EP0778112A1 - Process for making wall elements - Google Patents

Abstract

Walling blocks of concrete or similar material with variable dimensions and/or shape are made in open mould boxes (1) by placing at least one blanking piece (12) within the mould box (1). The blanking piece (12) is made of elastic, compressible material and is in the shape of a rectangular prism with a height (H) in the unloaded state corresponding to the height of the box (1). The remaining space (16) is filled with concrete (15) which is then compressed by a plunger (14) covering the cross-section of the box so that the blanking piece (12) is compressed at the same time. The side walls (3,4,5,6) of the box are then removed, the plunger (14) is raised, the blanking piece (12) is released and the walling block (20) allowed to harden.

Description

The invention relates to a method for producing wall elements made of concrete or the like building material with variable dimensions and / or shape on a manufacturing system and a manufacturing system implementing this method.

The mentioned wall elements can be, for example, more or less large-sized bricks, industrially prefabricated wall segments or entire wall panels, which are preferably made of concrete filled and compacted, but also of appropriate building materials - e.g. based on calcium silicate hydrate.

Known manufacturing plants have a top-open molding box with a bottom and vertical side walls, which specifies the format of the wall element to be manufactured. By means of a filling device, which usually consists of a filling box open at the bottom, the molding box is filled with customarily arranged concrete material (or a corresponding building material), which is compressed by a press die which can be lowered into the molding box from above.

This known production system has disadvantages in that only one wall element of a single format is ever produced with one and the same molding box and the press ram coordinated with it in terms of format can be. In the event of a format change, the production system must be converted using mold boxes and press rams of different formats. This undesirably limits the capacity of such a manufacturing facility. In addition, different formats of mold boxes and press dies must be produced and kept in stock for the production of different-sized wall elements, which means a considerable investment and storage effort.

A manufacturing plant such as is known from DE 44 08 845 A1 already provides a certain remedy for the problems discussed above. In this production system, at least one side wall of the molding box can be positioned at a variable distance from its opposite side wall. The result of this is that a dimension of the molding box, for example its length, can be set variably. In order to be able to use one and the same press ram in the case of different mold box sizes, one side wall of the mold box can be displaced in height so that it can yield downwards under the action of the press ram when it is lowered into the mold box.

A certain variability with regard to one dimension of the wall element is already achieved by the known manufacturing plant. A complete industrial prefabrication of building exterior walls, however, requires greater flexibility in the shaping of the individual wall elements. With such a prefabrication, an outer wall of a building is broken down into various wall elements "like a puzzle", whereby it should ideally be achievable that all wall openings, for example for windows, doors, wall openings for vents, and inclined wall closures, such as in the gable area of an outer wall, into the shape of the individual wall elements can be included in their manufacture. It is therefore not sufficient to only be able to produce different formats, but cutouts, bevels etc. must be able to be formed in the individual wall elements. In itself, this is not possible in the case of wall element production with the known manufacturing system.

The invention is therefore based on the object of specifying a method for producing wall elements on a production plant with a substantially cuboid shaped, open-topped mold box that enables a high degree of flexibility with regard to dimensioning and shaping of the wall elements produced therewith.

This object is achieved by a method with the method steps specified in claim 1. The essence of the invention is the use of mold recess bodies made of an elastically compressible material in the mold box, these mold recess bodies having the shape of a straight prism with a height in the unloaded state, which corresponds to the height of the mold box. With the aid of this shape-cutting body, a practically arbitrary tear-open shape of the wall element can therefore be achieved within the molding box, which generally has a cuboid basic shape. For example, bevels on the wall element can be produced by triangular shape recess bodies in their base area, such as are necessary for a wall element to be placed in the gable area of an outer wall of a building.

Surprisingly, it has now emerged in the course of the development of the invention that, despite their simplicity, elastically compressible form recess bodies are very well suited for the purpose according to the invention. It has been found that the bodies survive the impact of the press ram and the associated compression on the order of about 10% of their height without damage. Essentially, there is a compression of the mold recess body directed only in the pressure direction of the press ram, since at right angles either the molding box itself forms a rigid boundary surface for the surfaces of the mold recess body lying thereon or the concrete material adjoining the corresponding mold surface of the mold recess body due to the pressurization by the press ram builds up a corresponding counterpressure, which practically completely prevents bulging of the mold recess bodies transversely to the pressing direction of the ram.

In this respect, the molded surfaces of the recess bodies remain flat despite their flexibility and compressibility.

Furthermore, the use of the compressible form recess body also has a favorable effect in connection with the demolding of the compressed wall element. When the mold recess bodies are relieved, they expand again, so that their mold surfaces adjacent to the concrete material carry out a relative displacement to the concrete material. This effectively prevents the concrete material from adhering to the mold surfaces of the mold recess bodies. The latter can therefore be removed very easily without impairing the surface quality of the wall element.

Advantageous developments of the method according to the invention are specified in subclaims 2 to 5. Thus, several wall elements can be produced in one mold box at the same time in one production cycle by forming separate mold spaces in the mold box with the aid of mold recess bodies. The mold recess bodies thus form subdivisions in the mold box.

For mold recess bodies with a limited base area, it may be advantageous to place the mold recess body on the inside of the mold box - e.g. to fix on the floor or in the lower area of the side wall - preferably by a releasable glue. This prevents the mold recess body from being moved or falling over during the filling process of the molding box with concrete material.

Furthermore, it is advantageous to use a set of basic mold recess bodies within the scope of the method according to the invention, which are dimensioned and shaped, for example, according to components that regularly recur in house construction. As an example, there are shape cut-out bodies for standardized door or window openings or for wall openings in which ventilation fans are used. Wall outlets with a clear cross-section of 20 cm x 20 cm are required for the latter. Accordingly, a shape recess body has Forming such a wall passage this base area and a height of 40 cm corresponding to the height of the molding box if a wall element with a standard thickness of 36 cm is to be produced.

Fig. 1A bis F

schematische Vertikalschnitte durch eine Fertigungsanlage für Mauerelemente in nacheinanderfolgenden Schritten des erfindungsgemäßen Verfahrens,

Fig. 2 bis 4

schematische Vertikalschnitte durch die Fertigungsanlage mit unterschiedlichen Ausführungsformen von Formaussparungskörpern,

Fig. 5

eine schematische Draufsicht auf einen befüllten Formkasten mit eingesetzten Formaussparungskörpern,

Fig 6

einen schematischen Vertikalschnitt durch eine Fertigungsanlage mit einen Formaussparungskörper in einer weiteren Ausführungsform.

The claim 6 characterizes a manufacturing plant for wall elements made of concrete or the like building material for performing the method according to one of the claims discussed above. Advantageous refinements of this production system can be found in subclaims 7 to 11. To avoid repetition, reference is made to the explanation of this production system in the following description, in which exemplary embodiments of the method according to the invention and the production system used for this are explained in more detail with reference to the accompanying drawings. Show it

1A to F

schematic vertical sections through a production plant for wall elements in successive steps of the method according to the invention,

2 to 4

schematic vertical sections through the production plant with different embodiments of shape-cutting bodies,

Fig. 5

1 shows a schematic top view of a filled molding box with inserted molding recess bodies,

Fig. 6

a schematic vertical section through a manufacturing plant with a shape-saving body in a further embodiment.

1A to E has a molding box 1 which is open at the top and which is composed of a base plate 2 and four vertical side walls 3, 4, 5, 6 (see also FIG. 5). The four side walls 3 to 6 are rigidly connected to one another in a frame-like manner and can be lifted up from the underlay sheet 2 by means of a lifting device (not shown).

For filling the molding box 1 with concrete material with the side walls 3 to 6 lowered, a filling device 7 is provided, which is arranged laterally above the same with respect to the starting position of the molding box 1 shown in FIGS. 1A to C. It has a fixed base plate 8, which is aligned in the vertical direction with the upper edge 9 of the molding box 1. Furthermore, the filling device 7 has a funnel-shaped filling box 10 which is open at the bottom and which can be filled with concrete material from above by a conveying device (not shown). The concrete material is arranged on a conventional concrete mixing plant.

To introduce the concrete material into the molding box 1, the filling box 10 can be moved back and forth in the horizontal direction above the molding box 1, as a result of which the concrete material can fall into the molding box 1 through the lower filling opening 11 of the filling box 10. The width of the filling opening 11 corresponds to the width b (see FIG. 5) of the molding box 1, the extent of the back and forth movement depends on its length 1.

In order to be able to produce relatively large wall elements, the length 1 of the molding box 1 is, for example, 2 m, its width b e.g. 1 m and the height h 40 cm. The height direction of the molding box 1 corresponds otherwise to the thickness direction of the wall element produced therein, so that a wall element with a standard thickness of 36.5 cm can be produced with a molding box of a height of 40 cm due to the compression of the concrete material to be explained.

In order to be able to produce wall elements that deviate from the rectangular basic shape and basic dimensions of the molding box 1, according to the method according to the invention, mold recess bodies 12 made of an elastically compressible material, such as polystyrene foam, are inserted into the empty molding box 1. These shape recess bodies 12 basically have the shape of a straight prism with a height H, which corresponds to the height h of the molding box 1. In the exemplary embodiment shown in FIG. 1, the shape cutout body 12 has the basic shape of a right-angled triangle and is - as in the circled detailed view 1A can be seen - inserted at one end of the molding box 1 so that its shaped surface 13 practically formed from the hypotenuse of the base enables the formation of a wall element with an oblique side surface. This side surface can form part of the end of a gable wall on the side facing the aisle, for example.

The description of the actual production system is to be supplemented to the extent that a press ram 14 is provided above the molding box 1 and can be lowered into the molding box 1 by means of a hydraulic drive device (not shown). Correspondingly, the press ram 14 has a base area which corresponds to the clear base area of the molding box 1, that is to say in the present case just under 2 m × 1 m.

The sequence of the method according to the invention is to be discussed as follows:

After the individual preparation of the molding box 1 by inserting the desired molding recess body (s) 12, the filling box 10 filled with concrete material is moved over the molding box 1, so that the concrete material 15 is filled into the molding space 16 remaining in the molding box 1 (FIG. 1A). The trailing edge 17 of the filling opening 11 of the filling box 10 smoothes the surface of the concrete material 15 so that the molding space 16 is completely and cleanly filled with concrete material 15 (FIG. 1B).

Then the press ram 14 is lowered (arrows 18 in FIG. 1C) and thus moves into the molding box 1. As a result, the concrete material 15 is compressed and, at the same time, the shape-saving body 12 is compressed in the vertical direction. The compacting of the concrete material 15 can additionally be supported by a vibration excitation of the molding box 1. For this purpose, the washer 2 is mounted on a vibration device, not shown.

Regarding the compression process, it should be noted that the shape-cutting body 12 compresses only in the vertical direction, but not in bulges in the horizontal direction, since the compression pressure prevailing in the concrete material 15 counteracts such a bulging tendency. In spite of the elasticity of the mold recess body 12, the mold surface 13 thus remains flat.

In the shut-down state of the press ram 14, the frame of the molding box 1 forming the side walls 3 to 6 is then lifted up to a level above the press ram 14 with the aid of the lifting device (not shown) (arrows 19 in FIG. 1D). As a result, the wall element 20 formed from the concrete material 15 and the mold recess body 12 are laterally detached.

As shown in Fig. 1E, the ram 14 is then lifted upwards together with the frame part of the side walls 3 to 6 (arrows 19, 21). This relieves the mold recess body 12 and expands into its original shape in the vertical direction. It therefore projects upwards beyond the wall element 20, as shown in FIG. 1E. It is now possible to remove the mold recess body 12 (arrow 22) and to remove the wall element 20 on the base plate 2 for complete hardening (FIG. 1F).

It should be pointed out that basically a system according to DE 44 08 845 A1 can also be used as the production system, in which a side wall (e.g. side wall 3) is designed to be variably displaceable. In conjunction with the method according to the invention shown here, very different configurations of wall elements can then be achieved with a set of fewer shape-cutting bodies 12.

As is clear from FIGS. 2 to 4, shape recess bodies 12 can be designed as full bodies (FIG. 2). In the embodiment of the invention shown in FIG. 3, the shape-cutting body designated as a whole by 12 'is divided into two partial bodies 23, 24 in a vertically extending plane. According to FIG. 4, the shape cutout body 12 ″ is divided into two partial bodies 25, 26 in a horizontal plane. This embodiment is advantageous if a complete removal of the mold recess body 12 ″ is difficult.

FIG. 5 shows the high variability for the shape of the wall elements 20 ′, 20 ″ to be produced using the method according to the invention using an obvious example.

Thus, by using different, individually shaped mold cutout bodies 12, specifically cut out of a polystyrene foam block, as shown in FIG. 5 in their design and arrangement, in a manufacturing cycle in a mold box 1 by forming separate mold spaces with the help of these mold cutout bodies 12 Wall elements 20 ', 20' '(or more of them) can be produced simultaneously. In the case of the wall element 20 ', a small wall opening 27 is additionally provided with the aid of the mold recess body 12 located there, which would have to be sawed out of the wall element 20' in a complex manner without the method according to the invention. This wall opening 27 is used, for example, to insert a fan for the motor ventilation of a bathroom.

The mold recess bodies 12 can also have partially round basic shapes, as shown in FIG. 5 below. The arch 28 formed in the wall element 20 ″ by the corresponding shape-cutting body 12 can, for example, form the lintel of an arch window in the installed state of the wall element 20 ″.

With reference to FIG. 5, it should also be pointed out that, for example, the two shape cut-out bodies 12 are fastened to the base plate 2 at the wall opening 27 or the round arch 28 by means of a releasable adhesive connection. This prevents the mold recess body 12, which is provided with a relatively small footprint, from falling over when the mold box 1 is filled with concrete material.

6 shows a further alternative embodiment for a shape recess body 12. The latter is in with a rigid substructure Form of a box 29 open at the top, into which an elastically compressible partial body 30 is inserted. The box 29 is formed, for example, by four vertical sheet metal walls arranged in a plan view in a rectangular shape, of which three walls 31, 32, 33 are visible in FIG. 6. The height H 'of the box 29 corresponds to the thickness d of the wall element 20 to be produced. Halfway up the box 29, an intermediate floor 34 is welded between the sheet metal walls 31, 32, 33, on which the cuboidal, elastically compressible partial body 30 sits. Its upper side 35 is aligned with the upper edge 9 of the molding box 1 in the unloaded state.

In the compression process analogous to FIG. 1C, the press die 14 now moves into the molding box 1 until it ends with the upper edges 36 of the box 29.

The advantage of this type of mold recess body is that although the height difference is compensated for during compression, a clean trailing edge is obtained towards the wall element 20 during the compression process, since practically the entire molded surface 13 of the mold recess body 12 consists of sheet metal. The part of the partial body 30 made of polystyrene foam, which has to compensate for the degree of compaction of the concrete material 15, is compressed to the height of the box 29.

Claims (11)

Method for producing wall elements from concrete material or the like building material with variable dimensions and / or shaping on a production plant which has a molding box (1) open at the top, with the following method steps: - Inserting at least one mold recess body (12, 12 ', 12'') made of an elastically compressible material into the mold box (1), the at least one mold recess body (12, 12', 12 '') having the shape of a straight prism with a height (H) in the unloaded state, which corresponds to the height (h) of the molding box (1), - Filling the free molding space (16) of the molding box (1) with concrete material (15), - Compacting the concrete material (15) by moving in a press ram (14), the pressure area of which corresponds to the base area of the molding box (1), from above into the molding box (1) with simultaneous compression of the at least one mold recess body (12, 12 ', 12'' ), - removing the side walls (3, 4, 5, 6) of the molding box (1), - Lifting the press ram (14) upwards while simultaneously relieving the pressure on the at least one mold recess body (12, 12 ', 12''), - Removing the at least one shape recess body (12, 12 ', 12''), and - Hardening the wall element (20, 20 ', 20''). A method according to claim 1, characterized in that in a production cycle in a molding box (1) by forming separate molding spaces (16, 16 ') with the aid of mold recess bodies (12), a plurality of wall elements (20', 20 '') are produced simultaneously. A method according to claim 1 or 2, characterized in that the at least one mold recess body (12, 12 ', 12'') is fixed on the inside of the mold box (1). A method according to claim 3, characterized in that the at least one form recess body (12, 12 ', 12'') by a releasable Gluing is fixed to the inner wall of the molding box (1). Method according to one of claims 1 to 4, characterized in that shape cut-out bodies (12, 12 ', 12'') are used from a set of basic shape cut-out bodies, which are preferably dimensioned and shaped according to components that recur regularly in house building. Production plant for wall elements made of concrete material or the like building material for carrying out the method according to one of claims 1 to 5, with - an open-topped mold box (1) with a bottom (8) and vertical side walls (3, 4, 5, 6), - A filling device (7) for filling the molding box (1) with concrete material (15), and - a press ram (14) which can be lowered from above into the molding box (1) for compacting the filled concrete material (15) into a wall element (20, 20 ', 20''), marked by
at least one mold recess body (12, 12 ', 12'') which can be inserted into the molding box (1) and which has the shape of a straight prism with a height (H) in the unloaded state, which corresponds to the height (h) of the Molding box (1) corresponds. Production system according to claim 6, characterized in that the at least one mold recess body (12, 12 ', 12'') is divided in a vertical plane. Production system according to claim 6, characterized in that the at least one mold recess body (12 '') is divided in a horizontal plane. Production system according to one of claims 6 to 8, characterized in that the entire mold recess body (12) consists of an elastically compressible material, preferably of polystyrene foam. Production system according to claim 6, characterized in that the at least one mold recess body (12) has a rigid substructure (29) on which an elastically compressible partial body (30) sits. Production system according to claim 10, characterized in that the substructure is designed as a box (29) open at the top, the height of which corresponds to the thickness (d) of the wall element and in the opening which points upwards, the partial body (30) which projects beyond the box in the unloaded state. is arranged.

Images