RU2794678C1 - Method for manufacturing a reinforced concrete block room for a mobile workshop for block housing construction - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention can be used in the construction of monolithic reinforced concrete structures, namely in the manufacture of three-dimensional elements such as block rooms for ground housing and public construction of buildings and structures, as well as for underground construction under extreme conditions. The method of manufacturing a reinforced concrete block room for a mobile block house-building shop is characterized by the fact that it is carried out by the method of lowering concrete laid in layers. Initially, a formwork stand is equipped in the pit with the dimensions of the block room, for which fixed vertical decks are installed along the perimeter of the pit, consisting of internal and external parts, the distance between which is equal to the thickness of the wall of the block room, a movable horizontal deck fixed on jacks is installed inside the vertical deck located at the bottom of the pit, a fixed horizontal floor deck is installed on top of the pit above the vertical decks. Four rolls of polymer film are movably fixed at the top and bottom of the horizontal floor deck, the edges of the film are fixedly fixed on the horizontal deck, reinforcing cages, consisting of horizontal and vertical meshes, are installed inside the formwork. Before laying the first layer of concrete, the horizontal deck is placed below the upper edge of the inner part of the vertical deck by the thickness of the concrete layer, then reinforcing cages are laid on the horizontal deck and the first layer of concrete is laid into the formwork along the entire perimeter with a concrete pump, then the horizontal deck with the concrete pump located on it is gradually lowered with the first layer of concrete using hydraulic jacks at a speed of 0.8-1 cm/min down to an elevation on the vertical deck equal to the thickness of the layer. Simultaneously with lowering of the first concrete layer, a polymer film is lowered along the vertical deck, and the first layer of concrete is obtained along the entire perimeter of the walls of the block room. After hardening of concrete, the layer is treated with adhesive impregnation from above and reinforcing cages are installed. Then all these steps are repeated for each of the remaining layers of concrete. For the manufacture of the last wall layer of concrete, temporary wooden beams and a polymer film are laid on the horizontal floor deck in the gutters and a horizontal reinforcing cage is installed. The horizontal frame is connected through nodes with the vertical reinforcing frame, then the horizontal concrete layer and the last vertical concrete layer are simultaneously laid on the base of the horizontal floor deck and on the vertical concrete layer, forming a single element. The finished block room is held for 24 hours to gain strength, then it is lifted up with the help of jacks, removed from the formwork and placed on a trolley for transportation.

EFFECT: reduction in labour intensity and a simplification of the procedure for manufacturing a block room.

1 cl, 10 dwg

Description

The invention relates to construction and can be used in the construction of monolithic reinforced concrete structures, namely in the manufacture of three-dimensional elements such as block rooms for ground housing and public construction of buildings and structures, as well as for underground construction under extreme conditions.

Known molding post for the manufacture of three-dimensional blocks, described in the patent of the Russian Federation No. 2026778, published on 20.01.1995. which includes external formwork panels, a pallet, a core, a piping system for supplying a coolant, a concrete trestle for a concrete paver hopper with a guide nozzle, the core and outer panels are each equipped with a removable part that extends them in height by the required block size, the guiding nozzle of the concrete paver hopper is hinged to with a funnel and a drive-lock, while the funnel has a height equal to the height of the removable parts of the outer shields and the core, along the perimeter of the ceiling plate of which seats are made, along the perimeter of the base of the removable part of the core - edges congruent to them.

The disadvantage of the forming post is the high cost of materials, the complexity and complexity of execution, since it is a fixed stationary installation.

A known method of manufacturing block rooms from monolithic reinforced concrete, described in the application for the invention No. 94003774 with priority 02/01/1994, published on 11/27/1995, which consists in the manufacture of block rooms from monolithic reinforced concrete, including the installation of metal formwork with fasteners, pouring hard concrete, stripping. As an internal and external formwork, a box of separate metal sheets is used, freely supported by a retaining closing contour installed in the lower part. Sheets have stiffening ribs connected to the contour. The ceiling formwork contains rubber plates mounted on roller bearings. The plates are connected to the parallel walls of the inner formwork with the possibility of removing these plates.

The disadvantage of the proposed method is the complexity in manufacturing, the high cost of manufacturing due to additional installations of rubber plates.

A known method of manufacturing a reinforced concrete volumetric block, described in the author's certificate SU No. 1798454, with a priority of 11/29/1990, published 02/28/1993, which is selected as a prototype. The method consists in the fact that the manufacture of a block-room in the warm season can be carried out directly at the construction site, and at negative temperatures in heated enclosed spaces. Method for making a room block includes concreting the floor slab, installing the reinforcing frame of the walls and the spatial frame of the coating connected to each other, tensioning the wall frames and the mesh covering on both sides, the mesh size of which is less than the size of the concrete aggregate, fastening insulation and sheet material to the wall frame and plastering the walls on both sides, according to the invention, before concreting the floor slab, a spatial reinforcing frame of the slab is laid, after which flat wall frames are installed with fastening to the latter, the spatial frame of the coating is laid, followed by its connection with the wall frame, then the insulation and sheet material are installed on the inside of the coating, the floor slab is concreted , and after it hardens, the walls are plastered down in layers and alternately from the inside and outside with holding intervals between layers of at least 24 hours at a positive ambient temperature, after which the coating is concreted with grouting its inner surface with a cement-lime mortar flowing through the grid cells.

Specified The method of manufacturing a reinforced concrete block-room has many advantages, but a number of disadvantages.

The disadvantages of the method of manufacturing a reinforced concrete block room are:

- the complexity of execution and manual labor.

- the need for a prepared site for the manufacture of the product.

- the complexity of installing reinforcing cages without guide conductors.

- production time due to phased processes is delayed.

- Rise in the cost of work in the winter season.

- increased material consumption for the finished product.

- the need for equipment when concreting the floor.

- mechanical troweling machines are not used.

- manufactured block rooms can only be used for one-story construction.

Thus, the main disadvantages of manufacturing volumetric reinforced concrete block described in the prototype are the high complexity of the process and the complexity of the technology.

The technical objective of the proposed method is to reduce the complexity and simplify the manufacturing technology of the block room.

The technical problem is achieved by the fact that the method of manufacturing a reinforced concrete block room for a mobile block house building workshop is characterized by the fact that it is carried out by the method of descending concrete with laying in layers, according to the invention, initially in a pit with the dimensions of a block of the room, a formwork stand is equipped, for which it is installed along the perimeter pits - fixed vertical decks, consisting of inner and outer parts, the distance between which is equal to the thickness of the block-room wall, inside the vertical deck, a movable horizontal deck is installed, fixed on jacks located at the bottom of the pit, a fixed horizontal floor deck is installed on top of the pit above the vertical decks; four rolls of polymer film are movably fixed above and below the horizontal floor deck, the edges of the film are fixedly fixed on the horizontal deck, reinforcing cages consisting of horizontal and vertical meshes are installed inside the formwork; before laying the first layer of concrete, the horizontal deck is placed below the upper edge of the inner part of the vertical deck by the thickness of the concrete layer, then reinforcing cages are laid on the horizontal deck and the first layer of concrete is laid into the formwork along the entire perimeter with a concrete pump, then the horizontal deck with the concrete pump located on it is gradually lowered the first layer of concrete using hydraulic jacks at a speed of 0.8-1 cm / min to a mark on the vertical deck equal to the thickness of the layer, simultaneously with the lowering of the first concrete layer, a polymer film is lowered along the vertical deck, while receiving the first layer of concrete along the entire perimeter of the walls block rooms, after hardening the concrete from above, the layer is treated with adhesive adhesive impregnation and reinforcing cages are installed; then, all the above steps are repeated for each of the remaining layers, and before making the last wall layer of concrete, temporary wooden beams, a polymer film are placed in the gutters on the horizontal floor deck, and the reinforcing cage of the floor slab is installed, the skeleton of the floor slab is connected to the reinforcing cage of the wall, then on the base of the horizontal floor deck and on the last concrete wall layer, a concrete layer is simultaneously laid, forming a single element; the finished block room is kept for 24 hours to gain strength, then it is lifted up with the help of jacks, removed from the formwork, and placed on a trolley for transportation.

A block room is a spatial block of given dimensions with walls, door and window openings, and a floor slab.

To implement a method for manufacturing a reinforced concrete block room for a mobile block house building workshop, a mobile collapsible underground formwork stand is used, located inside the pit, with moving horizontal wall decks, using the stand, the concrete mixture is reinforced, laid and compacted by the descending concrete method. The underground formwork stand is made of a fixed horizontal floor deck, fixed vertical wall decks installed along the perimeter of the underground formwork stand, and horizontal movable wall decks that are installed inside the vertical wall decks located along the entire perimeter of the block and fixed to hydraulic jacks. Hydraulic jacks are installed at the bottom of the excavated pit. The fixed horizontal floor deck is provided with beam troughs that are mounted on inventory racks and serve to temporarily support the floor after it has been constructed .

The concrete mixture is laid using a concrete pump installed on movable rails, the concrete mixture is supplied and laid alternately in layers, with a layer height equal to part of the height of the vertical deck, while the second and subsequent layers of the concrete mixture are laid only after the previous layer is laid along the entire perimeter formwork stand, further filling of the vertical and horizontal decks is resumed only after the laying is completed and the previous concrete layer has gained the necessary strength.

When arranging a mobile collapsible formwork stand on a fixed horizontal floor deck, gutters for temporary wooden beams are arranged, a polymer film is laid, in addition, a polymer film is placed on the inside of the vertical deck with the possibility of its vertical movement along each vertical deck. As a moving element on the stand, a horizontal deck is used, which is initially placed 50-60 cm (thickness of one layer of concrete) below the top of the vertical deck and the horizontal ceiling. Into the inner formwork vertical space before laying the concrete layers on a movable horizontal deck, and then reinforcing cages are installed on top of each of the laid layers of concrete after it has hardened. The reinforcement cage consists of horizontal and vertical grids, thereby forming a spatial reinforcement cage. After laying the first layer of concrete with a height of, for example, 50 cm on a horizontal deck, it is lowered, holding the upper part of the concrete layer with a protruding part of the reinforcing cage, and the concrete layer is pre-treated with adhesive adhesive impregnation to prevent separation from the total mass of concrete.

Then they begin to lay the second layer of concrete, lowering the horizontal deck down at a speed of 0.8-1 cm / min for the concrete to gain the necessary strength and compact it, while the polymer film inside the vertical space of the formwork moves together with the concrete; after lowering the second layer to a depth of 50 cm, and the first layer to a depth of 1 meter, the next layer of concrete is laid. This interval of the speed of lowering the horizontal deck, equal to 0.8-1 cm/min, is determined empirically and is optimal.

After gaining design strength, processing the upper part of the layer with adhesive adhesive impregnation and installing reinforcing cages, continue to lower the horizontal deck at the same speed and sequentially create all the necessary layers of concrete, in accordance with the standard size of the cube of the room, until the first layer sinks to a given depth , for example, 3 meters, then the last concrete wall layer is laid. Simultaneously with the last wall concrete layer, a horizontal concrete floor is created, and temporary wooden beams are installed in the floor troughs while the concrete mixture is laid in the formwork, supported on the last concrete layer after it has been hardened, and a plastic film is pre-installed on the wooden beams and on the fixed horizontal deck of the floor. . After the bulk element of the block room has reached its design strength for 24 hours, hydraulic jacks, acting on the horizontal decks, raise the volumetric element upwards, insert metal beams under it, mounted on trolleys for movement from the stand.

Placing a polymer film on the inner side of the vertical deck and on the horizontal deck during the arrangement of the formwork stand with the possibility of its vertical movement in conjunction with the use of walls and the presence of reinforcing cages as a moving element in the stand, the use of intermediate adhesive adhesive impregnation for technological seams between layers concrete, eliminates defects in concrete, in the case when the formwork carries along a part of the weak concrete of the wall or ceiling, as a result of which shells can form, reinforcement is exposed. The technology of high-quality concreting simplifies the installation of temporary wooden beams in the gutters of the horizontal floor deck, resting in the openings on the concrete walls, to further maintain the concrete floor until the installation of the room block. It also helps to simplify the technology by lowering down during the concreting process of the horizontal deck of the wall, which is initially placed 50-60 cm (the thickness of the concrete layer) below the top of the vertical deck, and installing reinforcing cages inside the formwork space.

The invention is illustrated by drawings, where the stages of concreting are shown schematically in Fig.1-8 (frontal section):

- Fig.1 - Initial position of the underground formwork stand;

- figure 2 - Laying the first concrete layer in the formwork;

- figure 3 - Application of adhesive adhesive impregnation on the first concrete layer and laying the second concrete layer;

- figure 4 - Application of adhesive adhesive impregnation on the second concrete layer and laying the third concrete layer;

- Fig.5 - Application of adhesive adhesive impregnation on the third layer and laying the fourth concrete layer;

- Fig.6 - Application of adhesive adhesive impregnation on the fourth layer and laying the fifth concrete layer;

- Fig.7 - Application of adhesive adhesive impregnation on the fifth layer and laying the sixth concrete layer simultaneously with the horizontal concrete floor;

- Fig.8 - Rise from the underground formwork stand up volumetric reinforced concrete block room;

- Fig.9. – Top view of the formwork stand;

- Fig.10. - General view of the finished block-room (3D).

The method is carried out as follows.

Initially, a pit in the form of a cube is prepared on site for the manufacture of a reinforced concrete block-room with the corresponding dimensions of the room block for the installation of an underground collapsible formwork stand. Before installing the stand, it is necessary to take protective measures against the collapse of the walls of the pit.

Inside the pit, an underground collapsible formwork stand is installed (Figure 1.), Consisting of a formwork installed on the outside of each of the walls of the cube room. The formwork consists of a fixed horizontal floor deck 1, a fixed vertical deck 2, a movable horizontal deck 3, hydraulic jacks 4 installed at the bottom of the pit, on which deck 3 is fixed. Four rolls of polymer film 5 are installed on the outside of deck 2 above horizontal deck 1 with the possibility of moving the film from each roll inside the vertical deck 2 and four more rolls are installed with the possibility of moving the film inside the deck 2 under the horizontal floor deck 1 from the inside of the deck 2, while the film from all the rolls along the perimeter is rigidly fixed to the movable deck 3 with its edges. In addition, the polymer film is still laid and fixed on the horizontal deck of the floor 1. The horizontal deck of the floor 1 and the vertical deck of the wall 2 are fixed, and the horizontal deck of the wall 3 is lowered or raised under the influence of hydraulic jacks 4.

Vertical deck wall 2 (figure 1) consists of 2 fixed parts (internal and external), which are located at a distance from each other, equal to the wall thickness of the block room. In addition, the upper edge of the inner part of the vertical deck 2 is flush with the horizontal deck 1, and the upper edge of the outer part of the deck 2 is above the upper edge of the inner part of the deck 2 by the thickness of the concrete layer.

After alignment, fixing and commissioning on the stand, the horizontal deck 3, fixed on the hydraulic jacks 4 is at a distance equal to the thickness of the first layer of concrete, for example, 50cm (Fig.1) from the upper edge of the inner part of the vertical deck 2. Then to deck 3 install reinforcing cages and start laying the first layer of concrete into the formwork. The first layer of concrete 6 (figure 1) is laid around the entire perimeter of the cube of the room on the horizontal deck 3 using a concrete pump, then they begin to lower the horizontal deck 3 with the first layer of concrete on it using hydraulic jacks 4 at a speed of 0.8-1 cm/ min to the mark on the vertical deck of the wall, equal to 50 cm. Simultaneously with the lowering of the first concrete layer 6, a polymer film 5 is lowered along the vertical deck 2, fixed to the horizontal deck 3. In this case, the first layer of concrete is obtained along the entire perimeter of the walls of the block room. Then the top layer is treated with adhesive adhesive impregnation (for example, CERESIT CT 19 BETONCONTACT) and reinforcing cages are installed. Then repeat these steps for laying all, for example, six layers of concrete, with a cube room height of 3m (Fig.2-7). In the manufacture of the last wall layer of concrete, the concrete is laid simultaneously also on the entire horizontal deck of the floor 1, and thus the entire reinforced concrete structure forms a spatial block-room.

The finished block room is kept for strength gain - 24 hours and then lifted up with the help of jacks (Fig. 8), removed from the formwork, and placed on a trolley for transportation.

An example of the implementation of the method.

Consider the implementation of the method for the manufacture of a block room with a size of 3x3x3 meters on an underground formwork stand. In the initial state, the horizontal deck 3 (figure 1) is lowered relative to the vertical deck 2 (figure 1) by 50 cm. The polymer film 5 (figure 1) is fed into the deck 2 from its outer and inner sides from eight rolls located on top and from below relative to the fixed floor deck 1, all the edges of the film 5 are fixed on the movable horizontal deck 3 for further movement of the polymer film with the movable horizontal deck at a speed of 0.8-1 cm/min. Inside the formwork space, reinforcing cages are installed on a movable horizontal deck 3. Then, monolithic concrete for the first layer is fed into the formwork system, where the concrete mixture is placed in the space between the outer and inner parts of deck 2 on a horizontal deck 3 50 cm thick, gaining minimal strength from the effects of external and internal factors.

After curing on the upper part of the first concrete layer (figure 2) apply adhesive adhesive impregnation 7 (for example CERESIT CT 19 BETONKONTAKT ) and install reinforcing cages, which connected with the frames of the first layer of concrete to fasten the concrete layers 6, then hydraulic jacks 4 are turned on for lowering, the horizontal deck 3, together with the first layer of concrete 6, is lowered down at a technological speed of 0.8-1 cm/min simultaneously with concrete along the inner part of the vertical deck 2 the polymer film 5 moves. The upper part of the first layer of concrete 6 is kept by the accelerated reinforcing cage from separation from the total mass of the concrete layer. Vertical Deck 2 gives shape to the concrete wall element.

To obtain the second layer of concrete (figure 3) the first concrete layer 6 is lowered by lowering the deck 3 to a depth of 100 cm relative to the top of the deck 2. The horizontal deck 3 stops. The second layer of concrete 6, 50 cm high, begins to be laid, after gaining the necessary strength, an adhesive adhesive impregnation 7 is applied and a reinforcing cage is installed. Then, to create the third layer, deck 3 is lowered to a depth of 150 cm, in order to additionally eliminate the separation or rupture of the resulting concrete layers between the vertical decks 2 and the layers of concrete, there is a thick polymer film 5, which is fixed on deck 3 and moves along with the concrete, creating minimal friction between deck 2 and concrete. When stopped, there is no adhesion of the "concrete - deck" pair. The third self-compacting concrete layer 6 is laid (figure 4), gaining the necessary strength, after which an adhesive adhesive impregnation 7 is applied, this layer is lowered with subsequent technological operations. Similarly, the following (fourth and fifth) layers 6 (Fig.5,6) are stacked at a depth of deck 3 equal to 200 cm and 250 cm. Then the horizontal deck of the wall 3 is lowered to a depth of 300 cm (Fig.7). To create a sixth wall (vertical) layer and a horizontal layer for the floor slab, temporary wooden beams 8 (Fig. 7) are placed in the gutters first on the horizontal floor deck 1, a polymer film 5 is laid, a reinforcing cage of the floor slab is installed on deck 1 (in the horizontal plane ), this frame is connected through the nodes of the reinforcing cage of the wall (vertical plane) of the vertical deck 2 on the base of the horizontal floor deck 1 prepared in this way and on the vertical fifth concrete layer 6, they begin to lay simultaneously the horizontal concrete layer and the vertical sixth layer of concrete 6, without separating these layers, forming a single element.

After gaining design strength within 24 hours, the bulk element of the reinforced concrete block room of hydraulic jacks 4 on the horizontal deck of the wall 3 rises above the underground mobile collapsible formwork stand. Under the volumetric block 11, metal I-beams are installed, mounted on movable carts, for moving to the storage site.

Thus, compared with the prototype, the claimed method is simpler in implementation technology and less laborious.

Claims (1)

A method for manufacturing a reinforced concrete block room for a mobile block house building workshop, characterized in that it is carried out by the method of sinking concrete with laying in layers, characterized in that initially a formwork stand is installed in the pit with the dimensions of the block room, for which fixed vertical decks are installed along the perimeter of the pit , consisting of internal and external parts, the distance between which is equal to the thickness of the block-room wall, inside the vertical deck, a movable horizontal deck is installed, fixed on jacks located at the bottom of the pit, a fixed horizontal floor deck is installed on top of the pit above the vertical decks; four rolls of polymer film are movably fixed above and below the horizontal floor deck, the edges of the film are fixedly fixed on the horizontal deck, reinforcing cages consisting of horizontal and vertical meshes are installed inside the formwork; before laying the first layer of concrete, the horizontal deck is placed below the upper edge of the inner part of the vertical deck by the thickness of the concrete layer, then reinforcing cages are laid on the horizontal deck and the first layer of concrete is laid into the formwork along the entire perimeter with a concrete pump, then the horizontal deck with the concrete pump located on it is gradually lowered the first layer of concrete using hydraulic jacks at a speed of 0.8-1 cm / min to a mark on the vertical deck equal to the thickness of the layer, simultaneously with the lowering of the first concrete layer, a polymer film is lowered along the vertical deck, while receiving the first layer of concrete along the entire perimeter of the walls block rooms, after hardening the concrete from above, the layer is treated with adhesive adhesive impregnation and reinforcing cages are installed; then repeat all the above steps for each of the remaining layers, and before making the last wall layer of concrete on the horizontal floor deck, temporary wooden beams, a polymer film are laid in the gutters and the reinforcing cage of the floor slab is installed, the skeleton of the floor slab is connected through nodes with the reinforcing cage of the wall, then, a concrete layer is simultaneously laid on the base of the horizontal floor deck and on the last concrete wall layer, forming a single element; the finished block room is held for 24 hours to gain strength, then it is lifted up with the help of jacks, removed from the formwork and placed on a trolley for transportation.

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