EP1431015B1 - Process for making reinforced concrete beams and installation for the execution of this process - Google Patents
Process for making reinforced concrete beams and installation for the execution of this process Download PDFInfo
- Publication number
- EP1431015B1 EP1431015B1 EP03360144A EP03360144A EP1431015B1 EP 1431015 B1 EP1431015 B1 EP 1431015B1 EP 03360144 A EP03360144 A EP 03360144A EP 03360144 A EP03360144 A EP 03360144A EP 1431015 B1 EP1431015 B1 EP 1431015B1
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- EP
- European Patent Office
- Prior art keywords
- moulding
- zone
- beams
- assembly
- designed
- 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.)
- Expired - Lifetime
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- 238000009434 installation Methods 0.000 title claims abstract description 25
- 238000000034 method Methods 0.000 title claims abstract description 19
- 239000011150 reinforced concrete Substances 0.000 title description 7
- 238000000465 moulding Methods 0.000 claims abstract description 58
- 238000004519 manufacturing process Methods 0.000 claims abstract description 39
- 239000004567 concrete Substances 0.000 claims abstract description 24
- 230000000712 assembly Effects 0.000 claims abstract 8
- 238000000429 assembly Methods 0.000 claims abstract 8
- 238000002360 preparation method Methods 0.000 claims description 32
- 230000002787 reinforcement Effects 0.000 claims description 19
- 125000006850 spacer group Chemical group 0.000 claims description 17
- 238000009415 formwork Methods 0.000 claims description 14
- 230000003014 reinforcing effect Effects 0.000 claims description 14
- 239000002184 metal Substances 0.000 claims description 7
- 238000005266 casting Methods 0.000 claims description 6
- 238000003860 storage Methods 0.000 claims description 6
- 238000005520 cutting process Methods 0.000 claims description 5
- 238000003466 welding Methods 0.000 claims description 3
- 238000006073 displacement reaction Methods 0.000 claims 1
- 238000001035 drying Methods 0.000 abstract 1
- 239000011513 prestressed concrete Substances 0.000 description 7
- 238000004873 anchoring Methods 0.000 description 6
- 210000001520 comb Anatomy 0.000 description 3
- 238000000151 deposition Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 208000023178 Musculoskeletal disease Diseases 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 235000021189 garnishes Nutrition 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 210000002435 tendon Anatomy 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000013519 translation Methods 0.000 description 1
Images
Classifications
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- 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
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
-
- 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
- B28B23/043—Wire anchoring or tensioning means for the reinforcements
-
- 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
Definitions
- the present invention relates to a method of manufacturing concrete beams obtained by molding in a molding bench.
- the invention also relates to an installation implementing this method and comprising at least one molding zone provided with a molding bench.
- Concrete beams are generally reinforced concrete beams, in which case the concrete is reinforced with metal reinforcements, or prestressed concrete beams, in which case concrete is in addition, put under stress by prestressing tendons stretched during the molding phase and then relaxed after curing the concrete.
- the molds used for the manufacture of this type of beams extend over a great length, for example from 60 to 120 meters, and are each cut into a number T of longitudinal sections, by means of spacers or spacers. formwork combs, for manufacturing a number T of beams forming a set.
- These molds are joined in a molding bench, which has a number M of parallel molds between them, which may have different sections.
- each molding bench allows the simultaneous realization of a number M of sets of beams, which can have different lengths and sections.
- each mold is prepared individually and manually by one or more operators who set up the reinforcing cages and the spacers or formwork combs at locations defined according to the length of the reinforced concrete beams to be manufactured, as described for example in the publication EP-A-0 606 794 .
- they add prestressing cables that run the full length of the molds and are pulled by a tensioning device, as described for example in the publication WO-A-97/18070 .
- prestressed concrete beams After pouring and hardening of the concrete, the prestressing cables are released and then cut inside the molds, either with a blowtorch or by a circular saw, with all the risks and difficulties that this represents: difficult access, alteration of the mold walls, heavy soiling, danger for the operator, etc.
- the finished beams are then demolded one by one which, added to the previous tasks, immobilizes the molding bench over a very long period of time.
- the current manufacturing process does not allow to consider optimal management of the production tool, nor better working conditions for operators.
- the present invention aims to overcome these disadvantages by proposing a new semi-automated or automated manufacturing process, which eliminates the difficult tasks related to the handling of heavy elements and difficult working positions, ensures accurate manufacturing of reinforcements, deportes in out of the molding molding bench the pre-molding and post-molding processing operations, thereby reducing the downtime of the molding bench, allows a high production flexibility and optimizes the overall efficiency of the manufacturing plant .
- the invention also relates to a manufacturing facility of the type indicated in the preamble, characterized in that it comprises at least one preparation zone of at least one set of pre-assembled elements positioned relative to the other depending on each beam to be manufactured and comprising at least reinforcing cages, this preparation zone being disposed outside said molding zone, and gripping means arranged to take a single piece of said set of elements pre-assembled of said preparation zone and depositing it in the molding bench of said molding zone, before pouring the concrete.
- the installation 10 makes it possible to manufacture reinforced concrete or prestressed concrete beams, of different sections and lengths.
- the beams are reinforced by metal reinforcements only, while in the second case, these beams are further stressed by metal prestressing cables.
- the Figure 1A illustrates an example of prestressed concrete beam 1, reinforced by reinforcement cages 2 and stressed by prestressing cables 3.
- the beam 1 as illustrated has a substantially rectangular section, given by way of non-limiting example. , this section can be square, frustoconical, T or any other section suitable for molding.
- This installation 10 makes it possible to implement a new manufacturing process in which the beams 1 are manufactured by molding in a molding bench 40 comprising several molds 41 and whose length makes it possible to manufacture in each mold 41 several beams 1, called by following a set of beams 1.
- the prestressing cables are removed and, consequently, the stressing operation of these cables before molding and then cutting these cables after demolding.
- the installation 10 comprises several work zones and in particular a preparation zone A of sets of pre-assembled elements 5, a molding zone B of the beams 1, an evacuation zone C of the beams 1 manufactured (cf. Fig. 2 and 3 ).
- This installation 10, and more particularly the preparation zone A is automated and controlled by one or more controllers receiving computer data from a design office relating to the various beams 1 to be produced (length, section, number and location of the cages reinforcement 2, number of prestressing cables 3, location of form spacers 4 and anchors 6, etc.).
- the molding zone B comprises a molding bench 40 of reduced length compared to conventional molding benches, for example 30 to 70 meters instead of 100 to 150 meters.
- This molding bench 40 comprises several parallel molds 41 of different sections, mounted on foundations 40 '(cf. Fig. 2 and 3 ). This particular arrangement gives this molding bench 40 a very great flexibility in the production management to simultaneously produce beams 1 of sections and of different lengths.
- the number of molds 41 may be different, as well as their section and length.
- These molds 41 can also be adjustable in width and / or depth by means of movable walls.
- the preparation zone A makes it possible to prepare, apart from the molding bench 40, in parallel thereto and at human height, sets of pre-assembled elements 5 extending over the entire length of this bench.
- Each set of pre-assembled elements 5 corresponds to one of the molds 41 and comprises an arrangement of reinforcing cages 2, formwork spacers 4, anchoring pieces 6 and prestressing cables 3 determined in FIG. function of the beams 1 to manufacture.
- This preparation zone A comprises, in the example shown, a frame machine 20 which is a standard machine for automatically manufacturing frames 2a used in the composition of the reinforcement cages 2. These frames 2a are made by folding a wire, for example in the form of a rectangle.
- This frame machine 20 is fed by a reel 21 carrying four coils 22 of wire of different diameters, for example 6, 8, 10 and 12 mm.
- the frame machine 20 will automatically use one or the other diameter of wire to make frames 2a of different dimensions and strength depending on the beams 1 to be manufactured.
- the preparation zone A comprises another reel 23 carrying three coils 24 of wire of the same diameter, for example 5 mm.
- These three son constitute mounting frames 2b used in the composition of the frame cages 2. They are unwound simultaneously and positioned parallel, for example, in a triangle to be welded, by a welding station 25, on three sides of the frames 2a of the same reinforcement cage 2.
- a conveyor belt 26 arranged between the frame machine 20 and the reel 23 makes it possible to bring the frames 2a towards an operator who grasps the frames 2a one after the other and presents them next to the welding machine 25 (cf. Fig. 4 ).
- the gaps between the parallel frames 2a of the same reinforcement cage 2 are of course defined for each beam 1 to be manufactured. If the beams 1 to be manufactured have a length less than or equal to 8 meters, for example, a cage will be made of reinforcement 2 by beam 1. If their length is greater than 8 meters, two, or even three, reinforcement cages 2 per beam 1 will be realized.
- a reinforcement cage 2 When a reinforcement cage 2 is completed, it is transferred to a preparation mat 28 by a supply chain 27 (cf. Fig. 4 ).
- This preparation mat 28 extends parallel over the entire length of the casting bench 40 and receives the reinforcing cages 2 aligned one behind the other, as they are finished, and in the exact order their intended position in the corresponding mold 41.
- the formwork spacers 4 and the anchoring pieces 6 (cf. Fig. 6 ) are interposed between the reinforcing cages 2, their handling being for example carried out by a spreader (not shown) placed at the beginning of the preparation mat 28.
- prestressing cables 3 are threaded through the reinforcing cages 2 , formwork spacers 4 and anchors 6 along the entire length of the preparation belt 28.
- the introduction of these prestressing cables 3 can be performed either manually, semi-automatically, or automatically using of a specific machine which is not the subject of the present invention.
- a set of pre-assembled elements 5 corresponding to a predetermined mold 41 is obtained.
- the formwork spacers 4 make it possible to delimit the beams 1 between each other in the same mold 41 and consist, for example, of a perforated metal plate whose number of holes corresponds to the number of prestressing cables 3.
- the anchoring pieces 6 are used both for transporting said assembly 5, between the preparation A and molding B zones, and for the attachment of the prestressing cables 3 to the traction devices 50, 51 provided on the molding bench 40. example consist of metal combs.
- this preparation zone A is designed to allow the operator to work in good ergonomic conditions, the conveyor belt 26 and preparation 28 being located at height of man, and to avoid any handling, the progress of the reinforcement cages 2 being controlled manually by push button, without physical effort.
- the set of pre-assembled elements 5 is then conveyed into the appropriate mold 41, in a single operation, by specific gripping means 31 attached to the anchoring pieces 6.
- These gripping means 31 are suspended from a rudder 30 , the latter being movable in translation along the three axes X, Y, Z on a traveling crane (cf. Fig. 3 and 5 ).
- These gripping means 31 are arranged to lift in one piece each set of pre-assembled elements 5 by applying a tension to tension the prestressing cables 3, prevent buckling and facilitate its introduction into the mold 41 and that the introduction of said prestressing cables 3 in the traction devices 50, 51 described below.
- the overhead crane spans the preparation A and B molding zones to allow the gripping means 31 to pass easily from one to the other A, B and C zones.
- a new set of pre-assembled elements 5 can be prepared in the preparation zone A for filling another mold 41.
- the prestressing cables 3 are tensioned by traction devices, commonly called trimmers 50, 51, disposed at the ends of the molds 41 in suitable pits 42 provided in the foundations 40 '(cf. Fig. 6A-6C ).
- trimmers 50, 51 are provided: a fixed trimmer 50 and a trimmer 51 movable in rotation about a pivot 52 integral with the foundations 40 'between a rest position (cf. Fig. 6A ) in which it does not exert any traction on the prestressing cables 3 and a working position (cf. Fig.
- trimmers 50, 51 in which it exerts a traction on these prestressing cables 3 in the direction of their length.
- Rooms anchoring 6 sets of pre-assembled elements 5 provided at the ends for locking the prestressing cables 3 in the trimmers 50, 51.
- These trimmers 50, 51 are designed to allow automatic threading of the prestressing cables 3 by a vertical movement from top to bottom and undoing by reverse movement. They are formed of parallel slats 53, vertical and separated by intervals 54 allowing the introduction of a prestressing cable 3 at intervals 54 (cf. Fig. 6C ). This new design saves a lot of time and automates threading.
- prestressing cables are threaded manually and individually through through holes.
- the movable trimmers 51 are each moved by a jack 55 of force, articulated at its two ends between a pivot 56 integral with the foundations 40 'and a pivot 57 integral with the trimmers 51.
- a removable stop 58 makes it possible to limit the stroke of the movable tread 51, this abutment 58 being actuated by another jack 59.
- the movable trimmers 51 make it possible to achieve a partial tension of the prestressing cables 3, for example 30 at 50% of the total voltage.
- the final tensioning is carried out unitarily on each prestressing cable 3 by means for example of a monofilar jack.
- each mold 41 is demolded in a single operation by the gripping means 31 of the rudder 30 which raises in one piece all the beams 1 and deposited on transport means 60 provided in the discharge zone C. A this effect, handling hooks (not shown) are provided in the upper part of the beams 1 to hook the gripping means 31 of said lifter 30.
- the transport means consist, in the example shown, of an evacuation trolley 60 of the same length as the molding bench 40 and placed in parallel, between the molding bench 40 and the preparation mat 28 (cf. Fig. 2 and 3 ).
- This evacuation trolley 60 is movable longitudinally for example on rails 61. It moves in front of a cutting station 62, where the prestressing cables 3 are cut between the successive beams 1, to separate the beams 1 from each other. the same set.
- the cutting station 62 may comprise a torch, a circular saw, a chainsaw or any other suitable means.
- the beams 1 may be conveyed transversely to an evacuation station 63 or longitudinally to the outside of the building for example, where the beams 1 are stored on a storage area (not shown), either in packets on pallets, either individually depending on their length.
- the manufacturing method according to the invention and the installation implementing this method can significantly improve both the working conditions of the operators, the productivity of the production tool and the quality. beams 1 manufactured. Indeed, all the painful tasks inherent in traditional manufacturing are removed.
- the prestressing cables 3 being housed inside the reinforcement cages 2 and pretended during their placement in the molds 41 are not likely to come into contact with the demolding oil covering the bottom and the walls of the molds. molds 41.
- the manufacture of the reinforcing cages 2 being offset outside the molds 41 and computer-assisted ensures very good accuracy.
- the absence of risky intervention such as the cutting of the prestressing cables 3 in the molds 41 makes it possible to preserve them and to avoid soiling.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
- Moulds, Cores, Or Mandrels (AREA)
- On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
- Rod-Shaped Construction Members (AREA)
Abstract
Description
La présente invention concerne un procédé de fabrication de poutres en béton obtenues par moulage dans un banc de moulage. L'invention concerne également une installation mettant en oeuvre ce procédé et comportant au moins une zone de moulage pourvue d'un banc de moulage.The present invention relates to a method of manufacturing concrete beams obtained by molding in a molding bench. The invention also relates to an installation implementing this method and comprising at least one molding zone provided with a molding bench.
Les poutres en béton, utilisées généralement dans le bâtiment et le génie civil, sont généralement des poutres en béton armé, dans ce cas, le béton est renforcé par des armatures métalliques, ou des poutres en béton précontraint, dans ce cas, le béton est, en plus, mis sous contrainte par des câbles de précontrainte tendus pendant la phase de moulage puis détendus après durcissement du béton.Concrete beams, generally used in building and civil engineering, are generally reinforced concrete beams, in which case the concrete is reinforced with metal reinforcements, or prestressed concrete beams, in which case concrete is in addition, put under stress by prestressing tendons stretched during the molding phase and then relaxed after curing the concrete.
De manière classique, les moules utilisés pour la fabrication de ce type de poutres s'étendent sur une grande longueur, par exemple de 60 à 120 mètres, et sont découpés chacun en un nombre T de tronçons longitudinaux, au moyen d'intercalaires ou de peignes de coffrage, pour la fabrication d'un nombre T de poutres formant un ensemble. Ces moules sont réunis dans un banc de moulage, qui comporte un nombre M de moules parallèles entre eux, pouvant avoir des sections différentes. Ainsi, chaque banc de moulage permet la réalisation simultanée d'un nombre M d'ensembles de poutres, pouvant avoir des longueurs et des sections différentes. Jusqu'à présent, chaque moule est préparé individuellement et manuellement par un ou plusieurs opérateurs qui mettent en place les cages d'armature et les intercalaires ou peignes de coffrage à des emplacements définis en fonction de la longueur des poutres en béton armé à fabriquer, comme décrit par exemple dans la
Pour effectuer ces opérations préparatoires, les opérateurs travaillent penchés au-dessus des moules, ce qui est une position très inconfortable, engendrant une fatigue prématurée et des troubles musculo-squelettiques. Ce travail est donc très long et fastidieux. De plus, il monopolise le banc de moulage pendant de longues périodes, ces temps d'immobilisation étant variables selon la complexité des poutres à fabriquer. Lors de la mise en place des câbles de précontrainte dans les moules, ces câbles n'étant pas sous tension sont en contact avec l'huile de démoulage présente dans le fond et sur les parois des moules, ce qui peut être préjudiciable pour les performances techniques des produits finis. La mise en place des cages d'armature et des intercalaires de coffrage étant manuelle, la précision de leur positionnement est relative et non reproductible.To perform these preparatory operations, the operators work bent over the molds, which is a very uncomfortable position, causing premature fatigue and musculoskeletal disorders. This work is very long and tedious. In addition, it monopolizes the molding bench for long periods, these downtimes being variable depending on the complexity of the beams to be manufactured. When placing the pre-stressing cables in the molds, these cables that are not live are in contact with the demolding oil present in the bottom and on the walls of the molds, which can be detrimental to the performances. finished product techniques. The setting of the reinforcement cages and formwork spacers is manual, the accuracy of their positioning is relative and not reproducible.
Lors de la fabrication de poutres en béton précontraint, après coulage et durcissement du béton, les câbles de précontrainte sont relâchés puis coupés à l'intérieur des moules, soit au chalumeau, soit par une scie circulaire, avec tous les risques et difficultés que cela représente : accès difficile, altération des parois des moules, salissures importantes, danger pour l'opérateur, etc. Les poutres finies sont ensuite démoulées une à une ce qui, rajouté aux tâches précédentes, immobilise le banc de moulage sur un laps de temps très long. Le procédé de fabrication actuel ne permet pas d'envisager une gestion optimale de l'outil de production, ni de meilleures conditions de travail pour les opérateurs.During the manufacture of prestressed concrete beams, after pouring and hardening of the concrete, the prestressing cables are released and then cut inside the molds, either with a blowtorch or by a circular saw, with all the risks and difficulties that this represents: difficult access, alteration of the mold walls, heavy soiling, danger for the operator, etc. The finished beams are then demolded one by one which, added to the previous tasks, immobilizes the molding bench over a very long period of time. The current manufacturing process does not allow to consider optimal management of the production tool, nor better working conditions for operators.
La présente invention vise à pallier ces inconvénients en proposant un nouveau procédé de fabrication semi-automatisé ou automatisé, qui supprime les tâches pénibles liées à la manutention d'éléments lourds et aux positions de travail difficiles, garantit une fabrication précise des armatures, déporte en dehors du banc de moulage de moulage les opérations de préparation avant moulage et de traitement après moulage et de ce fait réduit les temps d'immobilisation du banc de moulage, permet une grande souplesse de production et optimise le rendement global de l'installation de fabrication.The present invention aims to overcome these disadvantages by proposing a new semi-automated or automated manufacturing process, which eliminates the difficult tasks related to the handling of heavy elements and difficult working positions, ensures accurate manufacturing of reinforcements, deportes in out of the molding molding bench the pre-molding and post-molding processing operations, thereby reducing the downtime of the molding bench, allows a high production flexibility and optimizes the overall efficiency of the manufacturing plant .
Dans ce but, l'invention concerne un procédé de fabrication du genre indiqué en préambule, dans lequel le banc de moulage comporte au moins un moule agencé pour permettre la fabrication d'au moins une poutre, caractérisé en ce qu'il comporte au moins les étapes suivantes, dont une au moins est effectuée de manière semi-automatique ou automatique :
- a) on prépare, en dehors dudit banc de moulage, au moins un ensemble d'éléments pré-assemblés comprenant au moins les cages d'armature entrant dans la fabrication de ladite poutre, ces éléments étant positionnés l'un par rapport à l'autre à des emplacements prédéterminés en fonction de la poutre à fabriquer,
- b) on prélève cet ensemble d'éléments pré-assemblés d'un seul tenant à l'aide de moyens de préhension pour le déposer à l'intérieur dudit moule,
- c) on coule le béton dans ledit moule,
- d) après durcissement du béton, on démoule ladite poutre fabriquée d'un seul tenant à l'aide desdits moyens de préhension, puis
- e) on l'évacue vers une aire de stockage.
- a) outside of said molding bench, at least one set of pre-assembled elements comprising at least the reinforcement cages used in the manufacture of said beam are prepared, these elements being positioned relative to one another; other at predetermined locations depending on the beam to be manufactured,
- b) this set of pre-assembled elements is taken in one piece by means of gripping means to deposit it inside said mold,
- c) pouring the concrete into said mold,
- d) after hardening of the concrete, said integrally manufactured beam is demolded by means of said gripping means, then
- e) evacuated to a storage area.
Dans ce but, l'invention concerne également une installation de fabrication du genre indiqué en préambule, caractérisée en ce qu'elle comporte au moins une zone de préparation d'au moins un ensemble d'éléments pré-assemblés positionnés les uns par rapport aux autres en fonction de chaque poutre à fabriquer et comprenant au moins des cages d'armature, cette zone de préparation étant disposée en dehors de ladite zone de moulage, et des moyens de préhension agencés pour prélever d'un seul tenant ledit ensemble d'éléments pré-assemblés de ladite zone de préparation et le déposer dans le banc de moulage de ladite zone de moulage, avant coulage du béton.For this purpose, the invention also relates to a manufacturing facility of the type indicated in the preamble, characterized in that it comprises at least one preparation zone of at least one set of pre-assembled elements positioned relative to the other depending on each beam to be manufactured and comprising at least reinforcing cages, this preparation zone being disposed outside said molding zone, and gripping means arranged to take a single piece of said set of elements pre-assembled of said preparation zone and depositing it in the molding bench of said molding zone, before pouring the concrete.
Des modes de réalisation avantageux de ce procédé et de cette installation sont définis dans les revendications 2 à 8 et 10 à 18, respectivement.Advantageous embodiments of this method and plant are defined in
La présente invention et ses avantages apparaîtront mieux dans la description suivante d'un mode de réalisation, donné à titre d'exemple non limitatif, en référence aux dessins annexés, dans lesquels :
- les
figures 1A et 1B représentent en perspective, respectivement, un exemple de poutre réalisée par le procédé et l'installation selon l'invention et un exemple de cage d'armature entrant dans la fabrication de cette poutre, - la
figure 2 représente une installation selon l'invention en vue de dessus, - la
figure 3 représente l'installation de lafigure 2 en coupe transversale, - la
figure 4 représente la zone de préparation des cages d'armature en vue de côté, - la
figure 5 représente les moyens de préhension des cages d'armature en vue longitudinale, et - les
figures 6A à 6C représentent les dispositifs de traction des câbles de précontrainte respectivement en vues partielles de côté en position de repos et en position de travail et en vue de face.
- the
Figures 1A and 1B represent in perspective, respectively, an example of a beam produced by the method and the installation according to the invention and an example of a reinforcement cage used in the manufacture of this beam, - the
figure 2 represents an installation according to the invention in plan view, - the
figure 3 represents the installation of thefigure 2 in cross-section, - the
figure 4 represents the zone of preparation of the reinforcement cages in view from the side, - the
figure 5 represents the gripping means of the reinforcement cages in longitudinal view, and - the
Figures 6A to 6C represent the traction devices of the prestressing cables respectively in partial side views in the rest position and in the working position and in front view.
En référence aux figures, l'installation 10 selon l'invention permet de fabriquer des poutres en béton armé ou en béton précontraint, de sections et de longueurs différentes. Dans le premier cas, les poutres sont renforcées par des armatures métalliques uniquement, alors que dans le second cas, ces poutres sont en plus mises sous contrainte par des câbles de précontrainte métalliques. La
Cette installation 10 permet de mettre en oeuvre un nouveau procédé de fabrication dans lequel, on fabrique les poutres 1 par moulage dans un banc de moulage 40 comportant plusieurs moules 41 et dont la longueur permet de fabriquer dans chaque moule 41 plusieurs poutres 1, appelées par la suite un ensemble de poutres 1.This
Ce nouveau procédé est décrit pour la fabrication de poutres 1 en béton précontraint, mais s'étend bien entendu à la fabrication de poutres en béton armé. Il se caractérise par le fait que :
- ◆ on prépare, pour chaque
moule 41 et en dehors dudit banc demoulage 40, un ensemble d'éléments pré-assemblés 5 comprenant notamment des cages d'armature 2 (cf.fig. 1B ), des câbles deprécontrainte 3, des intercalaires decoffrage 4 et des pièces d'ancrage 6 (cf.fig. 5 et6 ), ces 2, 3, 4, 6 étant positionnés les uns par rapport aux autres à des emplacements prédéterminés en fonction dudit ensemble deéléments poutres 1 à fabriquer, - ◆ on prélève ledit ensemble d'éléments pré-assemblés 5 d'un seul tenant par des moyens de
préhension 31 pour le déposer à l'intérieur duditmoule 41, - ◆ on répète cette opération autant de fois qu'il y a de
moules 41 à garnir, - ◆ on met sous contrainte les câbles de
précontrainte 3, - ◆ on coule le béton dans les
moules 41, - ◆ après durcissement du béton, on démoule les ensembles de
poutres 1 fabriqués l'un après l'autre d'un seul tenant par lesdits moyens depréhension 31, - ◆ puis, pour chaque ensemble de
poutres 1, on sectionne les câbles deprécontrainte 3 entre deux intercalaires decoffrage 4 consécutifs pour séparer lespoutres 1 les unes des autres avant de les évacuer vers une aire de stockage.
- ◆ for each
mold 41 and outside saidcasting bench 40, a set of pre-assembledelements 5 is prepared, comprising in particular reinforcing cages 2 (cf.Fig. 1B ),prestressing cables 3,formwork spacers 4 and anchoring parts 6 (cf.Fig. 5 and6 ), these 2, 3, 4, 6 being positioned relative to each other at predetermined locations according to said set ofelements beams 1 to be manufactured, - Said
pre-assembled assembly 5 is taken in one piece by means of grippingmeans 31 for depositing it inside saidmold 41, - ◆ repeat this operation as many times as there are
molds 41 to garnish, - ◆ the
prestressing cables 3 are stressed, - ◆ the concrete is poured into the
molds 41, - After hardening of the concrete, the sets of
beams 1 manufactured one after the other in one piece by said grippingmeans 31 are demolded, - ◆ then, for each set of
beams 1, theprestressing cables 3 are cut off between twoconsecutive form spacers 4 to separate thebeams 1 from each other before discharging them to a storage area.
Pour la fabrication de poutres en béton armé, on supprime les câbles de précontrainte et, par conséquent, l'opération de mise sous contrainte de ces câbles avant moulage puis de sectionnement de ces câbles après démoulage.For the manufacture of reinforced concrete beams, the prestressing cables are removed and, consequently, the stressing operation of these cables before molding and then cutting these cables after demolding.
Pour mettre en oeuvre ce procédé, l'installation 10 comporte plusieurs zones de travail et notamment une zone de préparation A des ensembles d'éléments pré-assemblés 5, une zone de moulage B des poutres 1, une zone d'évacuation C des poutres 1 fabriquées (cf.
La zone de moulage B comporte un banc de moulage 40 de longueur réduite par rapport aux bancs de moulage classiques, par exemple de 30 à 70 mètres au lieu de 100 à 150 mètres. Ce banc de moulage 40 comporte plusieurs moules 41 parallèles, de sections différentes, montés sur des fondations 40' (cf.
La zone de préparation A permet de préparer, en dehors du banc de moulage 40, en parallèle de celui-ci et à hauteur d'homme, des ensembles d'éléments pré-assemblés 5 s'étendant sur toute la longueur de ce banc de moulage 40. Chaque ensemble d'éléments pré-assemblés 5 correspond à un des moules 41 et comporte un agencement de cages d'armature 2, d'intercalaires de coffrage 4, de pièces d'ancrage 6 et de câbles de précontrainte 3 déterminé en fonction des poutres 1 à fabriquer.The preparation zone A makes it possible to prepare, apart from the
Cette zone de préparation A comporte, dans l'exemple représenté, une machine à cadres 20 qui est une machine standard permettant de fabriquer automatiquement des cadres 2a entrant dans la composition des cages d'armature 2. Ces cadres 2a sont réalisés par pliage d'un fil métallique, par exemple en forme de rectangle. Cette machine à cadres 20 est alimentée par un dévidoir 21 portant quatre bobines 22 de fil métallique de diamètres différents, par exemple de 6, 8, 10 et 12 mm. Selon le type de poutres 1 à fabriquer, la machine à cadres 20 utilisera automatiquement l'un ou l'autre diamètre de fil métallique pour réaliser des cadres 2a de dimensions et de résistance différentes selon les poutres 1 à fabriquer.This preparation zone A comprises, in the example shown, a
La zone de préparation A comporte un autre dévidoir 23 portant trois bobines 24 de fil métallique d'un même diamètre, par exemple de 5 mm. Ces trois fils constituent des armatures de montage 2b entrant dans la composition des cages d'armature 2. Ils sont dévidés simultanément et positionnés parallèlement, par exemple, en triangle pour être soudés, par un poste à souder 25, sur trois côtés des cadres 2a d'une même cage d'armature 2. Un tapis transporteur 26 disposé entre la machine à cadres 20 et le dévidoir 23 permet d'amener les cadres 2a vers un opérateur qui saisit les cadres 2a l'un après l'autre et les présente en regard du poste à souder 25 (cf.
Lorsqu'une cage d'armature 2 est terminée, elle est transférée vers un tapis de préparation 28 par une chaîne d'amenée 27 (cf.
L'agencement de cette zone de préparation A est conçu pour permettre à l'opérateur de travailler dans de bonnes conditions d'ergonomie, les tapis transporteur 26 et de préparation 28 étant situés à hauteur d'homme, et pour éviter toute manutention, l'avancement des cages d'armature 2 étant commandé manuellement par bouton poussoir, sans effort physique.The arrangement of this preparation zone A is designed to allow the operator to work in good ergonomic conditions, the
L'ensemble d'éléments pré-assemblés 5 est ensuite acheminé dans le moule 41 adéquat, en une seule opération, par des moyens de préhension 31 spécifiques accrochés aux pièces d'ancrage 6. Ces moyens de préhension 31 sont suspendus à un palonnier 30, ce dernier étant mobile en translation selon les trois axes X, Y, Z sur un pont roulant (cf.
Pendant cette opération de transfert, un nouvel ensemble d'éléments pré-assemblés 5 peut être préparé dans la zone de préparation A pour garnir un autre moule 41.During this transfer operation, a new set of
Lorsque le banc de moulage 40 est prêt, c'est-à-dire que le ou les moules 41 sont garnis d'ensembles d'éléments pré-assemblés 5, les câbles de précontrainte 3 sont mis en tension par des dispositifs de traction, appelés communément des chevêtres 50, 51, disposés aux extrémités des moules 41 dans des fosses 42 adéquates prévues dans les fondations 40' (cf.
Lorsque toutes ces opérations préparatoires sont terminées, le béton est coulé dans les moules 41. Après durcissement du béton, les chevêtres 51 mobiles reviennent dans leur position de repos pour relâcher la tension sur les câbles de précontrainte 3 et le démoulage des poutres 1 peut commencer. Chaque moule 41 est démoulé en une seule opération par les moyens de préhension 31 du palonnier 30 qui soulève d'un seul tenant l'ensemble des poutres 1 et le dépose sur des moyens de transport 60 prévus dans la zone d'évacuation C. A cet effet, des crochets de manutention (non représentés) sont prévus en partie supérieure des poutres 1 pour accrocher les moyens de préhension 31 dudit palonnier 30.When all these preparatory operations are completed, the concrete is poured into the
Les moyens de transport sont constitués, dans l'exemple représenté, d'un chariot d'évacuation 60 de même longueur que le banc de moulage 40 et placé en parallèle, entre ce banc de moulage 40 et le tapis de préparation 28 (cf.
Il ressort clairement de cette description que le procédé de fabrication selon l'invention et l'installation mettant en oeuvre ce procédé permettent d'améliorer considérablement à la fois les conditions de travail des opérateurs, la productivité de l'outil de production et la qualité des poutres 1 fabriquées. En effet, toutes les tâches pénibles inhérentes à une fabrication traditionnelle sont supprimées. Les câbles de précontrainte 3 étant logés à l'intérieur des cages d'armature 2 et prétendus lors de leur mise en place dans les moules 41 ne risquent pas d'entrer en contact avec l'huile de démoulage recouvrant le fond et les parois des moules 41. La fabrication des cages d'armature 2 étant déportée à l'extérieur des moules 41 et assistée par ordinateur permet de garantir une très bonne précision. L'absence d'intervention à risque telle que la coupe des câbles de précontrainte 3 dans les moules 41 permet de les préserver et d'éviter les salissures. Enfin, l'utilisation des moules 41 étant parfaitement optimisée puisque l'ensemble des opérations de préparation et de traitement des produits finis s'effectue en dehors du banc de moulage 40, celui-ci n'est occupé que pendant le coulage du béton et son durcissement. Il est donc possible d'effectuer un nombre maximum de rotations et de rentabiliser l'investissement financier de l'installation de façon optimale. Un autre avantage réside également dans la souplesse de la production grâce à la longueur réduite du banc de moulage 40 et à la variété de moules 41 possible. Cette installation 10 peut donc répondre rapidement à la demande du marché même pour des très petites séries, aussi bien pour des poutres en béton précontraint que pour des poutres en béton armé.It is clear from this description that the manufacturing method according to the invention and the installation implementing this method can significantly improve both the working conditions of the operators, the productivity of the production tool and the quality.
La présente invention n'est pas limitée à l'exemple de réalisation décrit mais s'étend à toute modification et variante évidentes pour un homme du métier tout en restant dans l'étendue de la protection définie dans les revendications annexées.The present invention is not limited to the embodiment described but extends to any modification and variation obvious to a person skilled in the art while remaining within the scope of protection defined in the appended claims.
Claims (18)
- A method for manufacturing concrete beams (1) obtained by moulding in a moulding bench (40) comprising at least one mould (41) designed to allow the manufacture of at least one beam (1), characterised in that it comprises at least the following steps, at least one of which is carried out semi-automatically or automatically:a) outside the said moulding bench (40) at least one assembly of preassembled elements (5) is prepared, comprising at least reinforcing cages (2) involved in the manufacture of the said beam (1), these elements (2, 3) being positioned with respect to each other at predetermined locations according to the beam (1) to be produced,b) this assembly of preassembled elements (5) is picked up in a single block by means of gripping means (31) and it is deposited inside the said mould (41),c) the concrete is poured into the said mould (41),d) after the concrete has hardened, the said manufactured beam (1) is removed from the mould in a single block using gripping means (31), then,e) it is carried away towards a storage area.
- A method according to Claim 1, in which the moulding bench (40) comprises several moulds (41), each mould (41) being designed to allow the manufacture of a beam assembly (1), characterised in that in the preparation stage (a) and outside the said moulding bench (40), several assemblies of preassembled elements (5) are successively prepared by completing them by formwork spacers (4) to separate the beams (1) of a single assembly from each other, each assembly of preassembled elements is picked up in a single block by means of gripping means (31) in order to deposit it inside each mould (41),
- A method according to Claim 2, characterised in that it is designed to allow the manufacture of beams (1) having different sections and lengths, the moulds (41) of the said moulding bench (40) having different sections and the formwork spacers (4) of each assembly of preassembled elements (5) being disposed at different intervals.
- A method according to Claim 2, characterised in that in the preparation stage (a) and outside the said moulding bench (40), the said assemblies of preassembled elements (5) are completed by prestressing cables (3) which are passed inside the reinforcing cages (2) and the formwork spacers (4).
- A method according to Claim 2, characterised in that in the preparation stage (a) and outside the said moulding bench (40), the said assemblies of prefabricated elements (5) are completed by anchors (6) disposed at least at the ends and designed to allow the displacement of these assemblies under tension by the said gripping means (31) and the automatic threading of the prestressing cables (3) in traction devices (50, 51) of the moulding bench (40).
- A method according to Claim 1, characterised in that in the preparation stage (a) and outside the said moulding bench (40), the said reinforcing cages (2) are produced at least in a semi-automatic manner.
- A method according to Claim 2, characterised in that after the concrete has set, each assembly of manufactured beams (1) is removed from the mould in a single block, then it is deposited in an evacuation zone outside the said moulding bench (40).
- A method according to Claims 4 and 7, characterised in that in the evacuation zone, the prestressing cables (3) are divided between two consecutive formwork spacers (4) to separate the beams (1) of the same assembly before evacuating them towards a storage area.
- An installation (10) for the manufacture of concrete beams (1), comprising at least one moulding zone (B) provided with a moulding bench (40), characterised in that it comprises at least one preparation zone (A) for at least one assembly of preassembled elements (5) positioned with respect to each other according to each beam (1) to be manufactured and comprising at least reinforcing cages (2) involved in the manufacture of the said beam (1), this preparation zone (A) being disposed outside the said moulding zone (B), and gripping means (31) designed to remove the said assembly of preassembled elements (5) in a single block from the said preparation zone (A) and deposit it in the said moulding bench (40) of the said moulding zone (B), before casting the concrete.
- An installation (10) according to Claim 9, characterised in that the said preparation zone (A) comprises at least one frame machine (20) designed to automatically produce frames (2a) from metal wires and at least one feeder (23) for metal wires and a welding station (25), both designed to assemble the said frames (2a) by assembly reinforcements (2b) so as to form the said reinforcing cages (2).
- An installation (10) according to Claim 9, in which the moulding bench (40) comprises several moulds (41) and has an adapted length to produce a beam assembly (1) in each mould (41), characterised in that the said preparation zone (A) comprises at least one preparation belt (28) designed to receive assemblies of preassembled elements (5) comprising at least several reinforcing cages (2) and formwork spacers (4) positioned in mutual relationship at predetermined locations according to each beam assembly (1) to be manufactured in each mould (41).
- An installation (10) according to Claim 11, characterised in that the said moulding zone (B) comprises traction devices (50, 51) provided at the ends of the said moulds (41) and designed to tension the prestressing cables (3) provided in the said assemblies of preassembled elements (5).
- An installation (10) according to Claim 12, characterised in that for each mould (41) the traction devices (50, 51) comprise at least one fixed beam (50) and one beam (51) that can rotate around a fixed pivot (52), these beams (50, 51) being formed by ribs (53) that are vertical, parallel and separated by gaps (54) to receive the said prestressing cables (3).
- An installation (10) according to Claim 9, characterised in that it comprises an evacuation zone (C) for the manufactured beams (1), this evacuation zone (C) being disposed outside the said moulding zone (B) and comprising at least transport means (60) for the said beams (1) towards at least one storage area.
- An installation (10) according to Claims 11 and 14, characterised in that before casting the concrete, the said gripping means (31) are designed to remove each assembly of preassembled elements (5) from the preparation zone (A) and to deposit it in one of the moulds (41) in the moulding zone (B) and, after the concrete has been cast and has hardened, to remove each manufactured beam assembly (1) in a single block from the mould and to deposit it on the said transport means (60) of the said evacuation zone (C).
- An installation (10) according to Claims 12 and 15, characterised in that the said gripping means (31) are designed to apply tension to the said assemblies of preassembled elements (5) as they move from the preparation zone (A) to the moulding zone (B) to tighten the prestressing cables (3).
- An installation (10) according to Claims 12 and 15, characterised in that the said evacuation zone (C) comprises at least one cutting station (62) designed to divide the prestressing cables (3) between the formwork spacers (4) to separate the beams (1) of the same assembly before they are stored.
- An installation (10) according to Claim 10, characterised in that it comprises at least one automaton designed to control at least the frame machine (20) in an automated manner according to the data relating to the beams (1) to be produced.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR0215970A FR2848589A1 (en) | 2002-12-16 | 2002-12-16 | Method of fabrication of precast concrete beams involves preparing prefabricated armature cages for positioning in mould prior to pouring concrete |
FR0215970 | 2002-12-16 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1431015A1 EP1431015A1 (en) | 2004-06-23 |
EP1431015B1 true EP1431015B1 (en) | 2008-11-19 |
Family
ID=32338865
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP03360144A Expired - Lifetime EP1431015B1 (en) | 2002-12-16 | 2003-12-15 | Process for making reinforced concrete beams and installation for the execution of this process |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP1431015B1 (en) |
AT (1) | ATE414598T1 (en) |
DE (1) | DE60324756D1 (en) |
ES (1) | ES2318101T3 (en) |
FR (1) | FR2848589A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102717431B (en) * | 2012-07-06 | 2014-08-13 | 重庆亲禾预制品有限公司 | Prefabricated beam production method |
CN113752378A (en) * | 2021-09-10 | 2021-12-07 | 北京好运达智创科技有限公司 | Rubber bar and steel strand penetrating and drawing system before box girder pouring |
CN114030077B (en) * | 2021-11-15 | 2023-04-14 | 中国建筑土木建设有限公司 | Tensioning jack mounting equipment for beam field and prestressed cable tensioning method for precast beam |
CN114102837A (en) * | 2021-11-16 | 2022-03-01 | 安徽省路港工程有限责任公司 | System for automatically transporting concrete and pouring precast beam |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2699951B1 (en) * | 1992-12-29 | 1995-03-03 | Saret France Sa | Method for manufacturing prestressed concrete beams and beams obtained by this method. |
EP0812252A1 (en) * | 1995-11-14 | 1997-12-17 | FMG Verfahrenstechnik AG | Process and device for producing longitudinal mouldings of a pourable material, especially foundation mats |
FR2790991B1 (en) * | 1999-03-17 | 2001-05-25 | Rector Sa | EQUIPMENT FOR THE MANUFACTURE OF PRESTRESSED CONCRETE BEAMS AND METHOD OF IMPLEMENTATION |
-
2002
- 2002-12-16 FR FR0215970A patent/FR2848589A1/en not_active Withdrawn
-
2003
- 2003-12-15 DE DE60324756T patent/DE60324756D1/en not_active Expired - Lifetime
- 2003-12-15 EP EP03360144A patent/EP1431015B1/en not_active Expired - Lifetime
- 2003-12-15 ES ES03360144T patent/ES2318101T3/en not_active Expired - Lifetime
- 2003-12-15 AT AT03360144T patent/ATE414598T1/en not_active IP Right Cessation
Also Published As
Publication number | Publication date |
---|---|
ES2318101T3 (en) | 2009-05-01 |
ATE414598T1 (en) | 2008-12-15 |
DE60324756D1 (en) | 2009-01-02 |
EP1431015A1 (en) | 2004-06-23 |
FR2848589A1 (en) | 2004-06-18 |
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