EP0353637B1 - Forming element with a plastic forming board and process for producing it - Google Patents

Abstract

A forming board for formwork systems for concrete is made of granular PVC obtained during the recycling of copper electric cables and/or waste plastics similar to this granular PVC. The granular PVC or waste plastics are combined into a solid body using a binder consisting of foamed plastics. The steps in the manufacture of the forming board are: production of a mixture of granular PVC, polyurethane and possibly other additives; moulding of the mixture; cooling of the moulded mass. The forming board (1) so obtained is assembled in the frame of a formwork so that the edges (6) are flush with the frame or so that the forming board projects slightly above the frame (26).

Description

The present invention relates to a formwork panel for system and large-area formwork with a formwork panel made of plastic and a method for its production.

Formwork panels for system and large-area formwork, as are known for example from DE-OS 36 38 537, consist of a frame made of metal and / or wood on which formwork panels made of plywood or chipboard are mounted. A major disadvantage of these known formwork panels or formwork panels is that they are damaged by abrasion and mechanical injuries from nails, vibrating bottles, etc. The panels are exposed to the weather and otherwise come into contact with water on the components. By absorbing water, these known formwork panels swell in length and thickness, which quickly renders them unusable leads, so that an exchange with a new record becomes necessary. In addition, rolled slabs create a bad joint pattern in the concrete parts that are switched with them. This is also due to the fact that the fastening screws with which the formwork panel is fastened to the frame are drawn through the swelling panel into the panel and become apparent on the concrete parts produced with this formwork panel. In addition, such formwork panels lose up to 30% of their strength due to the absorption of water, which either reduces the quality of the concrete due to the deflection of these formwork panels or reduces the speed of concreting.

The length growth of the plywood formwork panels due to the water absorption also causes the frame of the formwork panel to be deformed especially at the edge, so that the connection points of several formwork panels connected to one another in system formwork have leaky points. Cement milk can escape at these leaky areas, which leads to bleeding of the concrete in this area and consequently to a deterioration in the quality of the concrete.

The so-called marble effect occurs on formwork panels with phenolic resin-coated formwork panels, i.e. the concrete parts made with such formwork panels have different marble-like colors, which is usually undesirable in exposed concrete. In addition, this leads to a deterioration in the liability of subsequent plants on such concrete parts.

Another disadvantage of formwork panels made of wood is that once damaged panels can no longer be repaired meaningfully and therefore, although still statically in order with a high financial outlay new formwork sheets need to be replaced.

Despite the use of release agents, cleaning the usual system formwork takes a lot of time and therefore costs. Concrete deposits on the formwork panel or frame are often removed with a metal hammer or scraper. Wooden formwork panels can also be damaged by cleaning, which ultimately leads to their uselessness.

A particular weak point in formwork panels is their edge or edge area, since these areas are exposed to special mechanical loads on the one hand and the many end-grain layers are very absorbent on the other. Sealing the entire panels and in particular these areas with silicone or the like only extends the service life of such formwork panels only insignificantly.

Because of these disadvantages, various attempts have been made to replace the wooden formwork panels. For example, it is known to manufacture formwork panels entirely from metal. Then, however, it is no longer possible to nail or work with other woodworking equipment, so that formwork inserts for possible cutouts and breakthroughs can no longer be produced with justifiable economic outlay. Metal surfaces are also relatively difficult to clean from concrete residues once they have hardened. All these disadvantages are avoided by formwork panels made of plastic, as are known for example from WO-A-87/05353 or the German utility model 86 17 602.1. The reason why such formwork panels made of plastic have so far not been able to establish themselves on the market, although they have all the disadvantages mentioned Avoiding plywood formwork panels is because these plastic formwork panels are too heavy on the one hand and too expensive to manufacture on the other. The increased weight of the formwork panels with comparable mechanical stability leads to considerable additional work on the construction site and thus to an increase in construction costs. The increased manufacturing costs of the formwork panels made of plastic lead to an increase in the price of the system and large-area formwork equipped with them.

From DE-A-20 10 003 a formwork or formwork panel made of permanently elastic plastic for structuring exposed concrete is known. Since this is a special application and not standard formwork technology, the increased manufacturing costs and weight do not play a major role. The permanent elasticity also makes them unsuitable as a replacement for conventional plywood formwork panels.

It is therefore an object of the present invention to provide formwork panels made of plastic and formwork panels equipped therewith which approximately correspond in weight and mechanical stability to conventional formwork panels made of plywood and, moreover, are cheaper to produce than known formwork panels made of plastic. Furthermore, it is an object of the present invention to provide a method for producing such formwork panels.

This problem is solved by the characterizing features of claim 1. Because we use waste PVC granulate as the basic material for the formwork panel, which is obtained when copper is recovered from electrical cables, the manufacturing costs are reduced considerably, since this basic material is almost free of charge is available. This is due to the fact that there is no economically justifiable and safe disposal concept for such PVC or plastic waste. Recycling this plastic waste can therefore save the economy considerable costs.

The fact that the waste PVC granulate is foamed by means of a foamable plastic results in comparison conventional formwork panels made of plastic reduce weight while maintaining mechanical stability. By using a foamable plastic as a binder, the costs are also reduced since less binder is required.

The composition of PVC granulate, which is obtained when copper is recovered from electrical cables, varies widely. In addition to various types of PVC, it also contains other plastics, textiles - e.g. from cable identification threads -, metal parts, especially copper, and other foreign substances. For this reason, other plastic wastes are also suitable which correspond in their physical and surface chemical properties to this PVC granulate. For example, shredded plastic bottles, such as those used for dishwashing and liquid detergents, or shredded plastic dishes, etc., can also be used instead of PVC granulate or in addition. Since the PVC granulate or corresponding plastics do not react with the foamable binder, the extremely different composition does not interfere or the use of plastic waste of very different composition, which can also be contaminated, is possible.

Polyurethane (PU) has proven to be particularly suitable as a foaming binder. The fact that the foamable binder contains polyurethane which sets with water simplifies the production of the formwork sheet according to the invention.

In the advantageous further development of the formwork panel according to claim 4, the panel is provided with a protective coating, which increases the service life the formwork panel extended. For example, this protective cover can be made of polyurethane, which can be sprayed on, spread on, rolled up or cast. The protective coating can also be in the form of a wood veneer layer, a glass flow, a plastic flow, a net, etc. In accordance with the embodiment according to claim 5, hollow glass beads and / or silicon and / or metal chips and / or mineral substances and / or plastics and / or the fibrous substances are added to this protective coating to increase the abrasion resistance.

According to the advantageous development of the invention according to claim 6, tensile impact agents are added to the PVC granulate to improve the screen line and / or to increase the stability. Such additives are finely ground tire rubber, quartz sand, light additives, e.g. Hollow aluminum silicate. By adding additives, the spaces between the comparatively coarse-grained and irregularly shaped PVC granulate are filled, which leads to an increase in stability.

In order to further improve the mechanical properties of the formwork panel according to the invention, reinforcement is penetrated in the embodiment according to claim 7. This reinforcement can consist of a glass, plastic or metal mesh. Lattice structures made of metal or plastic or hollow profiles made of metal or plastic are also suitable.

In the embodiment of the invention according to claim 8, the reinforcement in the form of metal bars or in the form of a metal grid is not poured into the formwork panel, but is only on the side facing away from the concrete Formwork panel, i.e. mounted on the back of the formwork panel. Since a reinforcement, in particular made of metal, always represents an additional weight, the formwork panel can be used with or without reinforcement as required.

Since the edge area and the edges of a formwork sheet are exposed to the strongest mechanical loads during assembly, edge protection is provided according to claim 8. According to the advantageous development of the invention According to claim 10, this edge protection consists of a particularly resistant plastic which is finally cast into the surface of the formwork panel flush with it.

According to the advantageous development according to claim 11, the formwork panel can be designed in the form of integral foam. This embodiment has the advantage that the abrasion-resistant protective coating cannot be produced in a separate operation but during the molding of the plate by producing a highly compressed foam on the surface. The edge protector can also be produced in this way at the same time as the plate is manufactured.

The front of the plate, ie the side of the plate that comes to rest on the concrete, is profiled in the embodiment according to claim 12, so that any structure can be given with the exposed concrete created with such formwork panels.

Claim 13 teaches an advantageous method for producing a formwork panel according to the invention. The subclaims 14 to 16 relate to advantageous developments of this method. In the particularly advantageous embodiment of the method according to claim 16, the frame serves as the shape for the formwork panel, i.e. the formwork sheet is foamed directly into the frame. This eliminates the need to fasten the formwork panel to the frame, since the formwork panel adheres excellently to the metal frame when it is not yet solidified.

Claim 17 is directed to a formwork panel which has the formwork panel according to the invention.

Claim 18 claims a formwork panel, in particular with a formwork panel according to one of the preceding claims, which is characterized in that the edge side of the formwork panel is flush with the frame or protrudes slightly above the frame. This configuration ensures that the individual formwork panels lie close together when the formwork panels are assembled. Since plastic and in particular formwork panels made of plastic according to one of the preceding claims have a certain basic elasticity, a homogeneous concrete surface is achieved almost without annoying joint marks. This makes it possible to use formwork panels of different sizes without recognizing the different sizes on the concrete surface. Basically, an orderly joint pattern is guaranteed. At the same time, the directly adjacent formwork panels prevent cement milk from escaping in the joint area and thus preventing the concrete from bleeding out in this area.

In the advantageous embodiment of the invention according to claim 19, the seal between the individual formwork panels or formwork panels is further improved in that the individual formwork panels are provided with sealing lips. According to the advantageous development according to claim 20, these sealing lips at least partially cover the frame, which leads to a further improved sealing and also prevents contamination of the covered part of the frame. This is particularly advantageous since dried concrete residues can be removed from the sealing lips made of plastic much more easily than from metal due to the poorer adhesion. With conventional formwork panels, concrete residue dried on the metal frame is often removed by hammer blows, which ultimately leads to a deformation of the frame and thus to an impairment of the function of the formwork plate. This disadvantage is avoided by covering the parts of the frame that come into contact most often with liquid concrete. The sealing lips can consist of the same material as the formwork panel itself or of a different plastic. The sealing lips or the layer covering the frame are preferably made of pure PVC.

The advantageous development of the formwork panel according to claim 21 takes into account the fact that the mechanical loads in the edge region of the formwork panel are greatest. In addition, this configuration facilitates the assembly of the formwork panel on the frame, in particular if the formwork panel is simply glued to the frame.

In order to completely avoid the tedious cleaning of the metal frame from dried concrete residues and the disadvantageous "hammer cleaning", according to the development according to claim 22, the formwork panel completely encloses the frame with its edge region.

The advantageous embodiment of the invention according to claim 23 improves the cohesion between the frame and the formwork panel. This configuration is particularly advantageous if the plate and frame are glued together.

To increase the mechanical stability, the frame of the formwork panel according to the invention can also be provided in the usual way with cross struts. The frame can also have breakthroughs for tension rods and reinforcements for conventional spacers.

The formwork panels according to the invention can of course also be used otherwise, e.g. use as a fence or as outdoor flooring, etc. Compost containers and the like can also be produced from this plastic material.

• keine Wasseraufnahme und Beschädigung durch Witterungseinflüsse,
• keine nennenswerten Maßänderungen in Länge, Breite und Dicke,
• Die Schalplatte ist bei den üblichen Beschädigungen wie Nagellöcher, Bohrlöchern, Rüttelflaschenschäden und Kratzern verursacht durch die Armierung, ohne Probleme zu reparieren und wieder uneingeschränkt einzusetzen. Zur Reparatur eignet sich beispielsweise PU mit dem Löcher etc. ausgefüllt werden.
• Die Lebensdauer der erfindungsgemäßen Schalplatten aus Kunststoff ist im Vergleich zu herkömmlichen Platten erheblich Länger und entspricht in etwa der Lebensdauer des Rahmens. Damit werden drei bis fünf Neubelegungen der Schaltafel eingespart, die je ca. 1/3 des Neupreises einer Schaltafel ausmachen würden.
• Bei der Herstellung bzw. dem Zuschnitt der einzelnen Schalplatten entstehender Frässtaub kann bei der Herstellung neuer Schalplatten uneingeschränkt wieder verwendet werden.
• Verbrauchte Schaltafeln können problemlos entsorgt werden, da die Schalplatten zu 100 % bei der Neuherstellung von Schalplatten wieder verwendet werden können.
• Die statischen Eigenschaften der Schalplatte bleiben über die gesamte Lebensdauer voll erhalten.
• Die Kanten der erfindungsgemäßen Schalplatte können so gestaltet werden, daß im Gegensatz zu den bisher verwendeten Schalplatten ein kaum sichtbarer Fugenabdruck auf dem Beton entsteht, der Beton im Fugenbereich nicht ausblutet und somit Nacharbeit vermieden und Sichtbeton höchster Qualität überhaupt erst möglich wird.
• Die Betonstruktur wird gleichfarbig und matt, ohne jeglichen Marmoreffekt.
• Die Schalplatte ist nicht saugfähig und erfordert daher maximal 1/3 des Trennmittels, das die üblichen Schalplatten aus Holz benötigen. Die erfindungsgemäßen Schalplatten sind damit also wirtschaftlicher und umweltfreundlicher.
• Die Reinigung der Schaltafeln wird wesentlich erleichtert, da Beton an dem Material schlecht haftet.
• Die Produktion von Schalplatten mit besonderer Kantenausbildung zum Schutz der Schalplatte bzw. des Rahmens ist auf einfache Weise möglich. Ebenso läßt sich in beliebiger Weise die Oberfläche der Schalplatte strukturieren und profilieren, z.B. sägerauhe Holzstruktur.
• Der Einbau der Schalplatte in neue oder auch gebrauchte Schaltafeln wird wirtschaftlicher, da aufgrund der Möglichkeit die Schalplatte beliebig zu formen diese auch auf dem Rahmen aufgeklebt werden kann.
• Die erfindungsgemäße Schalplatte eignet sich besonders auch im Einsatz für Großflächenschalungen und Vorsatzschalungen, da sie sich mit üblichen Holzbearbeitungswerkzeugen bearbeiten, nageln, schrauben und kleben läßt.
• Die Abriebfestigkeit der erfindungsgemäßen Schalplatte liegt beim etwa 5 bis 9-fachen Wert herkömmlicher Schalplatten.
• Die Schalplatte besteht je nach Ausgestaltung zu 70 - 90 % aus Recycling-Material, das anderweitig nur sehr selten und in nicht ausreichender Menge eingesetzt werden kann und dessen Beseitigung äußerst problematisch ist, da es sich gefahrlos weder verbrennen noch deponieren läßt.

Compared to conventional formwork panels, the formwork panel according to the invention or a formwork panel equipped with it has the following advantages:

• no water absorption and damage due to weather influences,
• no significant dimensional changes in length, width and thickness,
• The formwork sheet can be repaired and used again without any problems with the usual damage such as nail holes, drill holes, vibrating bottle damage and scratches caused by the reinforcement. For example, PU with which holes etc. are filled is suitable for repairs.
• The lifespan of the plastic shuttering panels according to the invention is considerably longer in comparison to conventional panels and corresponds approximately to the lifespan of the frame. This saves three to five new assignments of the formwork panel, which would each make up about 1/3 of the new price of a formwork panel.
• Milling dust arising during the manufacture or cutting of the individual formwork panels can be reused without restriction in the production of new formwork panels.
• Used formwork panels can be disposed of easily because the formwork panels can be used 100% for the new production of formwork panels.
• The static properties of the formwork panel are fully preserved over the entire service life.
• The edges of the formwork panel according to the invention can be designed so that, in contrast to the formwork panels used to date, a barely visible joint impression is formed on the concrete, the concrete does not bleed out in the joint area and thus rework is avoided and exposed concrete of the highest quality is possible in the first place.
• The concrete structure becomes the same color and matt, without any marble effect.
• The formwork sheet is not absorbent and therefore requires a maximum of 1/3 of the release agent that the usual wooden formwork sheets require. The formwork panels according to the invention are thus more economical and environmentally friendly.
• Cleaning the formwork panels is made considerably easier, since concrete adheres poorly to the material.
• The production of formwork panels with special edges to protect the formwork panel or frame is possible in a simple manner. Likewise, the surface of the formwork panel can be structured and profiled in any way, for example rough sawn wood structure.
• The installation of the formwork panel in new or used formwork panels becomes more economical because of the possibility of shaping the formwork panel as desired, this can also be glued to the frame.
• The formwork panel according to the invention is also particularly suitable for use in large-area formwork and facing formwork, since it can be processed, nailed, screwed and glued using conventional woodworking tools.
• The abrasion resistance of the formwork sheet according to the invention is about 5 to 9 times that of conventional formwork sheets.
• Depending on the design, the formwork panel consists of 70 - 90% recycled material, which can otherwise only be used very rarely and in insufficient quantities and whose removal is extremely problematic, since it can neither be burned nor deposited safely.

Further details, features and advantages of the present invention will become apparent from the following description with reference to the drawing.

Fig. 1

eine Schrägansicht eines Teils einer Ausführungsform der Schalplatte mit teilweise entferntem Schutzüberzug,

Fig. 2

einen Schnitt durch die Darstellung von Fig. 1,

Fig. 3

eine Schnittdarstellung einer Schalplatte mit Kantenschutz,

Fig. 4

eine Schnittdarstellung einer Schalplatte mit Hohlräumen,

Fig. 5

eine Schnittdarstellung einer Schalplatte mit eingegossener Armierung,

Fig. 6

eine Schnittdarstellung einer Schalplatte mit einer auf der Rückseite der Schalplatte angebrachten Armierung,

Fig. 7 bis 13

schematische Darstellungen verschiedener Ausführungsformen einer erfindungsgemäßen Schaltafel.

It shows:

Fig. 1

2 shows an oblique view of part of an embodiment of the formwork panel with the protective covering partially removed,

Fig. 2

2 shows a section through the representation of FIG. 1,

Fig. 3

a sectional view of a formwork panel with edge protection,

Fig. 4

2 shows a sectional illustration of a formwork panel with cavities,

Fig. 5

2 shows a sectional illustration of a formwork panel with cast reinforcement,

Fig. 6

2 shows a sectional view of a formwork panel with a reinforcement attached to the back of the formwork panel,

7 to 13

schematic representations of various embodiments of a formwork panel according to the invention.

In the figures and in the description of the figures below, the same parts are designated with the same reference symbols.

Fig. 1 shows a part of a formwork sheet 1 according to the invention. Fig. 2 shows a section through the formwork sheet 1 according to Fig. 1. The formwork sheet 1 is made of PVC granulate, which is obtained when copper is recovered from electrical cables. This waste PVC is foamed into PU foam. In addition to PVC granules, polystyrene or polyethylene wastes or all plastic wastes are also suitable which have the same physical or surface chemical properties as the PVC granules and may be very dirty. In addition, wood waste such as Sawdust can be poured or foamed into the PU foam. In addition to PU foam, other foamable plastics, such as Use thermoplastics.

The formwork panel 1 shown in Fig. 1 and 2 is in front and back 3 and 5 with a reinforcement in Form of a metal mesh 7 provided. This reinforcement serves to improve the mechanical stability and can also consist of a glass or plastic fabric. Fibers or fibrous materials can also be embedded or foamed in as reinforcement.

A protective coating 9 is applied over the metal mesh 7. The protective cover 9 consists of a particularly abrasion-resistant material, e.g. Polyurethane mixed with mineral or fibrous substances or metals. Even if this is not so clearly expressed in FIG. 1, the protective covering 9 completely covers the formwork panel 9, also and particularly on the edge sides 6 of the panel.

Fig. 3 is a sectional view of a record 1, which is provided with an edge protector 11. The edge protector 11 is rectangular and covers the edge of the formwork panel 1 and, with approximately the same length, the front of the record 1. The edge protector 11 is either made of a particularly resistant plastic, such as Polyurethane, acrylic butadiene styrene, polystyrene or metal.

Fig. 4 shows a section through a formwork panel 1 in which cavities 13 are provided. The cavities 13 serve on the one hand to reduce weight and, on the other hand, reinforcements, for example in the form of tubes 15, can be introduced into these cavities if required.

Fig. 5 shows a further variant of the formwork sheet 1, in which a reinforcement in the form of flat iron 17 is poured or foamed. The flat band irons 17 are aligned parallel to the edge sides 6 and are completely enclosed by the plastic mass of the formwork panel. Depending on which tensile and compressive forces the formwork panel is exposed in use, you can also use undulated reinforcements or reinforcements in the form of profile pieces, not shown.

A further embodiment of the formwork panel 1 is shown in FIG. 6. In this embodiment, a reinforcement in the form of metal rods 19 is only attached to the back 5 of the formwork panel 1. So that this type of reinforcement does not require a change in the frame of a formwork panel equipped with it, the metal bars 19 run in recesses 21 in the formwork panel 1.

Various embodiments of formwork panels which have formwork panels of the type described above are described below with reference to FIGS. 7 to 13.

7 shows a first embodiment of a formwork panel with the formwork panel 1 according to the invention. The formwork panel has a frame 26 which is formed from a hollow profile with a rectangular cross section and rounded corners. The frame 26 is preferably made of steel or aluminum. In order to increase the stability, the frame 26 can additionally be provided with cross struts, not shown, in a known manner.

The formwork panel 1 is arranged with its rear side 5 on one of the shorter sides of the hollow profile 26 in such a way that the peripheral edge sides 6 of the formwork panel 1 are flush with one of the longer sides of the hollow profile or that the formwork panel projects slightly beyond the frame. This arrangement of the formwork panel on the frame of the formwork panel ensures that the formwork panels or their formwork panels installed in system formwork are practically closely spaced from one another. To the mutual sealing between To improve the individual formwork panels of the formwork panels installed in a system formwork, the edge sides 6 of the formwork panels are provided with a thin sealing lip 24.

The embodiment of the formwork sheet according to FIG. 8 corresponds to the embodiment of FIG. 7 with the difference that the sealing lip 24 not only covers the edge sides 6 of the formwork sheet but also completely one of the longer sides of the hollow profile 26. The embodiment according to FIG. 8 enables a simplified cleaning of the formwork panel, since the largest part of the metal frame is covered by the sealing lip 24 made of plastic and dried concrete residues can be removed from plastic much more easily than from metal.

The embodiment of the formwork panel according to FIG. 9 also corresponds to the embodiment according to FIG. 7 with the difference that the sealing lip 24 completely surrounds the frame 26 or the hollow profile 26. In this embodiment, it is completely prevented that concrete residues can solidify on the metal frame 26.

In the embodiment of the formwork panel according to FIG. 10, the section through the formwork panel 1 is U-shaped. These legs or edge regions 28 of the plate 1 engage in a corresponding recess 30 in the frame 26, so that the edge sides 6 of the formwork plate 1 are flush with the frame 26 or protrude only slightly beyond the frame 26. The formwork sheet 1 therefore encloses the frame 26 like a cap.

Fig. 11 shows a further switching off of a formwork panel with a formwork panel 1 which is U-shaped in section Legs or the extended edge regions 28 of the formwork panel 1 completely cover a long side of the rectangular hollow profile 26 in this embodiment. The recess 30 into which a corresponding thickening of the edge regions 28 of the formwork panel 1 engages is provided in a long side of the hollow profile 26 in this embodiment.

In the embodiment of the formwork panel according to FIG. 12, the frame or the hollow profile 26 is completely integrated into the edge region 28 of the formwork panel 1 or the formwork panel 1 completely surrounds the hollow profile. In this embodiment, the recess 30 and the associated thickening of the formwork panel are located on the inside of the frame 26.

The embodiment of FIG. 13 is comparable to that of FIG. 11. In order to avoid damage to the edge region 28 of the formwork panel 1 drawn over the frame 26 when handling the formwork panel at the construction site, the edge region 38 and the frame 26 are penetrated by two pins 32 which have a large projecting cap 34 in the region of the edge region 28. The edge area is protected from mechanical influences by the pins 32 or by the caps 34 located thereon. Pins 32 are removed immediately before assembly into the system formwork. Conventional dowel pins can then be inserted into the remaining openings.

In the embodiments of the formwork panel according to the invention described with reference to FIGS. 7 to 13, the formwork panel and frame are connected to one another by gluing. Alternatively or additionally, the formwork panel and frame can also be riveted or screwed in a conventional manner.

The production of the formwork panels or formwork panels described above is briefly explained below.

Shaped parts, sheets or endless belts etc. made of foamable plastics with possibly contained granules, reinforcements etc. are either produced continuously on double belt systems (PU foams) or discontinuously using molds (polystyrene). Reactive resins are used here as well as expanding polystyrene particles that contain propellant gas.

The formwork panels according to the invention can be produced using these methods, which, however, have to be specially modified.

In continuous production, the resin components are first produced in a mixing plant. The aggregates of shredded plastic waste or recycling material are added to this mixture and mixed. This process must be adapted exactly to the belt speed of the production plant.

The mixture is fed to the double belt system via special feed devices and metered in such a way that a constant amount is passed between the two belts. The double band can consist of perforated steel bands, which are supported from below by rollers, or chain-guided plates, which seal each other when they are next to each other, perforation is also required here.

• a) Aufgabestation und Dosierung
• b) Verdichtungszone
• c) Dampfzone und Befeuchtung
• d) Kühlzone
• e) Auslaufzone

Die Maschine produziert ein Endlos-Plattenband, das nach Austritt aus der Maschine längs und quer geteilt und an den Rändern nachbearbeitet werden kann.The material goes through several stages in the machine:

• a) Feed station and dosage
• b) compression zone
• c) steam zone and humidification
• d) cooling zone
• e) exit zone

The machine produces an endless plate belt that can be cut lengthways and crossways after leaving the machine and reworked at the edges.

The plate thickness is determined by the distance between the two tapes, which are sealed by side strips.

The reinforcement will run in continuously at the beginning of the machine and will be fixed in the tension and compression zone and foamed into the panel web.

To protect the steel strips, release agents can either be applied continuously again, or separating media in the form of foils, nonwovens or the like run. with, which can also remain on the plate surface.

The wear layers on the plate surface are applied after leaving the machine in the casting, spraying or rolling process, this can be done on the unprocessed belt as well as on the finished separated plates.

In batch production, the mixed mass is filled into molds, primarily of aluminum, which are provided with inwardly permeable nozzles which let steam pass through. into which steam is blown. The filled mold is closed and steamed in the exclave, cooled and then removed from the mold.

With this method, reinforcements can also be inserted, and it is also possible to use a wide variety Foam edge profiles or give structures to the board surface.

The wear layers can also be put directly into the mold or subsequently applied to the finished plate.

The molds used can be designed to be stackable so that they can be steamed as a package.

It is particularly advantageous to manufacture the formwork panel directly in the form of the formwork panel, i.e. the frame of the formwork panel is part of the form for the manufacture of the formwork panel. With appropriate devices that seal the frame against the concrete and back, it is possible to foam the formwork panel directly into the frame. In this way, the gluing to the frame takes place at the same time as the plate is being produced. Cutting and subsequent assembly are therefore no longer necessary.

Claims (23)

1. Forming board (1) for concrete shuttering systems which is - at least partially - made of plastic and which comprises a front (3) which is positioned so as to contact the concrete, a back (5), as well as lateral sides (6), characterized in that
   
   the forming board (1) contains waste PVC granules which are obtained in the recovery of copper from electric wires and/or in that the forming board (1) contains granules of plastic waste which in turn correspond to said PVC granulated material with regard to their physical and surface chemical properties, and
   
   that said PVC granules or said plastic waste corresponding to said PVC granules are bonded by means of a bonding agent in the form of foamed plastics.
2. Forming board in accordance with claim 1, characterized in that the bonding agent contains polyurethane.
3. Forming board in accordance with claim 2, characterized in that the bonding agent binds polyurethane with water.
4. Forming board in accordance with one of the preceding claims, characterized in that the board is provided with a protective coating (9) in the form of a layer made of polyurethane, a layer of veneer, a glass fibre quilt, a synthetic fibrous web, a netting etc.
5. Forming board in accordance with claim 4, characterized in that hollow glass beads and/or mineral materials and/or plastics and/or fibrous materials are added to said protective coating (9).
6. Forming board in accordance with one of the preceding claims, characterized in that the board (1) contains one or a combination of the following additives: finely ground tyre rubber, quartz sand, light aggregates such as hollow aluminium silicate.
7. Forming board in accordance with one of the preceding claims, characterized in that a reinforcement (7, 15, 19) has been inserted in the board (1).
8. Forming board in accordance with claim 7, characterized in that the reinforcement (19) is arranged at the back (5) of the forming board (1).
9. Forming board in accordance with one of the preceding claims, characterized in that the board (1) is provided with an edge protection (11) at said lateral sides (6) as well as at its edges.
10. Forming board in accordance with claim 9, characterized in that the edge protection (11) is made of a particularly resistant plastic in the form of polyurethane, acryl butadiene styrene or polysterene.
11. Forming board in accordance with one of the preceding claims, characterized in that the bonding agent in the form of foamable plastics is suitable for forming an integral foam.
12. Forming board in accordance with one of the preceding claims, characterized in that said front (3) of the board which contacts the concrete (1) has a cross-sectional profile.
13. Method for manufacturing a forming board in accordance with one of the previous claims, characterized by the following procedural steps:
    
    producing a mixture made of waste PVC granules which are obtained in the recovery of copper from electric wires and/or of waste plastics which correspond to saids PVC granulated material with regard to their physical and surface chemical properties, and polyurethane as a foamable bonding agent,
    
    foaming up the bonding agent and consequently the mixture,
    shaping the mixture, and
    
    cooling the foamed up and shaped mixture.
14. Method in accordance with claim 13, characterized in that the polyurethane binds with water and that hot water steam is added between the shaping of the mixture and the cooling of the shaped mass.
15. Method in accordance with claim 13 or 14, characterized in that the boards are continually produced by means of conventional continuous laminators as used in the production of PU-foam parts.
16. Method in accordance with claim 13 or 14, characterized in that the frame of a forming board serves as part of the mould for the production of a forming board.
17. Forming element for concrete shuttering systems with a frame (26) made of metal and/or wood and a forming board (1) made of plastic attached to the frame (26), characterized by a forming board (1) in accordance with one of the preceding claims.
18. Forming element for concrete shuttering systems with a frame (26) made of metal and/or wood and a forming board (1) attached to said frame (26), particularly in accordance with claims 1 through 16, characterized in that
    
    the forming board (1) is mounted to the frame (26) such that the lateral sides (6) of the forming board (1) lie level with said frame (26) or that the forming board (1) slightly juts out of the frame (26).
19. Forming element in accordance with claim 18, characterized in that the lateral sides (6) of the forming board (1) are provided with a sealing lip (24).
20. Forming element in accordance with claim 19, characterized in that said sealing lip (24) extends over the lateral sides (6) of the forming board (1) and, at least partially, over said frame (26)
21. Forming element in accordance with one of the claims 18 through 20, characterized in that the forming board (1) has a U-shaped cross section.
22. Forming element in accordance with one of the claims 18 through 21, characterized in that the lateral portion (28) of the forming board (1) completely surrounds the frame (26).
23. Forming element in accordance with one of the claims 18 through 22, characterized in that the forming board (1) in the lateral portion (28) whereby the forming board is attached to the frame (26), is thicker than in the remaining area and that the frame (26) has a corresponding recess (30) for receiving said thickened lateral portion (28).

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