EP2956283B1 - Method for producing a multilayer, reinforced concrete element - Google Patents

Description

The invention relates to a method for producing a multilayer, reinforced concrete element, wherein the multilayer, reinforced concrete element comprises at least a first concrete wall in combination with a reinforcing body, wherein the concrete element comprises an at least indirectly applied to the first concrete wall insulating layer and wherein the reinforcing body at least partially the first concrete wall protruding and the insulating layer is formed penetrating.

STATE OF THE ART

Precast concrete plays an important role in the construction industry. In view of increasing demands on energy efficiency, precast concrete elements have been fitted with integrated insulation layers at the factory for a number of years, in particular for reinforced concrete walls and ceilings with core insulation. Mostly, however, in the almost completely automated production process, insulating board products, in particular mineral wool and polystyrene, are introduced by hand.

The EP 1 010 828 B1 shows a further production of a wall panel with an inner shell and an outer shell made of concrete, which are connected to one another via carriers of a reinforcing body. After the outer shell has been produced, PU foam is applied to the inner side of the foam, which faces upward to apply the PU foam. The complementary concrete shell is then produced by immersion in a concrete bed and subsequent curing. A defined cavity for the PU foam body is not created, and a subsequent pouring with more concrete takes place on an undefined PU insulating layer surface. The not yet cured PU foam body, which is applied as a reaction mixture, is distributed by means of an air stream. The height of the cured foam results from the applied height of the reaction mixture, the height of which is again determined by the speed of the application for a given reaction time and has an irregular topography. A structural geometric limitation of the cavity is therefore not created, so that disadvantageously no insulating layer of a defined thickness can be formed.

A similar method discloses the EP 1 106 745 A2 , Here, a method for producing a prefabricated ceiling element is described as a prefabricated component, wherein two sheets of reinforced concrete by a plurality of lattice girder are spaced from each other, and wherein the lattice girders are embedded in the respective disc and wherein the end sections comprise at least the longitudinal bars with welded strut knot, and wherein the space between the panes is completely filled with foamed polyurethane. The resulting between the two discs cavity is filled with polyurethane foam during production already. The hardened polyurethane layer should support the structural-technical function of the lattice girders and the concrete slabs. It is further stated that such a production can advantageously be carried out economically on a circulation pallet plant in production operation. The required thermal insulation is adjustable over the thickness of the polyurethane layer, disadvantageously, however, the prefabricated ceiling element can be completed only with a sandwich construction, as two spaced apart concrete disc elements are necessarily necessary to define a cavity for the input of the reaction mixture to form the polyurethane layer.

DISCLOSURE OF THE INVENTION

The object of the present invention is to provide an improved method for producing a multilayer, reinforced concrete element, and in particular the object of the invention is to be able to form the insulating layer of a PU foam, preferably with different thicknesses in a flexible manner.

The problem underlying the invention is achieved by a method according to claim 1, advantageous embodiments emerge from the dependent claims.

• Als erster Schritt kann das Bereitstellen der ersten Betonwandung mit einem Bewehrungskörper erfolgen, wobei der Bewehrungskörper teilweise in die erste Betonwandung eingegossen ist. Dies kann durch Gießen und Aushärten der ersten Betonwandung in einer Gießform erfolgen, wobei während des Gießens ein Abschnitt des Bewehrungskörpers in die Betonwandung eingegossen wird (im Folgenden: eingegossener Abschnitt), und ein weiterer Abschnitt des Bewehrungskörpers kann aus der ersten Betonwandung hervorstehen (im Folgenden: hervorstehender Abschnitt). Es folgt anschließend der Schritt des Anordnens der ersten Betonwandung und dem daran angeordneten Bewehrungskörper mit einem vertikalen Abstand der Unterseite der ersten Betonwandung über einer Schüttung, insbesondere aus Quarzsand, der zuvor in ein Schüttungsbehältnis eingegeben und beispielsweise gerüttelt oder glattgestrichen wurde. Der hervorstehende Abschnitt ist dabei unterseitig der ersten Betonwandung angeordnet ist und taucht in die Schüttung ein, wobei die Schüttung insbesondere anschließend gerüttelt werden kann. Ein vordefinierter Freiraum verbleibt dabei zwischen der Oberfläche der Schüttung und der Unterseite der ersten Betonwandung. Anschließend folgt das Auffüllen des Freiraums mit einem Reaktionsgemisch zur Bildung von Polyurethanschaum, der eine Dämmschicht bildet. Anschließend folgt der Schritt des Aushärtens der Dämmschicht. In einem abschließenden Schritt kann die Betonwandung mit dem Bewehrungskörper und der an diesem Verbund ausgehärteten Dämmschicht aus Polyurethan aus der Schüttung entnommen werden und insbesondere vom Material der Schüttung befreit werden.

According to the invention, a method for producing a multi-layer, reinforced concrete element is provided, wherein the concrete element comprises a first concrete wall in combination with a reinforcing body and has an at least indirectly adjacent to the first concrete wall insulating layer, wherein the first concrete wall via a reinforcing body, in particular a GRP or Steel reinforcement body, is connected to the insulating layer and in particular with a second concrete wall. The method according to the invention comprises the following steps:

• As a first step, the provision of the first concrete wall can be carried out with a reinforcing body, wherein the reinforcing body is partially cast in the first concrete wall. This can be carried out by casting and curing the first concrete wall in a casting mold, during casting a portion of the reinforcing body is poured into the concrete wall (hereinafter: cast-in portion), and another portion of the reinforcing body can protrude from the first concrete wall (hereinafter: prominent section). Subsequently, the step of arranging the first concrete wall and the reinforcing body arranged thereon follows with a vertical distance of the underside of the first concrete wall above a bed, in particular of quartz sand, which has been previously introduced into a bed and, for example, shaken or smoothed. The projecting portion is arranged on the underside of the first concrete wall and immersed in the bed, the bed can be shaken in particular subsequently. A predefined free space remains between the surface of the bed and the underside of the first concrete wall. This is followed by the filling of the free space with a reaction mixture to form polyurethane foam, which forms an insulating layer. This is followed by the step of curing the insulation layer. In a final step, the concrete wall can be removed from the bed with the reinforcing body and cured on this composite insulating layer of polyurethane and in particular be freed from the material of the bed.

The essence of the invention consists in particular in that the concrete wall provided with the reinforcing body, for example with integrated metallic lattice girders or fiberglass anchors for forming the reinforcement body, upside down, ie. with the reinforcing body facing downwards, placed over a preferably vibratable bedding container or the like, in which the bed of flowable solids is provided, in particular of granules of fine granularity such as quartz sand. The filling height of the bed or the height at which the concrete wall is held above the surface of the bed can be set arbitrarily. Thus, the insulating layer can be formed highly flexible with different thicknesses. The thickness of the insulating layer may for example be a value of 2cm to 40cm, preferably for example from 5cm to 30cm and more preferably for example from 10cm to 25cm, as these thicknesses can be foamed particularly well with a reaction mixture. Reaction mixtures of polyol and isocyanate are particularly suitable for the production of polyurethane insulating layers, but the insulating layer may comprise any further insulating material, for example also a phenolic resin foam.

The reinforcement body need not be made in one piece and it may, for example, individual, preferably glass fiber reinforced polymer rods or baskets form the reinforcing body. Also, so-called shear mandrels are known, so that the reinforcing body in particular can also be constructed from a Schubdornsystem consisting of steel elements or fiber-reinforced polymer elements which form the shear mandrels.

Filling the clearance with the reaction mixture may be accomplished by a flexible casting system, such as a sprue system, a rigid or oscillating casting head, or a casting mandrel arranged to be located between the concrete element and the bed surface despite the presence of the reinforcing body can be moved. Preferably, however, the casting can also be done from the side, and the reaction mixture can enter the free space. The term casting also encompasses any type of spraying or spraying of the reaction mixture.

The bed can in principle be formed by any type of flowable solids and may also comprise mixtures of different solids. The bed should be suitable to form a barrier to the reaction mixture so as to form forming, wherein the reaction mixture, which in particular comprises the components polyol and isocyanate, can foam in about horizontally flat extending free space with vertically defined height.

For this particular quartz sand has been found to be suitable. The thus created cavity forms a defined cavity with a substantially flat, parallel to the first concrete wall extending extension between the surface of the bed as the lower boundary and the underside of the first concrete wall as the upper boundary, and this cavity can in particular by means of a distribution system over the entire surface with flowable Reaction mixture or another at least phased flowable mixture are filled to form the insulating layer after curing.

Following this, the second concrete wall can be cast onto the manufactured element or the insulated first concrete wall can be immersed in the still fresh (non-set) second concrete wall, so that the end component is a reinforced concrete sandwich element with two concrete walls and the intermediate insulating layer, in particular a PU Foam core insulation results.

It has been found that the use of a rigid polyurethane foam, which can be introduced as a liquid, reactive mixture in the free space, allows significant advantages in terms of a more efficient, automated production and / or a more energy efficient, slimmer component. It can by the inventive method an automated entry a polyurethane barrier layer as a liquid reaction mixture are made possible and integrated into the entire production process.

In a first preferred embodiment, the following process step takes place after curing of the insulating layer: Insertion of the first concrete wall with the reinforcing body in a casting mold, wherein the protruding portion and the insulating layer are arranged below the first concrete wall. It can then be done filling the mold with concrete, but preferably can take place the first concrete wall in the already reinforced and freshly concreted second wall.

The casting of the concrete for the second wall is usually carried out so before inserting the already cured first wall. The result is the second concrete wall, in which the protruding portion of the reinforcing body is at least partially also cast. In this embodiment, therefore, the projecting portion protrudes downwards. The mold is delimited upwards by the concrete wall. Depending on the amount of liquid concrete, which is introduced into the mold, the free space is thus selectively filled.

Optionally, the second concrete wall can also be formed such that the second concrete wall rests against the insulating layer, at least indirectly, by completely filling the free space. So it is then in the finished product no gap between the second concrete wall and insulation layer available. Alternatively, however, it can also be provided that the free space in the casting mold between the bottom of the casting mold and the insulating layer is only partially filled with liquid concrete, so that a gap remains between the insulating layer and the second concrete wall. Such a gap can be filled with concrete, for example, later on the site.

In a second preferred embodiment, it is provided that after curing, the composite of insulating layer and the first concrete wall is inserted with the reinforcing body in the mold, wherein the protruding portion of the reinforcing body and the insulating layer is disposed above the first concrete wall. In this case, the insulating layer can form the bottom of the mold thus created. The subsequent filling of this mold with liquid concrete will then cause inevitably the second concrete wall is at least indirectly brought into contact with the insulating layer. Preferably, the composite of the first concrete wall with the reinforcing body and the insulating layer is immersed in an already filled with concrete mold with the insulating layer facing down and the concrete is then cured for this process step. In This embodiment, no gap between the second concrete wall and insulation layer is generated.

An indirect concern also means a construction in which a further layer of material is provided between the concrete wall and the adjacent insulating layer, for example an insulating film. However, should a free, in particular filled with air gap between two layers are provided, the two layers are no longer in contact with each other.

During the filling operations, the concrete walls, which may basically be plate-shaped, are oriented substantially horizontally.

PREFERRED EMBODIMENTS OF THE INVENTION

Figur 1

den ersten Teil des Herstellungsverfahrens in mehreren Schritten,

Figur 2

den zweiten Teil des Herstellungsverfahrens in einer ersten Ausgestaltung in mehreren Schritten und

Figur 3

den zweiten Teil des Herstellungsverfahrens in einer zweiten Ausgestaltung in mehreren Schritten.

Further, measures improving the invention will be described in more detail below together with the description of preferred embodiments of the invention with reference to FIGS. It shows:

FIG. 1

the first part of the manufacturing process in several steps,

FIG. 2

the second part of the manufacturing process in a first embodiment in several steps and

FIG. 3

the second part of the manufacturing process in a second embodiment in several steps.

Figure 2c shows a finished reinforced concrete element 10, which was prepared by a method according to the invention. The reinforced concrete element 10 includes an overhead arranged first concrete wall 11 and a second concrete wall spaced therefrom 12. Between the two concrete walls 11 and 12, an insulating layer 14 is provided. The insulating layer 14 is applied to the first concrete wall 11, and between the insulating layer 14 and the second concrete wall 12, a free space 20 is formed.

Figure 3c shows an alternative reinforced concrete element 10. This corresponds largely to the structure of the reinforced concrete element after Figure 2c , wherein the free gap 22 is omitted. In this respect, the insulating layer 14 is now also on the second concrete wall 12. Between the insulating layer 14 and the adjoining concrete walls can be arranged, for example, plastic films or other layers of material.

In the embodiment according to Figure 2c a reinforcing body 13 is shown in the form of a steel reinforcement basket, visible in the space 20. In the Figure 3c the reinforcing body 13 is completely enclosed by concrete or the insulating layer 14 and therefore not visible.

Based on FIG. 1 Now, a first part of the manufacturing method according to the invention will be described. In FIG. 1a the reinforcing body 13 is inserted in a first mold 17. The first mold 17 is now partially filled with liquid concrete 22. The concrete then cures to the first concrete wall 11, see FIG. 1b , A section 13 "of the reinforcing body 13 is now cast in the first concrete wall 11. Another section 13 'of the reinforcing body 13 protrudes from the first concrete wall 11.

Subsequently, the resulting element of first concrete wall (11) and reinforcing body (13) is reversed, so that the protruding portion 13 'is arranged on the underside of the first concrete wall 11. Quasi head first now the reinforcing body 13 is immersed in a bed 15 with a defined depth, which is entered into a bed of bulk material 23, see Figure 1c , The bed 15 is formed by sand, in particular by quartz sand. But it is only the reinforcing body 13 with its protruding portion 13 'immersed in the bed 15. The first concrete wall 11 remains completely above and arranged at a distance from the bed 15. There thus remains a vertical space 16 between the first concrete wall 11 and the bed 15 in the hopper 23, see Figure 1d ,

The bed 15 can be shaken by means of a vibrator. In particular, after immersion of the reinforcing body 13, the shaking of the bed 15 is useful so as to distribute the bed as evenly as possible and to obtain a flat surface as possible.

The free space 16 is now completely filled with a flowable reaction mixture, in the present example PU foam made of polyol and isocyanate. In this case, or subsequently, the reaction mixture becomes solid and forms a composite of the insulating layer 14 with the first concrete wall 11 and the reinforcing body, see Figure 1e , In FIG. 1f Now, the intermediate product is shown, which comprises the first concrete wall 11, the adjacent insulating layer 14 and the reinforcing body 13.

Based on Figures 2 (first embodiment) and 3 (second embodiment), the further processing of the intermediate product is now after FIG. 1f to the finished reinforced concrete element 10 explained. However, depending on the application already the intermediate product FIG. 1f represent a finished reinforced concrete element.

In the first embodiment, the intermediate product is inserted into a second mold 18, see FIG. 3a , The reinforcing body 13 is inserted with its protruding portion 13 'down into the second mold 18. Spacers, not shown, can ensure that the reinforcing body 13 basically has a certain distance from the bottom 19 of the casting mold 18. In FIG. 2b It can be seen that now a free space 21 between the insulating layer 14 and the bottom 19 of the mold 18 is formed. Herein, the protruding portion 13 'of the reinforcing body 13 is arranged. This space 21 is now at least partially filled with concrete 22. There remains a gap 20, since the space 21 is only partially filled. But it is also possible that the space 21 is completely filled. So then the second concrete wall 12 is brought into contact with the insulating layer 14.

In the second embodiment, the intermediate product becomes FIG. 1f inserted into the second mold 18, that the protruding portion 13 'of the reinforcing body 13 facing upward and so that the first concrete wall 11 is disposed below the insulating layer 14, see FIG. 3a , In FIG. 3b is now the intermediate after FIG. 1f shown within the second mold 18. The first concrete wall 11 rests on the bottom 19 of the second casting mold 18. Now the mold 18 is filled from above with concrete 22. Due to gravity now puts the filled concrete 22 to the insulating layer 14, so that it is not provided in this embodiment, that a gap 20 between the insulating layer and the second concrete wall 12 is formed.

It is not necessary that the filling of the casting molds 17, 18 with concrete 22 (FIG. FIG. 1a . 2b, 3b ) or the filling of the free space 16 above the bed 15 with the insulating layer 14 (FIG. Figure 1e ) has to be done after inserting the reinforcing body 13 mandatory. Rather, the reinforcing body 13 can be immersed in the already filled with concrete or the insulating layer 14 form. The casting molds can be shaking to achieve a compaction of the concrete.

The invention is not limited in its execution to the above-mentioned preferred embodiment. Rather, a number of variants is conceivable, which of the solution shown makes use even in fundamentally different versions.

LIST OF REFERENCE NUMBERS

11

10 concrete element first concrete wall

12

second concrete wall

13

reinforcing body

13 '

projecting section of the reinforcement body

13 "

cast-in section of the reinforcement body

14

damp course

15

fill

16

vertical clearance

17

mold

18

mold

19

ground

20

gap

21

free space

22

liquid concrete

23

bulk container

Claims (7)

1. Method for producing a multi-layered reinforced concrete element (10), having at least one first concrete wall (11) in composite with a reinforcement body (13), the concrete element (10) comprising an insulating layer (14) bearing at least indirectly against the first concrete wall (11), and the reinforcement body (13) being designed to project at least partially out of the first concrete wall (11) and to penetrate the insulating layer (14), comprising the following steps:

   - provision of the composite of the first concrete wall (11) with the reinforcement body (13) projecting partially out of this,

   - provision of a heap (15), in particular in an upwardly open heaping container (23),

   - arrangement of the first concrete wall (11), together with the reinforcement body (13) arranged on it, above the surface of the heap (15), in such a way that a projecting portion (13') of the reinforcement body (13) is arranged on the underside of the first concrete wall (11) and is dipped only partially into the heap (15), so that a vertical free space (16) remains between the surface of the heap (15) and the underside of the first concrete wall (11),

   - filling of the free space (16) with a reaction mixture, and

   - setting of the reaction mixture to form the insulating layer (14).
2. Method according to Claim 1, characterized by the preceding step of the casting and setting of the first concrete wall (11), wherein, by means of the casting, a portion (13") of the reinforcement body (13) is cast into the first concrete wall (11) and a further portion (13') of the reinforcement body (13) projects out of the first concrete wall (11).
3. Method according to Claim 1 or 2, characterized by the further method steps, provided after the formation of the insulating layer (14):

   - provision of a casting mold (18),

   - insertion of the composite of the first concrete wall (11), of the reinforcement body (13) projecting partially out of this and of the insulating layer (14) formed into the casting mold (18), in particular, already filled with liquid concrete, the projecting portion (13') of the reinforcement body (13) and the insulating layer (14) formed being arranged underneath the first concrete wall (11),

   - filling of the casting mold (18) with liquid concrete (22) if this is not already prefilled with concrete,

   - setting of the second concrete wall (12), into which the projecting portion (13') and the reinforcement body (13) is at least partially cast.
4. Method according to Claim 3, characterized in that, during the filling of the casting mold (18) with liquid concrete (22) and the generation of the second concrete wall (12), a free space (21) formed between a bottom (19) of the casting mold (18) and the underside of the insulating layer (14) is filled only partially with liquid concrete (22), so that a free interspace (20) is formed between the insulating layer (14) and the second concrete wall (12).
5. Method according to Claim 3, characterized in that, during the filling of the casting mold (18) with liquid concrete (22) and the generation of the second concrete wall (12), a free space (21), formed between a bottom (19) of the casting mold (18) and the underside of the insulating layer (14), in the casting mold (18) is filled completely with liquid concrete (22), so that the insulating layer (14) and the second concrete wall (12) are formed so as to bear at least indirectly one against the other.
6. Method according to Claim 1 or 2, characterized by the further method steps, provided after the formation of the insulating layer (14):

   - insertion of the composite of the first concrete wall (11), of the reinforcement body (13) projecting partially out of this and of the insulating layer (14) formed into the casting mold (18), the projecting portion (13') and the insulating layer (14) being arranged above the first concrete wall (11),

   - filling of the casting mold (18) with liquid concrete (22), as a result of which, after setting, a second concrete wall (12) is formed, the projecting portion (13') of the reinforcement body (13) being cast in at least partially and preferably completely with the concrete of the second concrete wall (12).
7. Method according to one of the abovementioned claims, characterized in that, during the operations of filling the casting molds (18), the first concrete wall (11) and/or the insulating layer (14) are/is oriented essentially horizontally.

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