EP1883513A1

EP1883513A1 - Method and device for producing precast components and corresponding precast component

Info

Publication number: EP1883513A1
Application number: EP06753771A
Authority: EP
Inventors: Jürgen Rothermel
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-05-25
Filing date: 2006-05-22
Publication date: 2008-02-06
Also published as: WO2006125590A1; DE102005054087B3; AU2006251390A1; US20090241439A1; CA2606609A1

Abstract

The invention relates to a method and a device for producing precast components (1) that comprise a base (1') and a wall element (1'') using a concrete casting mold (2) having the shape of the precast component (1). The aim of the invention is to produce precast components in a single processing step and to allow for a firm connection between the concrete (4) and a natural stone (5). For this purpose, the concrete casting mold (2) is filled with concrete (4) with the visible side (3) of the wall element (1'') of the precast component (1) to be produced facing upward. At least one natural stone (5) is brought into a defined position in the unset concrete (4) in a depth of immersion sufficient for a reliable connection with the concrete (4) using at least one retaining element (9) and is maintained in this position until the concrete (4) has attained a strength sufficient to hold the position of the at least one natural stone (5). The precast component (1) is removed from the concrete casting mold (2) when the concrete has attained the respective strength.

Description

Method and device for producing precast components and

A prefabricated element

description

The invention relates to a method and an apparatus for producing a foot part and a wall part having prefabricated components using a concrete casting mold in the form of prefabricated component and precast components.

If such precast concrete elements are provided with a visible surface of natural stones, so it is known for example from DE 74 19 996 Ul to pour a precast component with a foot and a concrete wall and then to provide the visible surface of the wall part with natural stones.

This preparation is complicated, since it necessarily has several operations and only allows the processing of relatively flat natural stone material. The subsequent attachment of natural stones to the precast component is not of permanently high stability. In addition, rustic natural stones, such as found stones or quarry stones can not be processed in this way because of their irregular boundaries and their sometimes large thickness.

Furthermore, it is known from DE 43 01 1 18 C2 to produce flat precast components by casting a steel-reinforced base plate and then topping it with natural stones, the joints of which are then purged with a concrete mixture. In this way, however, only flat precast components can be produced.

Even with such a production of a precast component several steps are required. After pouring the bottom plate must be maintained until it is sustainable for the stones to be placed and only then can the stones placed and the joints between them are puttied. The latter is particularly complex and a firm connection between the bottom plate and the natural stones can not be guaranteed. Both the fissuring of the joints as well as between the natural stones and the bottom plate bad connections, gaps and cavities may arise, which leads to the breaking off of natural stones by the ingress of water and subsequent frost. Moreover, this manufacturing method requires the processing of uniformly processed natural stones, which have a flat contact surface and the same thickness and form relatively even joints with each other. Rustic natural stones such as boulders or quarry stones with irregular boundaries and different dimensions, especially large stones or even boulders can not be processed in this way.

Very often, as proposed for example by DE 198 01 378 A1 or DE 20 2004 019 390 U1, prefabricated building elements which are used as walls or floor slabs are produced in that natural stones are designed and poured over with concrete. In this case, of course, for example, by previous grouting must be prevented that the concrete flows to the front of the stones. In addition to the expense of the latter, only plate-shaped stones, paving stones or, as proposed by DE 18 32 191 Ul, natural stone chippings can be processed in this way. US Pat. No. 1,809,504 likewise provides such a method in which unhardened natural stones can also be processed. For this purpose, the natural stones are placed in a sand bed, which also keeps the concrete from the front of the stones. However, it is also necessary here to use reasonably uniform stone sizes in order to keep the cost of the required sand bed and the embedding of the stones within economically reasonable limits. However, the later visible side with the stone arrangement is not visible during processing and thus the result during the manufacturing process is not controlled and corrected if necessary. The sand embedding must be controlled manually and often prepared by hand, in particular, when different sized stones and very large stones are to be processed, wells for insertion of the stones in the sand must be created. From DE 16 59 106 Al a method and a device is known with the plate-shaped precast components can be produced by a flowable concrete slurry is placed in a shell mold, then placed in the natural stones and more or less strongly pressed. Thereafter, gutters are produced around the stones, in which concrete or mortar pulp is pressed in order to achieve better grip of the stone border frame with higher concrete density. The problem with this approach is that the concrete slurry for the introduction of the stones must be so viscous that the stones are worn, but are still depressible. This is problematic even with stones of different sizes, since the load capacity for a small stone, which weighs, for example, 1 kg, is much lower than for a much larger stone, for example, weighs 1 ton. In the latter case, it would be difficult, if not impossible, to set a concrete (mixture and time) so that it would bond with the stone and at the same time carry it so that it does not sink. It is also difficult to determine mixture and time so that all the stones, small and large, remain in the desired position and do not sink or change their position. If a concrete pulp is chosen with very tough consistency to avoid the latter, so stones that are to be placed deeper into the concrete must be pressed under high pressure in the concrete to bring them to the desired location, which is expensive. Moreover, a concrete that already carries the stones when they are introduced, only inadequately bonds with the stones, which necessitates the above-mentioned edging frames of compacted concrete or mortar in order to give the stones an additional secure hold. The latter requires an additional operation, which must be made by hand for irregularly shaped stones.

From DE 23 33615 A a method for applying an outer layer of stones or other particles on castings, in particular concrete slabs is known to provide them with a veneer. For this purpose, a flexible carrier, for example of plastic material, proposed in the surface of which the stones or particles are pressed or fixed by means of a binder as an aid. These flexible carriers are then pressed onto a casting compound, such as concrete. If the Gußmasse, such as the concrete is cured, the carrier can be peeled off, with the stones or particles detach from the carrier and remain as a veneer layer on the concrete slab. However, no production of a precast component with foot part and wall part is disclosed.

Above all, this method is only suitable for producing veneers of relatively small particles or small stones. Both the impressions in the surface of the flexible support, as well as the adhesion with the binder is not possible with larger stones, especially since this compound must be such that the stones or particles can be detached from the flexible support again to remain on the concrete without carrier residues sticking to them. In this way, only relatively small stones in the range of grit or gravel read, which are definitely under a weight of 1 kg. Larger stones can not be absorbed by flexible supports, neither by end ridges in the surface, nor by means of a binder. In addition, with this method, stones can be positioned only on one surface, but not arbitrarily spatially. The latter is desired for large stones, however, since unlike chippings or gravel, the individual stones are perceived visually and therefore a related freedom must be present to place a particular side of a stone, possibly with a definable board on the wall.

The invention is therefore an object of the invention to enable a production of precast components of the type mentioned in a single operation, at the same time to guarantee a solid connection between concrete and natural stones and almost any positioning of natural stones, especially very large, unhewn natural stones, in concrete to enable. Other objects are to allow a short residence time of the precast component in the concrete mold and to make prefabricated components and a method for their preparation available in their juxtaposition, the individual elements are not readily visible as such. The object is achieved with respect to the method according to the invention that the concrete mold filled with the visible side of the wall part of the finished precast component to be poured up with concrete and in the unabgebundenen concrete at least one natural stone by means of at least one holding element with an immersion depth for a secure connection with the concrete in brought a predetermined position and held in this position until the concrete has received a holding the position of at least one natural stone strength, being inserted as holding elements spacers for supporting the at least one applied natural stone in the concrete mold and the cast concrete, the spacers covered, and that the precast component is taken from the concrete mold, if its strength is sufficient.

Another erfϊndungsgemäße solution with respect to the method is that the concrete mold filled with the visible side of the wall part of the finished precast component to be poured up with concrete and in the unbound concrete at least one natural stone by means of at least one holding element with an immersion depth for a secure connection with the concrete in a predetermined position and held in this position until the concrete has received a holding the position of the at least one natural stone strength, serving as a holding element at least one suspension, which is attached to the non-immersing in the concrete surface, and that the precast component is taken out of the concrete mold if its strength is sufficient.

The object is achieved with respect to the device according to the invention characterized in that the device comprises spacers designed as holding elements which are inserted into the concrete mold to hold as a support the at least one natural stone and in a cast in the concrete mold concrete with an immersion in a predetermined manner position until a strength of the concrete that holds the natural stone in place has occurred. By the invention, it is possible to keep the concrete still so fluid during the introduction of natural stones that it wets the introduced stone surface and connects after setting with this, so that a solid connection between concrete and natural stones. It can be achieved by a corresponding mixing ratio of the concrete that the stones positioned in the concrete are to be held only for a short time, since the green hardness and thus the sustainability of the concrete for the stones occurs relatively quickly. This time to setting can be adjusted by the mixing ratio to the time required for stone positioning.

By means of the invention it is possible to process raw unhardened stones as they come from the quarry or have been shaped by nature (eg boulders). Plane surfaces for a support are not required. If e.g. Of course, the large gaps between them can be filled by placing smaller stones in the concrete by hand. A significant advantage of the invention, however, is that natural stones, especially very large stones can be positioned almost anywhere in the concrete. It is only important that the immersion depth ensures a secure hold of natural stone after curing of the concrete.

The invention is particularly well suited for producing very solid walls, such as embankment walls and noise barriers, as used in road construction, in hydraulic engineering, in the construction of railway lines, in vineyard construction or in hillside developments. The basic idea of the invention is that large natural stones - a grain size of 200 mm would be the lowest limit - can be inserted into the precast components mentioned above up to a considerable size of several tons as the visible side. It is essential that a holding or laying stones to the setting of the concrete in any orientation and with any depth of immersion in the concrete is possible. In this case, stones of very different sizes can be used, so that the gaps between completely irregularly shaped natural stones can be kept so low that the concrete hardly noticeable. Despite the sometimes very different size of the Natural stones, it is possible to create a relatively flat wall surface, because the stones can be brought into any desired installation position, for example, with beautiful or flat surfaces to the outside and it is also possible, large stones - for example, in an area of one or more tons - so sink far into the concrete that their visual side is almost on a level with smaller stones - for example, in the range of a few kilograms. The ability to select the visible side of the stones opens up many other design options besides producing relatively smooth walls. So you can deliberately install boards of natural stones or niches to create a wall that visually close to a natural rock wall and so to achieve a high aesthetic impact in landscaping. Thus, it can be seen that the possibilities of the invention go far beyond the previously known laminations and veneers of concrete walls. Rather, natural stone walls, possibly with heels or consoles for planting can be built, which blend into the landscape so that they are no longer readily identifiable as an artificial structure, indeed sometimes enrich the landscape.

By the invention, a prefabricated component can be produced in one operation in series machining. In particular, a production in a hall is possible, so that one is independent of weather and season. By a relatively deep embedding of natural stones in the still flowable concrete a solid connection between natural stones and concrete without significant gaps and cavities is achieved, the loads, especially alternating stresses of moisture and frost easily withstand many decades.

The fact that instead of flat stone slabs stone blocks can be processed, the stability and weather resistance is significantly increased. The stone blocks are massive and are firmly bound, so they can not crumble or fall off, as is often the case with wall facing with flat natural stones. Also a blooming of concrete, caused by the passage of calcium through natural Stones is hardly possible with the preferential use of large stones, so that the beautiful natural stone surface is permanently preserved.

The holding elements can be designed in different ways. A proposal is that as holding elements in the concrete casting spacers for supporting the at least one applied natural stone are inserted, wherein the cast concrete covers the spacers. In this case, the spacers are cast, so that it is expedient for this type of production of precast components, when a steel reinforcement also serves as a spacer.

However, if the immersion depths of the natural stones to be introduced are very different, or if one wishes to position the natural stones in a certain way in order to achieve certain effects, for example a corresponding aesthetic image, and finally determine the position definitively only during the insertion and viewing, it is expedient for the retaining elements to be suspended selected the concrete mold that hold the natural stone on its non-immersing in the concrete surface, in which case the natural stones are preferably suspended in each case at three points and by means of three height-adjustable adjusting means alignment of each natural stone is made. The particular advantage of this method is that the one who makes this positioning, the visual side of the future precast component has in mind and is thus able to make appropriate designs. It can then be brought by appropriate height adjustments of the adjusting means according to the future use of prefabricated components a flat side of the natural stone on the visible side, or it is possible to achieve projections and effects of any kind by selecting the surfaces. This type of positioning has the further advantage that even very large stones can be tightly joined together, so that the set back against the natural stone surface concrete is barely visible. For the attachment of the suspension or suspensions to the natural stones vacuum suction are conceivable, which are suitable for high holding power and rough surfaces. In the simplest case are also grippers an excavator arm or - for several stones - several appropriately trained arms with grippers used.

The device according to the invention can be trained and developed in every respect according to the method.

The holding elements for the at least one natural stone may be spacers which can be inserted into the concrete casting mold as a support for the at least one natural stone. Reference is made to the above statements regarding the method. Conveniently, however, the holding elements are suspensions that hold the at least one natural stone on the surface outside its immersion area in the concrete. At these suspensions are preferably arranged adjusting means for aligning the at least one natural stone by means of height adjustments. The stone can be held by means of all possible fasteners. Conveniently, vacuum cups are provided which are designed to adhere to a natural stone surface.

A short residence time of the precast element in the concrete mold is achieved according to the invention by a method in which the concrete mold is introduced before the concrete filling a stabilizing plate and the precast component after setting of the concrete, stored on the stabilizing plate, is removed.

With regard to the device, this object is achieved in that the concrete casting is designed such that a stabilizing plate can be inserted, which serves to remove the stored on her ligated, but not yet cured prefabricated component.

In this way it is possible to use a concrete casting mold together with holding elements for the

Use natural stone positioning effectively, since the green hardness is sufficient to remove the precast component on the stabilizing plate in stock. Becomes also selected a corresponding concrete mix, so relatively short production cycle times from one casting to the next are possible.

The invention further relates to prefabricated components, which are produced by the aforementioned method, and in particular precast components, which are not readily visible as such in the juxtaposition, since the precast components in the area adjacent surfaces have at least one natural stone with a supernatant, with a negative mold this at least one natural stone in the adjacent precast component corresponds such that they are ineinanderfugbar.

A development of the method provides that takes place to remove the hardened precast component pivoting of the concrete casting mold. In this way, the prefabricated component dissolves better from the mold and can be stored for example on their future footprint. It is of course expedient if a concrete mixture is used, through which the removal can be done relatively quickly, since the sufficient strength has occurred. This removal of the precast element from the concrete mold can, as already mentioned above, be accelerated by the fact that the freshly poured precast component is supported on the stabilization plate. It is possible that the stabilizing plate is not positioned horizontally in the concrete filling and the pivoting of the concrete mold is done to bring the stabilizing plate in the horizontal, so that the precast component is optimally supported. For example, it is possible to set the stabilizing plate vertically and to provide a 90 ° turn.

To stabilize the precast component to be cast, it is expedient to introduce at least one steel reinforcement or a steel-reinforced concrete slab into the concrete casting mold. If a steel-reinforced concrete slab is introduced, it may also serve as a stabilizing plate, in particular if the steel-reinforced concrete slab is introduced into the concrete casting mold as the base of the precast component to be cast becomes. It is also possible that this steel-reinforced concrete slab after insertion into the concrete mold serves as a limitation of the same.

Another possibility is that a mold closure plate which forms a wall of the concrete mold, serves as a stabilizing plate, wherein for curing the

Prefabricated component mounted on the mold closure plate and the concrete mold for the

Casting of the next prefabricated component is provided with a further mold closure plate. In this case, of course, so many mold closure plates should be present that during the entire curing time of the precast component, so this can be removed from the mold closure plate and this can be used again, a

Further production is possible.

If a stabilization plate, designed as a steel-reinforced concrete slab or as a form closure plate, is used, it can be provided that a holder for the stabilization plate is provided for removing a clamped precast component which can be moved away.

Of essential importance for the stability of the precast element is the immersion depth of the natural stones in the concrete. The immersion depth should be at least 20% of the volume of the at least one natural stone. In order to achieve a particularly high stability, however, it can also be provided that the immersion depth is at least half the volume of the at least one natural stone.

When positioning several large natural stones on the visible side of the prefabricated construction elements, of course, certain gaps occur, especially if unprocessed

Natural stones, such as boulders or raw quarry stones, are used. Then it may be appropriate that smaller natural stones are placed in the gaps in the concrete. Depending on the size of these natural stones, this arrangement can also be done with the said holding elements or it can also smaller natural stones are additionally inserted by hand, especially if their weight is not so great that they sink into the concrete. For this purpose, one can wait a short time, until the consistency of the concrete has become a little thicker.

Conveniently, a concrete mixture is used, which is so soft that natural stones in it are easily and arbitrarily positioned, but then so fast that the positions are fixed in a short time.

Conveniently, it can be provided that the visible on the visible side concrete is provided with a weather-resistant protective layer, which consists for example of epoxy resin or an epoxy resin mixture. As a result, erosion of exposed in the joints concrete can be avoided, which in particular has the advantage that it can not lead to contamination of natural stone surfaces, not to a blooming of the concrete in the joint area.

In order to install the prefabricated element without further concrete work in place immediately, it can be provided that a foot is poured, which is suitable as a later wall foundations. Of course, it is also possible that the precast component is cast with at least one connection reinforcement to connect it later with more poured concrete. Such connection reinforcements can be provided, for example, in the foot part to further increase the foundation, for example, when very large slopes have to be absorbed. In this case, the connection reinforcement projecting up from the poured concrete, so that a foundation part can be poured, which extends below the visible side of the precast component to the outside. However, it is also possible that the concrete mold is provided with a connecting reinforcement, which lies partially in the concrete mold and partially penetrates the concrete mold in a removable from this way. This then serves that the foot can be extended backwards, for example, when the foundation is to be connected by another concrete casting on the mountain side with the rock. Of course, the manufacture of the precast component is not limited to the fact that the surface of the concrete is aligned horizontally during casting. It can also be provided that the casting of the precast component takes place with a sloping concrete mold and a consistency of the concrete to be processed, which allows an inclined surface and an application of natural stones on this inclined surface.

It can also be provided that further natural stones are inserted into the concrete mold before the concrete is poured, whereby the back of the precast component is provided with natural stones, so that the precast component can be used as both sides provided with natural stones freestanding wall. In this way, walls, such as soundproof walls, build. Of course, then measures must be taken that the inserted natural stones are not encircled by the concrete. For this purpose, a corresponding embedding material may be provided which prevents this and after the casting is removable or, for example, sand, when removing the precast component drops.

In the aforementioned prefabricated components, the aesthetic effect can sometimes be disturbed by the fact that between two elements a straight and thus clearly visible Fugstelle made of concrete, whereby the individual prefabricated components are perceived in a composite wall. To avoid this, it can be provided that at least one overhanging natural stone is cast by means of a side wall of the concrete casting of variable wall elements on the adjoining side surfaces of the precast components to be cast.

In order to pour in the protruding natural stone or the protruding natural stones, it can be provided that vertically displaceable slides are provided as variable wall elements, which are moved upward until they abut the at least one natural stone. For the joining, it is of course expedient if the adjacent precast component has a corresponding negative mold, wherein such a negative mold the shape of the adjacent protruding natural stone should correspond. Such a negative mold can be prepared by protruding the supernatant of the natural stone into the concrete mold, defining variable wall elements on the side wall and covering the supernatant of the natural stone with agents not bonding to the concrete such that the supernatant of the natural stone after setting of the concrete is removable. In this way, prefabricated components are produced, which can interlock with their natural stone projections and negative forms exactly and so give a shapely, uninterrupted with respect to the visual impression surface of a larger wall, which also has a high stability through the teeth, whereby a mutual displacement of the elements can be prevented is, as it can occur for example by a subsidence.

Even for the use of heaviest means of transport, the sizes of prefabricated components to be produced in this way are often limited, in particular when the transport has to take place under or over bridges, over mountain routes with serpentines or through tunnels. For this case, it can be provided that prefabricated components can be made smaller to achieve larger walls and built on top of each other, or it can be provided that an additional increase of precast components is possible. This can be achieved, for example, that recesses are incorporated into the concrete casting in the crown region of the wall part, which serve to insert a wall increase in the direction of the wall on site. In such recesses and training, which are complementary to the recesses and are in the range of the footprint of aufzusetzenden precast component, could intervene. However, it would also be possible that further wall elements, such as other natural stones are inserted as a wall increase in the recesses, or it can also be placed as a further increase a noise barrier.

The fiction, contemporary device can be trained in all respects according to the described method and further education. Thus, for example, the concrete mold may be formed such that a stabilizing plate can be inserted, which is the removal of the stored on her ligatures, but not yet hardened prefabricated component is used. This stabilization plate may be a steel-reinforced concrete slab, which after casting serves as a component of the precast component, or it may be a form closure slab of the type already described.

Preferably, the concrete mold are assigned as stabilizing plates a plurality of mold closure plates, each serving to limit the concrete mold on one side, wherein the mold closure plates are removable with the precast components. Then the precast components can be stored on them until they cure and then they can be inserted back into the concrete mold. Thus, when the device is to be operated around the clock, the concrete mold must be associated with so many stabilizing plates, as new precast components can be poured during the curing of the precast components and removed on the mold closure plates. An expedient further embodiment is that the concrete mold for removing a hardened precast component is equipped with a pivoting device. Preferably, a pivoting should be such that the precast component then stands on the stabilizing plate.

In order to arrange the stabilizing plates on the concrete casting mold, it is expedient if this has a holder for inserting the stabilizing plate. As a stabilizing plate can serve a steel-reinforced concrete slab, which is inserted into the concrete mold, then to become part of the finished part component during casting. Of course, one of the abovementioned mold closure plates can also be held with the holder, which at the same time serve as re-usable stabilizing plates. Appropriately, the holder for the removal of the set component precast component is movable away.

The concrete mold may have openings for the introduction of connection reinforcements, which are then partly in the interior of the concrete mold and are partially stretched through the wall thereof and thereby from the gegos- protrude senen prefabricated component to connect the precast component later with another concrete casting can. In this type of connection reinforcements are then those that are located at the back of the precast component to be cast.

The following developments of the device serve to produce prefabricated components for a juxtaposition, which is not visible and grants a certain toothing: For this purpose, the concrete mold on at least one side wall having variable wall elements to be able to pour a protruding natural stone can. By means of these wall elements can then both the precast component with the supernatant natural stone, as well as the adjacent precast component, are produced with a corresponding negative mold. Also in this regard, reference is made to the method described above. As a variable wall elements vertically movable slide can be provided which can be moved up until they abut the at least one natural stone.

Another object of the invention are precast components that are made by the above method and its developments. On a particularly useful trained prefabricated component has already been made. A further embodiment consists in that a precast component in the crown area has recesses which serve to place a wall increase in the direction of the wall on site. Such recesses are expediently cast by a corresponding design of the concrete casting mold, it may, for example, be an insertable slide, which is then pulled out of the concrete casting mold to remove the precast component. Or there is a corresponding configuration of the concrete casting mold from which the cured precast component is removed after removal of the opposite mold closure plate.

The invention will be explained with reference to embodiments shown in the drawing. Show it Fig. 1 shows an embodiment of a concrete mold of the erfϊndungsgemäßen

Contraption,

2 shows an example of a device according to the invention with holding elements designed as spacers,

3 shows an example of a device according to the invention with retaining elements, which are designed as suspensions,

4 shows a finished part production with inclined position of the concrete casting mold,

5 shows a finished part production with variable wall elements,

Fig. 6 is a juxtaposition of precast components with protruding

Natural stones on the adjoining surfaces and

Fig. 7 shows a precast component with a patch wall increase.

1 shows an embodiment of a concrete casting mold 2 of the device according to the invention for the production of prefabricated building elements 1 with a foot part 1 'and a wall part 1. However, here only the concrete casting 2 is shown in a specific embodiment, with respect to the retaining elements 9 for the natural stones 5 as well refer to Figures 2 to 5. However, the position of the precast component 1 is symbolized by a dot-dash line 16, so that it can be seen which part of the concrete mold 2 the formation of the foot part 1 'and which Part of the formation of the wall part 1 "of the precast component 1 is used.

From the illustrated concrete casting mold 2, a stabilizing plate 6 is separable, which serves to remove a precast component 1, when this has reached the green hardness and thereby is removable. For casting the precast component 1, the concrete casting is pivoted in the direction of the arrow 13 ', so that the dot-dash line 16, which indicates the precast component 1, lies in a horizontal plane. In this position, the casting of the precast component 1 and the introduction of natural stones 5, which will be shown and described later. After casting and the achievement of the green hardness takes place by means of the pivoting device 13 pivoting in the direction of arrow 13 'until the stabilizing plate 6 is horizontal and then by means of the holder 8, the stabilizing plate 6 with the precast component 1 in the direction of arrow 8' can be moved away , This is followed by a storage of the prefabricated component 1 on the stabilizing plate 6 until the precast component 1 is cured.

If the stabilization plate 6 is a reusable plate, it is reinserted into the concrete mold 2. In this case, of course, several stabilizing plates 6 must be present so that a continuous production is possible. However, the stabilization plate 6 can also be a steel-reinforced concrete slab 6 ', which is integrated into the precast component 1 and forms its base 7. These details will be described in FIGS. 2 and 3.

In order to be able to better remove the prefabricated component 1 from the shuttering bottom 15 of the concrete casting mold 2, it can also be provided that the side plates 17 and 17 'can be moved away in the direction of the arrows 18 and 18'.

Fig. 2 shows an example of a device according to the invention formed as a spacer 10 holding elements 9. These are inserted into the concrete mold 2, this insertion, as shown, can be done on brackets or as spacers 10 and steel reinforcements can be inserted, which in the corresponding Height are positioned. For different thickness natural stones 5 can also be different positioning of the spacers 10 may be possible. It is then poured into the concrete 4 and then the natural stones 5 on the Spacers 10 laid so that they lie with a dip area 1 1 in the concrete 4.

Furthermore, it is shown in this embodiment, as a stabilizing plate 6, which is designed as steel reinforced concrete slab 6 ', in the concrete casting mold 2 is inserted as a side wall to later form the base 7 of the precast component 1. After reaching the green hardness of the precast component 1, the concrete mold 2, as shown in Fig. 1, pivoted 13 'until the concrete slab 6' is aligned horizontally, then to remove the precast component 1 of the concrete casting mold 2 characterized in that the holder 8 in Direction of the arrow 8 'the steel reinforced concrete slab 6' moves away with the precast component 1 so that it can cure completely. Thereafter, the concrete mold 2 is provided with a further steel-reinforced concrete slab 6 ', which in turn is held by means of the holder 8, so that the next casting of a precast component 1 can take place.

In this embodiment, the Stahlarmierten concrete slabs 6 'form the future footprint 7 of the precast components 1 and the spacers 10 remain as Stahlarmierung in the same, so that they also have a corresponding stabilization.

FIG. 3 shows an example of a device according to the invention with holding elements 9, which are designed as suspensions 14. In this embodiment, the suspensions 14 are attached to the natural stone 5, wherein these fasteners are made on the visible side 3 of the natural stone 5. These can be screwed connections or wedges, or preferably vacuum vacuums that hold on a natural stone surface. Appropriately, three suspensions are provided so that by means of adjusting means 12, the height adjustment is indicated by the double arrows, any alignment of a natural stone 5 is possible.

The introduction and alignment of the natural stone or stones 5 takes place after the pouring of the concrete 4. Then the natural stone 5 by means of this adjusting means 12 so held long in its position until the concrete 4 has set so that he carries natural stones 5.

If the curing of the precast component 1 has progressed so far that it can be removed, the concrete casting 2 can also be pivoted here in order to drive away the precast component 1 with the stabilization plate 6 (arrows 13 'and 8'). The precast component 1 can then fully harden on the stabilization plate 6. For the purpose of holding and driving away the stabilizing plate 6, holders 8, which function as described above, also serve here.

2, the stabilizing plate 6 is a mold closure plate 6 "which is reused after the curing of the prefabricated component 1. In this case, there is a storage space for the curing of the prefabricated components 1 and preferably as many mold closure plates 6 "that during the entire curing of the precast components 1 new can be poured.

Furthermore, it is shown in Fig. 3, as in the concrete mold 2 by means of openings 33, a connection reinforcement 20 can be inserted, which serves that to the foot part 1 'of the precast component 1 later another concrete casting for stabilizing the precast component 1 can be made locally ,

As a further embodiment, Fig. 3 shows that in the concrete casting mold 2 more natural stones 5 'can be inserted so that a further visible side 3' of the precast component 1 is formed. In this regard, reference is made to the above statements.

It is also possible to position the concrete casting 2 at an angle α to the horizontal 32 in an inclined position in order to cast the prefabricated component 1. Then the concrete 4 must have a consistency which allows an inclined surface 21 of the concrete 4 on then the natural stones 5 are positioned. The remaining embodiments can be carried out in the manner already described.

Fig. 5 shows a finished part production with variable wall elements, which serve as a side wall 23 or preferably as both side walls 23 of the concrete casting mold 2. These variable wall elements may be formed as vertically movable slide 24, which can perform a movement in the direction of the arrows 26 and thereby can be moved against a natural stone 5, which protrudes as overhanging natural stone 22 on the side wall 23. In such an embodiment, the concrete casting mold 2 expediently has on both side walls 23 such slides 24, which can be displaced by means of drives which are located in a housing 31.

In this case, the left prefabricated component 1 was prepared such that on a side surface 25, which adjoins the installation of another prefabricated component 1, a projection 28 of a natural stone 22 with the aid of 5 described device was generated.

Also with the apparatus described with reference to Fig. 5, a prefabricated structural element 1 of the type illustrated in Fig. 6 on the right side was prepared by coating the supernatant natural stone 22 of the left prefabricated structural element 1 with a non-concrete bonding agent 29, and then hineinzuragen in a concrete mold 2, the side wall was limited by the slider 24 to the protruding natural stone 5. In the casting, which is carried out thereafter, creates a negative mold 27 of the protruding natural stone 22 on the other precast component 1

In this way, prefabricated components 1 can be produced, each having an overhanging natural stone 22 and correspond to a precast component 1, which has a protrusion 28 corresponding negative mold 27.

Will then the two prefabricated components in the direction of arrow 30 together pushed, so there is an exact gearing, which provides both a clean viewing surface 3, in which the boundaries of the precast components 1 are no longer visible and in which the juxtaposed precast components 1 have a high degree of stabilization by the described mutual toothing. In this case, the finished part components 1, which are intended to be installed in a row, are preferably provided with protruding natural stones 28 and negative molds 27 on all adjoining side surfaces.

Fig. 6 also shows how larger and smaller natural stones 5 can be placed on the visible side 3 of the precast component 1, so that no larger concrete surfaces are more visible.

Finally, Fig. 7 shows a prefabricated component 1, which has a recess 19 at the upper side of the wall part 1 ", which can serve to insert a wall elevation 19. For example, a plate-shaped natural stone or plate-like natural stones can be placed on the prefabricated component 1 as a wall elevation 19 ' or it is possible in this way to set up a noise protection wall at the top. If negative forms 27 are produced instead of the recess 19, unhardened natural stones 5 can also be put on.

Of course, a recess 19 also serve that another prefabricated component 1 is placed, which has at its foot 1 'in the recess 19 a matching bar, so that, for example, for fixing a slope and precast components 1 can be arranged one above the other, where Of course, the layers can be added for stabilization.

The illustrated embodiments are of course only an example, it would for example also be possible to place a stabilizing plate 6 directly in the formwork floor 15, so that a removal of a precast component 1 without pivoting movement is possible upwards. It could also be cast steel plates 6 'at any other points of the precast component 1 to to achieve appropriate stabilization. Of course, the individual embodiments which have been described to the figures, or which are the claims and dependent claims can be removed, conceivable in other combinations.

Method and device for producing precast components and

A prefabricated element

Bezugszeichenuste

1 precast component

V foot part

1 "wall part

2 concrete casting mold

3 visible side

3 'further visible side

concrete

natural stones

5 'more natural stones for another side of view

stabilizing plate

6 'steel reinforced concrete slab

6 "mold closure plate

7 floor space

8 bracket

8 'arrow: driving away the holder

9 retaining elements

10 spacers

11 immersion area

12 actuating means

13 pivoting device

13 'arrow: swinging Suspension formwork line dash-dotted line: Position of the prefabricated element, 17 'side panels, 18' arrows: Wegfahrbarkeit the side panels recesses in the crown area of the wall part for a wall 'wall increase (natural stones, noise barrier, ...) connecting reinforcement surface of the concrete protruding natural stone side wall of the concrete mold of variable Wall elements as vertically movable slide formed adjacent or side surfaces of prefabricated components installed in a row Arrow: slide movement negative shape of a protruding natural stone in the adjacent precast component supernatant of natural stone not connecting with the concrete arrow: joining two prefabricated components housing for slide horizontal openings for the introduction of connecting reinforcements

Angle of inclination of concrete casting

Claims

Method and device for the production of prefabricated components and finished part component patent claims

1. A method for producing a foot part (T) and a wall part (1 ") having precast components (1) using a concrete mold (2) in the form of the precast component (1), characterized in that the concrete casting mold (2) the visible side (3) of the wall part (1 ") of the precast component (1) to be poured upwards filled with concrete (4) and in the unbonded concrete (4) at least one natural stone (5) by means of at least one holding element (9) with an immersion depth for a secure connection with the concrete (4) is brought into a predetermined position and held in this position until the concrete (4) has received a position holding the at least one natural stone (5) strength, wherein as retaining elements (9 ) Spacers (10) for supporting the at least one applied natural stone (5) in the concrete mold (2) are inserted and the cast-in concrete (4) covers the spacers (10), and that the precast component ( 1) is taken from the concrete mold (2), if its strength is sufficient.

2. A process for the production of a foot part (V) and a wall part (1 ") having precast components (1) using a concrete mold (2) in the form of the precast component (1), characterized in that the concrete mold (2) with the Visible side (3) of the wall part (1 ") of the precast component (1) to be poured upwards filled with concrete (4) and in the unbonded concrete (4) at least one natural stone (5) by means of at least one holding element (9) with an immersion depth for a secure connection with the concrete (4) placed in a predetermined position and so long in this Position is maintained until the concrete (4) has received a holding the position of the at least one natural stone (5) strength, serving as a holding element (9) at least one suspension (14), which at the not in the concrete (4) dipping Surface is fixed, and that the precast component (1) is taken from the concrete mold (2), if its strength is sufficient.

3. The method according to claim 2, characterized in that three suspensions (14) are provided, which hold the at least one natural stone (5) at three points.

4. The method according to claim 3, characterized in that by means of three height-adjustable adjusting means (12) alignment of the natural stone (5) is made.

5. The method of claim 2, 3 or 4, characterized in that at least one vacuum suction is used to attach the at least one suspension (14) on the natural stone (5).

6. The method according to claims 2, 3 or 4, characterized in that at least one gripper is used to attach the at least one suspension (14) on the natural stone (5).

7. The method according to any one of claims 1 to 6, characterized in that in the concrete casting mold (2) before the concrete filling a stabilizing plate (6) is introduced and that the precast component (1) after the setting of the concrete (4) on the stabilizing plate (6) in stock, is removed.

8. The method according to any one of claims 1 to 7, characterized in that for removing the hardened prefabricated component (1) is a pivoting (13 ') of the concrete casting mold (2).

9. The method according to claim 8, characterized in that the stabilizing plate (6) is not horizontally positioned in the Betonfiillung and the pivoting (13 ') of the concrete casting mold (2) takes place to bring the stabilizing plate (6) in the horizontal.

10. The method according to any one of claims 1 to 9, characterized in that for the stabilization of the precast component to be cast (1) at least one steel reinforcement or a Stahlarmierte concrete slab (6 ') in the concrete casting mold (2) is introduced.

11. The method according to claim 10, characterized in that the steel reinforced concrete slab (6 ') also serves as a stabilizing plate (6).

12. The method according to claim 11, characterized in that a steel-reinforced concrete slab (6) as a base (7) of the finished precast component to be cast (1) in the concrete casting mold (2) is introduced.

13. The method of claim 10, 1 1 or 12, characterized in that the steel-reinforced concrete slab (6 ') after insertion into the concrete casting mold (2) serves as a limitation thereof.

14. The method according to claim 8, 9 or 10, characterized in that a mold closure plate (6 "), which forms one of the walls of the concrete mold (2), as a stabilizing plate (6), wherein for curing the precast component (1) on the Mold closure plate (6 ") is stored, and that the concrete mold (2) for the casting of the next precast component (1) with a further mold closure plate (6") is provided.

15. The method according to any one of claims 7 to 14, characterized in that for removing a hardened precast component (1) has a holder (8) for the stabilizing plate (6) is provided, which is wegfahrbar.

16. The method according to any one of claims 1 to 15, characterized in that the immersion depth is at least 20% of the volume of the at least one natural stone (5).

17. The method according to any one of claims 1 to 15, characterized in that the immersion depth is at least half the volume of the at least one natural stone (5).

18. The method according to any one of claims 1 to 17, characterized in that a plurality of large natural stones (5) are positioned and then in the gaps smaller natural stones (5 ') in the concrete (4) are arranged.

19. The method according to any one of claims 1 to 18, characterized in that a concrete mixture is used, which is so soft that natural stones (5) are easily and arbitrarily positionable in her, but then so fast that the positions in fixed in a short time.

20. The method according to any one of claims 1 to 19, characterized in that on the visible side (3) visible concrete (4) is provided with a weather-resistant protective layer.

21. The method according to claim 20, characterized in that the protective layer consists of epoxy resin or an epoxy resin mixture.

22. The method according to any one of claims 1 to 21, characterized in that a foot part (V) is poured, which is suitable as a later wall foundation.

23. The method according to any one of claims 1 to 21, characterized in that the prefabricated component (1) is cast with at least one connection reinforcement (20) to connect it later with more cast concrete.

24. The method according to claim 23, characterized in that the connection reinforcement (20) in the foot part (1 ') is provided.

25. The method according to claim 23 or 24, characterized in that the connecting reinforcement (20) protrudes from the top of the cast concrete (4).

26. The method according to any one of claims 23, 24 or 25, characterized in that the concrete mold (2) is provided with a connection reinforcement (20) which lies partially in the concrete mold (2) and partly the concrete mold (2) in one of these interspersed removable way.

27. The method according to any one of claims 1 to 26, characterized in that the casting of the precast component (1) with an inclined concrete mold (2) and a consistency of the processed concrete (4), which has an inclined surface (21) and allows application of natural stones (5) on this inclined surface (21).

28. The method according to any one of claims 1 to 27, characterized in that to achieve a further visible side (3 ') more natural stones (5') in the concrete casting mold (2) are inserted before the concrete (4) is poured.

29. The method according to any one of claims 1 to 28, characterized in that by means of a side wall (23) of the concrete casting (2) of variable wall elements (24) on the adjacent side surfaces (25) of the precast components to be cast (1) at least one supernatant natural stone (22) is poured.

30. The method according to claim 29, characterized in that as a variable wall elements (24) vertically movable slide (24) are given, which moves so long up (26) until they abut the at least one protruding natural stone (22).

31. The method according to claim 29 or 30, characterized in that for the butting (arrow 30) of precast components (1) with at least one protruding natural stone (22) and those with a negative-form (27) of the supernatant (28) of the at least one natural stone (22) are provided.

32. The method according to claim 31, characterized in that the negative mold (27) is produced in that the supernatant (28) of the natural stone (22) protrudes into the concrete casting (2), variable wall elements (24) delimiting the side wall (23) and covering the overhang (28) of the natural stone (22) with means (29) not connecting to the concrete (4) such that the overhang (28) of the natural stone (22) is removable after setting of the concrete (4) ,

33. The method according to any one of claims 1 to 32, characterized in that in the crown region of the wall part (1 ") recesses (19) are incorporated into the concrete casting, which serve the insertion of a wall ramp (19 ') in the construction site on site.

34. Apparatus for carrying out a method according to one of claims 1 or 7 to 33 with a concrete mold (2) in the form of a precast component (1) with foot part (1 ') and wall part (1 "), characterized in that the device as Spacer (10) formed holding elements (9) which are insertable into the concrete mold (2) to hold as a support the at least one natural stone (5) and in a cast in the concrete mold (2) concrete (4) with a dip area (11) to position in a predetermined manner until a strength of the concrete (4) holding the natural stone (5) in position has entered.

35. Apparatus for carrying out a method according to one of claims 2 to 33 with a concrete mold (2) in the form of a prefabricated component (1) with foot part (1 ') and wall part (1 "), characterized in that the device at least one as at least one suspension (14) formed holding element (9), wherein the at least one suspension (14) on the natural stone (5) outside its immersion region (1 1) in the concrete (4) can be fastened to the at least one natural stone (5 ) and to position in a concrete poured into the concrete mold (2) with a dip area (11) in a predetermined manner until a strength of the concrete (4) holding the natural stone (5) in place has entered.

36. Apparatus according to claim 35, characterized in that three suspensions (14) are provided which hold the at least one natural stone (5) at three points.

37. Apparatus according to claim 36, characterized in that on the suspensions (14) adjusting means (12) for aligning the at least one natural stone (5) are arranged by means of height adjustments.

38. Apparatus according to claim 35, 36 or 37, characterized in that at least one vacuum suction device is provided for fastening the at least one suspension (14) to the natural stone (5).

39. Device according to claims 35, 36 or 37, characterized in that at least one gripper is provided for fastening the at least one suspension (14) to the natural stone (5).

40. Device according to one of claims 34 to 39, characterized in that the concrete mold (2) is designed such that a stabilizing plate (6) can be inserted, which is the removal of the stored on her ligated, but not yet cured prefabricated component (1). serves.

41. Device according to one of claims 34 to 40, characterized in that the concrete casting mold (2) for removing a hardened precast component (1) is equipped with a pivoting device (13).

42. Apparatus according to claim 40 or 41, characterized in that the concrete mold (2) as stabilizing plates (6) are associated with a plurality of mold closure plates (6 "), each serving to limit the concrete mold (2) on one side, wherein the Mold closure plates (6 ") in each case with the prefabricated components (1) are removable, stored on them the precast components (1) until their curing, and then they can be inserted back into the concrete mold (2).

43. Apparatus according to claim 40, 41 or 42, characterized in that the concrete casting mold (2) has a holder (8) for inserting at least one stabilizing plate (6).

44. Apparatus according to claim 40, 41 or 42, characterized in that in the concrete casting mold (2) as a stabilizing plate (6) a steel-reinforced concrete slab (6 ') can be inserted, which during casting part of the precast component (1).

45. Apparatus according to claim 43 or 44, characterized in that the holder (8) for the removal of the hardened precast component (1) is movable away.

46. Device according to one of claims 34 to 45, characterized in that the concrete mold (2) has openings (33) for the introduction of connection reinforcements (20), which are then partially in the interior of the concrete mold (2) and partially protrude to to connect the precast component (1) later with another concrete casting.

47. Device according to one of claims 34 to 46, characterized in that the concrete casting mold (2) has at least one side wall (23) which consists of variable wall elements (24) in order to be able to pour a protruding natural stone (22).

48. Apparatus according to claim 47, characterized in that as a variable wall elements (24) vertically movable slide (24) are provided which moves so long upwards (arrow 26), until they at the at least one protruding natural stone (22) nudge.

49. Prefabricated component, produced by a method according to one of claims 1 to 33.

50. Prefabricated component according to claim 49, characterized in that a precast component (1) in the region adjacent surfaces (25) at least one natural stone (22) having a projection (28) with a negative mold (27) of this at least one natural stone (22 ) in the adjacent prefabricated component (1) corresponds such that these (28 and 27) are intermeshable.

51. precast component according to claim 49 or 50, characterized in that it has recesses (19) in the crown area, which serve the placement of a wall elevation (19 ') in the wall direction on site.