SK9132Y1 - Building block, in particular formwork building block, method of its production - Google Patents

Abstract

The building block, in particular the concrete-based formwork building block, has two parallel oriented outer plates (1) with reinforcement (4). The cavity (3) is intended mainly for pouring a concrete mixture. The outer plates (1) are firmly connected to each other by a partition (2), preferably of non-metallic, non-concrete material. At least one reinforcement (4) is first inserted into the mold on each outer plate (1), and then concrete is poured into the mold. At least during the onset of setting, the concrete is extruded to the surface of the mold, which defines the outer side of the outer plates (1). A centrifugal force or gravity of the concrete itself is used to press the hardening concrete against the contact surface (7) of the mold, preferably with simultaneous vibration. Preferably, the concrete is poured into the mold in two stages, in the first phase the first outer plate (1) is cast into the mold in a horizontal position and the mold is rotated at least after partial hardening and the second outer slab (1) is cast. The advantage is a highly aesthetic appearance and repeated shape and dimensional accuracy of building blocks.

Description

Technical field

The technical solution relates to a building block based on concrete, intended for pouring a concrete mixture in the construction of walls, walls, fences and the like. The building block has both sides made as visible with a surface finish, which can be the final version. The solution also describes a new method of manufacturing building blocks with the possibility of vibrating the bodies of external plates to achieve a high quality of their surface.

Prior art

Known masonry and formwork building blocks are made of plain concrete by pressing. Formwork blocks perform the function of lost formwork and have a cavity large enough to be poured with a concrete mixture. Formwork blocks were originally created by changing the dimensions of masonry blocks. These are designed to be bonded together with mortar and have narrow cavities created to reduce weight and improve thermal insulation properties.

Formwork blocks have a relatively large thickness of the outer slabs, since simple concrete without reinforcement is used in the pressing and it is necessary to ensure the stability of the block at the pressure of the poured concrete mixture. The partitions connecting the two outer slabs are also relatively large, as they are made of the same concrete base and the concrete has a low tensile strength. As a result of these limitations, the formwork block has relatively thick elements that reduce the size of the cavity and the cavity is closed within the body of the respective block, there is no direct connection of the concrete mixture of adjacent blocks. The connection is secured by horizontal reinforcements, which are placed on the partitions of the blocks.

EP2096221 A2 describes a formwork block having two separate concrete parts connected by an insulating material to the grooves, but the connection of the concrete mixture between the blocks is still very limited. Formwork blocks made of insulating plastic material are similarly designed, as for example according to FR2937660 A1.

A disadvantage of the known formwork blocks is also the insufficient surface treatment. To create a visually acceptable form, the blocks are subsequently plastered or their surface is otherwise treated, usually only after the construction of a more complete part of the building.

A new technical solution for a formwork block is desired and is not known, which will better interconnect the concrete mix of adjacent blocks, have relatively thin outer slabs, and at the same time allow the final surface treatment to be created.

The essence of the technical solution

These shortcomings are substantially eliminated by a building block, in particular a concrete-based formwork building block, having two concrete-based outer slabs, between which a cavity is formed, intended in particular for pouring concrete mixes, and where the outer slabs are firmly connected to each other by a transverse element according to of this technical solution, the essence of which consists in that each outer slab has at least one reinforcement cast in it and the outer slabs are connected by at least one partition made of a material different from concrete. It is also advantageous if the partition is adapted to pass the concrete mixture from the cavity of the respective block to the cavity of the adjacent block, i.e. the partition does not significantly delimit and seal the cavity of the respective block.

The term external plate in this document refers to the part of the block which, after the construction of the respective construction work, has been located on the external surface. The outer plate is usually rectangular or generally square in shape and its dimensions determine the consumption of the number of blocks per 1 m ^{2 of} wall.

An essential feature of the presented technical solution is the use of reinforcement in the body of the outer slab, thanks to which the bending strength of the outer slab is significantly increased under the action of hydrostatic pressure of the poured concrete mixture, resp. also under the action of dynamic pressure of the concrete mixture during its vibration. The reinforcement in the outer plate makes it possible to reduce the thickness of the plate, thus freeing up more space in the cavity. An important feature is also the connection of the outer plates by means of a non-concrete partition, i.e. the outer plates are connected to each other at the required distance by a spacer element of a different material than the material of the outer plates themselves. Such an arrangement will allow to substantially change the dimensions and shape of the transverse element. The partition can be made of the same material as the reinforcement in the outer plates or a different material with better thermal insulation properties can be used. The task of the partition is to firmly and reliably maintain the mutual position of the outer slabs until the time of hardening of the concrete mixture in the cavity, or it can also form a support for the horizontal reinforcement laid through the cavities.

The reinforcement in the outer plates can be made of metallic materials, for example it can be formed by a conventional welded steel mesh or ribbed steel bars. The reinforcement in the outer plates can be made of non-metallic materials, it can be made of a composite material, for example based on basalt, basalt, glass2

SK 9132 Υ1 laminate and the like.

The partition can be made of metal, in a simple embodiment it is made of ribbed steel similar to the reinforcement in the outer plate, or such a partition can be part of a unit with reinforcements in both outer plates. In order to avoid heat transfer through the body of the partition, i.e. between the outer plates, it is suitable if the partition is made of a non-metallic material, even if the reinforcement in the outer plates is metallic. The partition can be made of plastic, composite, basalt and the like. It is also advantageous if the partition has a connecting element for connection to the reinforcement in the outer plate, in which case the partition also forms a means for ensuring sufficient coverage of the reinforcement in the outer plate.

The shape and design of the partition, as well as the number of partitions in one block, can be varied. Typically, the block will have two or three flat partitions at regular intervals. In a preferred arrangement, the flat partition has an obliquely guided element to ensure better shear stiffness. Depending on the type of material selected, the partition can have a compartment construction with at least two bars running perpendicularly, resp. substantially perpendicular to the plane of the outer plates and with at least one rod guided obliquely, preferably guided diagonally between the vertically guided bars.

Due to the fact that the partition does not prevent the poured concrete mixture from flowing between the cavities of the adjacent blocks, a significantly better load-bearing bond is achieved. Using formwork blocks made of plain concrete, the partitions divided the poured concrete mixture into separate parts, like columns, which were connected by horizontal reinforcement. However, when using a formwork block according to this technical solution, a continuous mass of concrete is formed.

The partition can be provided at the upper and / or lower edge with protrusions or grooves for inserting or catching a horizontally placed reinforcement, which is laid after the placement of a row of blocks. Such an element for the horizontally placed reinforcement can be in the middle of the partition, at its two edges or at various regular intervals.

A significant advantage of the present technical solution is that the material separation of the partition and the outer plates, as well as the use of reinforcement in the outer plates, can make these two main parts of the block more efficient. It is also advantageous if the outer plates are cast in a mold, so that they can have an outer surface made with a final surface treatment. For example, the outer surface may be completely smooth or patterned.

The edges of the outer surfaces may have edges adapted to better fit adjacent building blocks in a row or above each other. The edges of the outer plates can be fitted with a tongue and groove.

It is also advantageous if the outer plate not only has the final surface finish of the resulting wall, but also has openings for guiding installations, it can have, for example, an opening with an electrical installation box.

To increase the thermal insulation properties, a layer of insulator, for example foam or extruded polystyrene, can be attached to the inside of the outer plate. In such an embodiment, the partition passes through the insulator layer or is connected only to the insulator layer, and this is subsequently connected to the outer plate. The reduction of the thicknesses of the outer slabs leaves sufficient space for the required insulation thickness while maintaining a sufficient thickness of the load-bearing concrete in the cavities.

The shortcomings mentioned in the prior art are also eliminated by the method of manufacturing a building block comprising casting concrete into a mold, the building block having two external concrete-based slabs, the outer slabs being parallel and firmly connected to each other by a transverse element according to this technical solution. that the concrete of the outer slabs is pressed into the mold surface after pouring into the mold and at least during the onset of setting, which determines the outer side of the outer slabs, at least one reinforcement being inserted into the mold for each outer slab before pouring the concrete.

An important feature is the use of a mold, the surface of which determines the shape and design of the outer plate on its visible side, while the outer sides of both outer plates are formed. This means that two opposite sides of the block are formed, thus creating a visible surface on the outer sides of both outer plates. The inner sides of the outer plates, which delimit the inner cavity of the block, need not and usually will not be formed. At first sight, such a procedure appears to be problematic, since a classically oriented mold, i.e. for filling from above for both outer plates, would require the formation of a forming bevel, which would make it impossible to produce parallel facing sides of the outer plates.

In order to solve this shortcoming, centrifugal pouring of concrete into a mold or two-stage filling of a mold is used in this technical solution. In centrifugal casting, a mold rotation is used to extrude the concrete to the contact surface of the mold, which lasts at least during the onset of setting, i.e. at least until the concrete has a stiffness in the outer plates which allows demolding without damaging the shape. Since such centrifugal casting is more energy-intensive and may require, for example, heating of the molds to shorten the setting time, a two-stage mold filling method has been invented in which concrete is pressed against the contact surface of the mold by its own weight during setting. First, the mold is oriented so that it lies on one side, the contact surface of the mold is oriented horizontally, and a quantity of concrete corresponding to one outer plate is poured onto it. Before pouring the concrete, the reinforcement of the outer plate and the partition, resp. multiple partitions according to the dimensions of the block.

After pouring the concrete belonging to the first outer slab, the mold can be vibrated, for example by placing it on a vibrating table. At this stage, therefore, only one outer plate is cast, with a partition protruding from the top,

SK 9132 Υ1 resp. several partitions and possibly also reinforcement for the second outer plate. However, the second outer plate is cast only in the subsequent step, when the first outer plate has already solidified at least to such an extent that it allows the mold to be rotated without disturbing the shape and design of the first outer plate. After turning the mold, the second outer plate is cast in the mold similarly to the first, i.e. with the horizontal orientation of the contact surface of the mold, when the weight of the concrete itself and possibly also with vibration support presses the setting concrete against the mold surface. Thanks to the above-mentioned two-stage solidification process of one block, thin outer plates with a high-quality surface can be produced easily and very efficiently. Vibration and the use of reinforcement will ensure high strength of the block. The mold may have only one contact surface in which the first and second outer plates are cast in succession, or it may have two contact surfaces in which the second outer plate is cast only after the first contact plate has hardened and the mold has been rotated, but the first outer plate may not exempt. In this case, the second outer slab can be cast earlier, it is sufficient to achieve less stiffness of the concrete in the first outer slab. In this embodiment, the mold is decomposable so that a mutual separation of the contact surface of the mold from the molded surface of the outer plate can be achieved perpendicular to the molded surface.

The mold with two contact surfaces can be easily assembled into a detachable unit having four posts with a profile L. A stop is formed at both ends of each post, the distance between the stops on the post determines the distance of the contact surfaces of the mold. The contact surfaces are part of a tray into which the measured amount of concrete is gradually poured. Four columns on the outside surround both trays. In this example, the mold is composed by first inserting reinforcements connected by partitions and then closing it by closing the trays. Quick-release lever clamps are used for detachable connection of columns with trays. The mold is placed in a tray on a vibrating table and the measured amount of concrete is poured into the tray. The concrete is vibrated and the mold is stored outside the vibrating table, where solidification continues. After solidification to a state where the concrete poured into the first tray is no longer damaged, the mold is turned and placed with a long tray on a vibrating table, where the measured amount of concrete is poured into the second tray. After vibration, the mold is set aside and the concrete is allowed to harden. Subsequently, the lever clips are released, the posts are set aside and each tray is formed separately.

The advantage of the presented technical solution is a highly aesthetic appearance and high repeated shape and dimensional accuracy of building blocks compared to products that are pressed from plain concrete. The production technology does not require expensive equipment and can be quickly changed according to current requirements for different dimensions and surfaces of blocks. In a preferred embodiment, the mold may have replaceable inserts which form the contact surfaces of the mold, so that the desired design can be created, for example a smooth surface, imitation of a wooden surface, imitation of stone, cladding and the like.

Overview of figures in the drawings

The technical solution is explained in more detail with the help of Figures 1 to 7. The illustrated shape, height and width ratios of the block and the scale of dimensions of individual elements are only examples and should not be construed as limiting the scope of protection.

Figure 1 is a perspective view of a building block with three plastic composite partitions.

Figure 2 shows a plan view and Figure 3 a side view of a building block with reinforcements shown in the outer plates. In Figure 2, the outer plates are shown in dashed lines for clarity.

Figure 4 shows the connection of the partition with the reinforcements when viewed in the direction of the reinforcements.

Figure 5 shows a detachable mold for successive two-stage casting of a building block with inserted partitions and reinforcement.

Figure 6 shows a building block with an insulating layer.

Figure 7 shows a partition made of ribbed steel, the partition being connected to a reinforcement in the form of a welded mesh.

Examples of embodiments

Example 1

In this example according to Figures 1 to 5, the formwork building block is produced by two-stage casting into a detachable mold with two contact surfaces 7.

The mold has four columns with an L profile, which, when folded, encircle the trays in the corners. The inner bottom of the tray forms a contact surface 7, which in this example is smooth, without a pattern. The posts are equipped with lever quick-release clips and have stops at the ends that keep the trays at a firm and precise distance from each other. In this example, the mold is set to the outer dimension of the block 180 mm x 300 mm x 480 mm.

Inside the mold, clips are formed to hold the partition 2 together with the reinforcement 4 in a determined position, when the reinforcement 4 does not touch the contact surfaces 7, but at the same time has sufficient coverage with the concrete mixture. This po

SK 9132 Υ1 the bed approximately corresponds to the position of the reinforcement 4 in the middle of the thickness of the outer plate 1. Three partitions 2 with reinforcements 4 are inserted into the mold, which are in the form of straight steel bars made of ribs and pass through holes .

The two end partitions 2 are held by clamps approximately in the middle between the contact surfaces 7, the middle partition 2 being supported by reinforcements 4.

Thanks to the columns, the mold has an open construction, it basically consists of two simple flat molds connected into a spatial assembly. A measured amount of concrete is poured into a mold placed on one tray and the mold is placed on a vibrating table, where the poured concrete is vibrated, poured well and pressed against the contact surface 7 of the lower tray. After vibrating, the mold is removed from the table and left in a horizontal position, when the concrete hardens. After solidification, the mold is rotated 180 ° and placed on a second tray, into which the measured amount of concrete is then poured and vibrated again on a vibrating table. The concrete is allowed to set sufficiently and the mold is dismantled by releasing the lever clamps, removing the posts and removing the trays from the outer plates 1.

The outer plates 1 have a smooth surface on the outside and in this example are provided with a tongue and groove on the side edges. The outer plates 1 are firmly connected by the partitions 2 and are parallel to each other, the reinforcement 4 is cast inside the outer plates. The cavity 3 for pouring the concrete mixture is delimited by the inner sides of the outer plates 1, on the sides the cavity 3 does not have a tight delimitation, since the partitions 2 do not prevent leakage, resp. overflow of the concrete mixture.

In this example, the partitions 2 are made of plastic as moldings with a compartment construction which comprises two horizontally guided rods and two diagonal rods, which gives the partitions 2 high rigidity and stability at low weight. On the horizontal bars, the crosspiece 2 has grooves for accommodating a horizontally guided reinforcement, which is added to the laid blocks before pouring the concrete mixture.

The formwork building block has a high dimensional accuracy and a smooth surface of the outer plates, which is the final surface treatment of the resulting wall.

Example 2

In this example according to Figure 6, a layer of insulator 6 is applied on the inside of one outer plate 1, which can be, for example, foamed or extruded polystyrene. In this embodiment, the insulator layer 6 has a thickness of 150 mm, thanks to which the block has a high thermal resistance. The cavity 3 for pouring the concrete mixture has a width of about 150 mm, which is sufficient for use in the load-bearing wall. Due to the small thickness of the outer plate 1, sufficient space remains for the load-bearing reinforced concrete as well as for the insulation.

The block according to this example is particularly suitable for perimeter walls, where it directly forms the final visible surface on both sides and does not require any further plastering or insulation.

Example 3

The partition 2 in this example shown in Figure 7 is formed integrally with the reinforcement 4 of a steel welded mesh. Such a solution is simple and cheap, it can be used in cases where no thermal insulation properties of the finished wall are required, for example in the case of fencing and the like. The steel wires in the partition 2, which pass from one outer plate 1 to the other outer plate 1, represent a thermal bridge, but this is not problematic in many applications.

Industrial applicability

Industrial applicability is obvious. According to this technical solution, it is possible to industrially and repeatedly produce and use building blocks, in particular as formwork building blocks, which form a lost formwork, while the outer plates form a visible surface.

SK 9132 Υ1

List of reference marks

- outer plate

- partition

3 - cavity

- reinforcement

- connecting element

- insulator

- mold contact surface

Claims (16)

CLAIMS FOR PROTECTION A building block, in particular a concrete-based formwork building block, having two concrete-based outer slabs (1) oriented in parallel, between which a cavity (3) is formed, intended in particular for pouring a concrete mixture, and wherein the outer slabs (1) are firmly connected to each other by a transverse element, characterized in that each outer plate (1) has at least one reinforcement (4) embedded in it, the outer plates (1) are concrete castings and are interconnected by at least one partition (2) of different material from concrete. A building block, in particular a formwork building block, according to claim 1, characterized in that at least part of the outwardly oriented surfaces of the two outer plates (1) results from contact with the mold surface, preferably the outwardly oriented surfaces of both outer plates (1) are vibrated. Building block, in particular a formwork building block, according to claim 1 or 2, characterized in that the reinforcement (4) is made of metal, preferably of welded mesh or of ribbed steel. Building block, in particular formwork building block, according to claim 1 or 2, characterized in that the reinforcement (4) is non-metallic, preferably of laminate or basalt, or of a non-metallic composite. Building block, in particular formwork building block, according to any one of claims 1 to 4, characterized in that the partition (2) is made of a non-metallic material, preferably plastic or composite. Building block, in particular a formwork building block, according to any one of claims 1 to 5, characterized in that the partition (2) has a connecting element (5) for connection to the reinforcement (4). Building block, in particular formwork building block, according to any one of claims 1 to 6, characterized in that the partition (2) is flat and has the shape of a compartment structure with at least two bars running perpendicular to the plane of the outer plates (1) and at least one rod guided obliquely, preferably guided diagonally between the vertically guided rods. A building block, in particular a formwork building block, according to any one of claims 1 to 7, characterized in that the partition (2) is provided at the upper and / or lower edge with protrusions or grooves for inserting and / or catching horizontally placed reinforcement. A building block, in particular a formwork building block, according to any one of claims 1 to 8, characterized in that the outer plate (1) is provided with a tongue and groove. A building block, in particular a formwork building block, according to any one of claims 1 to 9, characterized in that it has a layer of insulation (6) on the inside of one outer plate (1). A method of manufacturing a building block comprising pouring concrete into a mold, the building block having two concrete-based outer plates (1), the outer plates (1) being parallel and firmly connected to each other by a transverse element, characterized in that the mold for each outer of the plate (1), at least one reinforcement (4) is first inserted, concrete is poured into the mold and then, at least during the onset of setting, the concrete is extruded to the surface of the mold, which defines the outer side of the outer plates (1). A method of manufacturing a building block according to claim 11, characterized in that the poured concrete is pressed against the surface of the mold by centrifugal force. A method of manufacturing a building block according to claim 11, characterized in that the concrete is poured into the mold in two stages and the poured concrete is pressed against the mold surface by its own weight, the first outer slab (1) being cast into the mold in a horizontal position and at least after partial solidification, the mold is rotated and the second outer plate (1) is cast. Method of manufacturing a building block according to claims 11 or 12, characterized in that the concrete is vibrated after pouring into the mold, preferably by placing the mold on a vibrating table. Method of manufacturing a building block according to any one of claims 11 to 14, characterized in that the concrete is poured into a mold with one contact surface (7) and the second outer slab (1) is poured only after the first outer slab (1) has been formed. A method of manufacturing a building block according to any one of claims 11 to 14, characterized in that the concrete is poured into a mold with two contact surfaces (7), the mold being detachable.