EP2532808A1 - Verfahren zum Gießen von Freiform-Betonstrukturen vor Ort - Google Patents

Verfahren zum Gießen von Freiform-Betonstrukturen vor Ort Download PDF

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Publication number
EP2532808A1
EP2532808A1 EP11004739A EP11004739A EP2532808A1 EP 2532808 A1 EP2532808 A1 EP 2532808A1 EP 11004739 A EP11004739 A EP 11004739A EP 11004739 A EP11004739 A EP 11004739A EP 2532808 A1 EP2532808 A1 EP 2532808A1
Authority
EP
European Patent Office
Prior art keywords
wax
concrete
adjusted
elements
formwork
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.)
Withdrawn
Application number
EP11004739A
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English (en)
French (fr)
Inventor
Silvain Oesterle
Axel Vansteenkiste
Fabio Gramazio
Matthias Kohler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Eidgenoessische Technische Hochschule Zurich ETHZ
Original Assignee
Eidgenoessische Technische Hochschule Zurich ETHZ
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Eidgenoessische Technische Hochschule Zurich ETHZ filed Critical Eidgenoessische Technische Hochschule Zurich ETHZ
Priority to EP11004739A priority Critical patent/EP2532808A1/de
Priority to PCT/EP2012/002457 priority patent/WO2012167948A2/en
Publication of EP2532808A1 publication Critical patent/EP2532808A1/de
Withdrawn legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
    • E04G11/04—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for structures of spherical, spheroid or similar shape, or for cupola structures of circular or polygonal horizontal or vertical section; Inflatable forms
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342—Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/346—Manufacture of moulds
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/10—Forming or shuttering elements for general use with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air

Definitions

  • the present invention relates to a method for on-site castings of free-form concrete structures according to the preamble of claim 1.
  • Said document discloses a method for casting and a formwork for casting concrete or concrete like elements where said elements may have an amorphous shape. This method allows a wide variety of shapes which could be symmetrical or asymmetrical. Said document starts with a solid formable material having a size larger than the element to be cast and a model of the element is then cut out creating the inner formwork. Said formable material is especially an expanded polystyrene based product which allows a remanufacturing of said elements. An outer load bearing support structure is applied against the inner formwork. Then fresh concrete is poured into the space or cavity delimited by the inner formwork. It is also mentioned that optionally reinforcements can be arranged in the cavity. After a time period within which the concrete was allowed to cure, the outer load bearing support structure and the inner form work parts are removed.
  • WO 2008/141 644 shows that full solid material as expanded polystyrene is used as formwork basis. It is not possible to create forms as disclosed in WO 2008/141 644 with a thin plastic material backing in bigger dimensions. The same is true for US 4,865,783 , disclosing a mould having five fixed sides and the concrete cannot be prepared on-site.
  • the method for casting concrete or concrete like elements where said elements may have an amorphous shape comprises the initial step of providing a mould, comprising a bottom surface and side surfaces, wherein the bottom surface is an adjusted surface having the curvature of the front surface of the concrete or concrete like element to be casted. Then molten wax is poured into the mould. After solidification of the wax a solid wax formwork element has been formed, which can be mounted on a construction site into an outer load bearing support structure creating a space or cavity of the concrete or concrete like element to be casted. After having poured fresh concrete or other concrete like material into the cavity, the concrete or other concrete like material is cured and the outer load bearing support structure as well as the solid wax formwork element are removed. Then the material of the solid wax formwork element can be directly reused for providing molten wax within the creation of a further solid wax formwork element.
  • Fig. 1 shows a schematic sketch of the different method steps used within an embodiment according to the invention. It is especially noted, that the method according to the invention, allows for a reuse of the material, wax 31, forming the inner structure or wax formwork element 30.
  • the fabrication of the inner structure starts within a specific fabrication site with an adjustable initially planar smooth surface 10 onto which a mould frame 20 can be positioned.
  • the fabrication site has received the general reference numeral 5 covering all steps executed at that site, which can also be a site on an installation site.
  • the mould frame 20 preferably has four sides spanning a rectangular form; however other polygonal forms are possible, but not preferred.
  • the lower edge 21 of the mould frame 20 is adapted to contact the initially planar surface 10 in a sealing manner.
  • Plan 10 is especially an adjustable material, e.g. a plastic sheet or a reinforced plastic sheet or a textile structure.
  • an adjustable material e.g. a plastic sheet or a reinforced plastic sheet or a textile structure.
  • Such a structure is known from the paper from Christian Raun et al. mentioned in the introduction of the specification.
  • the adjustable initially planar surface 10 will be manipulated in its height in the two plan dimensions in order to follow the free-form structure for the negative workform of the concrete.
  • the form of the surface 10 represents the positive form as the concrete will show up after the casting. This is shown for the surface 10 having received the reference numeral 10' for the adjusted surface.
  • the mould frame or outer frame work 20 is flexible and follows the curvature of the adjusted surface 10' and has therefore received the numeral 20' for adjusted mould frame walls.
  • the wax formwork element 30 is formed through melting pieces of wax 31 and pouring the wax in a molten state as molten wax 32 into the form provided on five sides by the adjusted elements 10' and 20'. Then the wax 31 solidifies and creates the wax formwork element 30.
  • the molten wax 32 is poured near and at the lowest part of the adjusted mould part elements 10' and 20'.
  • the adjustable mould frame parts 20 as well as the adjustable initially planar surface 10 can be equipped with heating elements, e.g. electric heating cables at their back surface to heighten the temperature of the frame to a temperature in the vicinity of the fusion temperature of the wax 31 to allow a controlled solidification of the molten wax 32 in the form.
  • the wax formwork element 30 is not a full solid but comprises a number of indentations 34 on its back as will be explained in connection with the description of Fig. 2A to 2F .
  • the aim of providing these indentations 34 is to reduce the weight of the wax formwork element 30 without compromising its stability.
  • the adjusted mould frame 20' is taken away and the wax formwork element 30 is taken from the fabrication site 5 which is shown with the arrow 15 to be mounted on-site on or within a support structure 40, which is here shown as a scaffold.
  • concrete is poured onto this structure being the wax formwork element 30, having walls within a side frame (not shown in Fig. 1 ), as will be explained in connection with Fig. 3 and 4 providing the concrete structure 50.
  • the wax 31 can be taken away and reused.
  • the wax formwork element 30 can then be destroyed on-site and wax chunks can then be reused according to arrow 16 for the transport from the installation site to the fabrication site 5 to model a new wax formwork element 30.
  • the fabrication site 5 can be provided at a complete different place than the installation site or it can be provided near the construction site.
  • Fig. 2A to Fig. 2F show different specific sub steps of the method according to an embodiment of the invention which is executed at the fabrication site 5. These sub steps explain and comprise features relating to the additional structural features of the indentations 34 in order to obtain a lighter weight wax formwork element 30.
  • the arrayed block 61 can have a square basic surface 62 and being of rectangular shape. Usually they are attached at their backside opposite to the surface 10 to fixation elements and or there might be guide elements between the different arrayed blockcolumns 61. It is noted that the blocks 61 do not touch each other but are separated by a small arrayed block gap 63 providing a distance between the blocks 61.
  • the arrayed block gap 63 is constant over the length of the blocks 61 or is slightly conical, wherein the lower square surface 62 near the adjustable initially planar surface 10 is smaller than the upper square surface on the opposite free ends of the block 61.
  • Said gap 63 is preferably the same between blocks 61 in different rows as well as in different columns of the array 60. These blocks could be moved by an actuator or by a robot bringing them into a specific predefined place.
  • the arrayed blocks 61 are placed as and in an irregular grid.
  • each arrayed block 61 may have a different lower surface 62 with different dimensions.
  • the lower surface 62 may be rectangular, having polygonal edges or is a circular disc. Therefore the gaps 63 can be of different thickness and also comprise a curvature if looked on from above. Such different sizes of the "foot" of the arrayed blocks 61 would be able to adjust to different curvatures and concrete pressure demands.
  • An arrayed block 61 is, in the simplest form, a vertical rod being adjustably attached to a frame structure and/or with adjacent arrayed blocks 61.
  • the arrayed blocks 61 are cylinders in the geometrical sense, thus comprising prisms etc..
  • the adjustable mould frame work 20 it positioned on the adjustable initially planar surface 10 and the adjustable surface 10 is formed according to a predefined free form curvature in two directions.
  • the adjustable surface 10 does not follow necessarily or exclusively a double curve geometry. This can be achieved as shown in section 3.1 of the Raun et al. publication.
  • the array 60 of elements 61 is positioned, as shown in Fig. 2C , wherein specific height positions of the elements 61 are provided in order to generate specific dimensions of a space or cavity between the surface 10', the frame work 20' and the single columns 61 as it will be explained in connection with Fig. 5 . It is also possible, that all or parts of the arrayed blocks 61 are heated as mentioned above.
  • the final stage is then taking away the wax formwork element 30 from the surface 10' and said wax formwork element 30 can then directly be used on site.
  • wax formwork element 30 it is possible to use the wax formwork element 30 to case single sided for e.g. deck like structures.
  • the wax 31 is cast on the adjusted mould 10' to form the wax formwork element 30.
  • the concrete 50 is casted. Removing and breaking away the wax form elements 30 allows reusing the basic material, the wax chunks 31 to prcparc new wax formwork elements 30 for the next project phases.
  • wax 31 for the fabrication of non-repetitive free-form formwork elements 30 out of a reusable material is a formative fabrication method, rather then a subtractive fabrication method and results only in minor material loss.
  • the wax formwork element 30 is reusable using only a reasonable amount of energy, since this relates to the energy needed to melt and to pour molten wax 32 into a new form which is only a fraction of the embodied energy of the wax itself. This is a far more efficient process then milling expanded polystyrene blocks.
  • the wax 31 is a one-time investment within the process and thus the cost decreases with the increased number of uses of the same wax 31 within the process.
  • the wax 31 can be more or less any kind of wax or polymer material having a softening point not lower than 70 degrees centigrade (70° Celsius) and having a melting point not higher than 90 degrees centigrade. Although it is possible to use a material having a melting point at a temperature higher than 100 degrees centigrade, such materials are not preferred since they require the use of more energy for converting the wax into its molten state.
  • One important feature of the wax or polymer material in this respect of the possible higher melting point is the fact that the material does not show cracking effects during shrinkage while solidifying and cooling down to ambient temperature. This is usually connected to the thermal expansion coefficient but is also a property of the material.
  • the wax 31 can be in general any thermoplastic material, defined as a material, especially a polymer, that becomes liquid, i.e. melts, when heated and can be remelted and remoulded, wherein the crackwidth after return to ambient temperature is below a predefined threshold not compromising structural integrity of the element.
  • a predefined threshold could be 0,5 millimeter, preferably below 0,2 millimeter.
  • the softening point should not be below said 60 or 70 degrees centigrade since the curing of the concrete raises the temperature of the form up to 40 or 50 degrees centigrade. Furthermore the wax form element 30 might be subjected to sun exposure which also raises the temperature of the wax form. Therefore it is preferred that the softening point of the wax should be around 70 to 80 degrees centigrade.
  • a further advantage of the process is the possibility to use the wax form directly to pour concrete on it without using any release agent.
  • the adjustable initially planar surface 10 is obtained through uniformly spaced individually actuated supports with a semi-rigid top surface. It is also possible to adjust the surface 10' without an adjustable semi-rigid continuous top surface. It is possible to use closed pack continuous supports with an elastic interpolating top surface. They can be actuated internally or shaped externally.
  • the adaptable edge solution is in fact a 2D-pin bed allowing to provide the adjusted mould frame walls 20.
  • the number of arrayed supports below the adjustable planar surface can be e.g. 36/meter 2 .
  • a very simple solution is using a box providing the mould frame 20 as in US 4,865,783 .
  • a continuous bed of pins with a number of e.g. 10'000/meter 2 is provided on the underside of the box.
  • the advantage of the pin bed relates to the larger curvature range through the increased number of arrayed supports/pins.
  • preparation of the pin bed is more expensive.
  • Fig. 3 shows a schematic perspective view of the use of two moulds 130 and 230 fabricated according to an embodiment of the invention.
  • Said wax formwork elements 130 and 230 lean against a supportive plate 41, being part of a standard formwork back structure, comprising C-beams 42 against which the negative wax form elements 130 and 230 are positioned.
  • the exact type of standard back structure can vary widely comprising different types of steel beams, wood beams, aluminium formwork systems etc..
  • the relationship between the scaffold parts is maintained through the usual tie rods 43 extending horizontally between the scaffold parts.
  • This back structure defines - together with the internal wax formwork elements - a cavity 51 which is - for illustrations purposes - half-filled with concrete 50.
  • the embodiment according to Fig. 3 does not use any steel reinforcement parts which might be positioned inside cavity 51.
  • Fig. 4 shows a cross section of Fig. 3 showing the hollow nature of the wax form elements 130 and 230 with indentations 34. These indentations are shown in a detailed partly transparent view of the wax form work element 30 in Fig. 5 .
  • the wax used was Paramelt Argueso Maco Reclaim Wax. Said wax has a softening point of 66 degree Celsius and a melting point of 77 degree Celsius. The density is 950 kg/m 3 .
  • the surface 35 opposite to the adjustable surface 10 as well as opposite to the mould frame 20 may comprise marks from the temperature shock when the molten wax 32 is poured into the frame. This can be countered through heating the frame parts or the arrayed blocks forming the indentations 34.
  • the indentations 34 are regular since regular arrayed blocks 61 can be chosen. In order to obtain a good structural integrity, the indentations 34 have a dimension of e.g. 10 to 15 centimetres.
  • the side walls 36 forming a grid of webs on the upper side of wax form work element 30 have preferably a dimension between 2 and 5 centimetres and more preferably between 2 and 3 centimetres.
  • the minimum dimension of an edge, shown as reference numeral 37 in Fig. 5 should not be less then 5 to 10 centimetres. The ratio between the dimensions mentioned is a preferred feature and important to obtain a better structural integrity.
  • the ratio between the thicknesses of the walls 36 against the size of the indentations 34 can vary between 1 to 2 and 1 to 7, preferably between 1 to 3 and 1 to 5.
  • the walls 36 can be slightly tapered so that the angle between the bottom 38 of each indentation 34 and the adjacent walls 36 is between 90.5 to 92 degrees, preferably about 91 degrees.
  • the minimum amount of wax below the indentations 34 e.g. the distance between the bottom 38 of each indentation 34 and the lower external surface 35 should not be smaller then 3 to 5 centimetres.
  • the relevant material thickness 39 varies in portions with a high curvature. Beside the effect on the structural integrity of the wax form element 30 the use of indentations 34 separated by webs 36 also decrease the weight of the wax form element 30.
  • Every wax form element 30 depends on the concrete structure to be formed and the equipment used. Applicant has successfully tested dimension between 20 centimetres and 3 meter, especially formwork elements for 2D dimensions of about m 2 . It is possible to increase the structural integrity of the wax form elements 30 through use of integrated armature reinforcements which can provide attachment points to neighbouring wax form elements.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)
EP11004739A 2011-06-10 2011-06-10 Verfahren zum Gießen von Freiform-Betonstrukturen vor Ort Withdrawn EP2532808A1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP11004739A EP2532808A1 (de) 2011-06-10 2011-06-10 Verfahren zum Gießen von Freiform-Betonstrukturen vor Ort
PCT/EP2012/002457 WO2012167948A2 (en) 2011-06-10 2012-06-11 Method for on-site casting of free-form concrete structures

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP11004739A EP2532808A1 (de) 2011-06-10 2011-06-10 Verfahren zum Gießen von Freiform-Betonstrukturen vor Ort

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EP2532808A1 true EP2532808A1 (de) 2012-12-12

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105121135B (zh) * 2013-02-21 2017-10-13 莱恩奥罗克澳大利亚私人有限公司 用于浇铸建造元件的方法
DE102017121280B3 (de) 2017-09-14 2019-02-28 Hegerl Peter Max Karl-Heinz, Lederer Ingo Michael GbR (vertretungsberechtigte Gesellschafter: Peter Hegerl, 93138 Lappersdorf; Ingo Lederer, 93138 Lappersdorf) Möbelstück und Verfahren zu dessen Herstellung
DE102017129740A1 (de) * 2017-12-13 2019-06-13 Peri Gmbh Schalung zur Erstellung eines Bauwerks
WO2019148242A1 (en) 2018-01-31 2019-08-08 The University Of Melbourne A variable shaping form
US10857678B2 (en) 2016-03-14 2020-12-08 Danmarks Tekniske Universitet Robotic system and method for manufacturing of objects
CN112814367A (zh) * 2020-12-31 2021-05-18 武汉楚天浩瑞科技发展有限公司 一种铝框覆塑钢制建筑模板
CN116735325A (zh) * 2023-08-03 2023-09-12 成都理工大学 保持弃渣土体原状结构的取样及抗剪强度测试方法

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DE102016119365A1 (de) * 2016-10-11 2018-04-12 BigRep GmbH Modulares Schalungssystem für die Herstellung von Betonelementen
CN111398004A (zh) * 2020-04-08 2020-07-10 安徽理工大学 一种新型圆柱体混凝土模具
CN115075546B (zh) * 2022-04-15 2023-07-14 深圳天安骏业投资发展(集团)有限公司 一种清水混凝土双曲面钢模板的制作方法
CN117494294B (zh) * 2024-01-03 2024-03-19 武汉博雅宏科技有限公司 混凝土布料任务动态控制方法及系统

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Publication number Priority date Publication date Assignee Title
US4865783A (en) 1985-02-13 1989-09-12 Oy Partek Ab Method of manufacturing a reusable mold
US5375809A (en) * 1992-07-01 1994-12-27 Wallace I. Stenzel Assembly for forming a poured concrete wall construction
JP2001105420A (ja) * 1999-10-08 2001-04-17 Maeda Seikan Kk コンクリート製品の製造方法
JP2003211429A (ja) * 2002-01-18 2003-07-29 Toyo Tire & Rubber Co Ltd 型枠意匠形成部及びその製造方法
WO2008141644A2 (en) 2007-05-18 2008-11-27 Newton Concrete Aps Amorphous formwork

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4865783A (en) 1985-02-13 1989-09-12 Oy Partek Ab Method of manufacturing a reusable mold
US5375809A (en) * 1992-07-01 1994-12-27 Wallace I. Stenzel Assembly for forming a poured concrete wall construction
JP2001105420A (ja) * 1999-10-08 2001-04-17 Maeda Seikan Kk コンクリート製品の製造方法
JP2003211429A (ja) * 2002-01-18 2003-07-29 Toyo Tire & Rubber Co Ltd 型枠意匠形成部及びその製造方法
WO2008141644A2 (en) 2007-05-18 2008-11-27 Newton Concrete Aps Amorphous formwork

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
CHRISTIAN RAUN, MATHIAS K. KRISTENSEN, POUL H. KIRKEGAARD: "Flexible Mould for Precast Concrete Elements", PROCEEDINGS OF THE INTERNATIONAL ASSOCIATION FOR SHELL AND SPATIAL STRUCTURES (IASS) SYMPOSIUM 2010, 8 November 2010 (2010-11-08)
CHRISTIAN RAUN, MATHIAS K. KRISTENSEN, POUL H. KIRKEGAARD: "Flexible Mould for Precast Concrete Elements", PROCEEDINGS OF THE INTERNATIONAL ASSOCIATION FOR SHELL AND SPATIAL STRUCTURES (IASS) SYMPOSIUM 2010, 8 November 2010 (2010-11-08), XP002663251 *

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105121135B (zh) * 2013-02-21 2017-10-13 莱恩奥罗克澳大利亚私人有限公司 用于浇铸建造元件的方法
US10857678B2 (en) 2016-03-14 2020-12-08 Danmarks Tekniske Universitet Robotic system and method for manufacturing of objects
DE102017121280B3 (de) 2017-09-14 2019-02-28 Hegerl Peter Max Karl-Heinz, Lederer Ingo Michael GbR (vertretungsberechtigte Gesellschafter: Peter Hegerl, 93138 Lappersdorf; Ingo Lederer, 93138 Lappersdorf) Möbelstück und Verfahren zu dessen Herstellung
DE102017129740A1 (de) * 2017-12-13 2019-06-13 Peri Gmbh Schalung zur Erstellung eines Bauwerks
WO2019148242A1 (en) 2018-01-31 2019-08-08 The University Of Melbourne A variable shaping form
CN112814367A (zh) * 2020-12-31 2021-05-18 武汉楚天浩瑞科技发展有限公司 一种铝框覆塑钢制建筑模板
CN116735325A (zh) * 2023-08-03 2023-09-12 成都理工大学 保持弃渣土体原状结构的取样及抗剪强度测试方法
CN116735325B (zh) * 2023-08-03 2023-10-27 成都理工大学 保持弃渣土体原状结构的取样及抗剪强度测试方法

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WO2012167948A2 (en) 2012-12-13

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