34 is supported on a transverse section 38.

Thanks to the above-mentioned means, it is possible to have, above the manufacturing area 16, prestressing reinforcements 40 constituted by a set of parallel wires, one end of which is anchored in the device 34 and the other end of which is anchored in the header 32.

Advantageously, the bench also comprises means for positioning the reinforcements 40. The set of wires forming the reinforcements 40 is preferably produced in the form of a sheet which is prepared beforehand and which is placed on a rotary reel mounted on a cart that can be moved along the bench. Thanks to such a device, it is possible to anchor the ply of wires first in the header 32, then in the anchoring device 34.

The main components of the bench, which have just been described briefly above, that is to say the body of the bench, the manufacturing area, the heating device, the tensioning and / or relaxation means reinforcements, and the means for fitting the reinforcements, are already known and do not form part of the present invention.

The structure and operation of these known elements are described in particular in French Patents 72 31 148 and 79 07 427 in the name of the Applicant.

Reference is now made to FIGS. 3 and 4 relating more particularly to the tracing means of the invention.

The installation of the invention makes it possible to manufacture reinforced or prestressed concrete elements, for example slabs, on the manufacturing area 16, according to construction information relating to the elements to be manufactured. This information relates at least to the geometry of the elements, that is to say their shapes, their dimensions and their thickness. They may include other additional information, for example relating to the order of handling and installation of elements on the site.

This various information is introduced into a file 42 which may relate, for example, to the pre-slabs to be manufactured for a client or for a given site.

In addition, a file 44 is provided in which the information relating to the pre-slabs to be manufactured is introduced, which are grouped by casting. This file also contains information relating to the dimensions of the manufacturing area, in order to be able to manufacture a set of slabs during the same pouring on the manufacturing area.

Files 42 and 44 can be produced in particular by appropriate software on WANG-type hardware.

The information from files 42 and 44 is applied to a processing unit 46 which includes memory means suitable for storing said information.

This processing unit can be constituted for example by equipment of the APPLE II type. The processing unit 46 is connected to a tracing member 48 and to a concrete vibration distribution member 50 by means of suitable connections, for example remote connections.

The processing unit 46 controls the tracing means 48 so that they materialize on the manufacturing area 16 the locations of at least part of the walls which will be added later on the manufacturing area, so as to completely define each mold corresponding to information stored in memory.

The processing unit 46 also controls the member 50 to subsequently distribute the concrete in the molds according to their geometry.

It should be noted that the processing unit 46 can also be used to control a drawing machine 52 capable of establishing the plans of the slabs on paper.

The processing unit 46 is arranged to constitute, from the raw file 42 of the slabs to be manufactured, defining their respective shapes, the file 44 of the elements which will be grouped together to be manufactured together, during the same casting, taking into account of the rectangular shape of the manufacturing area. For this, one can use any known software capable of ensuring a form filling.

The tracing member 48 is shown more particularly in FIG. 4. It comprises a self-propelled gantry that can be moved over the entire length of the bench on rails 54 arranged on either side of the manufacturing area 16, and integral with that -this. These rails are arranged in the immediate vicinity of the banks 16 and 16 ₂ of the bench.

The gantry includes a transverse and horizontal beam 56, a nozzle-carrying carriage 58 movable along this beam by means of a shaft 57 parallel to the beam and a reciprocating cable 59. The gantry further comprises a spray nozzle 60 carried by the carriage, and a programmable controller 62 connected to the memory means of the unit 46. The nozzle 60 is connected to a reservoir 61 of tracing liquid carried by the carriage 48, by means of a flexible pipe 63. With this nozzle is associated a solenoid valve 65 connected to the automaton 62 by a flexible electrical pipe 67.

The automaton 62, which can be a MERLIN-GERIN automaton, is capable of controlling the movement of the gantry on the rails 54 and the movement of the carriage 58 along the beam 56, as well as the operation (on and off) of the solenoid valve 65 for controlling the nozzle 60.

The nozzle 60 is thus displaceable according to a system with orthogonal axes to materialize on the manufacturing area 16 the locations of at least part of the mold walls to be attached.

The aforementioned tracing means are operative to project, by means of the nozzle 60, a tracing liquid in the direction of the bottom of the manufacturing area 16 on which have already been put in place prestressing reinforcements 40.

The tracing member 48 can be used both before the fitting of the reinforcements 40 and after the fitting of the latter.

The liquid used by the tracing member 48 may be a mixture of pasty white for the ceiling, water and soluble oil. Such a mixture has the following advantages: it is inexpensive, easy to use (flows by gravity), it does not dry in the paint mixture, it does not mark the decking of the manufacturing area or the undersides of the slabs, and it leaves a fine and uniform line even in the presence of mold release oil on the manufacturing area.

It is thus possible to obtain a line of white color having for example a width of 3 to 5 mm which is largely compatible with the manufacturing tolerances.

As shown in Figure 5, the tracing member 48 can be controlled to materialize, on the manufacturing area 16, the locations of at least part of the attached walls for the manufacture of different slabs. This involves manufacturing, among other things, a pre-slab 64, which extends over the entire width of the manufacturing area, two pre-slabs 64 ₂ and 64 ₃ of the same length, arranged one beside the other depending on the width of the manufacturing area, two pre-slabs 64 ₄ and 64 ₅ of the same length also arranged one next to the other on the manufacturing area, and a pre-slab 64 ₆ of width less than that of the manufacturing area.

The layout materializes the location of at least part of the mold walls, namely intermediate edges, for example on location 66, and transverse combs, for example on location 68.

The tracing member 48 is not programmed to trace the longitudinal edges 70 and 72 of the manufacturing area 16, the latter being in fact materialized by rules as described below with reference to FIGS. 6 and 7.

The invention also provides that the automaton 62 is programmed to draw marker symbols for the location of reservations, for example 74, and 74 ₂ , of electrical contacts, for example 76, and 76 ₂ , etc. Note that the location of a rectangular reservation, for example 74 ₁ , does not need to be completely traced. It suffices to materialize only two adjacent sides of the rectangle.

As shown in FIG. 6, an edge rule 76 disposed along an edge 70 or 72, comprises a series of profiles 78, of limited length, for example 3 meters long, arranged one after the other. . Each section 78, of square section, is connected by connecting arms 80 to hinges 82 placed outside the edges 70 respectively 72 of the manufacturing area. Each profile can pivot between, on the one hand, a closed position (shown in solid lines) where one of the longitudinal faces of the profile rests horizontally on a chamfered flat profile 84 and, on the other hand, an open position (shown in broken lines) where the profile 78 is pivoted outward relative to the manufacturing area. The profile 84 is welded, from place to place, by plug welds 86 on the metal deck constituting the manufacturing area 16. The hinges 82 are connected to the profiles 84 by connecting rods 88.

In the closed position, the profile 78 defines a vertical face 90 forming a molding wall for the subsequent casting of a pre-slab 92 which will have a chamfer in correspondence with the profile 84.

The profiles 78 are pivoted between their two extreme positions manually.

Attachment pieces 93 are also provided from place to place on the two lateral edges of the manufacturing bench for the anchoring of C-shaped locking pieces 95 suitable for blocking the profiles 78 on the profiles 84. Each piece 95 has a branch 95, with a heel 95 ₂ and suitable for being engaged under a part 93 by bearing on the decking of the manufacturing area 16, and a branch 95 ₃ parallel to the branch 95, and provided with a spout 95 ₄ capable of coming to bear on the top of the profile 78. The parts 95 are locked in position by applying a hammer blow in the direction of arrow F.

According to Figure 7, the profile 78 of the edge rule 76 has a removable riser 94 for molding elements, in particular of slabs, 96, of great thickness. This extension comprises a plate 98 which, in the closed position, extends the internal vertical face 90 of the profile upwards and inwards of the manufacturing area.

The plate 98 is connected to a base 100 by triangular gussets 102. The base 100 is suitable for being locked on the upper horizontal face of the profile 78 by means of a clamping wedge 104 interposed between the base and a console 106 integral with the profile 78. The wedge 104 slides inside a stirrup 108, in the shape of an inverted U, the ends of the branches of which are welded to the top of the base 200. The wedge 104 has a straight lower flank 110 able to bear on the top of the base 100 and a rectilinear upper flank 112 forming an angle of slight slope with the flank 110. The flank 112 is suitable for engaging under a flange 114 of the console 106. When the 'a force is exerted at the end of the shim 104, as represented by the arrow G in FIG. 8, for example by means of a hammer, the shim ensures the tightening of the extension 94 on the profile 78.

It will be noted that, in the open position, the profile rests on the decking of the manufacturing area 16 by an inclined part 106 of the console 106.

Figure 9 shows an intermediate rule 116 and a removable riser 118 suitable for covering the top of this rule to allow the molding of elements of greater thickness. The rule 116 can be arranged for example at location 66 illustrated in FIG. 5.

This rule comprises two parallel plates 118 ₁ and 118 ₂ connected by their opposite faces by two superimposed U profiles 120 ₁ and 120 ₂ . The base respectively 122 ₁ and 122 ₂ of each plate, which is intended to rest on the bottom of the manufacturing area, is folded outwards to define a chamfer in the profile of the slab subsequently cast.

The extension 118 comprises two parallel plates 124 ₁ and 124 ₂ joined together by a section 126 of square section. Spacing members 128 are arranged from place to place under the profile 126.

FIG. 10 shows a press 130 intended to hold an intermediate rule 116 in abutment on the bottom of the manufacturing area 16. The press 130 comprises a transverse beam 132 extending over part of the width of the manufacturing area 16 and terminated at one end 132 ₁ by a vertical foot 134 suitable for bearing by its base 136 on a vertical plate 138 provided on one of the banks of the manufacturing bench. The other end 132 ₂ of the beam 132 is cantilevered above the manufacturing area 16.

The press 130 also comprises a hooking member 140 which is fixedly mounted on the beam 132. This hooking member comprises two elements 142 and 144 joined at one of their ends by forming a V. The element 144 has a hook 146 suitable for anchoring in a ring 148 forming part of a series of rings arranged from place to place along the bench, outside the manufacturing area 16.

The press 130 further comprises at least one screw jack 150 mounted on a sleeve 152 suitable for sliding along the beam 132. The jack 150 which is arranged vertically comprises, at its lower part, a block 154 capable of coming to bear on the top of the rule 116 and, at its upper end, an operating member 156.

The rings 148 are integral with profiles 158, in the shape of an inverted U, which serve to support both a plate 138 and the decking of the manufacturing area 16.

Thanks to the presses 130, it is possible to maintain, at the desired locations, intermediate rules 116, possibly provided with risers.

When a cylinder 150 is screwed so as to maintain a rule 130, the beam 132 tends to tilt around the articulation of the hook 146 around the ring, but this tilting is prevented by the support of the foot 136 on the above plate 138.

The comb 160 shown in FIGS. 11 and 12 is part of the mold assembly and is intended to be placed transversely on the manufacturing area 16 at a location, such as 68, shown in FIG. 5. This comb comprises a profile in inverted U whose two branches form undercut walls to facilitate the removal of the comb after hardening of the concrete poured on the manufacturing area. The two branches 162 and 164 are provided with elongated vertical facing slots, respectively 166 ₁ , 166 ₂ , ... and 168 ₁ , 168 ₂ , ... for the passage of prestressing reinforcing wires 40 ₁ , 40 ₂ , ... the interval between two adjacent vertical slots corresponding to the interval "i" between two adjacent prestressing wires.

The profile further comprises two handles 170 to allow its handling.

The comb further comprises two locking members 172, and 172 ₂ constituted by an eccentric member or spacer respectively 174 ₁ and 174 ₂ whose rotation is controlled by a lever respectively 176, and 176 ₂ . The displacement of each of the handles is limited by two stops respectively 178, and 180 ₁ , and 178 ₂ and 180 ₂ 2. The locking member 172, is shown in a non-operating position in which the lever 176 is supported on the stop 178, and the member 174 ₁ , of elongated shape, is parallel to the direction of the prestressing wires.

The member 172 ₂ is shown in the blocking operating position in which the lever 176 ₂ is supported on the stop 180 ₂ and the member 174 ₂ is substantially perpendicular to the direction of the prestressing wires. It thus exerts a spreading action on the two wires 40 ₃ and 40 ₄ .

In another alternative embodiment, shown in FIG. 13, the comb 160 is held at each end by an assembly 181 comprising a tie-rod 181 ₁ , one end 181 _{2 of which} is bent and suitable for hanging behind a sloping threaded flat 183 provided along the entire length of the bench and on either side of it. The other end 181 ₃ of the tie rod is articulated to a link 181 ₄ , itself articulated to a lever 181 ₅ . The latter is articulated by an axis 181 ₆ on a support 181 ₇ itself fixed on the upper part of the comb. The comb 160 is locked in position by operating the two levers as shown by the arrow H.

The concrete distribution-vibration member 50 shown in FIGS. 14 and 15 comprises a bucket 182 supported by a self-propelled carriage 184 movable along the bench. The bucket 182 is provided with a rotary volume distributor 186 suitable for distributing the concrete over the entire width of the manufacturing area and a series of distribution flaps 1881,1882, ... each actuated independently by a jack 190 ₁ , 190 ₂ , ... to distribute the concrete selectively over the width of the bench.

• la perte de poids correspondant à une quantité de béton déversée;
• la distance parcourue par le chariot auto- moteur pendant cette perte de poids; et
• la largeur de distribution.

According to the invention, means are provided for slaving the speed of rotation of the distributor 186 and also the speed of advance of the carriage 184 on the bench as a function of three information points, namely:

• the weight loss corresponding to the quantity of concrete spilled;
• the distance traveled by the self-propelled trolley during this weight loss; and
• distribution width.

In order to determine the weight loss corresponding to an amount of spilled concrete, the member 50 is provided with weight sensors 192 ₁ , 192 ₂ , ... interposed between the bucket and the self-propelled carriage.

The member 50 is functionally connected to the processing unit 46 of the installation in order to take into account the information relating to the slabs, in particular as regards their geometry.

The processing unit also takes into account the density of the concrete, as input data, which can vary from one factory to another.

On the chassis of the carriage 184 are also fixed means for vibrating the poured concrete constituted by vibrating pads 194, and 194 ₂ connected to a vibration generator and capable of coming to bear on the vertical edges 16 ₁ and 16 ₂ of the manufacturing bench.

The chassis of the carriage 184 also supports, in a manner known per se, a retractable rotary brush 195 suitable for cleaning the manufacturing area, and a spraying boom for demolding oil (not shown).

After distribution and vibration of the concrete, the upper surface of the slabs must be roughened to facilitate the subsequent attachment of a layer of concrete which will be poured on site on the pre-slab already manufactured.

Until now, this treatment has been carried out by means of an expanded metal roller. However, such a roller cannot be passed over the surface of the slabs if there are obstacles, such as hooks, pending irons, etc.

The present invention recommends using a notching carriage 196 which can be moved along the bench, as shown in FIG. 16. This carriage comprises two vertical uprights 198 on which respectively slide two vertical uprights 200 which are joined together at their upper parts by a transverse beam 202. This beam and the uprights 200 are adjustable in height by means of at least one lever 204. From the beam 202 depend a multiplicity of teeth 206 which come to bear on a transverse bed base 208.

The teeth 206 are flexible and each formed, for example, from a section of concrete iron. They can be adjusted in height using the levers 204 according to the desired notching depth.

After the concrete has hardened and the tension exerted on the prestressing reinforcements has been relaxed, the latter are sectioned by an automatic chainsaw 210, as shown in FIG. 17. The chainsaw can be moved transversely on a beam 212 forming part of an auto carriage -motor 214 movable along the bench.

The chainsaw 210 comprises an abrasive disc 216 driven by a motor 218. This chainsaw can also be moved vertically, either downwards (plunge movement) or upwards (lift movement).

The carriage 210 comprises, placed in front of the disc 216 at a distance corresponding substantially to half the interval "1" between two successive elements (predales) 220 and 222, a photoelectric detection assembly comprising an emitter E and a detector D This assembly is suitable for controlling the stopping of the carriage and the starting of the chainsaw when the assembly detects the end of a pre-slab, for example pre-slab 220.

In this way, the chainsaw ensures the cutting of the reinforcing wires 40 in a sectioning direction which is located midway between the slabs 220 and 222 (FIG. 18).

As shown in FIG. 19, the chainsaw 210 furthermore comprises means for resetting the depth of cut to take account of the wear of the disc 216. These means comprise two detectors 224 and 226 placed at different levels above the manufacturing area 16.

These means act on the adjustment of the chainsaw so that the lower part of the disc is located between the respective levels of the two detectors 224 and 226.

Figure 19 shows, from left to right, three different situations, respectively. In the first situation, the disc 216 is set too high; in the second situation, the disc 216 is located at an intermediate level between the two detectors and, in the last situation, the disc is at a level that is too low, that is to say below the level of the two detectors 224 and 226.

The registration being made, the carriage 210 is placed in the vertical position of the prestressing wires 40, near a bank, then the saw plunges by a constant value measured by a number of turns of a ball screw. The cutting can then begin.

The installation of the invention lends itself particularly well to the production of prestressed concrete elements, in particular slabs, comprising an insulating plate on the underside.

In the prior art, an insulating plate is placed on the manufacturing area and the concrete is then poured onto the plate. Such a technique has a major drawback in that the insulation slows down the subsequent hardening of the poured concrete under the action of the heating means arranged under the manufacturing area.

The invention makes it possible to avoid such a drawback thanks to the fact that the concrete elements are poured in a normal manner on the manufacturing area and are then subjected to an insulating plate on the underside, and this on another post of the installation.

In a first variant, means are provided for holding stapling profiles 228 on the bottom of the manufacturing area 16 in the longitudinal direction of the bench (FIG. 20). These profiles will later be used to fix an insulating plate by means of clips crossing the thickness of the plate and coming to anchor in the longitudinal profiles on the underside of the concrete element.

The profile 228 has a bottom wall 230, pierced by the staples, and which is arranged flat on the bottom of the manufacturing area 16. The profile further comprises two wings 232 and 234 which project upwards from from the bottom wall 230, while moving away from one another. These two wings are then folded back towards each other, forming a V-shaped profile, the point of which is directed towards the bottom wall. The external sides 236 and 238 of the V-shaped profile are adapted to separate the two initially parallel branches of a clip introduced by force through the bottom wall.

The means for holding the profile 228 consist of shims 240 interposed between the profile and a wire 40 of prestressing armature (Figure 20). Such a wedge has the profile of a split ring, provided with a central opening 242 capable of being clipped around a wire 40, and is provided with radial extensions 244 and 246 capable of coming to bear on the internal flanks of the part in V above.

When a pre-slab is provided for subsequently receiving an insulating plate, a number of stapling profiles 228 are placed on the bottom of the manufacturing area at regular intervals and each profile is then held by means of several wedges 240.

We then proceed to the manufacture of the slabs as indicated above.

A pre-slab 248 thus obtained is then placed on a stapling bench comprising a table suitable for successively receiving an insulating plate 250 and the concrete element 248 (FIG. 21). Staples 252 are then forcibly introduced, vertically and from bottom to top, through the plate 250 and through the bottom wall 230 of a profile 228. The two branches 254 and 256 of the clip thus pierce this wall of bottom and are then deflected by the external sides 236 and 238 of the profile 228.

The clips 252 are thus retained by the profile and cannot be released from the latter due to the spacing of the two branches.

The installation comprises, following the manufacturing area 16, a stapling bench 258 described with reference to FIGS. 22 to 25. The bench 258 comprises a frame formed by a number of feet 260 which support a table horizontal formed by five parallel profiles 2621 "", 262 ₅ , suitable for successively receiving an insulating plate 250 and a concrete element, for example a pre-slab 248 coming from the manufacturing area and incorporating stapling profiles as described previously.

The stapling bench 258 also includes a movable carriage 264, movable longitudinally between the legs 260 and under the table of the bench. This carriage 264 supports four staplers 266 ₁ , 266 ₂ , 266 ₃ and 266 ₄ each movable in the corridor formed between two adjacent sections forming the table of the bench.

The distance between the different staplers strictly corresponds to the distance between the profiles previously embedded in the pre-slab 248.

These staplers are advantageously pneumatic staplers controlled from a pressure source 268 carried by the carriage 264.

As the carriage advances, the staplers introduce, from place to place, through the insulating plate 250, staples 252 which will be housed in the different profiles 228, according to the principle described above with reference in Figure 20.

To allow precise positioning of the insulating plate and the pre-slab on the bench, there is an adjustable stop beam 270 forming a reference support. This stop beam which extends horizontally in the longitudinal direction of the table is adjustable in position by means of a flywheel 272 and a locking handle 274.

There is also an eclipsable stop 276, controlled by a jack 278, which extends over the entire width of the stapling bench and which is intended to position the insulating plate 250 (Figures 22 and 24).

The bench also supports a saw 280 movable longitudinally on the bench and suitable for cutting the insulating plate according to the desired width. The saw 280 comprises a bracket 282 movable along the bench and a saw block 284 adjustable horizontally in position relative to the bracket. This saw block supports a circular saw 286 arranged vertically and in the longitudinal direction of the stapling bench.

In another alternative embodiment, not shown in the drawings, the tracing means described above are used to materialize on a table, generally situated in the extension of the production bench, the contours of the concrete elements, in particular of the slabs, in front receive an insulating plate.

To do this, we use the same processing unit as that used for tracing on the manufacturing area.

There are then on this table insulating plates of standard dimensions (for example 2.50 meters by 0.50 meters) or cut to correspond to the planned dimensions of the slabs,

The tracing member is then piloted to deposit glue, either in the form of a continuous net, or in the form of studs, at locations determined according to a defined program.

For example, one can have a thread of peripheral adhesive and a thread along the diagonals of each plate, or peripheral studs plus central studs.

For this, the carriage 58 of the member 48 shown in Figure 4, will advantageously include another nozzle provided specifically for spraying the glue.

Once the adhesive has been deposited on the insulation plate, it is then centered and placed, for example by means of a traveling crane, the pre-slab on the insulation plates already glued. The natural pressure due to the self-weight of the pre-slab ensures the tightening of the adhesive.

• a) une colle à prise rapide (entre 5 et 20 minutes par exemple) pour permettre la manutention des prédalles isolées thermiquement, et cela rapidement;
• b) une colle à prise plus lente résistant aux hautes températures, afin d'avoir une bonne tenue du collage dans le cas d'un incendie, car la sous-face isolante joue aussi un rôle de protection à l'égard des incendies.

Two adhesives will advantageously be used on the same pre-slab:

• a) a quick setting glue (between 5 and 20 minutes for example) to allow the handling of thermally insulated slabs, and this quickly;
• b) a slower setting adhesive resistant to high temperatures, in order to have good bonding resistance in the event of a fire, since the insulating underside also plays a protective role with regard to fires.

The installation as described above makes it possible to carry out the following sequence of operations: installation then tensioning of the prestressing reinforcements; tracing the locations of the mold walls; installation of the vertical contours of the molds as well as any reservations; distribution and vibration of concrete in molds; notching concrete still fresh; heating the bench to harden the concrete; slackening of the tension of the reinforcements; shearing of reinforcements in the intervals between the cast elements; and possible installation of insulating plates on the underside of the elements.

As already indicated, the tracing can be carried out before the reinforcement is tensioned.

On the other hand, the central unit can be used to manage the stock of manufactured elements, that is to say to schedule the elements according to each site or each customer and the sequence of use of the elements.

Claims (27)

1. Installation for the production of reinforced concrete elements, especially prestressed-concrete slabs or pre-slabs (64₁, 64₂ etc.), by means of a bench comprising a production area (16) of predetermined shape and a moulding appliance suitable for defining a set of moulds, the base of which is formed by the production area (16) and the vertical contours of which are defined by walls (76, 116, 160) attached to the said production area, characterized in that it comprise:

a processing unit (46) possessing memory means suitable for receiving, via a transmission line, a plurality of files (42, 44) containing information relating to the elements to be produced and regarding at least the geometry of these, each file regarding a group of elements which can be produced together with a good filling of the predetermined shape of the production area (16); and

tracing means (48) controlled by the processing unit (46) in order to mark on the production area (16) the locations of at least some of the attached walls (116, 160), so as to define each mould completely in accordance with the memorized information relating to it.

2. Installation according to Claim 2, characterized in that the processing unit (46) comprises means which, starting from a primary file (42) of the elements to be produced, are suitable for constructing the file (44) of the elements so as to be produced together during the same casting.

3. Installation according to one of Claims 1 and 2, characterized in that the tracing means (48) comprise a self-propelled gantry movable over the entire length of the bench, this gantry comprising a transverse beam (56), a nozzle-holder carriage (58) movable along this beam, a spray nozzle (60) carried by the carriage, and a pro- gramable automatic control (62) connected to the memory means of the processing unit (46) and suitable for commanding the movement of the gantry and of the carriage and the functioning of the nozzle (60).

4. Installation according to Claim 3 characterized in that the automatic control (62) is programmed also to trace marker symbols for the location of reserved places (74₁, 74₂, etc.), of electrical studs (76₁, 76₂, etc.), with the aid of the tracing means (48).

5. Installation according to one of Claims 3 and 4, characterized in that the nozzle (60) of the tracing means (48) is intended for the projecting a tracing liquid in the direction of the bottom of the production area (16), on which, if appropriate, prestressing reinforcements (40) have already been put in place.

6. Installation according to one of Claims 1 to 5, characterized in that the mould set comprises, in combination, edge gauges (76) forming the outer longitudinal walls of the moulds, and intermediate gauges (116) and combs (160) suitable to be arranged respectively in the longitudinal direction and transverse direction of the bench at the locations marked by the tracing means.

7. Installation according to Claim 6, characterized in that the edge gauges (76) comprise profiles (78) -of square cross-section which are connected by means of connecting arms (80) to hinges (82) arranged on the outside of the edges (70, 72) of the production area and suitable for pivoting between, on the one hand, a closing position, in which one of the longitudinal faces of the edge profile rests horizontally on a chamfered flat profile (84) fastened to the bottom of the production area (16) and, on the other hand, an opening position, in which the profile (78) is pivoted outside the production area, pieces (95) being provided for locking the edge gauges in the closing position.

8. Installation according to Claim 7, characterized in that the edge profile (78) comprises a removable raising block (94) for the moulding of elements of great thickness, this raising block comprising a plate (98) which, in the closing position, extends the inner vertical face (90) of the profile upwards and towards the inside of the production area.

9. Installation according to Claim 8, characterized in that the raising plate is connected to a base (100) suitable to be locked on the profile (78) by means of a clamping wedge (104) interposed between the base and a bracket (106) fixed to the profile.

10. Installation according to Claim 6, characterized in that the intermediate gauges (116) each comprise two parallel plates (118₁, 118₂) connected on their two mutually confronting faces by means of two superposed U-shaped profiles (120₁, 120₂), the base (122₁, 122₂) of each plate intended for resting on the bottom of the production area (16) being bent outwards to define a chamfer, and a removable raising block (118) suitable for capping the top of the intermediate gauge.

11. Installation according to Claim 10, characterized in that it comprises presses (130) for keeping the intermediate gauges (116) bearing on the bottom of the production area (16), each press comprising a transverse beam (132) terminating at one end in a vertical foot (134) suitable for bearing on one of the edges of the bench, a catch member (140) mounted in a stationary manner on the beam and equipped with a hook suitable for being anchored in a ring (148) forming part of a series of rings arranged at intervals along the bench on the outside of the production area, and a screw jack (150) mounted on a sleeve (152) suitable for sliding on the beam, the screw jack being equipped with a bearing block (154) suitable for coming in contact with the top of the intermediate gauge or, where appropriate, of the raising block.

12. Installation according to Claim 6, characterized in that the comb (160) comprises a profile in the form of an upturned U, the two branches (162, 164) of which are provided with mutually confronting elongate slots (166₁, etc., 168₁, etc.,) for the passage of wires (40₁, 40₂, etc.,) of prestressing reinforcements, the profile also comprising at least one blocking member (172_i, 172₂) consisting of an eccentric member or spacer (174₁, 174₂) actuated by means of a handle (176₁, 176₂) so as to bear on two adjacent tensioned wires of a prestressing reinforcement, thereby spacing them apart.

13. Installation according to Claim 6, characterized in that the comb (260) is retained at each end by means of an assembly (181) comprising a tie (181₁), one end of which catches behind a running inclined flat bar (183) provided over the entire length of the bench and the other of which is articulated on a blocking lever (181₅), itself articulated on the comb.

14. Installation according to one of Claims 1 to 13, characterized in that the moulding appliance comprises, furthermore, means (50) for the distribution and vibration of the concrete in the moulds, the said means being controlled from the processing unit (46).

15. Installation according to Claim 14, in which the means for the distribution and vibration of the concrete comprise a skip (182) supported by a self-propelled carriage (184) movable along the bench, the said skip being equipped with a rotary volume distributor (186) suitable for distributing the concrete over the entire width of the production area and a series of distribution flaps (188₁, 188₂, etc.) actuable independently in order to distribute the concrete selectively over the width of the bench, characterized in that it comprises means for controlling the rotational speed of the distributor (186) and the speed of advance of the carriage (184) on the bench as a function of three information pick-ups, namely:

the weight loss corresponding to a poured quantity of concrete;

the distance covered by the self-propelled carriage during this weight loss; and

the distribution width.

16. Installation according to Claim 15, characterized in that weight sensors (192₁, 192₂, etc.) are interposed between the skip (182) and the self-propelled carriage (184).

17. Installation according to one of Claims 14 to 16, characterized in that it comprises, to obtain the corrugation of the fresh concrete distributed by the means for the distribution and vibration of the concrete, a corrugating carriage (196) movable along the bench and comprising a vertically adjustable transverse beam (202), from which depends a multiplicity of flexible teeth (206) coming to bear on a transverse bearer (208).

18. Installation according to one of Claims 1 to 17, characterized in that it comprises, for severing the prestressing reinforcements between the elements obtained after the setting of the concrete, an automatic disc-type cutter (210) movable transversely on a self-propelled carriage (214) movable along the bench.

19. Installation according to Claim 18, characterized in that the carriage (214) comprises, located in front of the disc (216) at a distance corresponding substantially to half the interval (1) between two successive elements (220, 222), a photoelectric detection assembly (E, D) suitable for commanding the stopping of the carriage and the starting of the cutter when the assembly detects the start of a concrete element (220).

20. Installation according to one of Claims 18 and 19, characterized in that the cutter (210) comprises means for readjusting the cutting depth, comprising two detectors (224, 226) located at different levels.

21. Installation according to one of Claims 1 to 20, intended for the production of prestressed- concrete elements having an insulating board (248) on the underface, characterized in that it comprises means (240) for retaining on the bottom of the production area (16) longitudinal stapling profiles (228) suitable for serving subsequently for the fastening of the insulating board by means of staples (252) passing through the thickness of the board and being anchored in the profiles.

22. Installation according to Claim 21, characterized in that the retention means are wedges (240) interposed between a profile (228) and a prestressing reinforcement wire (40).

23. Installation according to one of Claims 21 and 22, characterized in that the stapling profiles (228) have a bottom wall (230) transpierceable by the staples, and two wings (232, 234) which project upwards from the bottom wall and which are bent towards one another, to form a V, the tip of which is directed towards the bottom wall, the outer flanks (236, 238) of the V-shaped part being suitable for spacing apart the two initially parallel branches (254, 256) of a staple (252) introduced forcibly through the bottom wall.

24. Installation according to one of Claims 21 to 23, characterized in that it comprises, after the production area (16), a stapling bench (258) comprising a table (262₁, 262₂, etc.) suitable for successively receiving an insulating board (250) and a concrete element (248) coming from the production area (16) and incorporating stapling profiles (228), and a plurality of staplers (226₁, 226₂, etc.) movable longitudinally under the said table in order to introduce staples (252) at intervals through the insulating board (250) and into each of the stapling profiles (228).

25. Installation according to one of Claims 1 to 20, intended for the production of prestressed- concrete elements having an insulating board (248) on the underface, characterized in that the tracing means (48) operate so as to trace the contour of an insulating board on a table located generally in the extension of the production bench and so subsequently to arrange a glue at selected locations on the insulating board deposited on the table.

26. Process for the production of reinforced- concrete elements, especially prestressed-concrete slabs or preslabs (64_i, 64₂, etc.), by means of a bench comprising a production area (16) of predetermined shape and a moulding appliance suitable for defining a set of moulds, the base of which is formed by the production area (16) and the contours of which are defined by walls (76, 116, 160) attached to the said production area, characterized in that it comprises the operations of storing in memory, via a transmission line, a plurality of files containing information relating to the elements to be produced and regarding at least the geometry of these, each file regarding a group of elements which can be produced together with a good filling of the predetermined shape of the production area; executing on the production area, as a function of one of the said files at a time, traces marking the locations of at least some of the attached walls, so as to define each mould completely in accordance with the memorized information relating to it; putting the vertical contours of the moulds in place; and casting the concrete into the set of moulds.

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