EP1664460A1

EP1664460A1 - Bottom shuttering method for producing and erecting concrete slabs on construction sites

Info

Publication number: EP1664460A1
Application number: EP04786773A
Authority: EP
Inventors: Roland Weber
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-09-11
Filing date: 2004-09-13
Publication date: 2006-06-07
Also published as: WO2005026469A1; DE112004000047D2

Abstract

The invention relates to a method for producing flat precast concrete parts while using a bottom-like base surface in-situ at a construction site. To this end, the invention provides that at the construction site, the bottom-like base surface is, when constructing the building, pulled out before completely concreting the ground level bottom and/or cellar floor level. A shuttering form that can be used for series production is placed on the bottom-like base surface. The bottom shuttering is not changed between successive concreting phases, and precast concrete parts are produced in-situ in stacks and are preferably brought to the stacks and/or removed therefrom by means of a crane in order to achieve a time independence for trades.

Description

Floor formwork process for the production and assembly of concrete slabs on construction sites

description

The present invention relates to the above-mentioned stress and thus relates to the creation of flat precast concrete parts on site.

Reference is first made to the following property rights, which are fully integrated for the purposes of disclosure: DE 101 36 648, DE 101 62 027, PCT / EP 02/08144, DE 101 48 940, DE 102 20 208, DE 102 25 765, DE 102 25 766, DE 101 62 029, DE 101 52 980, DE 101 62 028, DE 102 16 088, DE 102 18 408, DE 102 20 211, DE 102 20 210, DE 102 20 209, DE 101 36 647, DE 101 46 339, DE 102 00 822, DE 102 20 242, DE 102 33 145, DE 102

50 806, DE 102 43 083, DE 102 47 596, DE 102 50 283, DE 102

51 850, DE 102 60 809, DE 103 02 184, PCT / DE 03/00156, DE 103 02 186.

In particular, reference is made to the procedure known as the bottom formwork method and the corresponding devices of the inventor, cf. DE 103 02 186 AI, in particular with regard to the formwork details and the crossbeams for series production.

Floor formwork processes are used to handle large and thin concrete slabs. In parts of the method from DE 103 02 186, construction methods are used in particular in 7 Λmerika and England under the name “tilt-up method ^w” . Both methods use a sole as a formwork floor and work in the assembly process with the hoists from the essentially completely finished sole, e.g. B. in industrial hall construction. This has several disadvantages. For example, the sole must be made in front of the roof, ie outdoors, which can result in poor quality due to rain and / or snow. It is even more important that the sole has to be completed before the finished part can be produced, which significantly delays the construction process. In addition, there is a wind sensitivity when erecting and assembling, which limits the maximum erectable wall height. In the tilt-up process, mobile cranes with a high load moment must be used to assemble large erectable walls. In addition, due to the limitation of the truck crane load moment, a transverse transport of prefabricated concrete parts manufactured in one place in a formwork is usually very expensive. In principle, it is also possible to work with other lifting devices, but especially when cranes with cross transport, such as crawler cranes, are used, a large number of problems occur on an already concreted surface. The pressure on the sole must not exceed certain limit values in order not to destroy the sole. This applies in particular if, as usual, pipes and the like are laid in the sole.

An alternative and often preferred method of construction consists in first producing supports, trusses and roofs and then under their protection a quality-appropriate sole. This procedure is often significantly faster in the appointment, because the production time of the sole is not on the so-called critical path of the overall completion of the building.

It is desirable to provide at least some of the aforementioned problems with at least partial relief.

The object of this invention is to provide something new for commercial use.

The solution to this problem is claimed in an independent form. Preferred embodiments can be found in the subclaims.

A first essential aspect of the invention thus provides that at an early point in time, that is to say before a large-scale application or creation of the sole, a sub-base is provided for at least one form of formwork that can be used in series production, and the flat precast concrete parts produced therein are produced on-site in a pile, the Precast concrete parts are preferably transversely transported to the heap and / or later to the installation site using a small-lever crane; a crawler crane and / or alternatively a mobile crane and / or a mobile crane with panel truck and / or truck operation can preferably be used as the crane; Small lever arm means preferably with a radius below 25 m, particularly preferably below 15 m lifting radius. The serial production site stockpile distance will typically be less than 300 m, maximum 500 m if crawler cranes are used. As precast concrete elements such. B. flat walls, perforated facades or Pi, W ~ *, ceilings come into consideration. A first variant of the method and of the equipment provides, as is possible in principle, to use a solid base instead of a base layer which is preferred in production, e.g. B. preferably to create a removable, transportable steel structure (z. B. girder grate) and preferably to use multiple times. The multiple use can in particular by stacking. Dividing (stack casting) or by always new excavation from a Sereinform, as known in principle from series production.

It is relevant for series production that the formwork floor does not have to be changed between individual concreting cycles. H. that it only has to be designed once, e.g. B. 10 to 100 to perform concreting cycles; Furthermore, a reusable edge formwork is used and this is preferably inclined with Stur_z. inclined and firmly connected to the ground in order to avoid opening. This enables both a tilt-up procedure and, as required, vertical lifting.

While it is possible to create a solid base that is different from the sole surface, in the particularly preferred variants of the invention, in particular for reasons of cost, the speed of assembly and disassembly and also due to the better stability (settlement, stacking loads or tensile strength due to adhesive forces) Small part of the sole brought forward in terms of time, whereby this is to be limited so that a crawler crane can move close to the head or sideways (usually with a radius of less than 10 m of its main boom) and very high with the smallest possible lever arm Lift loads, move them and / or turn them vertically.

This scheduling of the sole is particularly advantageous, because by introducing the stockpile, trades become more independent of each other and parallel to the finished one. "~ _Ss

It is considerably more practical for the process, since otherwise the crawler cranes become large, heavy, unwieldy and expensive, and, moreover, the crawler cranes can no longer move their load between the often narrow columns of a hall and thus disrupt the construction process. By appropriately attacking the crawler crane, these advantages can easily be realized, the clear passage widths for the crawler cranes then being, for example, at 6 m column grid approximately below 5.40 m.

This is important because it can quickly happen that cranes with their load can no longer drive between the often tightly spaced columns of a hall and thus disrupt the construction process. A lOOter Liebherr crawler crane, for example, already needs 5.05 m plus tolerance in clearance. Devices in the 160 to 250 t class typically require 6.80 to 7.50 m plus tolerance. Since the plate widths (and indirectly also their statically required thicknesses) increase with larger column grids, the weight grows practically square. Thus, the problem of limiting the crane sizes remains not only economically relevant, but also for the feasibility of the process. It should also be mentioned that as the crawler cranes are enlarged, the load on the lower sensitive pipes, which are hidden in them, are increasing, especially in their turning processes. The caterpillar rank size is and remains critical.

As already explained in the previous applications, wind forces have to be mastered, especially in the sensitive state of the large-area concrete disc turning vertically.

According to the invention, it is generally preferred if a crawler crane either moves in front of the head or next to the plate (see FIG. 1) and attacks there with at least one rope strand on a crossmember, preferably as presented in more detail below. In order to generate a rotary movement, it is generally preferred if a second strand engages, provided that the traverse is not placed on the ground at one end (possibly also in a holder) and is moved in with the crane in the direction of erection. The latter variant shortens the lever arm of the crane particularly favorably (just by moving it in the direction of rotation). It is then only necessary to ensure that the sole at the righting point (see Fig. 1) is not overloaded and that the considerable wind forces (e.g. 150 m ² x 20 kg / m ² = 3 t) continue at all times can be safely controlled by guides such as additional rope slings.

It is possible not to turn the crane superstructure when erecting when moving the crane from the top of the plate to the base; however, the sole or formwork may need to be suitably protected against caterpillar tracks. If, as preferred, the crane is next to the long side of the along the ballast bed, a rotary movement of the superstructure is preferably provided before the transverse transport of the plate can begin. Furthermore, and / or in addition, it is generally also necessary to provide for the then vertical plate to be rotated about its vertical axis.

It is possible to limit the diagonal during Aufri ^'chtens the hoist safely or avoid. It is also possible and preferred to provide for the grasping of the wind during assembly, in particular by means of control cables attached in the lower crane area, especially during lifting from the sole, which may result in "rough operation" of the construction processes with cold, black ice, heat, storm gusts etc. can be safely accomplished by a reliable assembly team.

While the above describes a possible embodiment, a further variant is particularly preferred (see FIG. 3), in which the crawler crane stands in front of the head of the concrete slab, in particular on a suitable surface, such as the ballast of a later sole, and in which Erecting and rotating the plate is operated more than one strand. For this purpose, it can be provided that an auxiliary crane is located on the opposite side of the crawler crane, which can preferably be an available mobile crane, which pulls the second strand during lifting and, depending on the stop mechanism, lifts a certain plate load, usually half the plate load.

It is particularly preferred, however, to drive the crawler crane in two strands in order to strike and handle Avoid control ropes with its safety risks especially during turning. The crawler crane operates in two-winch operation. Both winches pull to lift. One winch releases to turn while the other pulls up. Another particularly preferred (see FIG. 3) is the use of a second tip, which ensures that there is a distance between the two lifting cables in the plan. This also limits unintentional turning (wind, etc.) around the vertical axis, since both twisted ropes generate a restoring torque. The same applies to the pendulum movements of the plate. In two-winch operation of two ropes directed against each other (in the axial direction of the crane boom), strong inclined pulls can be generated according to plan and safely, thus limiting wind forces and the pendulum movements that occur during travel in the direction of the crane boom. A swinging of the plate or even hitting the main boom can be safely avoided.

While assembly methods and series production on site were previously described in detail separately, it is also possible to use the sole according to the invention for wall and slab formwork purposes with the very simple turning crossbars for small and relatively thick slabs known from the Anglo-Saxon tilt-up combine. With these, the plates with point anchors hang on ropes on the erecting mobile crane. Simple crossbeams and deflection rollers then ensure a statically determined introduction of anchor forces. This static determination offers considerable advantages. This method is particularly preferred for plates which can no longer be transported by road, but are nevertheless relatively light. This means that this type the rotating crossbar is a mature alternative, in particular for panels with less than approx. 40 - 60 m ² per panel. Protection is claimed for both the special trusses and for the use of the trusses in a construction process, in particular a construction process as described above which is a series production of parts on site on an advanced sole floor and / or another solid surface.

It is pointed out that the preferred product on the market in industrial construction, in particular in hall construction, is partition walls, particularly preferably fire protection walls which are installed between or actually in front of supports which have been installed in advance and span from support to support. So far, these panels were typically threaded into the grooves between the supports at a height of only 2 to 3 meters or otherwise suitably installed, with a suitable number of longitudinal joints.

While reference was made above to various other applications by the inventor, it should be explicitly pointed out that, according to the present invention, it is preferred and possible that the concrete slab lies below the crossbar and not above it before it is rotated vertically. As detailed below, this first requires careful consideration of the load transfer into the concrete slab, because due to the slab stiffness, statically determined force distribution between the anchor points cannot be assumed per se. This means that tensile forces have to be introduced here instead of compressive forces as before, and dangerous anchoring of the anchors must be avoided. A construction for the traverse is proposed, which is shown in particular in FIG. 3. The person skilled in the art can see from this figure that the construction has in particular the following features, individually or in combination:

Preferential fastening of the hangers at the top, so that lateral forces are not accidentally entered into the hangers when the traverse is turned vertically.

Hangers on the intermediate and head and foot pieces, in particular exclusively or at least essentially exclusively for the transmission of tensile forces perpendicular to the plate plane. Tensile forces occur when the panel is lifted and, in the case of thin and tall panels, immediately after they have been set down during final assembly as a result of kinking the panel. These hangers are particularly preferably arranged in at least two rows along the longitudinal axis of the cross member in order to prevent the plate from tilting relative to the cross member.

A head piece (see FIG. 5) particularly preferably at the (in the end position) upper plate end with at least one support for receiving its own weight in the vertical state, with which all forces act in the plane of the plate. Two spurs are preferably provided which, in a statically determined manner, enable the vertical forces to be diverted into the crossmember. Such supports are also possible at the base, but this means that the dead weight must be guided lengthways through the entire traverse. At least one attachment means preferably acts on the head piece, which, when lifting, has half its own weight and, when hanging, a maximum of the entire egg has to lift counterweight. This robust arrangement means that the greatest loads are concentrated at one point and not carried out by assembly joints etc.

Regarding certain details in the production and assembly process as well as the truss construction, in particular essential details, please note the following:

It is possible to statically determine the loads acting within the slab level and thus to clearly transfer them from the slab into the crossbar in all turning situations for the overall construction. A two-point bearing, such as. B. described in Fig. 5, in particular with spurs.

In contrast, the introduction of tensile forces from the plate into the hangers and into the head, foot and intermediate pieces of the traverse is much more difficult. Common anchors are too sensitive to pulling out and unwanted deformation of the plate and can trigger constraining forces, which are quite considerable in the case of somewhat thicker plates. The same applies to rigid anchors due to unwanted tolerances and displacements in the plate level. It is therefore preferred first of all to arrange the support for the prestressing force (see FIG. 4) as far as possible from the plate, particularly preferably arranged on the upper part of the crossmember. Unwanted longitudinal deformations of the anchor rod from .. plate movements are particularly low.

The fact that the early strength of the concrete, which is often unreliable in winter, is particularly whose prudence is to be shown, should be mentioned. However, the methods are particularly suitable here, especially when constraining forces are avoided.

Altogether, statically undetermined storage conditions represent a security risk, which is also one of the main reasons for the limited applicability of the American tilt-up method with its simple, few hanging points.

Handling is made much easier according to the invention, even for large slabs, in that six to approximately ten or fourteen anchor points are securely arranged in large slabs in order to ensure uniform support of the slab in the state of construction and to enable low reinforcement contents and thin thicknesses associated therewith.

Statically indefinite storage can be permitted, but a combination of one or more of the following measures can be taken to ensure that the negative effects remain limited or that forces are safely derived.

So initially no anchors are used in the deliberately thin plates, which pull out when overloaded. These include flat steel anchors and practically all installation anchors of all kinds that are customary in precast plants. The use of such installation anchors that are common in precast plants for on-site production is not considered to be insignificant in itself and is advantageous for the invention.

It is therefore preferably anchored through the plate and the counter plate on the opposite side is chosen so large that the maximum possible load from statically indefinite storage can be absorbed. This can be done, for example, with sufficiently large counter plates or line bearings (supports), which can preferably be used again after assembly. Although this may initially seem uneconomical and paradoxical, local overload can be tolerated. It is only important to ensure that the distance between the anchors is sufficiently large in relation to the plate thickness (which causes the constraining forces due to their rigidity). This is preferably chosen to be so large that a forced deformation does not exceed the additional safety margin.

The series-produced components, in particular rod-shaped or filigree series components, can be used in conjunction with perforated facades as a preferred application.

These perforated facades are preferably produced on construction sites, preferably with their element sizes that are no longer easily transportable by road. Ceiling heights of offices, shopping centers, hotels etc. are often so high (typically over 3 m and especially up to 4 - 5 m) that they no longer exceed. the road can be transported, or only inclined, and in expensive and limited available special low-loaders. Tilt-up is therefore also suitable as the production method, but the inventor's sole formwork method is preferred.

Protection is also claimed for the shape of the perforated facade element. This is fully or partially as described below. Due to the underlying idea of series production, it is preferably possible to integrate ceiling joists as a thickening of the otherwise initially flat element. These profiles can not be created on the usual tilting tables of the precast plants with the smooth side of the joist thickening (exposed concrete). Only the idea of a consequent series production and their execution preferably on site justifies the provision of complicated shaped formwork sets. This is considered particularly important. Typical series applications are over 10, in particular over 20 applications per construction site and more preferably in the use of at least essential parts of the formwork sets for several construction sites (steel parts, the molded ends for ceiling supports or edge beams, support templates and formwork aids such as Hydraulics and their stamps and borders used several times on different construction sites). Formwork sets and / or edges can be a fall, especially for. B. have a camber angle of 1:20 and / or be provided with in particular reusable wood, steel and / or plastic inserts and / or floors and / or edges for better loosening. The 1:10 to 1:40, preferably 1:20 inclination, enables many cycles in one formwork without dismantling or edge formwork when stripping.

Compared to conventional methods, it is now also proposed to use resolved elements that consist entirely or partially of flat facade panels for parapets and areas between the windows and supports and edge beams. This is described by the NEN manufacturing process possible, with a single integrated part must later be used on the construction site during the assembly process, which saves time and costs.

Such a preferred element is essentially ceiling-high and, depending on the weight and available lifting equipment, is preferably exciting over a grid, preferably with an integrated edge beam.

If necessary, ceiling or column anchoring reinforcement to be arranged can be represented by various known built-in parts (screw connections, rebend connections, loops etc.). A perforated facade element according to the invention is described only by way of example in FIG. 8.

The preferred sizes of such plates are preferably between approx. 15 m ² (limitation due to the ease of transportability of the parts conventionally produced in the factory) and 50 m ² (weight limitation due to commonly available hoists), particularly preferably between 20 and 40 m ² . This initially correlates weights from 5 to 15 t, which can be carried by standard tower cranes, but also for "conventional, used everywhere anyway and especially available without extra arrival and departure"(<80 t to 100 t for other standard applications However, it is important that these are facade elements that can often be installed directly from the outside, ie with very short crane lever arms, and even small and readily available mobile cranes (typically <60 t) carry a surprising amount low lever arms (typically 4 to 10 m), although this is rarely is used. The present invention makes use of this.

It should be mentioned that even easily available, smaller mobile cranes are well able to load a simple trailer themselves, pull it to the installation site and then assemble it directly. With a few, readily available equipment, this results in a rational and fast construction and assembly process.

An integrated component tends to require less panel thickness, since integrated beams or supports stiffen. Saving on concrete material and weight to be lifted or transported across is the advantage. The same applies to the reinforcement management and its content. The high quality of thin panel parts, which are manufactured horizontally in contrast to upright facade panels (vertical battery formwork in the FT plants), is also mentioned.

Variants of the American tilt-up method can be considered as the preferred assembly method, particularly preferably in connection with a sole edge formwork that can be easily dismantled in the foot area (e.g. a steel edge formwork, which is preferably held with a few bolts or only by magnets), which simplifies this Pulling out and rotating around a support line on the floor is not impeded.

The further assembly routine can be done as per. se known, ie for example in particular by lifting and placing on the lower ceiling, preferably in mandrel / cup centering and stiffening by auxiliary support on the lower ceiling. As far as the described invention is concerned, reference is made to the figures, insofar as these have not yet been discussed in the text. In these shows:

Fig. 1 above in the floor plan a typical arrangement of plate, traverse, sole, subsoil and crawler crane with single-strand lifting and erection around an erection line, Fig. 2 shows a typical arrangement before erection with two-strand operation in the top view and below in the floor plan with further details , Fig. 3 shows another two-line operation with details on the cable guides and crane booms, Fig. 4 purely as an example the construction of an intermediate piece with anchoring and support of the concrete slab, Fig. 5 purely as an example the construction of a head piece with various centers of gravity of the overall system, the shear force support and a construction to protect the lifting gear when buckling, FIG. 6 shows a cross section through the crossmember and its attached plate in the area of the foot piece with hangers and spreaders, FIG. 7 shows a movable inner part of a likewise compact mobile factory without rotating mode and without lifting hydraulics in the base part; the assemblies for transport are also explained, Fig. 10 shows a section through a perforated facade at the time of final assembly with integrated Column templates, beam and window opening, as well as the connection of the in-situ concrete ceilings.

LIST OF REFERENCE NUMBERS

Fig. Uppercarriage crawler crane gravel arrow: "in front of head" traverse (here with 3 crane shots) "erection line analogous to tilt-up" sole location: "next to the slab" long side of the slab / formwork

Fig. 2

12. Left line: Spur supports for loads in the plate level

13. Right line: trailer (train) 14. Auxiliary crane

15. First: lifting

16. Then: turn into the vertical

17. Lift two strands

18. Headpiece

19.Spurs

20.Hänger

21. Intermediate pieces

22. Foot piece

23rd row of hangers

24. Truss longitudinal axis

25th floor plan Fig. 3 26. Second tip (foldable) 26a. Second jib (fixed) 27. Angled pull in the direction of the boom is possible 28. Angle α 29. Spreader (option) 30. Distance of the lifting ropes 31. Main boom 32. Kink

^Fi 9- ⁴ 33. Pretension nut 34. Disc springs (elastic) 35. One of the 4-corner longitudinal stems of the tower section (diagonals not shown) 36. Knagge against lateral force overload 37. Bias preload 38. Anchor rod (hanger) 39. Connection nut ^• 40. Floor formwork 41. Concrete plate 42.-Abutment against pre-tension 43. Intermediate plates according to statics and general assembly 44. Anchor plate 45. Tilting direction when the crossbar is knocked off

F ^j g- 57th axis total center of gravity changeable (suspension points 58. variable attachment points so that plate can hang freely vertically 59. 60 61 Tower shot 62 Center of gravity of the axis 63 Center of gravity of the slab 64 Concrete slab 65 Support spur 66 Axis hanger (only indicated) 67 Truss of weight 68 Position vertical 69 Gges = Center of gravity of the crossbar + slab in line 57

FIG.

70. Crane hook = tilting axis overall system

71. Lifted lifting gear

72. Auxiliary struts

73. Line warehouse

74. Parallel articulated connection

Fig. 7

101. Larger series due to filling height also below the upper edge of the wall formwork (ie without converting the floor formwork) 102. Actuators 103. Folded for stripping 104. Be 105. Spindles of the actuators for loosening, closing, adjusting the outer wall formwork 106. Concrete floor formwork in contact (+) ( possibly) 107

108. Cross member as part of the horizontal base element (pre-assembled) 109. Height adjustment under base element

110. Swivel joints

111.Base plate

112. Underground

113. Slidably set or clamped in the Lindapter o. Glw. 114. Triangular strip, fixed, reusable .. without modification

Fig. 8

115. Belts in final assembly position or sling gear

116. Ceiling supports

117. next ceiling (usually in-situ concrete)

118. Option: Edge joist integrated + reinforced

119. Column template

120. Interior of the room

121. Installation of auxiliary support

122. Blanket before assembly (hardened)

123. Centering mandrel

124. Window opening

125. Exterior facade

Claims

claims

1. A process for the production of flat precast concrete parts using a sole-like subsurface on site at a construction site, characterized in that at the site of the construction site, the sole-like subsurface is preferred in the production of the building before complete concreting of the ground level and basement ceiling, on the sole-like A form of formwork that can be used in series production is arranged, whereby the floor formwork is not changed between successive concreting cycles and precast concrete parts are produced on site in a heap and brought to a heap by crane

^ are, in order to achieve a temporal independence of trades.

2. The method according to the preceding claim, characterized in that a bonding breaker layer and / or a separating film is applied to the otherwise unchanged floor formwork between concreting cycles.

3. The method according to any one of the preceding claims, characterized in that the precast concrete parts produced on the stockpile are cross-processed by means of a crane, in particular both towards and away from the stockpile.

4. The method according to any one of the preceding claims, characterized in that a transverse crane with a boom radius less than 15 m is used, in particular a crawler crane.

5. The method according to any one of the preceding claims, characterized in that a -hole facade is produced as a flat precast concrete part and this is in particular moved exclusively by means of a tower crane.

6. The method according to any one of the preceding claims, characterized in that an edge formwork is used, which is fixedly arranged on the floor and remains fixed between the concreting cycles, in particular an edge formwork with a fall of 1:20 is used.