RU2489254C2 - Method, device and formwork for making boards with curvilinear surface - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to construction, particularly, to production of boards with curvilinear surface. Proposed device comprises load-bearing frame composed of a set of rigid 3D carcasses with curvilinear bearing surface and rigidly interconnected by central beam. Besides it includes mounting platform coupled with said beam.

EFFECT: faster production.

7 cl, 6 dwg

Description

The invention relates to the field of construction and can be used in the manufacture of building structures of complex configuration, for example, in the construction of curved facade walls, internal non-bearing partitions of buildings and structures, and can also be used to form fences with curved generators.

Known curvilinear formwork Kvasha, where formwork is used, which gives the design curvature in three mutually perpendicular planes with sections open from above and from the side, while deck sheets are connected by stiffeners in the transverse and longitudinal directions. Using the specified formwork, it is possible to manufacture products with a curved surface (see application for invention No. 99127109, IPC 7 E04G 11/04, 2001).

The disadvantage of this formwork is the complexity in the manufacture and assembly, material consumption and inconvenience in operation. In addition, when using this formwork, it is impossible to simultaneously produce the required number of thin-walled and curved reinforced concrete structures having the same surface curvature.

Known formwork for having a rounded wall of a hollow body. The outer formwork is made up of two half-shells, and the segments forming the inner formwork have a shell made preferably of curved sheet metal, connected by parts, brackets, struts in the working position (see RF patent application No. 2004125641, IPC B28B 21/18 (2006.01), 2004 g.).

The disadvantage of this formwork is the complexity in the manufacture and assembly, material consumption and inconvenience in operation, because requires additional permutation operations when using it. In addition, when using this formwork, it is impossible to simultaneously produce the required number of thin-walled and curved reinforced concrete structures having the same surface curvature.

A known method of manufacturing a stress-reinforced domed ceiling, which uses pneumatic formwork formed by two shells of elastic material. When pouring concrete, reinforcement is used, which is installed with a bulge downward, and water is poured into the dome as it forms, providing targeted deformation of the working reinforcement. In the inner space between the layers of the reinforcement is placed sealed bags of elastic material, which are supplied with compressed air to create prestressing reinforcement (see RF patent for the invention No. 2160345, IPC 7 E04G 11/04, E04B 1/12, 2000) .

The disadvantage of this technical solution is the high complexity and material consumption. In addition, this method is intended to solve a specific problem - the construction of the domed arch of the building.

A known method of construction of domed reinforced concrete vaults using pneumatic formwork, through which the frame elements, reinforcing mesh, applied concrete are held. The exposure of the dome arch is carried out until the concrete strength is set, after which the formwork is dismantled (see RF patent No. 2213835, IPC 7 E04G 11/04, 2003).

The disadvantage of this technical solution is the high complexity and material consumption. In addition, this method is intended to solve a specific problem - the construction of the domed arch of the building.

All the technical solutions described above are intended for the manufacture of curved surfaces. However, mainly all devices and methods describe the creation of spherical or hemispherical domes of buildings.

A device and method for manufacturing concrete shells using flexible formwork are known. The specified device consists of a steel folded contour, in which the formwork itself is made of rubberized fabric. To support the entire structure, a metal support is installed, with steel threads hanging from the top to give a folded contour to the design form.

A method of manufacturing shells is that the concrete is evenly laid on a fabric formwork - a flexible formwork sags from the weight of the concrete, obtaining the first curvature. The second curvature of the shell can be imparted by the death of a freshly formed mass due to a change in the configuration of the folded contour (see "Studies of reinforced concrete, thin-walled spatial structures." Edited by V. V. Shugaev, USSR Gosstroy. NIIIZhB, 1991. p.5-37. Fig. .11a, b, p.22).

The disadvantages of this device and the method of manufacturing the shells are: the unevenness of the thickness of the product and the inability to control its thickness due to the sliding of concrete to the middle of the formwork at the time of its installation and in the future when the formwork sags until the concrete hardens, the shape of the future shell deviates from the design, because the formwork has an unstable surface in the form of a fabric surface, the upper surface of the shells is non-smooth. In addition, the resulting product does not have sufficient rigidity and strength, because the method of obtaining it does not allow reinforcing it. Another disadvantage of the known solution is the impossibility of simultaneously producing the required number of thin-walled and curved reinforced concrete structures having the same surface curvature.

A device and method for the manufacture of shells of negative curvature. The device comprises a support contour and a formwork attached to it. The contour is made in the form of a rigid spatial frame, and the formwork is made of two sheets of oriented or heat-shrinkable thermoplastic attached to the frame from the bottom and top. A method of manufacturing shells involves creating a formwork by heating oriented or heat-shrink sheet thermoplastics to a temperature of highly elastic state and subsequent cooling and laying the molding sand (see RF patent No. 2149963 IPC 7 E04G 11/04, E04G 9/10, 2000).

The disadvantages of this solution are the lack of rigidity and strength of the product, because the method of obtaining it does not allow reinforcing it. In addition, when using this solution, it is impossible to simultaneously produce the required number of thin-walled and curved reinforced concrete structures having the same surface curvature.

In the prior art there is no source closest to the proposed solution, which could be attributed to the prototype.

The problem solved by the invention is to simplify the production technology, increase the number of thin-walled panels having a curved surface and obtained simultaneously in a limited space, reduce the manufacturing time spent in terms of one panel while increasing the stiffness and strength of thin-walled curved products.

The problem is solved due to the fact that a device has been developed for the manufacture of panels with a curved surface - an arkob containing a support contour in the form of a set of rigid spatial frames having a curved support surface and rigidly interconnected by means of a central beam, with a mounting pad that is movably attached to the specified beam equipped with stops.

The assembly site consists of a set of rigid beams pivotally connected to the central beam, a set of transverse elements located on the beams with a sheet arranged on the transverse elements, made with the possibility of elastic bending.

The beams of the mounting site are interconnected at the outer ends by a rigid element that carries a stop.

The problem is also solved due to the fact that a formwork has been developed for the manufacture of panels with a curved surface - a formwork frame (cop), made in the form of strips pairwise arranged along the perimeter of the mesh frame and interconnected with a flexible separator installed between them.

The strips of formwork are made with the possibility of elastic bending.

Flexible splitter made of rope.

The problem is also solved due to the fact that a method has been developed for the manufacture of panels with a curved surface, which consists in preparing a set of formwork frames, which are sequentially installed on the mounting platform of the device in tiers, one above the other, the molding mixture is placed in each frame formwork before installing the next one, moreover, each subsequent formwork is separated from the previous one and from the installation site by laying a moisture-resistant element, then the bars of the installation site are lowered to the support loop and kept at a set of panels to complete the curing of the concrete.

The moisture resistant element is made of plastic or polyethylene.

The technical result from the use of the totality of the essential features of the new technical solution is to simplify the manufacturing process of curved panels and at the same time reduce the manufacturing time of panels spent per one panel by simultaneously producing in a limited space many thin-walled panels having a curved surface and with increased rigidity and strength. In this case, all panels have an identical curved surface.

The developed device with a curved support frame and an installation platform with stops for installing the formwork allows you to lay several formwork frames having the same geometric parameters at once, which reduces the time it takes to manufacture panels spent on one panel.

The implementation of the formwork (cop) in the form of strips in pairs located along the perimeter of the mesh frame and interconnected with a flexible separator installed between them, makes it possible to create thin-walled panels of the required curvature with increased rigidity and strength.

A flexible separator and mesh frame allow you to save the overall dimensions of concrete in the formwork when bending the latter together with the installation site and to ensure uniform thickness of the panels.

The presence of a mesh frame pairwise located around the perimeter and interconnected strips of formwork provides the possibility of installing a mesh frame to give the panels the necessary rigidity and strength.

Installing the set of formwork frames on the installation site in tiers, one above the other, laying the molding sand in each formwork frame before installing the next one with the separation of each subsequent formwork from the previous and the installation site by laying a moisture-proof element, and then changing the position of the installation platform and holding the kit panels to the complete hardening of concrete provides the opportunity to reduce the manufacturing time of panels spent in terms of one panel, due to the manufacture of one on a limited space of many thin-walled panels with a curved surface of the same specified curvature, possessing the required rigidity and strength.

Laying moisture-resistant plastic or polyethylene between each subsequent formwork to separate it from the previous one allows reducing the time it takes to manufacture panels, calculated in terms of one panel, due to the manufacture of many thin-walled panels simultaneously in a limited space. Also, the presence of moisture-resistant plastic or film provides each panel with a high quality of external surfaces, which subsequently facilitates the processing of the surface of the panel.

Due to the possibility of moving the beams of the installation site and the elastic bending of its sheet when lowering the end parts of the beams to the support contour, followed by exposure of the panel set to the complete hardening of concrete, the required surface curvature of the set of manufactured panels is achieved.

Figure 1 - General view of the device without the transverse elements of the mounting pad;

Figure 2 is a front view of the device with the formwork formwork laid on it, filled with molding sand;

Figure 3 is a view In figure 2;

Figure 4 - assembly diagram of the frame formwork (cop);

5 is a diagram of the supply of concrete;

6 is a diagram of the curvature of the panels according to the method.

In this invention, inventive devices are used for the manufacture of arched concrete products.

A device for the manufacture of panels with a curved surface - arkob (arkobeton), contains a support contour 1 in the form of a set of rigid spatial frames 2 having a curved support surface 3 and rigidly interconnected by a central beam 4. An assembly platform 5 is movably attached to the specified beam 4, equipped with stops 6.

The mounting platform 5 consists of a set of rigid beams 7 pivotally connected to the central beam 4. A set of transverse elements 8, made for example of boards or other material having rigidity, is laid on the beams 7. On the transverse elements 8 is a sheet 9, made with the possibility of elastic bending.

The beams 7 of the installation site are interconnected at the outer ends 10 by a rigid element 11 supporting the stop 6, which allows not only to give the installation site the necessary rigidity and stability, but also to ensure smooth and simultaneous lowering of all the beams 7 of the site in the process of making the panels curvilinear.

The formwork frame 12 (cop) for the manufacture of panels with a curved surface is made in the form of strips 13-1, 13-2, arranged in pairs along the perimeter of the mesh frame 14. The upper 13-1 and lower 13-2 strips are interconnected, for example, by screws 15. Between the strips 13-1, 13-2 installed a flexible separator 16 made of rope. Flexible separator 16 together with the formwork strips 13-1, 13-2 determine the thickness of the panel. Strips 13-1, 13-2 of the formwork are made with the possibility of elastic bending.

The size of the formwork frame 12 corresponds to the dimensions of the poured panel.

The strips 13-1, 13-2 of the frame formwork can be made of plywood or other material having strength and at the same time the possibility of elastic bending.

A method of manufacturing panels with a curved surface is carried out using the above devices (arkob and cop) (see Figure 4). The method consists in preparing a set of frame formwork (cops) 12 on a separate conductor. A moisture resistant element 17 made of plastic or polyethylene is laid on sheet 9 of the mounting pad 5 of the arkob. Then, the formwork frame 12 is alternately sequentially installed on the installation site of the device in tiers, one above the other. In each of the cops 12, after laying it on the mounting pad 5, the molding mixture is poured before the installation of the subsequent cop. Each subsequent cop 12 is separated from the previous one by a moisture-resistant element 17. After the prepared number of cops 12 is installed and filled with molding sand, the stops 6 of the mounting pad are removed and the outer ends 10 of the beams 7 of the mounting pad are gradually lowered to the frames 2 of the supporting circuit 1. As a result, the sheet 9 with the cops laid on them 12 lies on the curved surface of the frames 2 of the support contour 1. In this position, the system is fixed and the set of panels is held until the concrete is completely hardened.

The method is carried out using the described device and the formwork frame as follows.

Assembly of cops (see figure 4).

1. On a solid even base, lay the lower layer of the formwork - the lower strips 13-1, the size of which corresponds to the dimensions of the poured panel.

2. Next, lay a metal mesh - mesh frame 14 and fix it on the lower strips 13-1 of the formwork.

3. Along the contour of the lower strips 13-1 of the formwork, a flexible divider 16 is laid in two rows along the entire perimeter.

4. The upper strips 13-2 of the formwork are laid on top.

5. The upper strips 13-2 are attracted to the lower strips 13-1 with self-tapping screws 15, tightly tightening the entire structure of the cop.

The assembly of the first cop is over.

On a separate conductor (conditionally not shown), the number of cops required for one filling is made.

Next, the assembly and installation of arkob - a device for implementing the method.

Arkob is assembled from two elements.

1. Assemble the support contour 1, rigidly interconnecting by means of the central beam 4 and the lower longitudinal and transverse connecting elements rigid spatial frames 2 having a curved supporting surface 3.

2. A set of rigid beams 7 is attached to the central beam 4 on hinged loops. The beams 7 are fixed to the beam 4 in the spaces between the frames 2.

3. The beams 7 of the mounting pad are interconnected at the outer ends 10 by a rigid element 11 supporting the stop 6 and the beams 7 are installed in a horizontal position by setting the stop 6 in a vertical position.

4. A set of transverse elements 8, made for example of boards or other material having rigidity, is laid on the beams 7, onto which then a sheet 9 made with the possibility of elastic bending and a moisture-resistant element, for example, a polyethylene film 17 are laid (see Fig. 2, 3).

The prepared arkob is installed on a solid, level base.

Concrete pouring (see figure 4).

1. On the installation site 5 lay the first (lower) cop (frame-formwork 12). The device is ready to receive the molding mixture 18, for example, concrete. Concrete is poured into the finished formwork frame (cop) 12.

2. The concrete mixture is compacted and leveled with a vibrorail 19.

3. Excess concrete is removed from the cop.

4. A layer of moisture-resistant plastic or polyethylene is laid on top of concrete. The manufacturing step of the first panel is completed.

5. In the second step, a second cop is set on top of the first cop, similar to the bottom, and the filling process is repeated.

After the pouring of the second cop is completed, the third, fourth, etc. the cops.

Giving curvature.

Upon completion of the process of filling the set of panels, the mounting platform is lowered 5. To do this, the stops 6 and the outer ends 10 of the beams 7 of the mounting platform, joined by a rigid element 11, are removed, slowly lowered to the gradual sequential support of the transverse elements 8 and the mounting plate 9 on the curved surface of the support contour 1 arkoba. The beams 7 after lowering the mounting pad 5 are located below the level of the curved surface of the support contour 1. The edges of each cop (frame-formwork 12) are bent under their own weight, slipping relative to each other. Concrete in cops, bending, retains its overall dimensions due to the flexible separator. After the installation site 5 is completely lowered, the structure is fixed and remains in this position until the concrete mixture has completely hardened. To prevent the evaporation of water and the formation of cracks, the entire system is closed with a plastic film.

Upon reaching the strength of concrete, strips 13-1, 13-2 of the formwork of the cops are disassembled, starting with the top cop. The mesh frame remains poured with concrete in the panel. Finished panels are alternately removed by a crane and brought to the required mounting position.

Used properties of materials.

1. Liquid concrete (like all liquids) is practically incompressible.

2. Liquid concrete until the end of the hydration process (2-3 hours) does not change its properties.

3. Moisture-resistant plastic does not swell on contact with liquid concrete and preserves the surface plane of the future panel.

4. By lowering the cement milk in the lower part of the panels and protruding excess moisture on the upper part of the panels, the moisture-resistant element adheres to the lower part of the corresponding panel, easily separating from the upper part of the lower located panel.

Advantages of the proposed method of horizontal monolithic casting of reinforced concrete structures over existing methods of cassette casting at concrete plants:

1. The lack of expensive formwork and cassettes.

2. The lack of expensive and complex mechanisms for supplying concrete.

3. No need for concrete with increased ductility.

4. There is no need to use steaming chambers.

Purpose - the manufacture of building structures of complex configuration.

The method is simple, reliable, provides high-quality manufacturing of panels with a curved surface, with the necessary rigidity and strength. The device is easy to manufacture, convenient to operate, does not require large material and labor costs for its manufacture, and provides panels with a curved surface that have the necessary rigidity and strength in any conditions, on any construction sites, from any forming materials.

The device and formwork can be made using the simplest available materials inexpensive.

When implementing the method there is no need to use expensive equipment.

The method was tested at the experimental site. As a result of applying the method, durable panels were obtained having a curved surface of the same curvature.

Claims (7)

1. A device for the manufacture of panels with a curved surface — an arkob containing a support contour in the form of a set of rigid spatial frames having a curved support surface and rigidly interconnected by means of a central beam, with a mounting platform movably attached to said beam equipped with stops. 2. The device according to claim 1, characterized in that the mounting platform consists of a set of rigid beams pivotally connected to the central beam, a set of transverse elements located on the beams with a sheet arranged on the transverse elements, made with the possibility of elastic bending. 3. The device according to claim 1, characterized in that the bars of the installation site are interconnected at the outer ends of the rigid element bearing the emphasis. 4. Formwork for the manufacture of panels with a curved surface - a formwork frame (cop), made in the form of strips in pairs located along the perimeter of the mesh frame and interconnected with a flexible separator installed between them. 5. The formwork according to claim 4, characterized in that the strips of formwork are made with the possibility of elastic bending. 6. A method of manufacturing panels with a curved surface using the device according to claim 1, which consists in preparing a set of formwork frames, which are sequentially installed on the mounting platform of the device in tiers, one above the other, the molding mixture is laid in each formwork frame before installation of the next, each subsequent formwork is separated from the previous one and from the installation site by laying a moisture-resistant element, then the bars of the installation site are lowered to the support contour and the panel block is held to complete the curing of the concrete. 7. The method according to claim 6, characterized in that the moisture-resistant element is made of plastic or polyethylene.

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