WO2007122480A2 - Process for manufacturing building elements for making walls using filling material, particularly earth or the like - Google Patents

Process for manufacturing building elements for making walls using filling material, particularly earth or the like Download PDF

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Publication number
WO2007122480A2
WO2007122480A2 PCT/IB2007/001031 IB2007001031W WO2007122480A2 WO 2007122480 A2 WO2007122480 A2 WO 2007122480A2 IB 2007001031 W IB2007001031 W IB 2007001031W WO 2007122480 A2 WO2007122480 A2 WO 2007122480A2
Authority
WO
WIPO (PCT)
Prior art keywords
mould
process according
semi
building
building element
Prior art date
Application number
PCT/IB2007/001031
Other languages
French (fr)
Other versions
WO2007122480A3 (en
Inventor
Felix Paul Jaecklin
Original Assignee
Geotech Lizenz A.G.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Geotech Lizenz A.G. filed Critical Geotech Lizenz A.G.
Publication of WO2007122480A2 publication Critical patent/WO2007122480A2/en
Publication of WO2007122480A3 publication Critical patent/WO2007122480A3/en

Links

Classifications

    • 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
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • 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
    • B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
    • 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
    • B28B7/0002—Auxiliary parts or elements of the mould
    • B28B7/0008—Venting channels, e.g. to avoid vacuum during demoulding or allowing air to escape during feeding, pressing or moulding
    • 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
    • B28B7/0029—Moulds or moulding surfaces not covered by B28B7/0058 - B28B7/36 and B28B7/40 - B28B7/465, e.g. moulds assembled from several parts
    • B28B7/0035—Moulds characterised by the way in which the sidewalls of the mould and the moulded article move with respect to each other during demoulding
    • B28B7/0038—Moulds characterised by the way in which the sidewalls of the mould and the moulded article move with respect to each other during demoulding the sidewalls of mould and moulded article moving only past each other, e.g. box-shaped moulds which are lifted off from the moulding
    • 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
    • B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
    • B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
    • B28B7/183—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article for building blocks or similar block-shaped objects

Definitions

  • This invention refers to a process for manufacturing building elements for making walls using filling material, particularly earth or the like.
  • Such elements usually consist of beamed structures of large dimensions, that are made of reinforced concrete castings inside forms made of wood, steel, or other material.
  • the top of the form can be closed by means of a shaped panel, removable before taking out the moulded element.
  • the traditional type of forming process has a number of drawbacks.
  • Each form for forming the building elements is therefore engaged for several hours in order to produce just one building element and permits making a limited number of elements per day; the overall production process is therefore rather slow and, taking into account the high cost of each form, burdened with considerably high management costs.
  • the main aim of the present invention is to provide a process for manufacturing building elements for making walls using filling material, particularly earth or the like, which is considerably simple and practical and which allows producing numerous building elements quickly and at relatively low costs.
  • the above aim is achieved by the present Process for manufacturing building elements for making walls using filling material, particularly earth or the like, characterized in that it comprises the steps which consist in:
  • figure 1 is an axonometric view from above of a first mould used in the process according to the invention
  • figure 2 is an axonometric view from below of a second mould used in the process according to the invention
  • the figures from 3 to 6 show, in a succession of perspective views, the various phases of the process according to the invention.
  • 1 and 2 respectively have been indicated a first basic mould and a second upper mould, used in the present process for manufacturing building elements for making walls using filling material, particularly earth or the like.
  • the building element E consist in a pair of longitudinal beams Tl, substantially horizontal, and in a pair of cross beams T2, that join together the longitudinal beams and define the supporting bases of the building element E, permitting this to rest on the ground or on another building element E.
  • the first mould 1 consists in a substantially horizontal base the upper surface of which has forming grooves 3, intended in particular for the formation of the longitudinal beams Tl of the building element E.
  • the second mould 2 on the other hand, consists in a block that is hollow inside and which has a pair of inner compartments 4, for forming the cross beams T2 of the building element E, and an open bottom 5 that can be coupled at the top to the first mould 1.
  • the grooves 3 of the first mould 1 and the inner compartments 4 of the second mould 2 define an inner forming cavity for the building element E.
  • the second mould 2 On the upper surface of the second mould 2 a plurality of ducts 6 is obtained suitable for allowing the introduction of a building material M in fluid state, such as fresh concrete or the like, inside the moulds 1 and 2 coupled together.
  • a building material M in fluid state such as fresh concrete or the like
  • Alternative embodiments of the present invention cannot however be ruled out in which the second mould 2 is not made in a single body piece and, furthermore, consists in a series of units separated from one another but which can be assembled to define a shape analogous to that of the internally hollow block 2 shown in the figures.
  • first and the second moulds 1 and 2 can be made with different shapes and dimensions in order to define inner forming cavities shaped differently and, therefore, obtain other types of building elements E for making walls using filling material.
  • the process according to the invention first of all involves the step which consists in providing a plurality of first moulds 1 and at least one second mould 2 (figure 3).
  • the present process thus involves the positioning of the second mould 2 above one of the first moulds 1 and the filling of the inner cavity thus defined with the concrete M (figure 4).
  • the concrete M is left to harden in this position for a first preset period of time, until a semi-rigid semi-finished product S is obtained modelled inside the moulds 1 and 2.
  • the process according to the invention involves a lifting phase of the second mould 2 and a positioning phase of same at the top of another first mould 1 (figure 5).
  • the semi-rigid semi-finished product S just modelled is left resting above the first mould 1 which has allowed its forming, and is left to harden in this position for a second preset period of time suitable for allowing the complete curing of the concrete M until the building element E is obtained.
  • the building element E is removed from the relevant first mould 1 and, if necessary, is overturned and arranged in the position of end use.
  • the phases of the process according to the invention which consist in filling the second mould 2, allowing the concrete M to harden, lifting the second mould 2 and positioning it on another first mould 1, allowing the semirigid semi-finished product S to harden and then removing the building element E, can be repeated in succession for each of the first moulds 1 at disposal (figure 6).
  • the process according to the invention calls for a supplementary operation which consists in arranging a steel reinforcement inside the inner cavities defined by the coupling of the first moulds 1 to the second mould 2 before these are filled with concrete M.
  • Such supplementary operation consists in placing a reinforcement, not shown in detail in the figures, above each first mould 1 before the second mould 2 is positioned above them.
  • the removal of the building elements can therefore be done when the concrete has not yet completed curing, drastically reducing the time of use of the second mould, which can be conveniently used for the manufacture of numerous building elements one after the other.

Abstract

The process for manufacturing building elements (6) for making walls using filling material, particularly earth or the like, comprises the following steps : - providing at least one basic mould (1) and at least a second mould (2) substantially hollow and open on the bottom and which can be coupled at the top with the first mould to define an inner cavity (4) for forming a building element; - positioning the second mould above the first mould; - filling the inner cavity with a building material (M) in a substantially fluid state; - allowing the building material to consolidate inside the inner cavity of the moulds for a first preset period of time until a semi-rigid semi-finished product is obtained; - lifting the second mould, leaving the semi-rigid semi-finished product at the top of the first mould; - allowing the semi-rigid semi-finished product to harden at the top of the first mould for a second preset period of time until the building element (E) is obtained; - removing the building element from the first mould.

Description

PROCESS FOR MANUFACTURING BUILDING ELEMENTS FOR MAKING WALLS USING FILLING MATERIAL, PARTICULARLY EARTH OR THE LIKE
Technical Field
This invention refers to a process for manufacturing building elements for making walls using filling material, particularly earth or the like.
Background art
For making particular masonry works such as, for example, walls for retaining slopes and gradients at the side of roads, motorways, railways or the like, or the walls for creating drops between different urban levels, the use is known of different types of prefabricated building elements.
Such elements usually consist of beamed structures of large dimensions, that are made of reinforced concrete castings inside forms made of wood, steel, or other material.
The processes known for the manufacturing of building elements made this way usually call for the use of a hollow form closed at the bottom and open at the top, having an inner forming cavity that is filled with fresh concrete and from which the element is removed by raising once the concrete has reached a sufficient degree of consistency and rigidity.
To form the upper surface of the building element, the top of the form can be closed by means of a shaped panel, removable before taking out the moulded element.
The traditional type of forming process has a number of drawbacks.
In this respect, it must first of all be stressed that during lifting, the building element is subject to considerably high internal stresses and therefore, before it is removed from the form, to avoid breakages, cracks or distortions, the concrete must have completed its curing process and have reached a considerable degree of rigidity, and this requires particularly long periods of use.
Each form for forming the building elements is therefore engaged for several hours in order to produce just one building element and permits making a limited number of elements per day; the overall production process is therefore rather slow and, taking into account the high cost of each form, burdened with considerably high management costs.
It should be noted in fact that the inner cavity of traditional forms always has a rather complex and tortuous shape, is hard to produce and therefore rather costly.
Object of the Invention
The main aim of the present invention is to provide a process for manufacturing building elements for making walls using filling material, particularly earth or the like, which is considerably simple and practical and which allows producing numerous building elements quickly and at relatively low costs. The above aim is achieved by the present Process for manufacturing building elements for making walls using filling material, particularly earth or the like, characterized in that it comprises the steps which consist in:
- providing at least one basic mould and at least a second mould substantially hollow and open on the bottom and which can be coupled at the top with said first mould to define an inner cavity for forming at least one building element;
- positioning said second mould above said first mould;
- filling said inner cavity with a building material in a substantially fluid state;
- allowing said building material to consolidate inside said inner cavity for a first preset period of time until a semi-rigid semi-finished product is obtained;
- lifting said second mould, leaving said semi-rigid semi-finished product at the top of said first mould;
- allowing said semi-rigid semi-finished product to harden at the top of said first mould for a second preset period of time until said building element is obtained;
- removing said building element from said first mould. Brief description of the drawings
Further characteristics and advantages of this invention will appear even more evident from the detailed description of a preferred but not exclusive embodiment of a process for manufacturing building elements for making walls using filling material, particularly earth or the like, illustrated indicatively by way of non limiting example, in the attached drawings wherein: figure 1 is an axonometric view from above of a first mould used in the process according to the invention; figure 2 is an axonometric view from below of a second mould used in the process according to the invention; the figures from 3 to 6 show, in a succession of perspective views, the various phases of the process according to the invention. Embodiments of the Invention
With particular reference to the above figures, by 1 and 2 respectively have been indicated a first basic mould and a second upper mould, used in the present process for manufacturing building elements for making walls using filling material, particularly earth or the like.
In the particular embodiment of the invention shown in the figures, the building element E consist in a pair of longitudinal beams Tl, substantially horizontal, and in a pair of cross beams T2, that join together the longitudinal beams and define the supporting bases of the building element E, permitting this to rest on the ground or on another building element E.
The first mould 1 consists in a substantially horizontal base the upper surface of which has forming grooves 3, intended in particular for the formation of the longitudinal beams Tl of the building element E.
The second mould 2, on the other hand, consists in a block that is hollow inside and which has a pair of inner compartments 4, for forming the cross beams T2 of the building element E, and an open bottom 5 that can be coupled at the top to the first mould 1.
Once the moulds 1 and 2 have been coupled together, the grooves 3 of the first mould 1 and the inner compartments 4 of the second mould 2 define an inner forming cavity for the building element E.
On the upper surface of the second mould 2 a plurality of ducts 6 is obtained suitable for allowing the introduction of a building material M in fluid state, such as fresh concrete or the like, inside the moulds 1 and 2 coupled together. Alternative embodiments of the present invention cannot however be ruled out in which the second mould 2 is not made in a single body piece and, furthermore, consists in a series of units separated from one another but which can be assembled to define a shape analogous to that of the internally hollow block 2 shown in the figures.
It cannot furthermore be ruled out that the first and the second moulds 1 and 2 can be made with different shapes and dimensions in order to define inner forming cavities shaped differently and, therefore, obtain other types of building elements E for making walls using filling material.
For manufacturing the building elements E, the process according to the invention first of all involves the step which consists in providing a plurality of first moulds 1 and at least one second mould 2 (figure 3). The present process thus involves the positioning of the second mould 2 above one of the first moulds 1 and the filling of the inner cavity thus defined with the concrete M (figure 4).
The concrete M is left to harden in this position for a first preset period of time, until a semi-rigid semi-finished product S is obtained modelled inside the moulds 1 and 2.
Once this period of time has elapsed, the process according to the invention involves a lifting phase of the second mould 2 and a positioning phase of same at the top of another first mould 1 (figure 5).
During this phase, the semi-rigid semi-finished product S just modelled is left resting above the first mould 1 which has allowed its forming, and is left to harden in this position for a second preset period of time suitable for allowing the complete curing of the concrete M until the building element E is obtained. Once the curing of concrete M has been completed, the building element E is removed from the relevant first mould 1 and, if necessary, is overturned and arranged in the position of end use.
Meanwhile, the phases of the process according to the invention which consist in filling the second mould 2, allowing the concrete M to harden, lifting the second mould 2 and positioning it on another first mould 1, allowing the semirigid semi-finished product S to harden and then removing the building element E, can be repeated in succession for each of the first moulds 1 at disposal (figure 6).
To obtain building elements E that have particular resistance to traction, the process according to the invention calls for a supplementary operation which consists in arranging a steel reinforcement inside the inner cavities defined by the coupling of the first moulds 1 to the second mould 2 before these are filled with concrete M.
Such supplementary operation consists in placing a reinforcement, not shown in detail in the figures, above each first mould 1 before the second mould 2 is positioned above them.
Alternative embodiments of the present invention cannot however be ruled out in which this supplementary operation is implemented by placing a reinforcement inside the second mould 2 every time the second mould is lifted by one of the first moulds 1 and positioned above another first mould 1.
It has in fact been seen how the described invention achieves the proposed objects.
In this respect, the fact is emphasised that the particular solution of removing the building elements by lifting the second mould avoids submitting the elements themselves to hazardous stresses as occurs, on the other hand, in traditional manufacturing processes.
The removal of the building elements can therefore be done when the concrete has not yet completed curing, drastically reducing the time of use of the second mould, which can be conveniently used for the manufacture of numerous building elements one after the other.
Nor should it be forgotten that the particular solution of providing a plurality of basic moulds of rather simple shape and, therefore, of relatively low cost, permits setting up a complete system for manufacturing building elements with a particularly low economic investment.
The invention thus conceived is susceptible of numerous modifications and variations, all of which falling within the scope of the inventive concept.
Furthermore, all the details may be replaced by other elements which are technically equivalent.
In practice, the materials used, as well as the contingent shapes and dimensions, may be any according to requirements without because of this moving outside the protection scope of the following claims.

Claims

1) Process for manufacturing building elements for making walls using filling material, particularly earth or the like, characterized in that it comprises the steps which consist in:
- providing at least one basic mould and at least a second mould substantially hollow and open on the bottom and which can be coupled at the top with said first mould to define an inner cavity for forming at least one building element;
- positioning said second mould above said first mould;
- filling said inner cavity with a building material in a substantially fluid state;
- allowing said building material to consolidate inside said inner cavity for a first preset period of time until a semi-rigid semi-finished product is obtained;
- lifting said second mould, leaving said semi-rigid semi-finished product at the top of said first mould;
- allowing said semi-rigid semi-finished product to harden at the top of said first mould for a second preset period of time until said building element is obtained;
- removing said building element from said first mould.
2) Process according to claim 1, characterized in that said building material is concrete.
3) Process according to one or more of the preceding claims, characterized in that it comprises arranging a reinforcement inside said inner cavity.
4) Process according to one or more of the preceding claims, characterized in that said arranging comprises placing said reinforcement above said first mould before said positioning.
5) Process according to one or more of the preceding claims, characterized in that said arranging comprises placing said reinforcement inside said second mould before said positioning.
6) Process according to one or more of the preceding claims, characterized in that said reinforcement is made in steel.
7) Process according to one or more of the preceding claims, characterized in that it comprises overturning said building element removed from said first mould.
8) Process according to one or more of the preceding claims, characterized in that said providing comprises providing a plurality of said first moulds.
9) Process according to one or more of the preceding claims, characterized in that said lifting comprises lifting said mould from one of said first moulds and positioning the same at the top of another of said first moulds.
10) Process according to one or more of the preceding claims, characterized in that it comprises repeating said filling, said allowing to consolidate, said lifting, said allowing to harden and said removing for each of said first moulds.
11) Process according to one or more of the preceding claims, characterized in that said first mould comprises at least one substantially horizontal base.
12) Process according to one or more of the preceding claims, characterized in that the upper surface of said first mould has forming grooves.
13) Process according to one or more of the preceding claims, characterized in that said second mould comprises at least one internally hollow block having at least one inner compartment.
14) Process according to one or more of the preceding claims, characterized in that said second mould comprises a series of units which can be separated from one another and coupled to each other to define an internally hollow block having at least one inner compartment.
15) Process according to one or more of the preceding claims, characterized in that on said second mould is obtained at least one duct suitable for the introduction of said building material inside said inner cavity.
16) Process according to one or more of the preceding claims, characterized in that said building element comprises a pair of longitudinal beams, substantially horizontal, and a pair of cross beams placed in between said longitudinal beams and suitable for defining the supporting bases of the building element.
PCT/IB2007/001031 2006-04-21 2007-04-20 Process for manufacturing building elements for making walls using filling material, particularly earth or the like WO2007122480A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITMO20060130 ITMO20060130A1 (en) 2006-04-21 2006-04-21 PROCEDURE FOR THE MANUFACTURE OF BUILDING ELEMENTS FOR THE REALIZATION OF WALLS WITH FILLING OF REPLACEMENT MATERIALS, PARTICULARLY LAND OR SIMILAR.
ITMO2006A000130 2006-04-21

Publications (2)

Publication Number Publication Date
WO2007122480A2 true WO2007122480A2 (en) 2007-11-01
WO2007122480A3 WO2007122480A3 (en) 2008-02-07

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PCT/IB2007/001031 WO2007122480A2 (en) 2006-04-21 2007-04-20 Process for manufacturing building elements for making walls using filling material, particularly earth or the like

Country Status (2)

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WO (1) WO2007122480A2 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2923175A1 (en) * 2007-11-02 2009-05-08 Clotures Nicolas Soc Par Actio Fluid-concrete fence element e.g. plate, fabricating method, involves orienting mold such that opposite end of mold is located upwards, and casting concrete by outlet opening by maintaining section of outlet opening with full of concrete
WO2012054948A1 (en) * 2010-10-28 2012-05-03 Betonwerk Rieder Gesellschaft M.B.H. Method and apparatus for producing a precast concrete part

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1171701A (en) * 1966-02-24 1969-11-26 Eternit Ag Improvements in or relating to Apparatus for the Injection Moulding of Articles of Fibre Cement
DE1928728A1 (en) * 1969-06-06 1970-12-10 Wolf Dipl Ing Horst Lightweight hollow concrete ceiling blocks

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1171701A (en) * 1966-02-24 1969-11-26 Eternit Ag Improvements in or relating to Apparatus for the Injection Moulding of Articles of Fibre Cement
DE1928728A1 (en) * 1969-06-06 1970-12-10 Wolf Dipl Ing Horst Lightweight hollow concrete ceiling blocks

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2923175A1 (en) * 2007-11-02 2009-05-08 Clotures Nicolas Soc Par Actio Fluid-concrete fence element e.g. plate, fabricating method, involves orienting mold such that opposite end of mold is located upwards, and casting concrete by outlet opening by maintaining section of outlet opening with full of concrete
WO2012054948A1 (en) * 2010-10-28 2012-05-03 Betonwerk Rieder Gesellschaft M.B.H. Method and apparatus for producing a precast concrete part

Also Published As

Publication number Publication date
WO2007122480A3 (en) 2008-02-07
ITMO20060130A1 (en) 2007-10-22

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