SA93140361B1 - hollow core slabs - Google Patents

Abstract

Abstract: The present invention relates to a method for transversely cutting a prefabricated slab having one or more hollow longitudinal cores involving the insertion of a pair of expandable plugs into at least one of the said cores, and the plugs of one or more of the pair are placed a pair in a intended core so that they are far apart from each other on opposite sides of an intended cut line and the extension of the two plugs after their insertion serves to seal the respective core; insertion of a settable material into a portion of the blocked core or each blocked core between its own pair of spaced expanding plugs; and cut the slab transversely through the intended cut line, after at least partial hardening of the inserted hardenable material.

Description

$3 tile cutting hollow core slabs Full Description BACKGROUND: The present invention relates to the sealing and cutting of hollow core slabs for example; Concrete slabs have one or more cores. Pre-stressed concrete slabs with hollow cores are described and formed; m for example; In British Document No. 7785777850-M. Such tiles can be formed in a variety of ways: fie, extrusion, vertical, sheer compaction, or slip forming, and this is done for sale on pre-stressing beds with a length of It is approximately 001 meter. Substantively regular tiles of this length are formed by hollow cores extending longitudinally. Once the concrete 8618:0000 hardens in the continuous slab, a smaller independent slab is cut to a predetermined length than the longer ASL. The stand-alone tiles are then transported to construction sites or another place where they are required and used; For example; in the formation of floors of buildings. while cutting a larger tile into smaller tiles; It uses a mechanical sawing device and the saw blade is cooled in this tool using high pressure water. ye Large amounts of water mix with the concrete dust from the tiles during the cutting process; A thin layer of clay forms We fine slurry, which enters the cores that extend vertically with the direction of the cuts. The layer then dries and remains on the lower surfaces of the cores of the smaller tiles for a distance of at most 1.5 meters on either side of the cut.

’ and if hearts are not used at any later stage; This thin layer is of little importance. On the other hand, if the hearts of smaller tiles are to be used at a later stage; For example to move air to ventilate rooms; it is necessary to thoroughly clean the cores by removing all the dried slurry and any other debris which may have collected in the cores on their way to their intended place; during storage or installation. The process of cleaning hearts can be very expensive and take LT as well; the heart is usually blocked; Once it is cleaned; Preferred by both parties; to prevent any AT debris from collecting in it. And if the use for which hearts were put is eon, for example; air transport; Any, the two blocks on both sides must be air-tight, and thus holes will be provided in the lower sides or upper surfaces of the tiles, and ducted air will enter and exit from the hearts at precise locations. Layo shall not seep through both ends of the slab. Plugs made of (ph) concrete mortar are usually inserted into both ends of the cores in order to close them tightly. To ensure that the wet concrete does not extend into the cores during the tight sealing process and in order to seal them in a (Jind) way, a non-liquid plug should also be placed in advance. non-liquid stopper inside the hearts These stoppers are usually made of a hard insulation plastic material manufactured (use according to the correct design size of the hearts. The disadvantage of this stopper is that it is Glee in the manufactured product; the hearts are uneven They differ from each other in their sizes and shapes in a slab with hollow cores significantly and differ from their theoretical sizes and shapes 0. Thus, the plugs may not apply because they are of the wrong size or shape, and they will allow the concrete to seep la pie especially during concrete compaction. Also, the pressure of the concrete Flowing during cal has a tendency to push the plug forcefully into the core This is difficult to prevent by tightly fitting the plugs into the cores Nor does this method, even with restricted movement of concrete towards the plug core, air tight seal MT LY Yo at both ends of the cores This requires a special air pressure test to be performed on the cores

every heart; In addition to a smoking test that takes By to detect possible leaks from the heart. These operations are hampered by the fact that the Lager does not carry out cleaning and sealing operations on the construction site and usually as soon as the Ol is installed or immediately prior to its installation in the correct © locations for it. Therefore the whole process as described is related to the critical path of the general structural site program and due to the stressful nature of the process; They can take a long time, which leads to delays in the work on the site. GENERAL DESCRIPTION OF THE INVENTION: One of the objectives of the method to be described and illustrated later in this section is to provide 0 a method for tightly sealing selected cores in hollow-core tiles; It overcomes at least some of the above disadvantages. Another goal is to provide a method by which smaller tiles with hollow hearts can be cut without contaminating the selected hearts; The TIS cores were sealed tightly so that they became airtight during tile cutting. Gay is an aspect of the present invention; There is a method for transverse cutting of a Gia-manufactured V0 slab having one or more hollow longitudinal cores through at least one intended cut line. The method involves inserting a pair of expandable plugs into at least one of the several hollow cores mentioned. The two plugs of the pair or each pair may be placed in a concerned core so that they are so far apart from each other on opposite sides of an intended cutting line as to ensure that the expansion of the two plugs is blocked after they have entered their respective core. A material that can be hardened is inserted into part of the occluded core or each occluded core between the pair of spaced expanding plugs of each core. and after at least partial hardening of the hardenable material introduced; The slab is cut in the transverse direction through the intended cut line. An aperture or openings may be cut into the side of the slab directly adjacent to the part(s) of the core or cores into which the expandable plugs are to be inserted. This enables the “Yo” to insert the expandable plugs into the core or cores through the opening(s). And after you enter

Expandable tampons and the insertion of a material that can be hardened into the obstructed core or into each obstructed core; It is preferable to seal the opening(s) using material that can be hardened and make the surface of the closed hole or each closed opening flush with the surrounding part(s) of the slab slide. The material that can be hardened preferably consists of concrete and/or thin clay grout © and after JAY expandable plugs; It may need to be stretched. This may involve filling the inlet plugs with a liquid gas or substance under pressure. Expandable plugs may be balloon members and may be filled with a material that can be hardened to cause expansion. Yau than that; Expandable plugs can be flexibly stretched and arranged to expand voluntarily after insertion into a particular core. A release mechanism can be provided that allows self-expansion of the inserted plug. Expandable clogs can form; For example; of foam rubber. A set of pairs of expandable plugs can be inserted into one core in the prefabricated slab; This slab may be a concrete slab. The stopper pairs are spaced apart and each arranged around a different cut-off line. A set of sealed VO slab sections with hollow cores can be cut from the lise slab by cutting through the intended cut lines. It is customary for a Tae slab to have a set of longitudinal hollow cores. In this lad) it is preferable to seal each core in the slab by inserting at least one pair of expandable plugs into it and each core to be sealed tightly by inserting a material that can be hardened into it. Gay, 0 of a second face of the present invention; a section of a sealed hollow-core slab made by the Ga method provides for the above first face of the present invention. Brief Explanation of Drawings The present invention will be further described without limitation by reference to the accompanying drawings; Where: veo Figure 1: Lay shows in perspective a continuous slab with hollow cores on one end; YYVve

Figures A, B and C: show different cross-sections of hollow cores from hollow-core tiles of different heights; dE gat S: showing different steps in a method for sealing cores according to a first embodiment of the present invention; Fig. ©: showing the Uy plata Lay of an exposed end of a slab sealed by ly of a first 0" embodiment of the present invention; Figure +: shows one of the steps in the Gay core sealing method for a second embodiment of the present invention. Detailed Description The Ga hermetic sealing process of the present invention is normally carried out in the plant producing the Vo hollow core slab; However, it can be conducted; As Gal will be described in an embodiment; elsewhere; For example, on the site. Figure 6 shows Lewy from a perspective of one of the ends of a continuous slab with hollow cores (Y) hollow core slab resting on a casting base of its own (£) on which it was cast. connected along the length of the slab. La, however, can be removed. Chalk markings (01) placed on the upper part of the slab and in the transverse direction (op BL ced pal) divide the two independents (OY) 0 separately and indicate the place to be cut. The near end (17) Yo of the slab, as shown in Figure 1, is considered waste and should be disposed of.

l Figures IY “b” and AY show three different cross-sections of hollow cores. The cross-sections of the cores do not have to be circular as they can be, as shown in these various figures, non-circular shapes. It can take irregular shapes and may even differ in shape and size within the same slab.This is not always intended.Once the continuous slab is cast, it should be possible, in the first model at least, to seal the selected cores tightly at certain points.The figure shows ©” A view of the slab from the same perspective as in Figure 1, but by forming (VA) access holes in the upper part of the slab to find access to the selected hearts (1) at the selected locations. J Sng Access holes (VA) ) 0 longitudinally along the hearts at the intersection with the lines marked with chalk (V+) chalk lines that Ft A PI PY SAO Penetration holes in the slab manually or mechanically and the concrete is removed from the upper part of the slab at the same time it is cut from the surface 5 JS holes (VA) are preferred when the Alu Al is semi-moist and in the ripening period. of two independent adjacent tiles according to the first model of the invention. Figure A shows the gap where the access hole (VA) is cut in the upper part of the slab. The upper surface of the concrete shall be removed to a distance of 070 om an) on each side of the position at which the saw shall be cut later; That is, the position marked with chalk (01). Once the hearts are pierced and the desired amount removed from the upper surface of the slab, Led Yo is then inserted as shown in Figure cof. Two membrane bags or two deflated balloons (YY ) deflated bladders of or balloons of suitable diameter in the heart through the orifice (VA). One membranous bag is placed in each direction along the length of the heart at a distance of approximately 0*-01 cm from the position of the publication mark. Thus, they are placed so that the heart surrounds them and they are not placed in the empty space (Y +) empty space directly under the penetration hole (VA) Yo. Figure af shows the two membranous sacs (YY) when they are inflated inside the heart (1) .and in these

A

stage; The two membranous sacs are pressed against the inner surface of the heart (1) in such a way as to form an airtight seal between the surface of the heart and the membranous sac. The two membranous bags are tightly sealed inside to prevent them from being deflated by, for example, a clip or a lize form of valves, and after the two membranous bags are inflated and sealed tightly, the empty space (01) under the access hole is filled (01). VA) this is shown in Fig. D. The filling is a mixture of thin clay comprising concrete that has been removed from the upper part of the core to form a permeable vault and additional concrete; preferably with an additive of non-shrink thin clay grout additive 0 There are various other curing materials that can be used alternatively The mixture is placed in the space (01) between the two membrane bags (YY) and compacted, as necessary, completely by mechanical means. The effect resulting from filling the core with this concrete Dense, or a similar medium, is the pressure of the sides of the two membranous sacs (tila) towards the surfaces of the heart. The friction between the surfaces of the two membranous sacs and the inner surfaces of the core prevents 01 from pushing the two membranous sacs downward along the length of the core with the compressed concrete. Thus, an air-tight Lala seal is achieved by means of the two membrane bags and the slurry mixture. finally; The upper surface of the thin-textured clay mixture (YE) is leveled to make it level with the upper part of the slab (7). The re-filled penetration holes are then allowed to dry before the slab is cut. When re-stuffed, the cores are solid in cross-section. 0 After the stuffed hearts are sufficiently ripened, the continuous slab can be cut into smaller slabs. Figure © shows a continuous slab with cores, which were hermetically sealed according to the first model and cut into smaller slabs. The (V€) slab piece that was on the left side of the slab (VY) was removed before it was cut along line (01) shown in Figures 1 and PLAY at this stage. The drawing shows that Three of the hearts are still open at cle ph while the others (Yo) are clogged with a thin clay mixture (74) which sle the whole volume of the heart at the edges. and remain

The (Y1) residual water slurry resulting from the casting-based cutting process (4). Figure 7 shows a step in the second embodiment of the present invention. And in this form; Cores can be hermetically sealed either at the factory or on site. If this is done in the factory, it is done before or 0 after cutting the connected slab into independent slabs. But if this is on site, it can take place before or after installing the tiles in the place designated for them. And in this form; A smaller permeation hole (YY) forms the side of a slab over a selected core and a single membrane bag is placed in the hole directly below the hole. In this case; The membranous sac itself is the only seal and is filled with a thin cement-based slurry or similar sealing material such that the thin clay extends the membranous sac over the heart wall and is effectively sealed by the Taw Lesa. After that, the membrane bag, as in the previous model (Sag), fills the penetration hole (71) with thin clay based on cement (spat yg (VE) once again, as in the previous model. The filling is crimped and the filling forms a tight seal using ILE. This second form after cutting smaller tiles from larger tiles i.e. in factory ye or on site, a seal is usually formed near the YA end of the slab. This form of seal can be used at both ends. This form of airtight sealing can be done before cutting the tiles and also it can be done in a place close to the place where you want to cut the tiles, or Lad can be done at the point where you want to cut the slab so that the membrane bag is cut into two parts. Membrane ToS 70 - Enough and sufficiently ripened and then the seal will be maintained on both sides of the cut.In these embodiments the seal provided by the membrane bag by itself is only intended to be temporary.Insufficiency is expected Membrane bag during slab use However, the airtight seal provided by the adjacent or internal thin-textured concrete or slurry mixture is still Yo LS YYVE

\ Marks other than chalk marks may be used to show where the continuous slab is to be divided. None of these marks need to extend through the whole width of the slab; or even anywhere on the same slab. Yay from that measurements can be taken to subdivide the continuous slab from other related points.

0 and in either form; It can choose any number of hearts to be sealed. like that; The core itself need not be sealed at each cut point along the entire length of the long slab; However, Ta can be sealed in one or more smaller slabs. It does not matter whether an actual airtight core of is not used. Membrane bags in either model should be able to withstand use

0 roughness and contact; under pressure with the inner surface of the heart; which may have sharp protrusions. It may require Jara to extend it, or it may self-extend. In the first form; Other suitable seals such as expansion foam or foam rubber may be used in place of the membrane bags. In the first form; It is not necessary to use two membrane bags except when it is intended to use a heart for each

Vo is one of the sides of the cut. If a single QB is to be used then only one membranous sac is required to be placed at the tip of that heart. However, it may be useful to place a seal in the other core to ensure a suitable lay for the thin-bodied clay filler.

The whole sealing process in the first model takes place in a casting-based factory where the hollow-core slab is produced; Immediately after casting or at any time during the ripening period

0 before mechanical cutting of independent tiles. And given that the hearts are governed by blocking them on every side

both sides of a rhombic cut through the slab; Remains of water and cement are prevented from entering these blocked hearts. Once the tiles are cut, they are then transported to the construction site where they are installed. The heart remains tightly closed at all times. The membranous sac is left inside the heart; Eventually the Yo will lose the air in it and decompose. However, the cement repayment that was formed in the original in

11 Unlimited Air. A a, the slab remains completely intact and does not and as intended in the models described; By cutting the concrete from the slab to create an outlet to the cores, it is envisaged to produce a continuous slab containing these previously existing holes.

Claims (1)

VY Protections 1-1 method for transversely cutting a prefabricated slab (ae da time) having upper and lower Y sides and one or more hollow longitudinal core v; through a cutting line cut Tine at least one intent; the method includes: ¢ provide the slab with at least one aperture through one of the ° upper and lower sides in a core and at least one of the hollow cores 1 multiple mentioned; near at least one intended cut line; y insert at least one pair of expandable plugs from A through at least one aperture in the core locations core at least one of the several 9 hollow cores mentioned; the expandable plugs Ve of a pair or each pair shall be placed in a respective core spaced apart on 1 opposite sides of the cut line Intended at least one; VY to extend inserted plugs to plug the respective core or cores; VY to insert a settable material through at least one aperture Ve In the blocked core or in each blocked core between \o the pair of its own spaced expanding plugs to fill and seal the blocked core 1 or each blocked core Between the pair or pairs of 1 expanded fexpanded plugs and the slab is cut transversely through at least one V4 intended cut line to form “smaller individual slabs” containing a core Ye at least one hollow core blocked at least at one end after hardening 71 le partial setting least of the settable material YY inserted. 1 "- method (ad of claim 11) in which at least one aperture is cut in one of the Y upper and lower sides of the slab directly adjacent to the r positions of the core core or cores into which the expandable plugs 3 are to be inserted. 1 “- Method Gi of the oF protector also includes; When the settable material Y is inserted into the blocked core or in each blocked core v, at least one aperture is closed with the settable material. For closed aperture or for each closed aperture ° couter surface and outer surface leveling 1 for closed aperture or for each closed aperture with 7 slab side Ocean. settable material include Cum ;1 for protection element dg ;- method 1 or a mixture of both. 1 0— The ad method of protection ¢ also involves filling the inserted plugs with gas Y liquid or material under pressure to cause them to expand. 1 1- A method according to Claim 3 whereby the plugs are resiliently expandable 7 and expand voluntarily after being inserted into a relevant core. \ 7 method according to claim 1 wherein the expandable plug or each Y expandable plug is provided with a self-expansion mechanism 0 The method also includes the step of releasing the self-expansion mechanism -expansion mechanism or ‎YYVe Ve ¢ Each self-expansion mechanism to allow the inserted plug ° or each inserted plug to expand itself. ——A 1 method according to the element of protection, where the ALLEN expandable plugs Y consists of a rubber rubber that is 1. 1 4- method of claim 1 wherein the expandable plugs Y are 'balloon members' -0 1 method i of claim 1 wherein the slab slab is a concrete slab .concrete slab Y -11 method according to claim 0 ( Cua fill the inserted plugs with a material that can be hardened .settable material -11 1 method according to claim 1 where the slab has slab A set of 7 cut lines intended; a set of pairs of expandable plugs 1 is inserted into a single core of a prefabricated slab prefabricated through a set of apertures and separated pairs of plugs screw ° each other and arrange each around a different intended cut line; cut 1 set of sealed hollow core slab sections 7 of the prefabricated slab By cutting through the intended cut A lines. VY method according to the claim; Where the slab has a set of Y-cintended cut lines and a set of pairs of expandable plugs 3 are inserted into one core of the “prefabricated slab ¢” through a set of 8 holes. m and JS arranges them around a different cut line; A set of sealed hollow core slab sections 1 is cut from the prefabricated slab by 7 cuts through intended cut lines 1-4 method according to claim)¢ Where each core of the group of Y cores in the prefabricated slab is sealed by inserting at least one ¥ pair of expandable plugs into it and sealing each core ¢ Tightly by inserting the material that Say hardens the settable material into it. -15 1 method according to the oY protection element whereby each core of the group of hearts is closed by sockets 1 in the prefabricated slab. prefabricated slab by inserting at least one pair ¥ of expandable plugs into it and seal each core ¢ tightly by inserting settable material into it. yeah