NL1026233C2 - Method is for producing insulated flat concrete building components and involves the creation of an insulating layer on a base surface and a concrete pouring unit is moved from above along the base surface - Google Patents

Abstract

The method is for producing insulated flat concrete building components and involves the creation of an insulating layer (2a,2b) on a base surface and a concrete pouring unit is moved from above along the base surface. Thus concrete is poured onto the insulating layer. The poured concrete is allowed to harden to some degree and attachment occurs between the insulating layer and the concrete. Flat building components are then formed from the joined insulating layer and the concrete at cutting points crossways to the direction of movement. The insulating layer is provided with upright side walls (4a,4b) which extend at least to the height of the poured concrete. The side walls function as casting walls during the pouring of the concrete onto the insulating layer.

Description

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Brief description: Method for manufacturing insulated concrete flat building elements.

DESCRIPTION

The present invention relates to a method for manufacturing insulated concrete flat building elements comprising: - providing an insulating layer on a web, - moving a device 10 for pouring concrete at the top along the web, - during the movement of the device for pouring concrete, pouring concrete onto the insulating layer, - allowing the concrete poured onto the insulating layer to cure to some extent, whereby adhesion occurs between the insulating layer and the concrete, - distributing the thus created length of the insulating layer and concrete adhered to flat building elements by making cuts transversely to the direction of movement at the location of cut positions.

Such a method is known for manufacturing insulated channel plate floor parts. In this known manufacturing technique, which is also referred to by the term "Gleitfertiger", an insulation layer of polystyrene (EPS) is first laid on a web of, for example, 100 meters in length by sliding polystyrene sheets against each other at their ends. along this insulating layer a cart is moved which during this displacement pours concrete from different protective trays onto the insulating layer and at the same time ensures that parallel channels are created in the longitudinal direction of the path in the concrete. both longitudinal sides of the track use sliding shoes moving along with the cart of approximately 45 cm length.For pressing the concrete, the cart comprises vibrating shoes and / or vibrating feet and the like. concrete is very compact and dry in nature and therefore has a relatively high viscosity, which is necessary in advance that the concrete after: '5 passing the cart loses its shape.

The present invention has for its object to provide a method according to the preamble with which insulated concrete flat concrete elements can be manufactured with simple aids in a relatively simple manner, which building elements can inter alia form a good alternative to the known insulated channel plate floor parts, but which building elements are alternative could also perfectly serve as a roofing sheet or as a vertical (partition) wall. To this end, the method according to the invention is characterized in that the insulating layer is provided with upright side walls which extend to at least the height at which the concrete is poured, which side walls function as formwork walls during pouring of the concrete onto the insulating layer. As a result of the use of the upright side walls that function as formwork walls, there is no longer any need to use sliding formwork walls that can be used several times, as a result of which the device used for carrying out the method according to the invention can be carried out more easily. . Moreover, less compact and less viscous concrete can be used. More specifically, it is possible with the method according to the invention to manufacture building elements with a relatively low own weight, so that a considerable environmental benefit can be achieved because fewer raw materials and energy are required for the production of the building elements, while moreover the transport costs thereby be reduced.

Within the above-mentioned framework, it is preferred that the concrete is of the self-compacting type. Such concrete has a low viscosity, so there is no need to pour the concrete after pouring 1026233 "

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3 still to be pressed to obtain a good filling and density thereof.

Preferably, the insulating layer has an at least substantially 1; ,; closed bottom from which the raised side walls rise upwards i! extend. Thus, as it were, a tub is created for dumping 'I | 5 the concrete.

Further preferably, stiffening walls extend upwards from the bottom between the upright side walls. Such stiffening walls increase the rigidity of the insulated concrete flat building elements produced according to the method of the invention.

In order to enable a good laying of the building elements, if used as floor elements, the method according to the invention is preferably further characterized by providing vertical holes in the substantially closed bottom in the immediate vicinity of the cutting positions. These holes will be filled with concrete, resulting in good support points for the building elements, with support not taking place via material from the insulation layer, but via the concrete.

An important advantage of building elements manufactured according to the method according to the invention relative to insulated channel plate floor parts can be achieved if the method according to the invention providing recesses in open stiffening walls and / or in the bottom along at least a part of the circumference of a vertical passage 25 to be arranged later in a work in the building element. With the aid of such recesses, as a result of which local concrete instead of material of the insulating layer is present in the final building elements, a reinforcement can be created locally at the circumference of the vertical passage to be provided, such as a crawl hatch, whereby reinforcement on a building site 30 of the immediate vicinity of a vertical passage to be arranged in a work, for example by arranging a trimmer beam, such that 1026233-4 is usually necessary for channel plate floor parts, becomes superfluous or becomes at least less necessary.

The recesses then preferably extend transversely to the direction of movement, whereby a reinforced transverse relationship is created in the building element.

It is also preferred that the recesses are continuous vertical holes in upright stiffening walls and the bottom. The continuous nature of these holes allows maximum local reinforcement of the building elements.

For the purpose of limiting activities for providing a vertical recess in a building element in the work, it is furthermore preferred that, before the concrete is poured onto the insulation layer, spaces between upright stiffening walls and / or between an upright stiffening wall and a side wall can be filled with filling material with a lower hardness than that of the concrete. In this way it can in principle be prevented that concrete has to be drilled or sawn through in the work at a construction site, as a result of which the provision of a vertical recess in a construction element, for example for a crawl hatch, can take place simply and quickly.

Such filling material preferably corresponds to the material of the insulating layer.

In order to increase the strength of the building elements manufactured with the method according to the invention, it is preferable that before the concrete is poured onto the insulation layer, reinforcement such as preferably prestressed elements, such as cables, extending in the direction of movement, into the space which after the pouring of the concrete is taken in by the concrete, is applied whereby a compressive stress can be created in the concrete and / or larger spans can be achieved.

In order to facilitate the manipulation of the insulating layer, the insulating layer is preferably provided on the web by positioning insulating layer parts against each other. The dimensions of these insulating layer parts can be tailored to the requirements imposed on them because of manufacturability, manipulability and transport.

Although within the scope of the present invention it is quite possible to convert an insulating layer from identical insulating layer parts, the alternative can also be very advantageous if two different types of insulating layer parts are used with regard to design. In particular, one can think of an insulating layer part that extends over almost the entire length between two cutting positions and another type of insulating layer part that is applied locally at the location of the cutting positions and in which, for example, provisions such as holes are provided in the bottom, which can be advantageously as already explained above with reference to other preferred embodiments.

The invention also relates to insulated concrete flat building elements manufactured according to one method according to one of the preceding claims.

Finally, the invention also relates to an insulating layer part for use in the method according to the preferred embodiment described above, wherein the insulating layer is provided on the track by positioning insulating layer parts against each other. Such an insulating layer part is provided with upright side wall parts which, during pouring of concrete onto the insulating layer formed by insulating layer parts positioned against each other, act as formwork wall parts, wherein the side wall parts extend at least to the height at which the concrete is poured.

In order to ensure that neighboring insulating layer parts and / or building components manufactured therewith can be positioned well against each other, it is preferable that the insulating layer part is provided with a recess on one side and a complementarily formed protrusion on the opposite side. . A protrusion of one insulating layer part can thus be received in a recess of an adjacent insulating layer part. Such a connection can be used both if insulating layer parts with end faces are positioned against each other for the purpose of providing an insulating layer on a track, but also if, perpendicularly thereto, building elements are positioned laterally against each other in applied form.

The invention will be further elucidated on the basis of the description of preferred embodiments of the invention with reference to the following schematic figures:

Figure 1 shows in top view (parts of two) insulating layer parts;

Figures 2, 3, 4 show cross-sections according to II-II, III-III, IV-IV and Figure 1 respectively; Figure 5 shows in top view (parts of two) building elements;

Figures 6, 7, 8 show cross-sections according to VI-VI, VII-VII, VIII-VIII in figures 5 and 9 respectively;

Figure 9 shows in bottom view (parts of) the building elements according to Figure 5;

Figure 10 shows in top view a (part of an) insulating layer part at the location of a (later) vertical passage to be arranged in a work;

Figures 11, 12 show cross-sections according to XI-XI and XII-XII respectively in Figure 10;

Figure 13 shows in cross-section another building element manufactured according to the method according to the invention;

Figure 14 shows in cross-section the building element according to Figure 13 in applied form; and Figure 15 shows in cross-section a number of insulating layer parts positioned laterally against each other.

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Figure 1 shows two parts of insulating layer parts 2a, 2b / slid together at their end faces at the location of seam 1; ,. | (common reference number 2) of foam material such as polystyrene.

i; ! The width of each of these insulating layer parts 2 (and therefore the length of

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5 seam 1) is approximately 1.2 meters, while the length of these insulating layer parts 2 is approximately 8.0 meters. Of this length of the insulation layer parts 2 1s, therefore, per insulation layer 2 is approximately 0.8 meter visible in Figure 1.

Over the greater part of the length, the insulating layer parts 2 have a cross-section similar to FIG. 2. This cross-section shows a closed bottom with upstanding sidewalls 4a, 4b extending from bottom 3 on both longitudinal sides (common reference numeral 4). Parallel to these side walls 4, four parallel stiffening walls 5a, 5b, 5c, 5d (common reference number 5) extend between the side walls 4 from bottom 3, whereby dumping slots 6a, 6b, 6c, 6d, 6e fall between adjacent side walls 4 and stiffening walls 5. (joint reference number 6). The shape of the side walls 4 is slightly tapering towards the top. The stiffening walls 5 have a corresponding cross-section, which is otherwise not essential within the scope of the present invention. In principle it is conceivable, for example, that the stiffening walls 5 are slightly lower than the side walls 4. The shape of the pouring slots 6 corresponds to that of the side walls 4 and / or of the stiffening walls 5, albeit vice versa. Incidentally, this is also not essential within the scope of the present invention. For example, it is conceivable that the dump slots 6 are wider than the side walls 4 and / or the stiffening walls 5.

Near their two ends, the cross-section of the insulating layer parts 2 changes, as can be seen from Figures 3 and 4, which show the cross-section III-III and IV-IV in Figure 1. The stiffening walls 5 are not present at these ends, while at the end of the dump slots 6 holes 7a, 7b, 7c, 7d, 7e (collectively reference numeral 7) are present. The further closed bottom 3 is therefore somewhat open at that longitudinal position. Between the holes 7 and the associated end of the insulating layer part 2 there is still a thin protective layer 8a. 8b, 8c, 8d, 8e (common reference number 8), whereby the cross-section according to figure 4 shows a closed bottom 3.

By sliding a number of floor parts 2 against each other with their end faces, a path of, for example, 120 meters in length of insulating layer parts 2 can be obtained. It is noted here that the alternative is to use two different types of insulation layer parts instead of identical insulating layer parts 2, which are pushed against each other in a regular pattern, for example alternately. One type would then have a cross-section over the full length (of, for example, 7 meters) as shown in figure 2, while the other type of insulating layer part would correspond to the part already shown in figure 1 between the dash-dot lines 9a 9b, as a result of which seam 1 would logically be omitted and seams would be present at the location of the dash-dot lines 9a, 9b. It should be realized here that the Hjn, indicated by reference numeral 1 in figure 1, is the final dividing line where a separation, for example with a circular saw, is applied transversely to the longitudinal direction of the 120-meter-long insulating layer for distributing the length in individual insulated concrete flat building elements.

After the 120-meter-long track has been pushed against each other by insulating layer parts 2, a portal cart is moved in the longitudinal direction of the track. This portal cart comprises a funnel 11 (Fig. 6) which is provided on its underside with a number of outflow openings 12a, 12b, 12c, 12d, 12e (common reference number 12) which are at corresponding transverse positions as the respective dump slots 6. From funnel 11 which is filled with concrete of the self-compacting type, this concrete 10 is poured via the outlet openings 12 into the pouring slots 6. As a result, the pouring slots 6 and the holes 7 and other parts between the side walls 4 are made; t '' where there is no material of the insulating layer parts 2 filled with '; concrete 10 as shown in figures 5 to 8. In figure 5 the holes 7 which are not actually visible in top view are still shown with broken lines. In the bottom view according to figure 9, these holes 7 are clearly visible and filled with concrete 10. The concrete 10 in these holes 7 serves as support legs for the building elements so that they can be placed at their end ends on, for example, a foundation beam.

As soon as concrete has been poured over the full length of the insulating layer formed by insulating layer parts 2 pressed against each other, this is allowed to cure for some time until the concrete 10 has obtained sufficient dimensional stability. Subsequently, cuts are made at the location of seams 1, as a result of which separate building elements are created. When making these cuts, the screening layers 8 prevent material 10 from crumbling in the holes 7. During the hardening of the self-compacting concrete 10, an adhesion occurs between the concrete and the material of the insulating layer parts 2.

Figure 10 shows in top view a part of an insulating layer part 2 before concrete has been poured on it. The broken dashed line 13 indicates an area where a passage must ultimately be created at the construction site, for example for a crawl hatch. On two opposite sides of this region 13, a hole 14a, 14b is provided in the insulating layer part 2, both of which extend over the full height of the floor plate part 2. Between these holes 14a, 14b, the dump slots 6 are filled with filler elements 15a, 15b, 15c, 15d, 15e (common reference number 15) which have the same shape as the dump slots 6 and are made of the same material as the insulating layer part 2. Insofar as If the reinforcement wires would extend through the dump slots 6, these filler elements 15 should provide space for this.

10262333 10

After pouring concrete 10 onto the insulating layer part 2, the situation arises as shown in the cross-sections according to figures 11 and 12. The area 13 between the holes 14a, 14b is completely free of concrete 10 while the holes 14a, 14b are completely filled with concrete 10.

On the one hand, this means that a passage the size of area 13 can be made with relatively light tools in the work on location without having to go through concrete 10. The concrete 10 in the holes 14a, 14b ensures a reinforced transverse connection on the circumference of the passage, so that a separate notch can be dispensed with.

Figure 13 shows in cross-section a building element 21 comprising an insulating foam layer part 22 with a bottom 23 in which four parallel inverted T-shaped slot-shaped dump slots 24 are provided and which is provided with lost formwork edges 25a, 25b on its two opposite upper longitudinal edges. After sliding a number of insulating foam layer parts 22 together against each other and placing steel tension wires 26a, 26b (which, incidentally, could also be provided in pouring slots 6) in the pouring slots 24 and just above, concrete 27 is of the rapidly compacting type poured onto the insulating foam layer parts 22, the lost casing edges 25a, 25b of the insulating foam layer parts 22 serving as casing edges.

After the concrete 27 has hardened to a sufficient extent, the lost formwork edges 25a, 25b are broken off from the remaining part of the insulating foam layer parts 22, whereafter the resulting building elements 21 '(Fig. 14) can conversely excellently serve as roof elements 25 with the concrete 27 facing facing downwards, that is, to the interior of the building in question, while the material of the insulating foam layer parts 22 is directed upwards. A roof covering (not shown) is then applied to the insulating foam layer parts 22.

Figure 15 shows an insulating layer part 31 in cross-section with identical insulating layer parts 31 ', 31 "pushed against the longitudinal sides thereof and which are only partially visible in Figure 15. Each insulating layer part 31, which is made of EPS material, comprises at the longitudinal sides thereof have upright side walls 32 with five stiffening ribs 33 between them. reinforcement ribs 33 through which mirror 34 of the concrete has come to lie above the upper side of reinforcement ribs 33. The thickness of the upright side walls 32 is half the thickness of the individual reinforcement ribs 33. This means that the combined thickness of two upright side walls 32 of adjacent insulating layer parts 31 positioned against each other are equal to the thickness of a verse tide rib 33. On the underside of insulating layer part 31 a recess edge 35 is arranged on one longitudinal side and on the opposite longitudinal side a protruding edge 36, the shape of which is complementary to that of the recess edge 35. Thus the forms of adjacent insulating layer parts 31 ', 31 close and 31 "to each other.

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Claims (17)

Method for the production of insulated concrete. flat building elements comprising: - providing an insulating layer on a web, - moving a device for pouring concrete upwards along the web in a direction of movement, - moving the device for pouring concrete during the movement, pouring concrete onto the insulating layer, 10. allowing the concrete poured onto the insulating layer to cure at least to some extent, whereby adhesion occurs between the insulating layer and the concrete, - dividing the resulting length of the insulating layer and concrete adhered to one another flat building elements by arranging cuts at the location of cut positions transversely to the direction of movement, characterized in that the insulating layer is provided with upright side walls which extend to at least the height at which the concrete is poured, which side walls act as formwork walls during the cutting. pouring the concrete onto the insulation layer. Method according to claim 1, characterized in that the concrete is of the self-compacting type. 3. Method as claimed in claim 1 or 2, characterized in that the insulating layer has an at least substantially closed bottom from which the upright side walls extend upwards. Method according to claim 3, characterized in that upright stiffening walls extend upwards from the bottom between the upright side walls. 5. A method according to claim 3 or 4, characterized by providing vertical holes in the substantially closed bottom in the immediate vicinity of the cutting positions. 1026233- * W 6. Method as claimed in claim 3, 4 or 5, characterized by providing recesses in upright stiffening walls and / or in the; ; 1 bottom along at least a part of the circumference of a later in a work; j vertical passage to be provided in the flat building element. Method according to claim 6, characterized in that the recesses extend transversely to the direction of movement. A method according to claim 6 or 7, characterized in that the recesses are continuous vertical holes in upright stiffening walls and the bottom. Method according to one of claims 3 to 8, characterized by filling in spaces between upright stiffening walls and / or between an upright stiffening wall and a side wall, with filling material with a lower hardness, before the concrete is poured onto the insulation layer than that of the concrete Method according to claim 9, characterized in that the filling material corresponds to the material of the insulating layer. 11. Method as claimed in any of the foregoing claims, characterized by arranging, before the concrete is poured on the insulating layer, reinforcement in the space that is taken up by the concrete after pouring of the concrete. Method according to claim 11, characterized in that the reinforcement comprises prestressed elements that extend in the direction of movement. 13. Method as claimed in any of the foregoing claims, characterized in that the insulating layer is provided on the track by positioning insulating layer parts against each other. A method according to claim 13, characterized in that two different types of insulating layer parts are used with regard to design. Insulated concrete flat building element manufactured according to a method according to one of the preceding claims. 1026233 - h 16. Insulation layer part for use in the method according to claim 13 or 14 provided with upright side wall parts which, during pouring of concrete onto the insulation layer formed by insulating layer parts positioned against each other, act as cladding wall parts, wherein the side wall parts extend at least to the height at which the concrete is deposited. The insulating layer part according to claim 16, characterized by a recess on one side and a complementally formed protrusion on the opposite side. 10 1026233-