EP1422355B1 - Shuttering plate and methods of making and installing same - Google Patents

Abstract

The shuttering plate (10) is made from a concrete which is highly fluid to compact automatically when it is poured. Recesses (11) are provided for inserting reinforcement irons and in the recess area the concrete residual thickness around the reinforcement insert is preferably about 2mm. Independent claim describes method for manufacturing several shuttering plates by filling out the cavities between the pairs of plates with self-compacting concrete in one work step.

Description

TECHNICAL AREA

The present invention relates to a formwork panel made of concrete with reticulated reinforcing insert and with recesses, in the range of which openings for the insertion of reinforcing bars and / or fasteners can be produced in a simplified manner. Furthermore, the invention relates to a formwork for producing such formwork panels, a corresponding manufacturing method using such a formwork and a method for fixing such formwork panels in the production of a shuttering.

Shuttering slabs of the type considered can be used wherever concrete components such as floor slabs, ceilings but also walls have to be shut off at the edge or end, be it at the actual edge of the concrete components or, in sections with adjacent concreting, also between the individual sections. Due to their concrete material, the shuttering plates can be left as so-called lost formwork elements in the concrete component, but should be more reasonably priced parts for this reason.

The shuttering panels must be fixed to withstand the concrete pressure. For Deckenrandabschalungen an attachment to the wall crown is required, including additional elements such as brackets or the like can be used. Of course, a connection must also be made between the shuttering panels and the additional elements. Also should in Deckenrandabschalungen an external plaster or an external insulation well be attached to the shuttering plates.

For connecting concretions, the reinforcing bars between the sections must be able to be pulled through and thus also be able to be passed through the shuttering plates in order to connect the adjoining sections. The same applies to pipes or pipes that pass through between the sections. In the shuttering plates suitable openings must be present or attachable for each. However, the openings must also closely enclose the parts that have been carried out, so that the fresh concrete can not escape. In addition, a thrust toothing between the adjacent sections is desirable and, especially for floor panels, also the greatest possible tightness against water penetration.

STATE OF THE ART

From the EP 0 519 146 A1 Shuttering plates of the type mentioned for Anschlusbetonierungen are known, however, have a considerable thickness and are therefore quite heavy and unwieldy. Because of their considerable thickness, their longitudinal sides are slightly offset with respect to the surfaces, forming relatively rectangular grooves, in order to ensure that the outer edges of the longitudinal sides visible on the finished component are less wide and less conspicuous. Visible outer edges with the width of the known Abschalungsplatten would not be accepted at least in exposed concrete area. A prerequisite for the desired effect is, of course, that the resulting by wetting grooves are completely filled with fresh concrete, which is at least critical. If this is not the case, for example, there is a risk of spalling of concrete material.

In the known formwork panels, the recesses form windows which are only covered by the reinforcing insert. Since this is formed tissue-shaped, it comes to the exit of at least concrete milk from the fresh concrete. The known formwork panels are therefore, for example, as Deckenrandabschalungen as good as can not be used.

The known Abschalungsplatten are produced in at least approximately lying individual forms made of steel, wherein a concrete material is used with Schnellbinder. During filling, the molds have to be shaken so that the fresh concrete can reach all voids and fill them completely.

PRESENTATION OF THE INVENTION

One of the objects of the invention is to improve and further develop the previously known shuttering plates.

This object is achieved with regard to a first aspect of the invention by the features specified in claim 1. Thereafter, a Abschalongsplatte invention is characterized in that a self-compacting, highly-flowable concrete is used as the concrete material. This concrete, which is also highly resilient, is called "SCC concrete" according to the English "self contracting concrete" and has not been available on the market for a very long time. He is currently still relatively expensive.

An inventive formwork panel is further characterized in that it, apart from the recesses, has a uniform thickness between 10mm and 20mm.

The proposed by the invention use of the novel material pays off, inter alia, the fact that the shuttering plates can be made substantially thinner than previously possible, which material can be saved. According to a preferred embodiment of the invention, the thickness of the shuttering panels according to the invention outside the recesses is 15 mm. By this comparatively small thickness, the shuttering plates are of course also easier and more manageable. Your transport weight and volume will be reduced.

Another cost-reducing factor results from the particular flow properties of the new concrete material, which can already compact under its own weight and, for example, does not have to be shaken. This enables a highly efficient way of simultaneously producing a plurality of shuttering plates in a novel shape, which will be discussed later.

According to a further preferred embodiment of the invention, the shuttering plates in the region of the recesses on a concrete residual strength around the reinforcing insert around, so that it can not come to a leakage of fresh concrete or concrete milk during concreting. Also for this training, the high flowability of the concrete material used is advantageous.

In order to seal the joints resulting from connecting concrete on both sides of the shuttering plates to the adjacent concrete against water penetration, according to yet another preferred embodiment, the shuttering plate according to the invention is provided with a sealing plate extending transversely to it and laterally projecting above it.

For better anchoring of the sealing plate in the Abschalungplatte this can be provided at least one perforated plate, which is embedded in the Abschalungsplatte surface and firmly connected to the sealing plate.

The executed in particular as a metal sheet sealing plate may also be provided with a coating which connects waterproof with fresh concrete.

A further aspect of the invention according to claim 11 is a method for simultaneously producing a plurality of shuttering slabs comprising a formwork trough in which mold plates are set in pairs opposite each other, the mold plates having projections for forming the recesses in the shuttering plates and an armor insert between each pair of mold plates is arranged.

Preferably, the mold plates are thermoformed plastic sheets or plastic sheets by e.g. of polypropylene, polyethylene or polyvinyl chloride, preferably with a thickness in the range between 0.5 mm and 3 mm. Since deep-drawing technology sharp corners are not well feasible, in the region of the projections oblique angle and / or rounded shapes are preferred.

In order to realize the aforementioned residual strength in the region of the recesses and / or to set defined, at the projections even further beyond this projecting nubs be formed, which keep the mold plates in the region of the projections at a distance.

A method according to the invention for the simultaneous production of multiple shuttering slabs is the subject of claim 11. Thereafter, the cavities between the mold plate pairs with the self-compacting concrete or fresh concrete, if necessary, without shaking only poured out. In a single operation can be made in this way with a single dormant formwork several hundred Abschalungsplatten simultaneously.

In particular, in the closed version, i. in the presence of at least some concrete residual strength around the reinforcement insert in the region of the recesses, the shuttering panels according to the invention are very universally applicable, e.g. also for Deckenrandabschalung. By the aussenseitig here visible remaining recesses results in the further advantage that an applied plaster or adhesive for external insulation can additionally anchor in the recesses. Of course, the Abschalungsplatten can at least on one side also provided with a rough and / or textured surface and thereby the plaster or adhesive adhesion can be additionally improved. Non-smooth side surfaces of course support the connection to the adjacent concrete.

The mounting problem of the inventive shuttering slabs is very rational to solve that they can be easily nailed through the recesses through suitable counter-positions such as parking angle, wedges or the like or screwed. To anchor the nail or screw heads, large areas, or possibly even matched washers, may be used for the contours of the recesses.

BRIEF EXPLANATION OF THE FIGURES

Fig. 1

eine Abschalungsplatte nach der Erfindung mit einer Vielzahl von Aussparungen in einer Seitenansicht;

Fig. 2

die Abschalungsplatte von Fig. 1 im Schnitt (A-A)

Fig. 3

in einer Ausschnittsvergrösserung den Bereich um eine der Aussparungen herum, wobei zusätzlich die innen liegende und somit an sich nicht sichtbare Armierungseinlage dargestellt ist;

Fig. 4

in perspektivischer Teilansicht eine erfindungsgemässe Schalung zur Herstellung erfindungsgemässer Abschalungsplatten;

Fig. 5

einen Teil der Schalung von Fig. 4 in Aufsicht mit mehreren darin eingesetzten Formplatten;

Fig. 6

eine der Formplatten von der Seite;

Fig. 7

im Schnitt eine Abschalungsplatte gemäss Fig. 2 eingesetzt zur Abschalung eines bereits fertig betonierten Abschnitts einer in mehreren Abschnitten betonierten Deckenplatte;

Fig. 8

im Schnitt eine Abschalungsplatte gemäss Fig. 2 eingesetzt zur randseitigen Abschalung einer Decke;

Fig. 9

im Schnitt eine Abschalungsplatte nach der Erfindung, die mit einer quer zu ihr angeordneten und seitlich jeweils vorstehenden Dichtungsplatte versehen ist im beidseitig fertig einbetonierten Zustand; und

Fig. 10

in einer Darstellung gemäss Fig. 5 eine Schalung zur Herstellung von Abschalungsplatten mit Dichtungsplatte gemäss Fig. 9.

The invention will be explained in more detail with reference to embodiments in conjunction with the drawings. Show it:

Fig. 1

a Abschalungsplatte according to the invention with a plurality of recesses in a side view;

Fig. 2

the shuttering plate of Fig. 1 on average (AA)

Fig. 3

in a section enlargement, the area around one of the recesses around, in addition, the inner and thus not visible in itself reinforcing insert is shown;

Fig. 4

in a perspective partial view of a formwork according to the invention for the production of moldings according to the invention;

Fig. 5

a part of the formwork of Fig. 4 in plan view with several mold plates inserted therein;

Fig. 6

one of the mold plates from the side;

Fig. 7

in section a shuttering plate according Fig. 2 used for shuttering an already finished concrete section of a concrete slab concreted in several sections;

Fig. 8

in section a shuttering plate according Fig. 2 used for edge-on shuttering of a ceiling;

Fig. 9

in section, a shuttering plate according to the invention, which is arranged with a transversely arranged and laterally projecting sealing plate is in both sides finished concreted state; and

Fig. 10

in a representation according to Fig. 5 a formwork for the production of Abschalungsplatten with sealing plate according Fig. 9 ,

WAYS FOR CARRYING OUT THE INVENTION

The shuttering plate 10 of Fig. 1-3 has a height H corresponding to the thickness of the concrete component to be created, a greater length L and a much lower Thickness D on. It consists essentially of a self-compacting, highly flowable concrete. In the area of the recesses 11, which are oval here, the thickness of the Abschalungsplatte 10 is reduced, but there is also still preferably a certain Remaining thickness d of concrete available.

The side surfaces 13 of the Abschalungsplate 10 can be roughened on one or both sides, as shown, or otherwise structured. The two narrow sides 14, however, are preferably formed smoothly ensprechend the requirements as they are made of exposed concrete.

In the formwork 20 of 4 and 5 For example, a plurality of shuttering plates 10 can be produced simultaneously. The formwork 20 comprises an outer formwork trough 21, which can preferably be opened at least on one side. Inserted or set in this formwork trough 21 with its length L, for example, in a vertical orientation in pairs in opposite directions to each other form plates 22, which projections 23 for forming the recesses 11 in the shuttering plates 10 have. Between each pair of mold plates 22, a reinforcing insert 12 is arranged. In this form, the formwork 20 can be easily poured from above with the mentioned concrete material, which fills the cavities 24 between the mold plates 22. Because of the special properties of the concrete material can be dispensed with a shaking in the rule.

Fig. 6 shows one of the mold plates 22 from the side. In addition, protrusions 23 are further formed on the projections 23, by which in the formwork in pairs oppositely arranged mutually mold plates 22 are held at a small mutual distance, so that the concrete material during pouring also in the area between each two opposite projections 23 can pass. This ensures the mentioned residual thickness d in the area of the recesses 11 or allows a targeted adjustment of this residual thickness d.

The mold plates may be thermoformed plastic sheets or sheets by deep drawing. Since it is not possible to produce well-edged rectangular shapes during deep-drawing, the projections 23 are preferably made with non-right angles α and have an overall rounded design. During deep drawing, a structure for achieving the respective desired surface roughness or the like of the side surfaces 13 of the shuttering plates 10 can also be impressed directly into the mold plates. Smooth narrow sides 14 of the Abschalungsplatten arise simply by a sufficiently smooth formation of the side walls of the formwork trough 21st

Should, for example, an interlocking connection between the concrete of the concrete component to be peeled off and the undercut according to the invention is required in the region of the recesses 11, these could be produced, for example, by using resilient mold plates 22 of a rubber material.

The formwork 20 could advantageously also be designed so that several rows of pairs gegensinning each other arranged moldings 22 side by side in their place, of course, lateral partitions would also be used in the formwork. For an internal dimension of the formwork of e.g. 100 to 150 cm, a height H of the mold plates of about 20 cm and a mutual distance D of 15 mm could simultaneously 500 Abschalungsplatten 10 are poured in one operation.

Fig. 7 shows a Abschalungsplatte 10 according to the invention according to Fig. 2 used for Abschalung a portion 30 of a multi-section concreted ceiling tile, wherein in the representation of Fig. 7 the fresh concrete has already been poured into section 30. To support the Abschalungsplatte 10 against the pressure exerted by the fresh concrete pressure here a wooden wedge 31 is used, which is simply nailed by the Abschalungsplatte 10 in the region of a recess 11 from the side of the concreting 30 ago and on the other hand with the slab formwork 32. Because of the possibly only small residual thickness of the shuttering plate 10 in the region of the recesses 11, it is easy to drive the nail 33 through the concrete material of the shuttering plate 10 in this area. For better anchoring of the nail head is one of the contour of the Recess 11 adapted fitting 34 used in the manner of a large washer.

Shown is in Fig. 7 also, how a concrete iron 35 could be passed through an upper recess 11 of the shuttering plate 10. In reality, however, this will be the case in a plane offset from the plane of the drawing, and then, parallel to this, a concrete iron will pass through the lower recess. With a plugged onto the concrete iron 35 clamping element 36, which is also shown separately for clarity, the shuttering plate 10 is secured in its upper region against the concrete pressure.

Fig. 8 shows a shuttering plate 10 according to Fig. 2 used to edge-off a ceiling before concreting the same. Here, the shuttering plate 10 is arranged on the outside of the crown of a wall 40 and nailed from the outside with a shutter inside arranged Abstellwinkel 41. The parking angle 41 is in turn nailed to the slab formwork 42. With 43 is shown only schematically outside, inter alia, on the shuttering board 10 after concreting, for example, by gluing attached external insulation.

Fig. 9 shows a Abschalungsplatte 10 according to the invention, which is designed especially for the field of construction joints, which must be sealed against the passage of water, as could be the case, for example, in the illustrated floor panel 50. For this purpose, the shuttering plate 10 is provided with a sealing plate 51 projecting over its length L, arranged transversely to its height H and on both sides above it, for example, from a metal cup in the manner of a so-called joint plate. The sealing plate 51 substantially extends the path that would have to take from the soil 52 ago possibly ascending water in the gaps 53 and / or 54 on both sides of the shuttering plate 10 to the top of the bottom plate 50.

For better anchoring of the seal plate 51 in the Abschalungsplatte 10 are in the example of Fig. 9 above and below it still perforated plates preferably also made of metal, which are embedded in the formwork sheet surface and connected to the sealing plate 51, for example by welding.

Preferably, the sealing plate 51 is also provided with a coating 56 which has the property to connect waterproof with fresh concrete, whereby an absolutely tight seal can be achieved without further measures. A suitable coating material is for example from the EP 0 796 951 A1 known KSK mass, which is a mixture of soft bitumen, styrene-butadiene-styrene (SBS) and synthetic resins.

For producing the shuttering plates with transversely embedded sealing plate 51 according to Fig. 9 in a formwork according to Fig. 4 In addition to moldings of the type described, further elements for filling up the cavities inevitably resulting in the formwork have to be used, as described, for example, in US Pat Fig. 10 is shown. For these elements, the in Fig. 10 are designated 60, for example, it may simply be blocks of a sufficiently pressure-resistant plastic foam. Using such cavity-filling elements, the shuttering panels could also be modified in other ways, for example, by molding a skirting board which adjoins one of its narrow sides and widening it, making use of which the shuttering panels are placed on a base such as the one shown in FIG Fig. 8 could be glued on.

The height H of the shuttering panels according to the invention depends on the thickness of the concrete component to be produced, for which graded standard dimensions are the rule. Typical values are in the range of 16 cm - 40 cm.

The length L of the formwork slabs according to the invention is dimensioned according to practical aspects with regard to their production, handling and transport. Length measures in the range between 100 cm and 300 cm are preferred.

The thickness D of the shuttering slabs according to the invention should be as small as possible because of the amount of material to be used and its weight and, taking into account stability criteria and favorable manufacturability, as already mentioned above, preferably in the range between 10 mm and 20, preferably about 15 mm, selected.

The residual thickness d of the concrete material in the region of the recesses can be between only 0.5 mm and 5 mm, with a preferred value of about 2 mm.

The recesses are preferably arranged with a mutual grid spacing of 5 cm, corresponding to the grid spacing in which concrete iron is usually laid.

In order to enable the use of reinforcing steel mats in concreting, the recesses 11 could also be formed in the manner of notches to an edge or to one of the narrow sides 14 of the Abschalungsplatten 10 out, as in the right part of Fig. 1 is shown.

The recesses 11 should have at least a clear width of 10 mm. Other than shown in the figures, the shuttering panels could also be provided with more than two rows of recesses, gff. just to further reduce their weight.

A suitable self-compacting concrete is commercially available, for example, under the name "FLOWSTONE" from Dyckerhoff, D-65203 Wiesbaden.

For the reinforcing insert 12, a mesh or mesh having a mesh size of the order of magnitude of approximately 5 mm, which is preferably inherently tensile, or else a coarse meshed fleece may be used. As a material for plastic materials such as polypropylene, but also glass fibers or "ARAMID" come into question.

NAME LIST

10

Abschalungsplatte

11

recesses

12

net-shaped reinforcing insert

13

faces

14

narrow sides

20

formwork

21

formwork trough

22

mold plates

23

Projections on the mold plates

24

cavities

25

burl

30

finished concrete section of a ceiling slab

31

Wooden wedge 31

32

slabs

33

nail

34

spud

35

concrete iron

36

clamping element

40

outside wall

41

cancel angle

42

slabs

43

Exterior insulation

50

baseplate

51

sealing plate

52

damp soil

53

gap

54

gap

55

perforated sheets

56

coating

60

cavity-filling elements

H

Height of the shuttering plate

L

Length of the shuttering plate

D

Thickness of the shuttering plate

d

residual starch

Claims (14)

1. Shuttering panel (10) of concrete with a mesh-type reinforcing inlay (12) and with recesses (11), in the region of which recesses openings can be produced in a simplified manner for the passage of reinforcing bars (35) and/or fastening means (33), characterized in that the concrete material used is a self-compacting, high-flowability concrete, and in that, apart from the recesses (11), the plate has a uniform thickness (D) of between 10 mm and 20 mm.
2. Shuttering panel according to Claim 1, characterized in that it has, in the region of the recesses (11), a residual concrete thickness (d) around the reinforcing inlay (12), which is preferably from 0.5 mm to 5 mm, but in particular about 2 mm.
3. Shuttering panel according to either of Claims 1 and 2, characterized in that at least some of the recesses (11) are designed to be open towards an edge of the shuttering panel (10).
4. Shuttering panel according to one of Claims 1-3, characterized in that, apart from the recesses (11), it has a uniform thickness (D) of 15 mm.
5. Shuttering panel according to one of Claims 1-4, characterized in that it has at least one narrow side (14) which meets the requirements of exposed concrete in respect of its smoothness.
6. Shuttering panel according to one of Claims 1-5, characterized in that it has a rough and/or textured surface at least on one of its side faces (13).
7. Shuttering panel according to one of Claims 1-6, characterized in that the reinforcing inlay (12) is a mesh-type fabric, preferably with a mesh size in the region of 5 mm, or a large-mesh nonwoven fabric.
8. Shuttering panel according to one of Claims 1-7, characterized in that it is provided with a sealing plate (51) which extends over length (L), is arranged transversely thereto and projects laterally in each case.
9. Shuttering panel according to Claim 8, characterized in that, for better anchoring of the sealing plate (51) in the shuttering panel (10), at least one perforated plate (55) is provided which is embedded flat in the shuttering panel (10) and is fixedly connected to the sealing plate (51).
10. Shuttering panel according to either of Claims 8 and 9, characterized in that the sealing plate (51), which is embodied in particular as a metal sheet, is provided with a coating (56) which bonds watertight with fresh concrete.
11. Method for the simultaneous production of a plurality of shuttering panels according to one of Claims 1-10, characterized in that a mould (20) is used which comprises a mould trough (21) in which moulding plates (22) are placed in pairs in opposite directions to one another, wherein cavities (24) are present between the moulding plates (22), wherein the moulding plates (22) have projections (23) for forming the recesses (11) in the shuttering panels (10) and wherein a reinforcing inlay (12) is arranged between each moulding plate pair (22), and in which method self-compacting concrete is poured into the cavities (24) between the moulding plate pairs (22) in a single operation.
12. Method according to Claim 11, characterized in that the moulding plates (22) are plastic plates or films which are deformed by deep-drawing, preferably having a thickness in the range between 0.5 mm and 3 mm.
13. Method according to either of Claims 11 and 12, characterized in that projecting knobs (25) are formed on the projections (23) of the moulding plates (22), by means of which knobs moulding plates (22) which are each arranged in pairs in opposite directions to one another in the mould (20) are kept at a slight mutual spacing.
14. Method for fastening shuttering panels (10) according to one of Claims 1-10 in the production of a shuttering system, characterized by the shuttering panel (10) being nailed on, screwed on, or the like, through their recesses (11).

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