US3600481A - Method for more rapidly producing aeroconcrete building elements - Google Patents

Method for more rapidly producing aeroconcrete building elements Download PDF

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Publication number
US3600481A
US3600481A US873747A US3600481DA US3600481A US 3600481 A US3600481 A US 3600481A US 873747 A US873747 A US 873747A US 3600481D A US3600481D A US 3600481DA US 3600481 A US3600481 A US 3600481A
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Prior art keywords
die
mixture
elements
aeroconcrete
frames
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Expired - Lifetime
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US873747A
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English (en)
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Walter Lanz
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • B28B1/503—Moulds therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
    • B28B5/04—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping in moulds moved in succession past one or more shaping stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/28—Cores; Mandrels

Definitions

  • ABSTRACT OF THE DISCLOSURE A method for continuously producing building elements of aeroconcrete, wherein components of a multi-part form include bottom portions which are recirculated to a filling station after setting of the elements being produced while frames and inserts of the multi-part forms are recirculated after stabilization of the aeroconcrete which has been poured, and prior to the use are cleaned and greased.
  • the aeroconcrete is stabilized sufiiciently to permit removal of the die frames within about 36 minutes after pouring.
  • This invention relates to a method for mechanized production of building elements of aeroconcrete having hollow spaces, and a plant for carrying out this method.
  • a first solution resides in the idea that the most expensive and heaviest parts of the die, namely the die frame and the die insert should be recovered at a stage as early as possible of the production of the elements and should be made available for another casting operation.
  • the method according to this invention is characterized by providing a number of dies, repeatedly assembling, filling and providing with core means and separating wall means individual dies in a filling station at one end of conveyor means, removing said core means, separating wall means and frame portion from said bottom portion simultaneously or within short time intervals at the other end of said conveyor means after a transfer time corresponding to the time required for stabilisation of the mixture, and reconveying said core means, separating wall means and frame portions through a cleaning plant and a greasing plant to the filling station, while the building elements remain on the said bottom portion until complete setting of the mixture, whereafter the bottom portions are returned to the filling station.
  • the die frame and the cores or a single die insert comprising cores respectively are recovered practically at the same time, this allowing not only reduction of the number of die frames but also simplifies the retransport of the die frames and core inserts from the dismantling station to the casting and filling station.
  • the expanding agent specified in Swiss Patent No. 360,332 and consisting of 1-2 parts by volume of aluminum powder and 1-2 parts by volume of limestone powder may preferably be used.
  • This invention also relates to a plant for carrying out the above method, this plant comprising a production line having conveyor means for simultaneously transporting a number of dies from a filling station to a dismantling station, a cutting device in said dismantling station for removal of portions of the stabilized mixture extending upwardly from the die, a running period of said conveyor means from said filling station to said dismantling station adapted to the time interval required for stabilization of the mixture, and by means in said filling station following each other in the running direction of the conveyor means for positioning of the bottom portion of the die, for putting the frame portion of the die onto said bottom portion, for stirring and pouring said mixture and for inserting said core means and separating wall means.
  • the filling station comprises the necessary equipment for assembling and filling the dies.
  • This plant specifically adapted to the requirements of the production of aeroconcrete preferably has a first closed circulation for the die frames and die inserts which are retransported from the dismantling station through a cleaning station and a station for application of greasing mediums to the filling station, whereas in a second circulation the die bottoms with the dismantled elements are brought into a storing plant until the elements are completely set, and are retransported from this storing plant through a cleaning and greasing plant to the filling station.
  • a substantial advantage of the method and plant according to the invention resides in the fact that only the simplest, lightest and cheapest part of the die, namely the die bottom, is required until the elements have completely set.
  • FIG. 1 is an elevation of the important part of the plant
  • FIG. 2 is a top view of the part of the plant shown in FIG. 1,
  • FIG. 3 is a top View of a die
  • FIG. 4 is an elevation of this die
  • FIG. is a partial section of the die along line V-V in FIG. 3,
  • FIG. 6 is a partial section along line VIVI in FIG. 3, and
  • FIGS. 7-9 show details of a guiding device.
  • the plant illustrated in FIGS. 1 and 2 has a straight producing line along which casting dies or molds may be transported from a filling station to a dismantling station.
  • the filling station of the production line has a fixed work table 1, along which the casting dies may be advanced stepwise from the right to the left by means of a hydraulic cylinder 2 indicated in FIG. 2.
  • the die bottoms 3 schematically illustrated in FIGS. 1 and 2 as fiat sheets are put onto the table 1.
  • Individual die bottoms put on the table are then shifted to the left into position B by means of the advancing device 2, in which a die frame 5 is put onto the bottom from a return ramp 4 by means of a suitable hoist.
  • This conveyor line preferably consists of a suitable sliding Way along which the bottoms 3 of the dies may slide, and of a conveyor chain 10 having driving members, not shown, for driving one die each.
  • the dies are continuously shifted without vibration to the left-hand end of the sliding way by the chain 10.
  • Water, sand and portland cement may be fed to the mixer 6 from three containers 11, 12 and 13 through suitable dosing devices not shown, and through a common collecting funnel, while the expanding agent such as equal parts of aluminum and limestone powders, is directly fed to the mixer 6 from a small container 15.
  • a table 16 extends transversely to the direction of this conveyor way.
  • the dies arriving from the conveyor way on the table 16 may be shifted along this table into positions E and F.
  • a bracket 17 By means of a knife 18 in the form of a snowplow is supported above the table, the lower edge acting as a cutter being disposed at a distance above the table 16 corresponding to the height of the die, such that the die may be passed below the knife into position E practically without vertical clearance.
  • Two stacking trucks 19 and 20 are disposed at the side of the table 16, which are coupled with each other and may be displaced on a track along the table 16.
  • the stacking truck at the side of position F serves for taking up the die bottoms carrying elements, while the die bottoms with elements stacked above each other on the other stacking truck are simultaneously lifted out by means of a fork truck and may be transported into a warehouse, for example in which the elements are stored for setting.
  • Hoists 21 and 22 respectively are disposed above positions E and F, which serve for lifting the die insert and the die frame. respectively, from the die bottom and to life them onto the one of two conveyor bands 23 and 24 respectively.
  • the upper sides of both conveyor bands first pass through a cleaning device 25 and into a device 26 for greasing the die frames and die inserts, respectively, with a suitable greasing agent.
  • the cleaning device 25 may include nozzles for cleaning the frames and die inserts by means of vapour, compressed air, water, solvent agent or the like or a combination of several of these nozzles.
  • the greasing device 26 includes a spraying device for spraying preferably a mixture of fat and oil of such a consistency that fine vaporization and spraying and forming of continuous well adhering layers is possible. From the greasing device 26, the die inserts and die frames slide over the slide ways not designated to the places from where they are transferred onto the die bottom and into the already filled die respectively in the filling station.
  • FIGS. 3 to 6 the particular die is illustrated. It consists, as mentioned above, of the fiat die bottom 3, the die frame 5 and the die insert 8.
  • the die frame has the form of a rectangular frame of sheets 29 reinforced on the full circumference by U- profiles 30 welded to the sheets 29.
  • the die insert has a grid of separating walls 31 and 32 respectively of steel sheets welded to each other and disposed at right angles. These separating walls 31 and 32 form a honeycombed grid so that with the die insert 8 put into the frame 5 elongated chambers 33 of rectangular cross section are formed. Core portions made of welded sheets and centrally extending through four chambers 33 are connected to the transverse separating walls 31. As shown particularly in FIG. 6, the core portions substantially consist of a U-shaped bent metal-sheet canal 34 having two transversely extending cuttings 35 in each chamber 33. Each cutting 35 is closed by a V-shaped bent metal sheet 36 at its upper side and by means of metal sheets 37 at its faces, such metal sheets having a V-shaped cutting corresponding to the form of the metal sheet 36 at their upper end. The ends of the core portions are closed by means of end metal sheets 38. Finally, all core portions are closed at the upper side by means of a plane covering metal sheet 39.
  • the cores are somewhat wider at their upper side than at their lower side so that they may be lifted out of the mixture filling the chamber 33 relatively easily.
  • a core extends in longitudinal direction through each chamber 33, hvaing an upper continuous horizontal prismatic portion of the sectional form seen in FIG. 6 and three vertical column-shaped portions separated from each other by the cuttings 35.
  • These cores correspond to the hollow spaces of the finished elements or stones which thus have two solid lateral wall portions interconnected by two transverse ribs corresponding to the cuttings 35.
  • Rings 40 are provided at four crossings of separating Walls 31 and 32 respectively, at which the die insert may be lifted.
  • the die bottoms 3 returning from the store, cleaned and greased at their upper surface are put into the filling station in position A, they are provided with a die frame in position B and filled in position C to a predetermined height with the previously prepared mixture.
  • the mixer 6 is dimensioned for preparing quantities suitable for filling one die, and the required quantities of water, sand, portland cement and expanding agent are admitted from suitable dosing devices and mixed immediately after release of the previously prepared mixture.
  • the die is filled in a well known manner to such a height that at the end of its expansion the mixture slightly swells over the die so that in any case the die is completely filled and the excess material may be removed.
  • the mixture is again intensively stirred and distributed in the die so that all portions of the mixture, particularly constituents of different weight of the sand are uniformly distributed in the die.
  • the die insert 8 is then inserted whereafter the die arrives on the conveyor line 9.
  • the die insert 8 When the so treated die arrives in position E of the dismantling station, the die insert 8 is first lifted out and is put onto the conveyor band 23. When the next die is shifted into position E, the die laying in this position is pushed on into position F in which the frame is now lifted and put onto the conveyor band 24. After lifting out of the frame the die bottom together with the dismantled elements is shifted into the stacking, truck 19 placed in front of position F. While the stacking truck 19 is filled, several die bottoms with dismantled elements are. simultaneously removed from the stacking truck 20 by means of a fork lift truck not illustrated and are placed into the store for setting. When the stacking truck 19 is filled, both stacking trucks are shifted upwardly in FIG. 2 so that the stacking truck 20 unloaded in the meantime arrives again in front of position F and is gradually filled While the die bottoms with the dismantled elements are removed from the stacking truck 19.
  • the die inserts and die frames are cleaned and greased in the manner indicated above during their retransfer over the conveyor bands 23 and 24 parallel to the producing line, and then return directly to the filling station where they may be used again.
  • the elements which were produced in the manner explained above are left in storage for about 2 /2 days until the elements have completely set, whereafter the elements are shifted off and stacked or transported away, While the remaining die bottoms are cleaned and greased and returned to the filling station.
  • the production capacity depends in the first line from the time interval from the filling operation to dismantling. This time may be reduced to about 36 minutes when a mixture is used comprising 32-39, preferably 37.5 weight percent portland cement, 3932, preferably 37.5 weight percent sand, 2530, preferably 28.5 weight percent water and at least .5 Weight percent expanding agent. Further care must be taken that during the casting operation, the mixture has a relatively high temperature of 20- C., this being achieved by placing the plant in a room heated to at least 20 C. and preheating the Water to 30- 32 C.
  • the producing capacity is further determined by the sequence, that is, the time interval between each casting operation and dismantling operation respectively. Assuming that 20 dies are disposed between the filling station, and the dismantling station an interval of 1.8 minutes is required, that is, each casting operation must be completed within time intervals of 1.8 minutes.
  • the duration of the operating sequence is limited by the fact that the die insert must be put into the mixture poured into the die before development of gas begins. With the mixture indicated above, gas development begins relatively soon and care must be taken that the die insert is inserted not later than 4 minutes after the end of the casting operation.
  • a mechanical stirring device having by way of example a number of relatively small stirring propellers with vertical shafts or having a reciprocating stirring rake may be provided, which may be lowered into the die frame without, however, touching the bottom and damaging the layer of grease on the same.
  • the holding-down appliance may be a part of the vertically guided lifting appliance mentioned above for simultaneously lifting the die frame and die insert.
  • outer orienting angles 50 are mounted on levers 51 swingable round a shaft 52 by means of a double-acting hydraulic cylinder 53.
  • the levers 5 1 engage into and are axially guided in slit cuttings 54 of the table 16 in position F in all corners of the die bottom 3.
  • the orienting angles 50 are in their upper operative position shown in FIGS. 8 and 9, they tightly enclose the corners of the die bottom and thus exactly determine the position of this bottom.
  • the legs of angles 50 and 55 extending in the swinging direction have their ends bent outwardly for properly engaging and orienting the die bottom and engaging the die frame when swung into operative position.
  • the die bottoms have enlarged rim portions 56 butting against each other so that gaps are formed between adjacent die bottoms allowing entrance of the angles 50.
  • the angles 50* and 55 may be swung outwardly into a substantially horizontal inoperative position below the table 16 for allowing shifting of another die from position E into position F and for shifting a die bottom with dismantled elements from position F into the stacking truck.
  • die inserts of different type For producing elements of various forms, it is only necessary to use die inserts of different type.
  • the die frame and the die bottom may thus be used for all kinds of elements.
  • a method for mechanized production of building elements of aeroconcrete having hollow spaces which comprises the steps of:
  • a mixture of concrete and an expanding agent consisting essentially of 3239 weight percent cement, 39-32 weight percent sand, 25-30 weight percent water, and at least .5 weight percent expanding agent consisting essentially of 1-2 parts by volume of aluminum powder and 1-2 parts by volume of limestone powder with the mixture having a temperature of 20-35 C. when poured into the die cavities, and inserting core means and separating wall means, from a source thereof, into the die cavities at a first region along said path adjacent said first station within a time interval of not more than 4 minutes after pouring the mixture,

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Producing Shaped Articles From Materials (AREA)
US873747A 1966-06-08 1969-11-26 Method for more rapidly producing aeroconcrete building elements Expired - Lifetime US3600481A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
AT545466A AT263598B (de) 1966-06-08 1966-06-08 Verfahren und Einrichtung zur mechanisierten Herstellung von Hohlsteinen aus Gasbeton

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US3600481A true US3600481A (en) 1971-08-17

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US (1) US3600481A (xx)
AT (1) AT263598B (xx)
BE (1) BE699492A (xx)
CH (1) CH468876A (xx)
DE (1) DE1683888A1 (xx)
GB (1) GB1173070A (xx)
NL (1) NL6707875A (xx)
SE (1) SE336548B (xx)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020125593A1 (en) * 1999-06-21 2002-09-12 Rene Bergeron Apparatus and method for molding blocks
CN106166794A (zh) * 2016-08-26 2016-11-30 中民筑友科技投资有限公司 一种预制件生产线
CN110900815A (zh) * 2019-12-23 2020-03-24 东莞市中机建科实业有限公司 一种多用途混凝土预制构件生产线及其使用方法
CN113199615A (zh) * 2021-05-06 2021-08-03 优博络客新型建材(长兴)有限公司 一种建筑翻板自动化生产系统
CN113211602A (zh) * 2021-04-28 2021-08-06 涿州市忠科建材有限公司 一种蒸压加气混凝土砌块制作设备及其制作工艺
CN113547631A (zh) * 2021-07-16 2021-10-26 中钢集团郑州金属制品研究院股份有限公司 一种混凝土成型、预养护及清洗的自动化装置及工作方法

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2926379C2 (de) * 1979-06-29 1982-11-18 Greisel-Baustoff-Gmbh, 8359 Ortenburg Gasbetonelement mit Aussparungen, sowie Verfahren und Vorrichtung zur Herstellung
DE3005277C2 (de) * 1980-02-13 1982-06-24 Klaus 2000 Hamburg Köhler Kabelhalter, insbesondere für Betonbauteile
DE3162090D1 (en) * 1980-04-22 1984-03-08 Sicowa Verfahrenstech Process for the production of wall bricks based on sand-lime and apparatus for manufacturing crude bricks
AT391102B (de) * 1984-01-19 1990-08-27 Voest Alpine Ag Anlage zum herstellen von formsteinen aus schaumbeton
CN106272940A (zh) * 2016-08-26 2017-01-04 中民筑友科技投资有限公司 一种预制件生产线
CN108656336B (zh) * 2018-08-06 2023-07-14 泉州市三联机械制造有限公司 一种生产无机发泡混凝土墙板固定式可翻转的成型机及无机发泡混凝土墙板的生产工艺

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020125593A1 (en) * 1999-06-21 2002-09-12 Rene Bergeron Apparatus and method for molding blocks
US6814906B2 (en) * 1999-06-21 2004-11-09 Besser Company Apparatus and method for molding blocks
CN106166794A (zh) * 2016-08-26 2016-11-30 中民筑友科技投资有限公司 一种预制件生产线
CN110900815A (zh) * 2019-12-23 2020-03-24 东莞市中机建科实业有限公司 一种多用途混凝土预制构件生产线及其使用方法
CN113211602A (zh) * 2021-04-28 2021-08-06 涿州市忠科建材有限公司 一种蒸压加气混凝土砌块制作设备及其制作工艺
CN113211602B (zh) * 2021-04-28 2022-10-21 涿州市忠科建材有限公司 一种蒸压加气混凝土砌块制作设备及其制作工艺
CN113199615A (zh) * 2021-05-06 2021-08-03 优博络客新型建材(长兴)有限公司 一种建筑翻板自动化生产系统
CN113199615B (zh) * 2021-05-06 2022-07-08 优博络客新型建材(长兴)有限公司 一种建筑翻板自动化生产系统
CN113547631A (zh) * 2021-07-16 2021-10-26 中钢集团郑州金属制品研究院股份有限公司 一种混凝土成型、预养护及清洗的自动化装置及工作方法

Also Published As

Publication number Publication date
CH468876A (de) 1969-02-28
GB1173070A (en) 1969-12-03
NL6707875A (xx) 1967-12-11
AT263598B (de) 1968-07-25
DE1683888A1 (de) 1971-08-19
SE336548B (xx) 1971-07-05
BE699492A (xx) 1967-11-16

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