RU2718743C2 - Method and device for manufacturing of concrete hollow elements - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to method and device for production of concrete hollow elements, in particular, for production of parts of prefabricated elements, such as ceilings or walls. Proposed method comprises furnish of tray, installation of elements of moulding on tray, transportation of tray to reinforcement station where tensioning wires are laid and pre-tensioned in space defined by tray and elements of formwork. At that, at the stage tension wires are fixed in a tension stop, which to create preliminary tension moves relative to the tray in the first direction, indicating from the manufactured concrete hollow element. After creating pre-tension in tension wires between tension stop and tray, at least one retaining cantilever and/or at least one hydraulic punch is inserted. Tray is transported to the concreting station, wherein at least one first concrete layer is poured into the space defined by the tray and the formwork elements. Rod elements are inserted into the space defined by the tray and the formwork elements. At least one other concrete layer is poured into the space defined by the tray and the formwork elements. Pallet is transported to hardening station where concrete hardens. Tray is transported to the detachment station, in which tensioning wires, in particular, simultaneously, are detached. Device has at least one cleaning station, at least one formwork station, at least one reinforcement station, at least one concreting station, at least one hardening station or hardening chamber and at least one decanting station. Besides, the device also contains transportation device for transfer of trays between separate stations.

EFFECT: technical result is higher efficiency of prefabricated units’ parts production.

7 cl, 5 dwg

Description

The invention relates to a method and apparatus for the manufacture of concrete hollow elements, in particular for the manufacture of parts of prefabricated elements, such as ceilings or walls.

Concrete ceiling slabs are known from DE 10 2013 214 058 A1 and DE 71 39 155 U, which have substantially symmetrically formed, often cylindrical voids extending along the ceiling plate, as well as reinforcing elements that are prestressed and weakly reinforced. Typically, such ceilings from hollow elements are produced endlessly, for example, by continuous casting, in which either the extruder screws compress the concrete in the production line and create hollow contours, or the concrete mixer compresses the concrete in the production line above the core elements that create the contours of voids from negative forms. Ceilings from hollow elements are produced in a continuous process, while the continuous billet obtained by continuous casting is most often sawn into segments with a given length using a saw. The disadvantage of the continuous continuous casting method is that a significant amount of waste is obtained, transverse reinforcing bars, recesses, embedded parts or connecting elements in the transverse direction, and also protruding beyond the concrete part of the reinforcement, cannot be produced at high costs only.

Based on this, the object of the present invention is to provide a method and apparatus with which, in particular, avoiding the above disadvantages, it is possible to efficiently produce prestressed concrete hollow elements.

This problem is solved using the method with the features of claim 1 of the claims. In this case, the invention is based on the idea that hollow elements are made by circulation, in particular similar to concrete prefabricated integral elements. At the same time, on a pallet passing through different stations having formwork elements, a space is set that corresponds to the outer contour of the concrete hollow element being manufactured and into which concrete is then poured. The recesses can be easily implemented by introducing formwork elements. Tension wires may protrude laterally from the element. Embedded parts, as well as other connecting elements, in addition to protruding tensile wires, can be concreted into the elements. This facilitates installation with a power circuit at the construction site, since wires or connecting elements can be used to connect the hollow element to adjacent ceiling elements and walls. In addition, transverse and longitudinal reinforcements are possible. It is preferable that the steel pallet is designed so that the longitudinal formwork elements are installed or rigidly fixed and the transverse formwork elements are installed at the two ends of the pallet. Typically, formwork elements are placed on a pallet so that two or more hollow elements can be manufactured on a pallet next to each other.

The inventive method for manufacturing concrete hollow elements, in particular by circulation, has, for example, the following steps: providing a pallet, installing formwork elements on a pallet, then transporting the pallet to a reinforcement station, in which stress wires are laid in the space defined by the pallet and formwork and pre-stretched, then transporting the pallet to the concrete station, in which at least the poured formwork and the formwork elements are poured into the space one first layer of concrete, the introduction of the core elements into the space defined by the pallet and formwork elements, before, during or after the concrete is entered, then the pallet is transported to the hardening station or hardening chamber in which the concrete hardens, and then the pallet is transported to the docking station, in which release straining wires. It turned out that it is preferable if the first concrete layer is poured first, for example, approximately to the position of the lower edge of the voids being manufactured, then the core elements are introduced into the space defined by the pallet and formwork elements to form voids, and then into the space defined by the pallet and elements formwork, poured at least one other layer of concrete.

In this case, the tensioning wires can be guided through openings in at least two opposite formwork elements and on the side facing away from the space defined by the pallet and formwork elements, to be fixed in a tension and / or holding device. Additionally or alternatively, the tensioning wires can be mounted in a tension stop, which, in order to create prestressing, moves relative to the pallet in a first direction pointing from the concrete hollow member being manufactured.

According to one embodiment of the invention, stress wires can be attached to one side of the pallet, for example, on the transverse formwork elements or on the end sides of the pallet. The tension wires can lie at a vertical distance, usually 0-50 mm, above the pallet, and are installed in tension pads, which are fixed on the pallet next to the transverse formwork elements, at this vertical distance. Then, clamping bushings can be inserted on the tension wires outside the tension blocks. For example, hydraulic tension cylinders use tensioning sleeves to tension tension wires and pre-tension in tension wires. Thus, the pretension is applied to the tension wires from the outside. Typically, 10-20 tension wires are introduced into each hollow element, which are loaded with a pre-tension force of approx. up to 120 kN for each strain wire. The total pre-tensioning force for each hollow element is usually in the range of 1000-2000 kN.

These forces, for example, are transferred to the pallet through the tension pads. Therefore, it is preferred that the pallet is made very rigid. The idea is to increase its rigidity with the help of large steel beams or pour concrete.

In particular, new in the present invention is both the filling of pallets with reinforcing concrete and the post-tensioning of the pallet during the current production process using balancing wires, as described below. In this way, bending moments are transmitted to the pallet by the prestressing forces of the concrete element being manufactured, the pallet remains flat. Preferably, the balancing wires or strands can be selectively pulled and loosened to at least partially perceive and / or compensate for the deforming moments transmitted to the pallet by the prestressing forces of the concrete part being manufactured.

At least one holding bracket and / or at least one hydraulic punch may be inserted before, during, or after the pre-tensioning in the tension wires between the tension stop and the pallet to maintain prestress during subsequent manufacturing steps. It turned out to be advisable if the specified at least one holding console and / or the specified at least one hydraulic punch during the movement of the lift in the second direction, at least essentially perpendicular to the plane of the pallet, is inserted between the tension stop and the pallet. Advantageously, at least two spacer elements are provided between the tension stop and the pallet, i.e. holding consoles and / or hydraulic punch to absorb forces without creating significant stress points.

One of the specific embodiments of the invention for creating prestressing is, for example, to attach a tension / weakening stop to the side of the pallets. Drills through which stressing wires are held are provided in the stop. These drills are made in a tension stop, for example, in two or more rows one above the other. Stress wires that extend above the pallet can pass through the top row of drills. Then, balancing tensile wires that are fixed on the pallet from the outside can pass through the bottom row of holes. The tension forces that pass through the balancing wires, during the tensioning process, create equilibrium with respect to the tensioning wires on the pallet. The counterbalancing wires can alternatively be replaced by another solution which, when tensioned in the longitudinal direction, elastically deforms or compensates for the deformation path. The tension / release stop is set, for example, by means of guide mandrels in the longitudinal direction.

Basically, there are two different ways to pull wires:

1) Simultaneous tensioning of all wires with a tension / release stop (group tension).

On one side, the wires to be tensioned are attached to the pallet (passive side, without tension / weakening stop).

On the other side (active side) of the wire, which must be tensioned, as described above, are fastened in the tension / weakening stop, and this tension / weakening stop, if possible with fully retracted tension cylinders, is as close as possible to the edge of the pallet. After fastening all the wires that must be tensioned, on the tension / weakening stop one or several hydraulic cylinders presses on the tension stop in the direction of tension from the pallet and at the same time pulls all the wires.

At the end of the tensioning process, holding arms can be inserted between the tensioning / weakening stop and the edge of the pallet. The function of the holding consoles is to rely on the pallet for the tensile forces created by the tensioner. After inserting the holding consoles, the tensioning device can be removed. The idea is to hydraulically move the tension or weakening cylinders up and down so that they can move into or out of the area between the pallet and the tension / weakening stop.

2) Separate tension of all wires (separate tension).

On one side, the wires to be tensioned are attached to the pallet (passive side, without tension / weakening stop).

On the other side of the wire, which must be tensioned, as described above, are fastened in the tension / weakening stop, while the tension / weakening stop is already removed from the pallet at least along the weakening path and the design width of the retracted weakening cylinder, and the tension / weakening stop is protected by holding plates from displacement in the direction of tension to the pallet.

Then all the wires are pulled separately, for example, using conventional commercially available tensioning jacks.

The tension wires can be loosened, for example, by firstly indicating that at least one hydraulic punch presses the tension / release stop from the pallet in the tension direction so that the holding arms between the tension / release stop can be released and removed. After that, the holding pressure of the hydraulic cylinder gradually decreases; the tension forces that act on the tension / weakening stop, slowly press the hydraulic cylinder in the direction of tension. As soon as the hydraulic cylinder is pressed far enough, the tension forces no longer act on the fasteners of the tension wires on the tension / weakening stop, so that the fasteners of the wires can be disconnected, and the prestressed concrete part is removed from the pallet.

The above problem is also solved by means of a device for the manufacture of concrete hollow elements by the method of circulation of pallets. This device has, for example, at least one cleaning station, at least one formwork station, at least one reinforcement station, at least one concrete station, at least one hardening station and at least one forming station, and also a transport device for moving pallets between individual stations. Other stations can be integrated into the circulation device, for example, at least one plotter station in which markings, at least one compression station for compressing concrete, at least one leveling station for surface treatment and / or at least one storage station for intermediate storage of pallets. Preferably, this device is automated so that the pallets controlled by a computer are transported to individual stations, and the work steps to be performed at individual stations are carried out mechanically and / or with computer control. In accordance with the invention, the reinforcement station and / or the additional tension station may have a device for laying tension wires. Also, the reinforcing station and / or additional tensioning station may have means for creating prestressing tension wires. The forming station and / or the additional breaking station may also have means for releasing the stress wires.

The means for generating prestressing the tensioning wires have, for example, at least one, in particular a hydraulic tension cylinder, which can be detachably connected to pallets, which can be connected to the tensioning wires by means of clamping sleeves. Alternatively or additionally, the means for generating prestressing the tension wires may have at least one tension stop connected to the tensioning wires, which is additionally connected to balancing tensioning wires to create prestressing the tensioning wires.

Also, the reinforcing station and / or the additional tensioning station may have a device for introducing at least one holding console and / or at least one hydraulic punch between the pallet and the element connected to the tensioning wires, in particular a tension stop.

To fill voids in a concrete hollow element, a concreting station and / or some other device station may have means for introducing rod elements into the space defined by the pallet and formwork elements. For example, the transverse formwork elements, which can be made integral or in two parts, can contain, for example, round or quadrangular openings through which (core) pipes or profiles can move, creating voids in the concrete element. Bar elements, i.e. pipes or other profiles, for example, can move left and right through the drilling of the transverse formwork elements using a pipe pulling machine. Another solution is to simply move the profiles manually or with other technical support through drilling the transverse formwork elements, or lay them on top. Pipes or, respectively, profiles are preferably supported in the drillings of the transverse formwork elements. Also, hoses filled with liquid or gas can be used to create voids.

The longitudinal elements of the formwork can have a shear tooth system to create the corresponding form elements in concrete elements, with which a particularly strong concrete connection can be created, in particular for seismic zones, with the introduction of monolithic concrete.

Below the invention is explained in more detail on one of the embodiments and with reference to the drawing. Moreover, all the described and / or graphically depicted features themselves constitute the subject of the invention, regardless of their brief wording in the claims or references to them.

Schematically shown:

figure 1: a schematic sketch of the invention of the device;

figure 2: in perspective view, a pallet with concrete hollow elements;

figure 3: in the view in section of a fragment of a tension station;

figure 4: in perspective view another fragment of the tension station, and

figure 5: in the view in section of another fragment of the tension station.

Figure 1 shows a schematic sketch of a device for the manufacture of concrete hollow elements by the method of circulation of pallets. In the sequence of the production process, this device has a drive 1, a cleaning station 2, a plotter station 3, several formwork stations 4, reinforcement stations 5, a tension station 6, a concreting station 7, a drive 8, a control station 9, a stripping station 10, a hardening station 11, having several racks, other stripping stations 12, a release station 13 and an unloading station 14. The individual stations are interconnected by a transport device so that the pallets 15, in particular automatically, can be transported to the stations. For example, pallets 15 having friction drives are transported by circulating between stations.

Unlike the illustrated embodiment, having a separate tensioning station 6 and a separate breaking station 13, these stations can also be integrated into other processing stations.

Moreover, the manufacture of concrete hollow elements is carried out essentially in the following sequence.

From the drive 1, the empty pan 15 moves to the cleaning station 2. There, the pallet 15 is cleaned and, if necessary. lubricated by oil. After that, the pallet 15 is moved to the plotter station 3 and optionally marked there, for example, in the case of manually inserting embedded parts as an addition to the formwork.

Then the pallet 15 passes through one or more formwork stations 4, in which the formwork elements 16, 17 are installed on the pallet 15 and are fixed there. When formwork, the longitudinal formwork elements 17 are placed on the pallet along (in the x direction) to limit the manufactured hollow element 18 on the sides. In the transverse direction (y direction), the hollow member 18 is delimited by the transverse formwork elements 16.

Then, the pallet 15 thus prepared (moves) to one of the reinforcement stations 5 in which the reinforcing bars and / or tension wires 19 are introduced. Once the tension wires are introduced, the pallet 15 moves to the tension station 6. There, the tension wires 19, which usually extend along the pallet through the transverse formwork elements 16 and through the tension blocks 20, are pre-tensioned in more detail as described below. After this, at least one workstation (station 7 concreting) is concreting. Concreting is carried out, for example, by means of a concrete distributor performing layer-by-layer concreting. In this case, first a thin layer of concrete is distributed on the pallet 15, then the rod elements 21, for example, pipes that create voids, are pushed through the transverse formwork elements 16 from the outside, and then the second is concreted and, if necessary. another layer until the void inside the formwork elements 16, 17 is filled. Then, the filled pallet 15 is crimped, for example, using a separate vibrating-shaking station (not shown) or directly in the concreting station 7. The quality of the process of concreting and compression can be controlled in a separate station 9 control.

Optionally, the surface of the concrete elements 18 is leveled using a leveling device (not shown). The pallet 15 moves further and with the help of the device for servicing the racks moves into the hardening chamber 11. Formwork elements 16, 17 may be removed before and / or after the hardening chamber. In the hardening chamber 11, the concrete elements 18 are solidified on pallets 15. From the hardening chamber 11, the pallet 15 is discharged using a rack maintenance device. In a subsequent workstation 13, the tension wires 19 are unfastened. In this case, it is preferable that all the straining wires 19 are unfastened at the same time so that no cracks appear in the concrete element 18.

In the unloading station 14, the concrete elements 18 are unloaded from the pallets 15 and from there are fed to the storage location. The pallets 15 either through the intermediate storage 1, or directly enter the cleaning station 2.

Figure 2 shows a pallet 15 on which a concrete element 18 is provided. In figure 2 it can be seen that voids extending in the longitudinal direction are made in the left / lower concrete element 18. They are created when, before, during or after the concreting process, the core elements 21, for example pipes, are pushed through the corresponding holes 22 into the transverse formwork elements 16.

You can also see that in the left / lower concrete element 18 in the figure, longitudinally extending tensile wires 19 are provided, which in the illustrated example pass under voids. The tension wires 19 pass through the holes in the transverse formwork elements 16 and are guided outside the transverse formwork elements 16 through the tension pads 20. Outside the tension pads 20, clamp sleeves are placed on the tension wires 19 by means of which the hydraulic tension cylinders (not shown) tension the tension wires and create prestressing wires.

To absorb the pre-tension force, for example, approximately 100 kN for each tension wire 19, the rigidity of the pan 15 can be accordingly increased. 5, in this connection, an example is shown in which a concrete layer 23 is inserted under the top sheet of the pallet 15, in which the shell pipes pass for subsequent stress. The shell tubes 24 allow, through the strands for post-voltage, to impart to the pallet 15 a voltage which facilitates the passage of the neutral phase, if possible, in the plane of the top sheet. In other words, the moments created by the pretensioning of the tension wires 19 in the pallet 15 should be at least partially compensated by the targeted creation of the opposite moment by means of strands for post-voltage.

3 and 4, it is shown how the tension imparted to the tensioning wires 19 can be maintained during the manufacture of concrete hollow elements 18, i.e., in particular, during processing at the concreting station 7, control station 9, hardening station 11 and stations 10 , 12 formwork. In FIGS. 3 and 4, the tension wires 19 are tensioned in a stop 25, which, with the help of the guide pins 26, is mounted with the possibility of displacement relative to the pallet 15 parallel to the plane of the pallet. In this case, the tensioning wires 19 are guided through the tension block 20, fixed on the pallet 15, and are held in their position.

Between the lateral edge of the pallet 15 and the stop 25 in the depicted example, two hydraulic punches 27 and two holding consoles 28 are provided, while the hydraulic punches 27 allow the stop 25 to move relative to the pallet 15 along the guide pins 26, for example, for a given release of tension wires 19 after removing the holding brackets 28, in contrast to which the holding brackets 28 rest the stop 25 on the pallet 15. In contrast to the illustrated embodiment, the stop 25 can also be supported only by hered consoles 28 and to attenuate straining the wires 19 in a certain way to move differently, eg., via acting externally on the abutment 25, the counterbalancing straining wires (not shown).

The hydraulic punches 27 and / or the holding arms 28 can, by means of a lifting drive 29, for example, of any hydraulic device, be lifted in the gap between the pallet 15 and the stop 25 or, accordingly, can be lowered from it. So, for example, a lifting drive 29 may be provided in the tension station 6 to position the hydraulic punch 27 and / or the holding arms 28 after tensioning the tension wires 19 between the stop 25 and the pallet 15, and another lifting actuator may be provided in the fastening station 13 29, in order to remove the hydraulic punch 27 and / or the holding arms 28 between the stop 25 and the pallet 15 after unfastening the tension wires 19.

In general, the invention allows, by providing a device for tensioning the tensioning wires 19, in particular a separate tensioning station 6, and a device for a predetermined unfastening of the tensioning wires 19, in particular a separate breaking station 13, using the method or, accordingly, the device by the circulation method effectively and technologically reliably to produce prestressed concrete hollow elements 18. Prestressed concrete hollow elements 18 are characterized in that in them, due to the tension of the tensioning wires 19, a deis vuyuschee compressive stress on the concrete, which concrete in the application of tubular members 18 is superimposed on the force acting on their weight, as well as the external loads so that acting on the concrete tensile stresses are minimized or even eliminated. Due to this, it is possible to realize loaded with a higher load of concrete hollow elements 18 of the same size or, correspondingly, with the same load of more flexible concrete hollow elements 18.

LIST OF REFERENCE NUMBERS

1 drive

2 Cleaning station

3 plotter station

4 Formwork station

5 Reinforcement station

6 Tension station

7 Concreting station

8 drive

9 Control Station

10 Stripping station

11 Curing station

12 Stripping station

13 Docking Station

14 Unloading station

15 Pallets

16 Transverse formwork element

17 Longitudinal formwork element

18 Concrete hollow element

19 Tension wire

20 tension pad

21 Core element

22 hole

23 Concrete layer

24 Straining strand

25 emphasis

26 Guide pin

27 hydraulic punch

28 Holding Console

29 Lift drive

Claims (16)

1. A method of manufacturing a concrete hollow element, having the following steps, in particular by circulation: a) provision of a pallet (15); b) installation of the formwork elements (16, 17) on the pallet (15); c) transportation of the pallet (15) to the reinforcement station (5), in which tension wires (19) are laid and pre-tensioned into the space defined by the pallet (15) and formwork elements (16, 17); d) transporting the pallet (15) to the concreting station (7), in which at least one first concrete layer is poured into the space defined by the pallet (15) and formwork elements (16, 17); e) the entry of the rod elements (21) into the space defined by the pallet (15) and the formwork elements (16, 17); f) pouring at least one other concrete layer into the space defined by the pallet (15) and formwork elements (16, 17); g) transporting the pallet (15) to the hardening station (11), in which the concrete hardens; and h) transporting the pallet (15) to the release station, in which the straining wires (19), in particular at the same time, are unfastened, moreover, in step c), the tensioning wires (19) are fixed in the tension stop (25), which, in order to create a preliminary tension, moves relative to the pallet (15) in a first direction, pointing from the concrete hollow element being manufactured (18), and moreover, at least one holding bracket (28) and / or at least one hydraulic punch (27) are inserted between the tension wires (19) between the tension stop (25) and the pallet (15). 2. The method according to p. 1, characterized in that in step c) the tension wires (19) are passed through the holes in at least two opposite formwork elements (16) and on the side of these formwork elements (16) facing away from the space defined by the pallet (15) and the formwork elements (16, 17) are fixed in the tensioner and / or holding device (20, 25). 3. The method according to p. 1 or 2, characterized in that the at least one holding console (28) and / or the specified at least one hydraulic punch (27) when the lift moves in the second direction, at least essentially perpendicular to the plane of the pallet (15), enter between the tension stop (25) and the pallet (15). 4. The method according to p. 1 or 3, characterized in that at step h) said at least one holding console (28) between the tension stop (25) and the pallet (15) is removed and / or the specified at least one hydraulic punch (27) between the tension stop (25) and the pallet (15) is shortened to thereby move the tension stop (15) relative to the pallet (15) in a third direction opposite to the first direction. 5. A device for the manufacture of concrete hollow elements (18) by the method of circulation of pallets, in particular by the method according to one of the preceding paragraphs, having at least one cleaning station (2), at least one formwork station (4), at least one station (5) reinforcing at least one concreting station (7), at least one curing station or curing chamber (11) and at least one forming station (12), as well as a transport device for moving pallets (15) between the individual stations (1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14), characterized in that the reinforcement station (5) and / or additional tension station (6) has a device for laying tension wires (19), reinforcement station (5) and / or additional tension station (6) has means (20, 25) for creating a preliminary tension of the tensioning wires (19), and a station (12) for forming and / or an additional station (13) for unfastening has means (27) for unfastening the tensioning wires (19), and station (5) reinforcement and / or additional station (6) tension has a device (29) for input shey least one retaining bracket (28) and / or at least one hydraulic plunger (27) between the pallet (15) and connected to the prestressing wires (19) element, particularly a tension stop (25). 6. The device according to p. 5, characterized in that the means for creating a preliminary tension of the tensioning wires (19) have at least one, in particular detachably connected to pallets (15), a hydraulic tension cylinder (27), which with clamping sleeves can be connected to tension wires (19), and / or means for creating prestressing tension wires (19) have at least one tension stop (25) connected to tension wires (19), which is additionally connected to balancing tension wires wires to create pre-tensioning tension wires (19). 7. The device according to claim 5 or 6, characterized in that the concreting station (7) and / or another station has means for introducing the rod elements (21) into the space defined by this pallet (15) and the elements located on it (16, 17) the formwork and / or the pallet (15) is filled, at least in certain areas, with reinforcing concrete (23) and is equipped with selectively pulled and weakened balancing wires or tension strands (24), so that due to the prestressing forces of the manufactured concrete part (18) at least partially perceived The deforming moments introduced into the pallet (15).

Images