NL1029468C2 - Method for preparing pile for building, involves pouring concrete into mold arranged with polystyrene foam such that foam is enclosed by concrete, and curing concrete, partially - Google Patents

Abstract

The method involves arranging a polystyrene foam (4) and fixing elements (2) extending in longitudinal direction, in a mold (1). The concrete (7) is poured into the mold such that the foam is enclosed by concrete, and the concrete is partially cured. An independent claim is included for pile.

Description

METHOD FOR MANUFACTURING A PIPE WITH

FILLING ELEMENTS

The present invention relates to a method for manufacturing a pile; available on a pile with this method and on a pile.

i

The use of piles for supporting buildings has been known in the prior art for a long time. Piles that are currently being used can be manufactured in an efficient manner by pouring concrete into a mold, which mold gives the desired shape to the pile. The use of a mold offers advantages in that it is a relatively simple way of manufacturing piles. The disadvantage of this method for manufacturing piles is that only solid piles can be manufactured. These massive piles are relatively heavy and must be provided with relatively heavy longitudinal reinforcement. This means that the transport costs are relatively high.

Furthermore, from a structural point of view, not all concrete that is present in the solid concrete pile is necessary. Particularly a part of the concrete that is located around the core, that is to say the center of the pile could be constructively removed and removed! replaced by another material, preferably a lighter and / or cheaper material.

To date, however, there is no practical method available for manufacturing such piles. This has the consequence that, from a structural point of view, too much material is used to manufacture a pile, which has an unfavorable effect on the production costs and the transport costs of the pile. Furthermore, it also leads to a higher environmental impact.

1029468 3 '2

The present invention has for its object to provide a solution to the above-mentioned problems.

To that end, a first aspect of the present invention relates to a method for manufacturing a pile comprising the steps of: i) mounting a substantially fixed filling element and of at least one positioning means for positioning the filling element in a mold the mold; ii) pouring concrete into the mold such that the filling element is substantially enclosed by the concrete; iii) allowing the poured concrete to cure at least partially.

An advantage of this method is that a pile with an acceptable structural strength can be manufactured in which less concrete has to be used than with a conventional solid pile. This has a favorable effect on the production costs of the pile as well as on the environmental impact due to the production process.

By means of the positioning means it is possible to position the filling element at a desired position. The filling element is preferably positioned such that it is centrally located in the pile to be formed.

The positioning means preferably comprises a fixing element extending in the longitudinal direction of the mold, wherein during filling of step i) the filling element is arranged on the fixing element. By using a j | Such a fixing element makes it possible to easily and easily

quickly, preferably centrally with the pile to be formed, I

to fit the filling element in the mold. This has a favorable effect on, among other things, the production costs of the pile.

It is furthermore preferred if the positioning means comprise at least one spacer, the filling element being positioned before or during the execution of step ii) of the method according to the invention.

An advantage of the use of such spacers is that the filling element can be positioned relatively quickly and easily at the right place in the pile to be formed. Due to the presence of the spacers, which are preferably made of plastic, the filling element can be positioned during the pouring of the concrete. The pouring of the concrete will generally cause the filling element to float, or at least move to the top of the mold. By applying! spacers in the mold, this upward movement of the filling element is stopped and the filling element is positioned. A plurality of spacers are preferably used for positioning the filling element.

It is preferable if the spacer is attached to the reinforcement of the pile to be formed.

Hereby it is particularly advantageous when it is attached to longitudinal reinforcement of the pile. Furthermore, it is also possible for the spacers to be (removably) attached to the mold or a mold overlap that extends over the top of the mold. Such a mold overflow preferably comprises a metal plate.

It is further preferred if the positioning means substantially center the filling element in the pile to be formed. A pile pile is hereby obtained which very well absorbs the forces during, among other things, the pile-driving. Furthermore, less concrete is required that leads to reduced production costs and a reduced environmental impact.

1029468> * 4

The filling element is preferably made of material with a lower specific gravity than cured concrete. An advantage of this is that the pile is relatively light, which has a favorable effect on the transport costs of the pile.

It is preferable if the filling element extends substantially over the entire length of the mold. The advantage of this is that even less concrete needs to be used. This has a favorable effect on production costs as well as on the environmental impact.

Furthermore, it is preferred if the filling element is elongated in shape.

Furthermore, it is preferable if the filling element comprises separate parts. The advantage of this is that persons involved in manufacturing the pile can relatively easily attach the filling element, at least the individual parts thereof, to the fixing element. Furthermore, the filling element is then relatively easy to transport. This is particularly preferred when the pile is relatively long.

By means of the fixing element it is possible to position the filling element in the mold such that the filling element is centered in the pile to be formed.

The fixing element preferably comprises a mild steel rod, a prestressed steel wire or a prestressed plastic wire.

The filling element is preferably arranged at a distance from a first end and / or a second end of the mold, such that at least one solid end of the pile is formed when pouring the concrete. The advantage of this is that in this way a solid head and / or foot of the pile is obtained that can withstand relatively large loads during the pile-driving. An additional 1029468 * 5 advantage is that no soil can penetrate the pile during the pile driving.

Furthermore, it is preferable if longitudinal reinforcement is provided in the mold for carrying out step ii) of the method according to the invention, such that the longitudinal reinforcement is incorporated in the concrete. Such longitudinal reinforcement ensures that the chance of the pile breaking during transport and pile driving is reduced.

In a preferred embodiment, spiral reinforcement is applied to at least one end of the mold.

By applying such spiral reinforcement, the end of the pile is more resistant to the relatively large loads during the pile driving.

Furthermore, it is preferable if a reinforcement band extending along the inner circumference of the mold is provided on at least one end of the mold. Such a reinforcement band is preferably made of metal. An advantage of such a belt is that it can be placed in the mold relatively easily. An additional advantage is that the belt 20 can also be applied after the pile has hardened.

A further advantage of such a belt is that a head or a foot is obtained which can withstand the relatively large loads during the driving.

It is furthermore preferred if the filling element 25 comprises plastic material, ceramic material or light concrete.

In a preferred embodiment, the filling element comprises a plastic foam material, preferably polystyrene foam. The advantage of using foam material is that, on the one hand, it has a very low specific gravity and, on the other hand, offers relatively much strength.

This makes it possible to use piles with a very low 1029468! to produce a weight of 6 which has a favorable effect on the transport costs.

The filling element preferably comprises a tube. The advantage of such a filling element is that it is relatively strong, as a result of which relatively much concrete can be poured without being compressed. Furthermore, relatively little material is needed to manufacture a filling element with a relatively large size.

In a preferred embodiment, the filling element is a tube in which at least a part of the inside of the tube is provided with a fastening element extending over the inside diameter of the tube. Hereby it is preferred if the fixing element comprises a plastic foam material, such as polystyrene foam. The fixing element can then be arranged on the fixing element such that the tube is positioned.

Furthermore, it is preferable if the fixing element is removed after or during the execution of step iii).

A second aspect of the present invention relates to a pile available with the method described above.

A third aspect of the present invention relates to a pile comprising a hardened concrete casing and a core extending in the longitudinal direction of the pile, which core comprises a fixed filling element.

The advantage of such a pile is that it comprises relatively little concrete. As a result, the cost price of such a pile is relatively low. Furthermore, the environmental impact of such a pile is less since it comprises less concrete than a solid pile.

1029468 7 I * »*!

It is preferred if the filler element has a substantially circular cross-section.

Furthermore, it is preferred if the filling element is rod-shaped.

In a preferred embodiment the filling element is provided with a slot extending in the longitudinal direction of the filling element for arranging the filling element on the fixing element. The slot preferably extends to or beyond the center of gravity of the filling element.

It is preferred here that the slot width is smaller than the transverse dimension of the fixing element. The advantage of this is that the filling element can be applied relatively easily to the fixing element, and can be turned more easily if necessary. Near the end of the slot, the slot width is preferably larger than the transverse dimension of the fixing element. The filling element can hereby be applied even more easily to the fixing element and be held in the desired position.

It is preferred if at least one end of the pile is provided with a concrete valve. The advantage of such a valve is that a head and / or foot of the pile is obtained that can withstand relatively large loads during pile-driving. An additional advantage is that no soil can penetrate the pile during the pile driving.

Furthermore, it is preferable if the core is provided with a fixing element extending in the longitudinal direction of the pile. The advantage of such a fixing element is that it can be used as an earth rod / earth wire for, for example, an electrical system.

1 0294 6 8 8 * * i

Mentioned and other features of the method for manufacturing a pile and the pile according to the invention will be further elucidated hereinafter on the basis of a number of exemplary embodiments which are only given by way of example without the invention being thereby considered to be limited . Reference is hereby made to the accompanying drawings in which:

Figure 1 shows a view of a mold for manufacturing a pile according to the invention; Figure 2 shows a view of the mold of Figure 1, wherein a filling element is provided for manufacturing a pile according to the invention;

Figure 3 is a plan view of the pouring of concrete into the mold of Figure 2; Figure 4 is a view of a pile according to the invention;

Figure 5 shows a cross-section along the line IV-IV of the pile of Figure 4;

Figure 6 shows in cross-section a pile according to an embodiment of the invention;

Figure 7 is a view of a pile according to the invention;

Figure 8 shows a cross-section along the line VIII-VIII of the pile of Figure 7; Figure 10 shows a view of a pile according to an embodiment of the invention.

Figure 11 shows a cross-section of the pile of Figure 10.

Figure 12 shows a view of a pile according to an embodiment of the invention.

Figure 13 shows a cross-section of the pile of Figure 12.

1 0294 6 8> 9

Figure 14 shows a top view of a mold for manufacturing a pile according to the invention.

Figure 1 shows a view of a mold 1 for manufacturing a pile according to the invention. On the inside of the mold 1 a fixing element 2 is arranged in the longitudinal direction for fixing a filling element 4 (not shown). Furthermore, the mold 1 is provided with longitudinal reinforcement 3 extending in the longitudinal direction of the mold 1. This longitudinal reinforcement 3 ensures that the risk of breaking of the pile is reduced during transport and driving.

Figure 2 shows the mold of Figure 1, wherein a filling element 4 of preferably polystyrene foam is arranged around the fixing element 2. The filling element 4 is provided with a slot 5 over its entire length. Through this slot 5 it is possible to slide the filling element 4 over the fixing element. The slot 5 extends at least beyond the center of gravity 6 of the filling element. In order to ensure that the filling element 4 does not come loose from the fixing element 2 during pouring of the concrete 7 (not shown), the filling element is rotated such that the opening 8 of the slot 5 faces the top of the mold 1.

Figure 3 shows the pouring of concrete 7 into the mold 1. The pile is given the desired shape by means of the walls 9 and 10 and the bottom 11 of the mold. Possible shapes include square, pentagonal, hexagonal, octagonal or round. The longitudinal reinforcement 3 and the filling element 4 are completely surrounded by the concrete 7 during pouring. The fixing element 2 hereby ensures that the filling element 4 does not move to the top of the mold. The pouring of the concrete 7 continues until the upper edge of the walls 9 and 10 is reached. The whole is then allowed to cure for some time. The mold is optionally provided with a mold cover 5 (not shown) extending along the top of the mold

Figure 4 shows a pile 12 according to the invention. The pile 12 is provided with a filling element 13 extending in the longitudinal direction of the pile, the filling element being enclosed by a casing 14 of hardened concrete. The filling element 13 consists of a number of separate parts 13a and 13b, as a result of which the filling element could be fitted relatively easily during the manufacture of the pile 12.

The fixing element 15 which has served to hold the filling element 13 in place is visible. However, it is possible to remove this fixing element 15 during or after hardening of the pile 12. The pile 12 is further provided with longitudinal reinforcement 16 in order to ensure that the chance of the pile 12 breaking during transport and pile driving is reduced.

Figure 5 shows a cross-section of the pile 12 from

Figure 4. Here the filling element 13 is enclosed by a concrete jacket 1. The longitudinal reinforcement 16 is included in this concrete jacket. The filling element 13 is provided with a slot 17 which extends to the center of gravity 18 of the filling element. The filling element 13 rests against the fixing element 15. During the manufacture of the pile 12, the fixing element 15 and the filling element 13 are positioned such that the filling element 13 is centrally located in the pile 12. Furthermore, optional spacers 19 are indicated which further contribute to keeping the filling element 13 at the desired position during the production of the pile 12. However, the use of only one fixing element 15 is also possible.

Figure 6 shows an embodiment of the invention in which spacers 20 and 21 are used for positioning the filling element 52 during the manufacture of the pile 23. The spacers 20 are connected to the longitudinal reinforcement 24 which extend in the longitudinal direction of the pile 23 . During the manufacture of the pile 53, the spacer 21 has been connected to a mold overlay that was arranged on the top of the mold 25 (not shown). Optionally the spacers 20 can be used separately or separately spacer (s) 21. However, it is preferable to use them together.

Figure 7 shows a preferred embodiment of a pile 26 according to the invention. The pile 26 is provided with a filling element 27 which is located in the core of the pile 26. This filling element 27 is hereby surrounded by a concrete casing 28. This filling element 27 consists of a tube 29, preferably made of plastic, which is provided at one end with a fixing element 31 extending along the inner wall 30 of the tube. This fixing element 31 is preferably made of plastic foam material. The fastening element 31 herein sits tightly against the inner wall 30 of the tube 29. By making use of such an arrangement it is possible to position the tube 29 centrally in the pile 26 by being fitted around the fixing element 32. The pile 26 is furthermore provided with longitudinal reinforcement 33 which extends into the concrete casing 28.

Optionally to further guarantee that the tube 29 is held centrally in the pile to be formed during the manufacture of the pile 26 and spacers 34 and / or 12 are arranged. . The spacers 34 are attached to the longitudinal reinforcement 33 of the pile 26, the spacer 35 was connected to the mold and / or mold wrap (not shown) during the manufacture of the pile. During the manufacture of the pile 26, the tube 29 comes to lie against these spacers 34 and / or 35, as a result of which the tube 29 can be precisely positioned.

Figure 8 shows a cross-section of the pile 26 of Figure 6. The tube 29 is centrally located in the pile 26. In order to keep the tube 29 in place during manufacture, a fastening element 31 is arranged in the tube 29. This fixing element 31 is arranged around the fixing element 32. The tube 29 is surrounded by a sheath 28 of hardened concrete. Longitudinal reinforcement 33 is provided in this casing 28 for extra strength during transport. Furthermore, spacers 34 and / or 35 are included in the concrete casing 28. These spacers 34 and / or 35 are used during manufacture to position the tube 29 centrally in the pile 26.

Figure 9 shows a pile 36 according to an embodiment of the present invention. The filling element herein comprises a tube 37 of preferably plastic. The tube 37 is enclosed by a concrete jacket 38. Longitudinal reinforcement 39 is included in this concrete jacket 38. This longitudinal reinforcement 39 extends in the longitudinal direction of the pile 36 and reduces the risk of breakage of the pile 36 during transport and pile-driving. Furthermore, spacers 40 and 41 are provided. These spacers 40 and / or 41 are used during the manufacture of the pile 36 to position the tube 37 centrally in the pile 36.

Figure 10 shows a driven pile 42 according to the invention. This pile 42 is open at the top such that the filling element 43 which is centrally located in the pile 42 can be observed. This filling element 43 is surrounded by a concrete casing 44. In order to provide additional rigidity of the head and or the base of the pile, the upper end 5 and / or the lower end of the pile is provided with a circumference of the pile 42. extending reinforcement band 45.

Figure 11 shows a section of the pile 42 of Figure 10. The pile 42 herein comprises a filling element 43 which extends along a fixing element 46. The filling element 43 is surrounded by a concrete jacket 44 in which longitudinal reinforcement 47 is included. However, the head of the pile is open, at least the filling element 43 is visible from the outside. In the head, near the end of the pile, a reinforcement band 45 extending along the periphery 15 of the pile is provided.

Figure 12 shows a preferred embodiment of the present invention. The pile 48 herein comprises a concrete valve 49 (not shown) which ensures that a solid head 50 and / or foot is formed. The pile is furthermore provided with a concrete jacket 51

Figure 13 shows in cross-section the pile 48 of Figure 12. The pile 48 is provided with a solid head 50 and a concrete shell 51 which is provided with longitudinal reinforcement 52. Furthermore, a filling element 53 extends in the longitudinal direction of the pile 48. The concrete valve 54 is preferably integrated with the concrete casing 51 of the pile 48. Because of this solid head 50, the pile 48 is more resistant to the relatively large forces during the pile driving.

Furthermore, the pile 48 in the head 50 and / or the foot is preferably provided with so-called spiral reinforcement 54. This spiral reinforcement 54 makes the head 50 even more resistant to the large forces during the pile driving.

Figure 14 shows a long mold 55 in which the mold is divided into a number of sub-jigs 56. The sub-jigs 56 are separated from each other by means of end faces 57. By using such a long jig 55, several concrete piles can be batched manufactured.

Longitudinal reinforcement 58 and filler elements 59 are provided in sub-jigs 56. These filler elements are positioned with the aid of a fixing element 60 (not shown).

1 0294 6 8

Claims (44)

A method for manufacturing a pile, the method comprising the steps of: i) inserting a filling element in a mold and of at least one positioning means for positioning the filling element in the mold; ii) pouring concrete into the mold such that the filling element is substantially enclosed by the concrete; iii) allowing the poured concrete to cure at least partially. 2. Method as claimed in claim 1, wherein the positioning means comprises a fixing element extending in the longitudinal direction of the mold 15 and wherein the filling element is arranged on the fixing element during the execution of step i). 3. Method as claimed in claim 1 or 2, wherein the positioning means comprises at least one spacer, the filling element being positioned before or during the execution of step ii). 4. Method as claimed in claim 1, wherein the positioning means comprise at least a first and second positioning means, and wherein the first positioning means comprises a fixing element extending in the longitudinal direction of the mold and wherein the second positioning means comprises a spacer. 30 A method according to claim 1, 3 or 4, wherein the spacer is attached to the wall of the mold. 1 0294 6 8 Method according to claim 1, 3 or 4, wherein the spacer is attached to reinforcement of the pile to be formed. Method as claimed in any of the claims 1-6, wherein the positioning means substantially center the filling element in the pile to be formed. 8. Method as claimed in any of the claims 1-7, wherein the filling element has a lower specific gravity than cured concrete. 9. Method as claimed in any of the claims 1-8, wherein the filling element extends substantially over the entire length of the mold. The method of any one of claims 1-9, wherein the filler element is elongated in shape. The method of any one of claims 1-10, wherein the filler element comprises separate parts. 12. Method as claimed in any of the claims 1-11, wherein the filling element is arranged at a distance from a first end and / or a second end of the mold, such that pouring the concrete at least one solid end of the pile is formed. 13. A method according to any one of claims 1-12, wherein longitudinal reinforcement is provided in the mold for performing step iii) in the mold. I 1029468 A method according to any one of claims 1-13, wherein spiral reinforcement is applied to at least one end of the mold. A method according to any one of claims 1-14, wherein a reinforcing band extending along the inner circumference of the mold is provided on at least one end of the mold. 16. Method as claimed in any of the claims 1-15, wherein the fixing element comprises a mild steel rod, a prestressed steel wire or a prestressed plastic wire. 17. Method as claimed in any of the claims 1-16, wherein the filling element comprises plastic material, ceramic material or cardboard. A method according to claim 17, wherein the filling element comprises a plastic foam material, preferably polystyrene foam. 20 A method according to claim 17 or 18, wherein the filling element comprises a tube. 20. Method as claimed in any of the claims 1-19, wherein the filling element is a tube and wherein at least a part of the inside of the tube is provided with a fixing element. 21. Method as claimed in any of the claims 1-20, wherein after or during performing of step iii) the fixing element is removed from the pile. 1029468 * » The method of any one of claims 1-21, wherein the filling element is substantially solid. 23. Method as claimed in any of the claims 1-21, wherein the filling element is substantially liquid. Piling pile comprising a hardened concrete shell and a core extending in the longitudinal direction of the pile, which core comprises a substantially fixed filling element. 10 Pile according to claim 24, wherein the filling element has a substantially circular cross-section. 26. Pile according to claim 24 or 25, wherein the filling element is rod-shaped and is provided with a longitudinally extending slot for arranging the filling element on the fixing element. 27. Pile according to claim 26, wherein the slot width is greater than the transverse dimension of the fixing element. Pile according to claim 26 or 27, wherein the slot extends beyond the center of gravity of the filling element. 25 Pile according to one of claims 24 to 28, wherein the filling element has a lower specific gravity than cured concrete. Pile according to any of claims 24-29, wherein the filling element comprises plastic material, ceramic material or cardboard. 1 0294 6 8 »» Pile according to claim 30, wherein the filling element comprises a plastic foam material, preferably polystyrene foam. Pile according to claims 30 or 31, wherein the filling element comprises a tube. j Pile according to any of the claims 24-32, wherein the filling element is a tube in which at least a part of the inside of the tube is provided with a fixing element. 34. Pile according to one of claims 24-33, wherein the filling element extends substantially over the entire length of the pile. Pile according to one of claims 24 to 34, wherein the filling element is elongated in shape. A method according to any of claims 24-35, wherein the filling element is centered in the pile. Pile according to one of claims 24 to 36, wherein the filling element comprises separate parts. 25 Pile according to one of claims 24-39, wherein at least one end of the pile is provided with a concrete valve. Pile according to one of claims 24 to 38, wherein the concrete shell is provided with longitudinal reinforcement. 1029468 * * · » 40. Pile according to one of claims 24-39, wherein at least one end of the concrete shell is provided with spiral reinforcement. Pile according to one of the claims 24-30, wherein at least one end of the mold is provided with a reinforcing band extending along the inner circumference of the mold. 42. Pile according to one of claims 24-41, wherein the core is provided with a fixing element extending in the longitudinal direction of the pile. Pile according to any of claims 24-42, wherein the fixing element comprises a mild steel rod, a prestressed steel wire or a prestressed plastic wire. Pile-driven pile available according to the method of one of claims 1-23. 1 02946 8