EP0625414A1 - Process for increasing the adhesion in prestressed concrete sleepers or similar products of improved fatigue strength with grouted anchoring and forming apparatus for carrying out the process - Google Patents

Process for increasing the adhesion in prestressed concrete sleepers or similar products of improved fatigue strength with grouted anchoring and forming apparatus for carrying out the process Download PDF

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Publication number
EP0625414A1
EP0625414A1 EP93113953A EP93113953A EP0625414A1 EP 0625414 A1 EP0625414 A1 EP 0625414A1 EP 93113953 A EP93113953 A EP 93113953A EP 93113953 A EP93113953 A EP 93113953A EP 0625414 A1 EP0625414 A1 EP 0625414A1
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EP
European Patent Office
Prior art keywords
concrete
shaped rod
zones
prestressing
drawn
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP93113953A
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German (de)
French (fr)
Inventor
Frithjof Dipl.-Ing. Schimpff
Klaus-Dieter Dipl.-Ing. Rinne
Wolfgang Dipl.-Ing. Keller
Wolfgang Dipl.-Ing. Puntke
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Wayss and Freytag AG
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Wayss and Freytag AG
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Publication date
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Publication of EP0625414A1 publication Critical patent/EP0625414A1/en
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/08—Members specially adapted to be used in prestressed constructions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
    • B28B23/046—Post treatment to obtain pre-stressed articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
    • B28B23/06—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed for the production of elongated articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/28—Cores; Mandrels
    • B28B7/30—Cores; Mandrels adjustable, collapsible, or expanding
    • B28B7/303—Cores; Mandrels adjustable, collapsible, or expanding specially for making undercut recesses or continuous cavities the inner section of which is superior to the section of either of the mouths
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B3/00—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails
    • E01B3/28—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails made from concrete or from natural or artificial stone
    • E01B3/32—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails made from concrete or from natural or artificial stone with armouring or reinforcement
    • E01B3/34—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails made from concrete or from natural or artificial stone with armouring or reinforcement with pre-tensioned armouring or reinforcement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/20—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of concrete or other stone-like material, e.g. with reinforcements or tensioning members
    • E04C3/26—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of concrete or other stone-like material, e.g. with reinforcements or tensioning members prestressed
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/02—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance
    • E04C5/03—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance with indentations, projections, ribs, or the like, for augmenting the adherence to the concrete
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/08—Members specially adapted to be used in prestressed constructions
    • E04C5/10—Ducts

Definitions

  • the invention relates to a method for reducing slippage in a sleeper-like, permanently vibrating, precast concrete element with prestressing with subsequent composite, as described in the preamble of claim 1, and to shaped rods for carrying out the method.
  • a disadvantage of this method is that the cross-section of the prestressing rod has to be enlarged, or higher-quality prestressing steel has to be used, which leads to considerable economic disadvantages due to higher material costs, particularly in the case of mass-produced finished parts that are scarcely calculated due to the large number of productions.
  • the invention has set itself the task of eliminating the harmful cracking by manufacturing improvements without increasing the preload.
  • the basis of the measures according to the invention is the knowledge found by in-depth tests that a permanent increased slip occurring between the precast concrete and the tie rod in the crack area of the concrete is the cause of the gaps in the cracks even after the precast element has been relieved. Accordingly, all of the measures proposed according to the invention to achieve the object aim to reduce the slip between the prestressing rod and the precast concrete.
  • Improvements to these three factors, alone or in combination, can achieve the solution to the task at hand, largely preventing slippage between the prestressing rod and precast concrete and thus avoiding inadmissibly large crack widths in the concrete that no longer close when the load is released.
  • the object is achieved by means of measures as described in the characterizing part of claim 1 and shaped rods for carrying out the method.
  • prestressing bar and grout can be increased by using surface-profiled bars. It is known per se to prestress generic finished parts with end-anchored, ribbed tension rods, but only where no or slight deflections of the rod axis are provided. This condition does not apply to generic thresholds. Prestressed concrete sleepers of the generic type have previously been prestressed with hairpin-shaped smooth tensioning rods.
  • the applicant has caused the production of a steel with the required diameter for use in generic prestressed concrete sleepers, which combines the advantages of smooth steel with those of the ribbed one, namely a cold drawn smooth steel, in the surface of which hollows are subsequently pressed in by cold working. By using such bars, the bond between the tie rod and grout is significantly improved.
  • Destruction of the grout has its cause - even if the regulations are adhered to - insufficient strength of the grout compared to the strength of the high-quality precast concrete, while at the same time avoiding a loose reinforcement to limit the crack widths. They can be avoided by increasing the strength of the grout beyond the value specified in the guidelines for grout in prestressed concrete, except for the strength of the surrounding precast concrete.
  • the invention is based on the new finding that a grout with strengths far above the prescribed value is required to prevent the harmful slippage.
  • Appropriate designs of a shaped rod for carrying out the method according to claim 4 contain the device claims 5-13, according to claim 14 the device claim 15.
  • the shaped bars according to claims 5-9 and 15 are independent training forms for solving the method according to claim 1. With their help, permanent recesses are created on the outer surfaces of the tensioning channel in the concrete with the help of displacement bodies which emerge from a smooth cylindrical outer surface of the shaped bar .
  • a further economic embodiment of the method according to claim 1 contains claim 19.
  • FIGS. 1.1 and 1.2 show a prestressed concrete sleeper as an example of a prefabricated part 1 according to the invention made of concrete 2.
  • prestressing channels 3 are arranged with the aid of shaped rods, into which the prestressing rods 4 - in the example in the form of a hairpin - are inserted after the concrete has hardened.
  • FIG. 2.1 shows in cross section a shaped rod 5 inserted into the concrete 2 according to claim 3 with ribs 6 and in FIG. 2.2 the same cross section with the fracture-rough inner surfaces 7 of the tensioning channel 3 that arise after the shaped rod 5 has been pulled out.
  • FIG. 3.1 shows in cross section a molded rod 8 inserted into the concrete 2 according to claim 5 with a displacement body 9 that can be moved mechanically outwards in the installed state and in FIG. 3.2 the same rod after the displacement body 9 has been pivoted out.
  • FIG. 4.1 shows a shaped rod 10 according to claim 6 with a tubular jacket 11, which has zones of high rigidity 12 and zones of low rigidity 13; in this case, the changing stiffnesses are generated by different wall thicknesses of the jacket 11.
  • Figure 4.2 shows the same cross section after pumping up the jacket in still soft concrete 2.
  • the pressure medium can spread through channels 14 in the jacket to all zones of low stiffness 13, the expansion of which in the fresh concrete creates the recesses 15.
  • FIG. 4.3 shows the zones of low rigidity 13 with connecting channels 14 in a top view of the inner surface of the jacket 11.
  • Figure 5.1 shows a tubular shaped rod 16 with perforations 17 according to claim 8, which has an inflatable membrane 18 in the cross section immediately after the installation of the rod.
  • FIG. 5.2 shows the same shaped rod 16 after inflating the membrane 18 and expanding it through the perforations 17 to form recesses 19 in the concrete 2.
  • Figures 6.1 and 6.2 show a shaped rod 20 with a tooth-like element 21 according to claim 17.
  • Figure 6.3 shows the clamping channel 22 created by pulling while rotating the shaped rod 20.
  • Figures 7 u. 8 show exemplary embodiments according to claim 9, in which the shaped rod 23 has a tubular jacket 25, 28 with zones of greater rigidity 26, 29 and zones of lower rigidity 27, 30.
  • the tubular jacket is displaced on the shaped bar by compression in the longitudinal direction of the shaped bar, so that the zones with less rigidity bulge and thereby produce recesses in the fresh concrete.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Reinforcement Elements For Buildings (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
  • Rod-Shaped Construction Members (AREA)
  • Joining Of Building Structures In Genera (AREA)

Abstract

In order to avoid permanent cracks in the case of prestressed-concrete sleepers with post-tensioning which are subjected to high loading, it is proposed to use as stressing reinforcement, in place of the hitherto-used smooth hairpin-shaped stressing bars, those of profiled cold-drawn steel. <IMAGE>

Description

Die Erfindung betrifft ein Verfahren zur Schlupfminderung in einem schwellenartigen dauerschwingbelasteten Betonfertigteil mit Vorspannung mit nachträglichem Verbund, wie es im Oberbegriff des Anspruchs 1 beschrieben ist, sowie Formstäbe zur Durchführung des Verfahrens.The invention relates to a method for reducing slippage in a sleeper-like, permanently vibrating, precast concrete element with prestressing with subsequent composite, as described in the preamble of claim 1, and to shaped rods for carrying out the method.

Bei durch Dauerschwingbeanspruchung hoch belasteten mit Vorspannung mit nachträglichem Verbund hergestellten Betonfertigteilen - vornehmlich bei Eisenbahnschwellen - die besonders hohe Betonfestigkeiten von über 60 N/mm² aufweisen, können im Bereich der großen Zugspannungen Risse im Beton entstehen, die sich bei Entlastung nicht wieder vollständig schließen. Diese bleibenden Risse können zu dauernden Schäden und zur Zerstörung der Fertigteile führen (z.B. bei Schwellen, indem bei weiteren Lastwechseln von unten Partikel in den Riß einwandern und die Rißbreite fortschreitend vergrößern).In the case of prefabricated concrete parts, which are highly stressed by permanent vibration with subsequent prestressing - especially with railway sleepers - and which have particularly high concrete strengths of over 60 N / mm², cracks can occur in the concrete in the area of high tensile stresses, which do not close completely again when relieved. These permanent cracks can lead to permanent damage and destruction of the finished parts (e.g. in sleepers, in that particles continue to enter the crack and further increase the width of the crack as the load changes from below).

Zur Verminderung derartiger Schäden ist es bekannt, die Vorspannung zu erhöhen, um die Zugspannung stärker zu überdrücken. Nachteilig bei diesem Verfahren ist, daß der Spannstabquerschnitt vergrößert, oder höherwertiger Spannstahl verwendet werden muß, was - besonders bei wegen großer Fertigungszahlen knapp kalkulierten Massenfertigteilen - zu erheblichen wirtschaftlichen Nachteilen durch höhere Materialkosten führt.To reduce such damage, it is known to increase the pretension in order to suppress the tensile stress more. A disadvantage of this method is that the cross-section of the prestressing rod has to be enlarged, or higher-quality prestressing steel has to be used, which leads to considerable economic disadvantages due to higher material costs, particularly in the case of mass-produced finished parts that are scarcely calculated due to the large number of productions.

Die Erfindung hat sich zur Aufgabe gestellt, die schädliche Rissebildung durch Herstellungsverbesserungen ohne Erhöhung der Vorspannkraft zu beheben.The invention has set itself the task of eliminating the harmful cracking by manufacturing improvements without increasing the preload.

Grundlage der erfindungsgemäßen Maßnahmen ist die durch eingehende Versuche gefundene Erkenntnis, daß ein zwischen Fertigteilbeton und Spannstab im Rißereich des Betons entstehender bleibender erhöhter Schlupf die Ursache für das Klaffen der Risse auch nach Entlastung des Fertigteiles ist. Entsprechend zielen alle zur Lösung der Aufgabe vorgeschlagenen erfindungsgemäßen Maßnahmen darauf ab, den Schlupf zwischen Spannstab und Fertigteilbeton zu vermindern.The basis of the measures according to the invention is the knowledge found by in-depth tests that a permanent increased slip occurring between the precast concrete and the tie rod in the crack area of the concrete is the cause of the gaps in the cracks even after the precast element has been relieved. Accordingly, all of the measures proposed according to the invention to achieve the object aim to reduce the slip between the prestressing rod and the precast concrete.

Der Schlupf zwischen Fertigteilbeton und Spannstab hängt im wesentlichen ab von drei Faktoren:

  • · der Güte des Verbunds zwischen Spannstab und Verpreßmörtel
  • · der Qualität und der Festigkeit des Verpreßmörtels, der die bei der Kraftübertragung aus dem Spannstab in den Fertigteilbeton auftretende Schubkraft überleitet, und
  • · der Güte des Verbunds zwischen dem Verpreßmörtel und der Innenfläche des Spannkanals im Beton des Fertigteils.
The slip between the precast concrete and the prestressing rod essentially depends on three factors:
  • · The quality of the bond between the prestressing rod and grout
  • · The quality and strength of the grout that transfers the shear force that occurs when the force is transferred from the prestressing rod to the precast concrete, and
  • · The quality of the bond between the grout and the inner surface of the prestressing channel in the concrete of the precast element.

Verbesserungen an diesen drei Faktoren können für sich oder in Kombination die Lösung der gestellten Aufgabe, weitgehende Verhinderung des Schlupfes zwischen Spannstab und Fertigteilbeton und damit Vermeidung unzulässig großer, sich bei Entlastung nicht mehr schließender Rißbreiten im Beton, bewirken.Improvements to these three factors, alone or in combination, can achieve the solution to the task at hand, largely preventing slippage between the prestressing rod and precast concrete and thus avoiding inadmissibly large crack widths in the concrete that no longer close when the load is released.

Die Aufgabe wird gelöst durch Maßnahmen, wie sie im kennzeichnenden Teil des Anspruchs 1 beschrieben sind, sowie Formstäbe zur Durchführung des Verfahrens.The object is achieved by means of measures as described in the characterizing part of claim 1 and shaped rods for carrying out the method.

Der Verbessung des Verbunds zwischen Spannstab und Verpreßmörtel kann durch Verwendung von oberflächenprofilierten Stäben gesteigert werden.
Es ist an sich bekannt, gattungsmäßige Fertigteile mit endverankerten, gerippten Spannstäben vorzuspannen, jedoch nur dort, wo keine oder geringfügige Umlenkungen der Stabachse vorgesehen sind. Diese Bedingung ist bei gattungsmäßigen Schwellen nicht gegeben.
Spannbetonschwellen der gattungsmäßigen Art werden bisher mit haarnadelförmig gebogenen glatten Spannstäben vorgespannt. Glatte Spannstäbe werden verwendet, weil die Biegung bisher bekannter gerippter Stähle mit einem - bezogen auf den Stabduchmesser - relativ kleinen Biegedurchmesser zu Sprödbrüchen im Verformungsbereich beim Biegen oder später beim Spannen führen kann, und weil der Beton im Spannkanal am Stabwiderlager im Bereich der Stabkrümmung beim Spannen von den Rippen zerstört werden würde.The improvement of the bond between prestressing bar and grout can be increased by using surface-profiled bars.
It is known per se to prestress generic finished parts with end-anchored, ribbed tension rods, but only where no or slight deflections of the rod axis are provided. This condition does not apply to generic thresholds.
Prestressed concrete sleepers of the generic type have previously been prestressed with hairpin-shaped smooth tensioning rods. Smooth prestressing bars are used because the bending of previously known ribbed steels with a - in relation to the bar diameter - relatively small bending diameter can lead to brittle fractures in the deformation area when bending or later during tensioning, and because the concrete in the tension channel on the bar abutment in the area of the bar curvature during tensioning would be destroyed by the ribs.

Die Anmelderin hat die Herstellung eines Stahles mit dem erforderlichen Durchmesser für die Verwendung in gattungsgemäßen Spannbetonschwellen veranlaßt, der die Vorteile des glatten Stahls mit denen des gerippten verbindet, nämlich eines kaltgezogenen glatten Stahls, in dessen Oberfläche nachträglich durch Kaltverformung Mulden eingedrückt werden. Durch Verwendung derartiger Stäbe wird der Verbund zwischen Spannstab und Verpreßmörtel erheblich verbessert.The applicant has caused the production of a steel with the required diameter for use in generic prestressed concrete sleepers, which combines the advantages of smooth steel with those of the ribbed one, namely a cold drawn smooth steel, in the surface of which hollows are subsequently pressed in by cold working. By using such bars, the bond between the tie rod and grout is significantly improved.

Zerstörungen des Verpreßmörtels haben Ihre Ursache - auch bei Einhaltung der Vorschriften - in einer zu geringen Festigkeit des Verpreßmörtels gegenüber der Festigkeit des hochwertigen Fertigteilbetons bei gleichzeitigem Verzicht auf eine schlaffe Bewehrung zur Begrenzung der Rißbreiten. Sie können durch Erhöhung der Festigkeit des Verpreßmörtels über den in den Richtlinien für den Verpreßmörtel in Spannbetonkonstruktion vorgeschriebenen Wert hinaus möglichst bis auf die Festigkeit des umgebenden Fertigteilbetons vermieden werden. Erfindungsbegründend ist die neue Erkenntnis, daß ein Verpreßmörtel mit weit über dem vorgeschriebenen Wert liegenden Festigkeiten erforderlich ist, um den schädlichen Schlupf zu verhindern.Destruction of the grout has its cause - even if the regulations are adhered to - insufficient strength of the grout compared to the strength of the high-quality precast concrete, while at the same time avoiding a loose reinforcement to limit the crack widths. They can be avoided by increasing the strength of the grout beyond the value specified in the guidelines for grout in prestressed concrete, except for the strength of the surrounding precast concrete. The invention is based on the new finding that a grout with strengths far above the prescribed value is required to prevent the harmful slippage.

Zur Verbesserung des Verbunds zwischen Verpreßmörtel und Fertigteilbeton muß eine bessere Verzahnung zwischen Verpreßmörtel und Innenfläche des Spannkanals erreicht werden. Dabei scheiden verlorene, im Beton verbleibende, gewellte Hüllrohre, wie sie normalerweise im Spannbetonbau verwendet werden, aus Kostengründen aus.To improve the bond between the grout and the precast concrete, better interlocking between the grout and the inner surface of the prestressing channel must be achieved. Lost corrugated cladding tubes that remain in the concrete, as are normally used in prestressed concrete construction, are excluded for cost reasons.

Bisher wurden die Spannkanäle bei gattungsgemäßen Fertigteilen durch vor dem Betonieren eingebaute und im Grünzustand des Betons wieder gezogene glatte Formstäbe gefertigt. Derartig hergestellte Spannkanäle weisen relativ glatte Innenflächen auf, die die bei der Kraftübertragung aus den Spannstäben in den Fertigteilbeton auftretenden Schubkräfte in der Trennfläche nicht übertragen können.Up to now, the clamping channels for generic prefabricated parts have been manufactured by means of smooth shaped bars that were installed before concreting and pulled out again when the concrete was green. Tensioning channels produced in this way have relatively smooth inner surfaces which cannot transmit the thrust forces occurring in the precast concrete during the force transmission from the tensioning bars in the parting surface.

Der Mangel wird durch die Herstellung von Verzahnungen in der Trennfläche zwischen Verpreßmörtel und Fertigteilbeton behoben. Zweckmäßige Verfahren zur Herstellung wirksamer Verzahnungen sind in den Unteransprüchen zahnungen 2-4,14,16-18 beschrieben.The deficiency is remedied by the production of toothing in the separating surface between grout and precast concrete. Appropriate methods for producing effective gears are described in the subclaims 2-4,14,16-18.

Zweckmäßige Ausbildungen eines Formstabes zur Durchführung des Verfahrens nach Anspruch 4 enthalten die Vorrichtungsansprüche 5 - 13, nach Anspruch 14 der Vorrichtungsanspruch 15.
Die Formstäbe nach den Ansprüchen 5 - 9 und 15 sind selbstständige Ausbildungsformen zur Lösung des Verfahrens nach Anspruch 1. Mit ihrer Hilfe werden bleibende Ausnehmungen mit Hilfe von Verdrängungskörpern, die aus einer glatten zylindrischen Mantelfläche des Formstabes heraustreten, auf den Außenflächen des Spannkanals im Beton erzeugt. Eine weitere wirtschaftliche Ausgestaltung des Verfahrens nach Anspruch 1 enthält Anspruch 19.Appropriate designs of a shaped rod for carrying out the method according to claim 4 contain the device claims 5-13, according to claim 14 the device claim 15.
The shaped bars according to claims 5-9 and 15 are independent training forms for solving the method according to claim 1. With their help, permanent recesses are created on the outer surfaces of the tensioning channel in the concrete with the help of displacement bodies which emerge from a smooth cylindrical outer surface of the shaped bar . A further economic embodiment of the method according to claim 1 contains claim 19.

Die Erfindung wird anhand von Ausführungsbeispielen in den Figuren 1-9 erläutert.
Es zeigen:

Figur 1.1 u. 1.2
eine Spannbetonschwelle mit Vorspannung mit nachträglichem Verbund; 1.1 im Längsschnitt, 1.2 im Querschnitt.
Figur 2.1 u. 2.2
einen mit Hilfe eines Formstabes hergestellten Spannkanal im Querschnitt nach Anspruch 3; 2.1 im eingebauten Zustand des Formstabes, 2.2 im Zustand nach dem Ziehen des Formstabs.
Figur 3.1 u. 3.2
einen Formstab im Querschnitt nach Anspruch 5; 2.1 im eingefahrenen, 2.2 im ausgefahrenen Zustand des Verdrängungskörpers.
Figur 4.1, 4.2, 4.3
einen mit Hilfe eines Formstabes nach Anspruch 6 hergestellten Spannkanal; 4.1, 4.2 im eingebauten Zustand des Formstabs im Querschnitt; 4.1 vor dem Aufpumpen des schlauchartigen Mantels, 4.2 nach dem Aufpumpen, 4.3 Anordnung der Zonen von geringerer Steifigkeit auf der Innenseite des Mantels.
Figur 5.1, 5.2
einen Formstab nach Anspruch 7 im Querschnitt; 5.1 vor, 5.2 nach dem Aufpumpen der Membrane.
Figur 6.1, 6.2, 6.3
einen mit Hilfe eines Formstabes nach Anspruch 14 hergestellten Spannkanal; 6.1 mit eingebautem Formstab im Querschnitt, 6.2 im Längsschnitt in Stabachse durch das zahnartige Element, 6.3 eine Innenansicht des Spannkanalabschnitts mit gewindegangartiger Ausnehmung.
Figur 7
einen Längsschnitt durch einen Formstab nach Anspruch 10 und 11.
Figur 8
einen Längsschnitt durch einen Formstab nach Anspruch 12 und 13.
The invention is explained using exemplary embodiments in FIGS. 1-9.
Show it:
Figure 1.1 u. 1.2
a prestressed concrete tie with pre-tensioning with a subsequent bond; 1.1 in longitudinal section, 1.2 in cross section.
Figure 2.1 u. 2.2
a clamping channel made with the help of a shaped bar in cross section according to claim 3; 2.1 in the installed state of the shaped rod, 2.2 in the state after pulling the shaped rod.
Figure 3.1 u. 3.2
a shaped rod in cross section according to claim 5; 2.1 in the retracted, 2.2 in the extended state of the displacement body.
Figure 4.1, 4.2, 4.3
a tensioning channel produced with the aid of a shaped bar according to claim 6; 4.1, 4.2 in the installed state of the shaped cross-section; 4.1 before inflating the tubular jacket, 4.2 after inflating, 4.3 arranging the zones of lower rigidity on the inside of the jacket.
Figure 5.1, 5.2
a shaped rod according to claim 7 in cross section; 5.1 before, 5.2 after inflating the membrane.
Figure 6.1, 6.2, 6.3
a tensioning channel produced with the aid of a shaped bar according to claim 14; 6.1 with built-in shaped rod in cross section, 6.2 in longitudinal section in the rod axis through the tooth-like element, 6.3 an interior view of the clamping channel section with a thread-like recess.
Figure 7
a longitudinal section through a shaped bar according to claim 10 and 11.
Figure 8
a longitudinal section through a shaped bar according to claim 12 and 13.

Figur 1.1 und 1.2 zeigen eine Spannbetonschwelle als Beispiel eines erfindungsgemäßen Fertigteils 1 aus Beton 2. In dem Fertigteil 1 sind mit Hilfe von Formstäben Spannkanäle 3 angeordnet, in die nach Erhärten des Betons die Spannstäbe 4 - im Beispiel in Haarnadelform - eingelegt sind.FIGS. 1.1 and 1.2 show a prestressed concrete sleeper as an example of a prefabricated part 1 according to the invention made of concrete 2. In the prefabricated part 1, prestressing channels 3 are arranged with the aid of shaped rods, into which the prestressing rods 4 - in the example in the form of a hairpin - are inserted after the concrete has hardened.

Figur 2.1 zeigt im Querschnitt einen in den Beton 2 eingelegten Formstab 5 nach Anspruch 3 mit Rippen 6 und in Figur 2.2 denselben Querschnitt mit dem nach dem Ausziehen des Formstabs 5 entstehenden bruchrauhen Innenflächen 7 des Spannkanals 3.FIG. 2.1 shows in cross section a shaped rod 5 inserted into the concrete 2 according to claim 3 with ribs 6 and in FIG. 2.2 the same cross section with the fracture-rough inner surfaces 7 of the tensioning channel 3 that arise after the shaped rod 5 has been pulled out.

Figur 3.1 zeigt im Querschnitt einen in den Beton 2 eingelegten Formstab 8 nach Anspruch 5 mit mechanisch nach außen bewegbarem Verdrängungskörper 9 im Einbauzustand und in Figur 3.2 denselben Stab nach dem Ausschwenken des Verdrängungskörpers 9.FIG. 3.1 shows in cross section a molded rod 8 inserted into the concrete 2 according to claim 5 with a displacement body 9 that can be moved mechanically outwards in the installed state and in FIG. 3.2 the same rod after the displacement body 9 has been pivoted out.

Figur 4.1 zeigt einen Formstab 10 nach Anspruch 6 mit schlauchartigem Mantel 11, der Zonen hoher Steifigkeit 12 und Zonen geringer Steifigkeit 13 aufweist; in diesem Fall werden die wechselnden Steifigkeiten durch unterschiedliche Wandstärken des Mantels 11 erzeugt.FIG. 4.1 shows a shaped rod 10 according to claim 6 with a tubular jacket 11, which has zones of high rigidity 12 and zones of low rigidity 13; in this case, the changing stiffnesses are generated by different wall thicknesses of the jacket 11.

Figur 4.2 zeigt denselben Querschnitt nach dem Aufpumpen des Mantels in noch weichem Beton 2. Dabei kann das Druckmittel durch Kanäle 14 im Mantel zu allen Zonen geringer Steifigkeit 13, durch deren Ausdehnung in den frischen Beton die Ausnehmungen 15 erzeugt werden, sich ausbreiten.Figure 4.2 shows the same cross section after pumping up the jacket in still soft concrete 2. The pressure medium can spread through channels 14 in the jacket to all zones of low stiffness 13, the expansion of which in the fresh concrete creates the recesses 15.

Figur 4.3 zeigt die Zonen geringer Steifigkeit 13 mit verbindenden Kanälen 14 in einer Aufsicht auf die Innenfläche des Mantels 11.FIG. 4.3 shows the zones of low rigidity 13 with connecting channels 14 in a top view of the inner surface of the jacket 11.

Figur 5.1 zeigt einen rohrförmig ausgebildeten Formstab 16 mit Perforationen 17 nach Anspruch 8, der im Innern eine aufpumpbare Membran 18 aufweist, im Querschnitt unmittelbar nach dem Einbau des Stabes.Figure 5.1 shows a tubular shaped rod 16 with perforations 17 according to claim 8, which has an inflatable membrane 18 in the cross section immediately after the installation of the rod.

Figur 5.2 zeigt denselben Formstab 16 nach Aufpumpen der Membran 18 und deren Ausweitung durch die Perforationen 17 unter Bildung von Ausnehmungen 19 im Beton 2.FIG. 5.2 shows the same shaped rod 16 after inflating the membrane 18 and expanding it through the perforations 17 to form recesses 19 in the concrete 2.

Figur 6.1 und 6.2 zeigen einen Formstab 20 mit zahnartigem Element 21 nach Anspruch 17.Figures 6.1 and 6.2 show a shaped rod 20 with a tooth-like element 21 according to claim 17.

Figur 6.3 zeigt den durch Ziehen unter drehender Bewegung des Formstabs 20 entstandenen Spannkanal 22.Figure 6.3 shows the clamping channel 22 created by pulling while rotating the shaped rod 20.

Figuren 7 u. 8 zeigen Ausführungsbeispiele nach Anspruch 9, bei denen der Formstab 23 einen schlauchförmigen Mantel 25, 28 mit Zonen größerer Steifigkeit 26, 29 und Zonen geringerer Steifigkeit 27, 30 aufweist. Der schlauchförmige Mantel wird durch Stauchung in Formstab-Längsrichtung auf dem Formstab verschoben, so daß sich die Zonen mit geringerer Steifigkeit aufwölben und dabei Ausnehmungen in dem frischen Beton erzeugen.Figures 7 u. 8 show exemplary embodiments according to claim 9, in which the shaped rod 23 has a tubular jacket 25, 28 with zones of greater rigidity 26, 29 and zones of lower rigidity 27, 30. The tubular jacket is displaced on the shaped bar by compression in the longitudinal direction of the shaped bar, so that the zones with less rigidity bulge and thereby produce recesses in the fresh concrete.

Claims (19)

Verfahren zur Schlupfminderung in einem dauerschwingbelasteten Fertigteil mit Vorspannung mit nachträglichem Verbund, dessen stählerne Spannstäbe in Spannkanälen verlegt sind, die mit Hilfe von in den Beton eingelegten, im Grünzustand des Betons gezogenen Formstäben geformt und nachträglich mit Verpreßmörtel verpreßt sind, dadurch gekennzeichnet,
daß der Verbund zwischen Spannstab (4) und Fertigteilbeton (2) durch Maßnahmen an mindestens einem der drei nachstehenden für den Verbund konstitutiven Faktoren gesteigert wird: · Verbesserung des Verbunds zwischen Spannstab und Verpreßmörtel durch Einlegen kaltgezogener Spannstäbe, in deren sonst glatten Mantelfläche muldenförmig Vertiefungen eingepreßt sind. · Erhöhung der Festigkeit des Verpreßmörtels durch Verwendung eines an sich bekannten Ankermörtels E1 der Firam Pagel oder eines gleichwertigen Mörtels als Verpreßmörtel. · Verbesserung des Verbunds zwischen Verpreßmörtel und Fertigteilbeton durch Ausnehmungen in der Betonoberfläche des Verpreßkanals, die über den vom Formstab freigehaltenen Querschnitt hinausgehen, in für den gewünschten Verbund ausreichender Anzahl und Form versehen wird. Process for reducing slip in a prefabricated part subject to permanent vibrations with prestressing with subsequent composite, the steel prestressing rods of which are laid in prestressing channels, which are shaped with the aid of shaped rods inserted into the concrete, drawn in the green state of the concrete, and subsequently pressed with grout, characterized in that
that the bond between the prestressing rod (4) and the precast concrete (2) is increased by taking measures on at least one of the three factors which are constitutive for the bond: · Improvement of the bond between the prestressing bar and grout by inserting cold-drawn prestressing bars, in the otherwise smooth surface of which trough-shaped depressions are pressed. · Increase the strength of the grout by using an anchor mortar E1 from Firam Pagel known per se or an equivalent mortar as grout. · Improvement of the bond between grout and precast concrete through recesses in the concrete surface of the grouting channel, which go beyond the cross section kept free by the molded bar, in sufficient number and shape for the desired bond. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß an sich bekannte chemische Mittel, mindestens bereichsweise, auf dem Formstab aufgetragen werden, daß die Erhärtung des Betons im Nahbereich der von dem chemischen Mittel berührten Innenfläche des Spannkanals behindert wird und daß der nicht erhärtete Beton nach Erhärtung des übrigen Betons durch geeignete ebenfalls bekannte Mittel - z.B. Blasen, Bürsten, oder Spülen - aus dem Spannkanal entfernt wird.A method according to claim 1, characterized in that known chemical agents are applied to the shaped rod, at least in some areas, that the hardening of the concrete is hindered in the vicinity of the inner surface of the tensioning channel which is touched by the chemical agent, and that the uncured concrete after hardening the rest of the concrete is removed from the tensioning channel by suitable, likewise known means - for example blowing, brushing or rinsing. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß ein Formstab (5) mit Längsrippen (6), deren Zwischenräume sich mit Beton füllen zur Schalung des Spannkanals (3) verwendet wird, und daß der Formstab nach Einbringen und Verdichten des frischen Betons gezogen wird und dabei den zwischen den Rippen eingeschlossenen Beton unter Hinterlassung einer rauhen Bruchfläche (7) mitreißt.Method according to Claim 1, characterized in that a shaped rod (5) with longitudinal ribs (6), the spaces between which are filled with concrete, is used to form the tensioning channel (3), and in that the shaped rod is drawn after the fresh concrete has been introduced and compacted, and this entrains the concrete enclosed between the ribs, leaving a rough fracture surface (7). Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß beim Einbringen des Betons örtlich aus der Mantelfläche des Formstabes Verdrängungskörper nach außen gedrückt werden, die an der Innenfläche des Spannkanals entsprechende Volumen des Betons verdrängen, daß die Verdrängungskörper unter Zurücklassung bleibender Ausnehmungen im Beton hinter die Mantelfläche des Formstabes eingezogen werden und danach der Formstab aus dem Beton gezogen wird.A method according to claim 1, characterized in that when the concrete is introduced, displacement bodies are pressed outwards locally from the outer surface of the shaped rod, which displace corresponding volumes of concrete on the inner surface of the tensioning channel, that the displacement bodies leave behind recesses in the concrete behind the outer surface of the The shaped rod are pulled in and then the shaped rod is pulled out of the concrete. Formstab (8) zur Durchführung des Verfahrens nach Anspruch 4, der vor dem Einbringen des Betons in die Schalung eingelegt und nach ausreichender Verdichtung des Betons im Grünzustand des Betons gezogen wird, dadurch gekennzeichnet, daß die Verdrängungskörper (9) aus formstabilem Material - z.B. Metall oder hartem Kunststoff- bestehen, die mechanisch aus dem Formstab (8) nach außen bewegbar sind.Shaped rod (8) for carrying out the method according to claim 4, which is inserted into the formwork before the concrete is introduced and is drawn after the concrete has been sufficiently compacted in the green state of the concrete, characterized in that the displacement bodies (9) are made of dimensionally stable material, for example metal or hard plastic, which can be moved mechanically out of the molded rod (8). Formstab (10) zur Durchführung des Verfahrens nach Anspruch 4, der vor dem Einbringen des Betons in die Schalung eingelegt und nach ausreichender Verdichtung des Betons im Grünzustand des Betons gezogen wird, dadurch gekennzeichnet, daß er von einem elastischen schlauchartigen Mantel (11) umhüllt ist, der im Wechsel Zonen (12) von hoher und Zonen (13) von geringer Steifigkeit aufweist und aufpumpbar ist, wobei nach dem Aufpumpen die Verdrängungskörper (15) im wesentlichen von den Zonen mit geringer Steifigkeit gebildet werden.Shaped rod (10) for carrying out the method according to claim 4, which is inserted into the formwork before the concrete is introduced and is drawn after the concrete has been sufficiently compacted when the concrete is green, characterized in that it is encased by an elastic tubular jacket (11) , which alternately has zones (12) of high and zones (13) of low stiffness and can be inflated, the displacement bodies (15) being essentially formed by the zones with low stiffness after being inflated. Formstab zur Durchführung des Verfahrens nach Anspruch 4, der vor dem Einbringen des Betons in die Schalung eingelegt und nach ausreichender Verdichtung des Betons im Grünzustand des Betons gezogen wird, dadurch gekennzeichnet,
daß der Formstab · rohrförmig ist, · aus elastischem dehnfähigem Material besteht, · mit Wendeln oder im Abstand verlegten Ringen aus einem Material, daß gegenüber dem des Formstabes eine wesentlich geringere Dehnfähigkeit aufweist,
und · aufpumpbar ist, und daß der Ringabstand bzw. die Ganghöhe der Wendeln und die Wandstärke des Rohres so gewählt sind, daß sich in den bewehrungsfreien Abschnitten beim Aufpumpen des Rohres Verdrängungskörper von vorbestimmter Größe bilden.Shaped rod for carrying out the method according to claim 4, which is inserted into the formwork before the concrete is introduced and is drawn after the concrete has been sufficiently compacted in the green state of the concrete, characterized in that
that the shaped rod Is tubular, · Made of elastic, stretchable material, With coils or spaced rings made of a material that has a much lower stretch than that of the shaped rod,
and · Is inflatable, and that the ring spacing or the pitch of the coils and the wall thickness of the tube are selected such that displacement bodies of a predetermined size are formed in the reinforcement-free sections when the tube is inflated. Formstab (16) zur Durchführung des Verfahrens nach Anspruch 4, der vor dem Einbringen des Betons in die Schalung eingelegt und nach ausreichender Verdichtung des Betons im Grünzustand des Betons gezogen wird, dadurch gekennzeichnet, daß er als perforiertes Rohr (16) ausgebildet ist, das im Innern eine schlauchförmige, aufpumpbare Membrane (18) aufweist, die, indem sie durch die Perforationen (17) der Rohrwandung aus der Mantelfläche des Formstabes heraus ausdehnbar ist, die Ausnehmungen (19) im Spannkanal erzeugenden Verdrängungskörper formt.Shaped rod (16) for carrying out the method according to claim 4, which is inserted into the formwork before the concrete is introduced and is drawn after the concrete has been sufficiently compacted in the green state of the concrete, characterized in that it is designed as a perforated tube (16) which has a tubular, inflatable membrane (18) which, by being expandable through the perforations (17) of the tube wall from the outer surface of the shaped rod, forms the recesses (19) in the displacement body producing the tensioning channel. Formstab (23,24)zur Durchführung des Verfahrens nach Anspruch 4, der vor dem Einbringen des Betons in die Schalung eingelegt und nach ausreichender Verdichtung des Betons im Grünzustand des Betons gezogen wird, dadurch gekennzeichnet, daß auf dem Formstab (23,24) verschiebbar ein schlauchförmiger Mantel (25,28) angeordnet ist, der durch geeignete bekannte Mittel zur Wellenform zusammenstauchbar ist und die Wellenform durch Ziehen des Formstabs und/oder Zugeinwirkung auf den Mantel rückbildbar ist.Shaped rod (23, 24) for carrying out the method according to claim 4, which is inserted into the formwork before the concrete is introduced and is drawn after the concrete has been sufficiently compacted in the green state of the concrete, characterized in that it can be displaced on the shaped rod (23, 24) a tubular jacket (25, 28) is arranged, which can be compressed to form a wave by suitable known means and the waveform can be reconstructed by pulling the shaped rod and / or pulling the jacket. Formstab (23,24) nach Anspruch 9, dadurch gekennzeichnet, daß der schlauchförmige Mantel (25,28) ringförmige Zonen wechselnder Steifigkeit aufweist und daß die Zonen geringerer Steifigkeit (27.30) mit Hilfe des Stauchdrucks zu Wellen zwischen den Zonen größerer Steifigkeit (26,29) aufwölbbar und die Aufwölbungen durch Entspannen des Mantels (25,28) bzw. Ziehen des Formstabs (23,24) rückbildbar sind.Shaped rod (23, 24) according to claim 9, characterized in that the tubular jacket (25, 28) has annular zones of varying stiffness and that the zones of lesser stiffness (27.30) use the compression pressure to form waves between the zones of greater stiffness (26, 29) can be arched up and the bulges can be restored by relaxing the jacket (25, 28) or pulling the shaped rod (23, 24). Formstab (23) nach Anspruch 10, dadurch gekennzeichnet, daß im Mantel (25) die Zonen (26) größerer Steifigkeit aus einem Material bestehen, das gegenüber den Zonen (27) geringerer Steifigkeit einen höheren E-Modul aufweist.Shaped rod (23) according to claim 10, characterized in that in the jacket (25) the zones (26) of greater rigidity consist of a material which has a higher modulus of elasticity than the zones (27) of lower rigidity. Formstab (24) nach Anspruch 10, dadurch gekennzeichnet, daß die Zonen (29) größerer Steifigkeit eine gegenüber den Zonen (30) geringerer Steifigkeit größere Wanddicke aufweisen.Shaped rod (24) according to claim 10, characterized in that the zones (29) of greater rigidity have a greater wall thickness than the zones (30) of lower rigidity. Formstab nach Anspruch 10, dadurch gekennzeichnet, daß die Zonen größerer Steifigkeit durch Einlegen einer ringförmigen Bewehrung herstellbar sind.Shaped rod according to claim 10, characterized in that the zones of greater rigidity can be produced by inserting an annular reinforcement. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß mit mindestens einem festen über die Mantelfläche hinausstehenden zahnartigen Element versehene Formstäbe in den Beton eingebaut und nach ausreichender Verdichtung und Formstabilität des Betons drehend aus dem Beton gezogen und gewindegangartige Ausnehmungen erzeugt werden, und danach der Spannkanal gereinigt wird.A method according to claim 1, characterized in that molded rods provided with at least one tooth-like element projecting beyond the lateral surface are installed in the concrete and, after sufficient compression and dimensional stability of the concrete, are rotated out of the concrete and thread-like recesses are produced, and then the tensioning channel is cleaned . Formstab zur Durchführung eines Verfahrens nach Anspruch 14, der vor dem Einbringen des Betons in die Schalung eingelegt und nach ausreichender Verdichtung des Betons im Grünzustand des Betons gezogen wird, dadurch gekennzeichnet, daß die zahnartigen Elemente Bürstenform aufweisen.Shaped rod for carrying out a method according to claim 14, which is inserted into the formwork before the concrete is introduced and is drawn after the concrete has been sufficiently compacted in the green state of the concrete, characterized in that the tooth-like elements have a brush shape. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß ein Formstab mit gewindeartiger Oberfläche verwendet wird, der mit drehender Bewegung schraubenartig aus dem formstabil verdichteten Beton herausbewegt wird.A method according to claim 1, characterized in that a shaped rod with a thread-like surface is used, which is moved out of the dimensionally stable compacted concrete in a screw-like manner with a rotating movement. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die mit Formstab hergestellte Betonfläche des Spannkanals nach Erhärtung mit Hochdruckwasserstrahl aufgerauht wird.A method according to claim 1, characterized in that the concrete surface of the tensioning channel made with shaped rod is roughened after hardening with a high pressure water jet. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die Betonfläche des Spannkanals durch die Perforation eines rohrförmigen Formstabs mit Vakuum behandelt und durch Absaugung der Zementschlempe entwässert, verfestigt und aufgerauht wird.A method according to claim 1, characterized in that the concrete surface of the tensioning channel is treated with vacuum through the perforation of a tubular shaped rod and is dewatered, solidified and roughened by suction of the cement slurry. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß aufgrund des verbesserten Verbundes der Spannstäbe im Fertigteilbeton die Endverankerungen der Spannstäbe nach ausreichender Erhärtung des Betons ausgebaut und wieder verwendet werden.A method according to claim 1, characterized in that, due to the improved connection of the prestressing rods in the precast concrete, the end anchorings of the prestressing rods are removed and reused after the concrete has hardened sufficiently.
EP93113953A 1993-05-08 1993-09-01 Process for increasing the adhesion in prestressed concrete sleepers or similar products of improved fatigue strength with grouted anchoring and forming apparatus for carrying out the process Withdrawn EP0625414A1 (en)

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PT624697E (en) 2000-12-29
ES2112216T1 (en) 1998-04-01
ES2112216T3 (en) 2000-11-01
ATE194862T1 (en) 2000-08-15
EP0624697A1 (en) 1994-11-17
ES1026242U (en) 1994-04-01
EP0624697B1 (en) 2000-07-19
ES1026242Y (en) 1994-09-01

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