WO2009027352A2

WO2009027352A2 - Method and device for the production of a concrete ceiling element

Info

Publication number: WO2009027352A2
Application number: PCT/EP2008/061046
Authority: WO
Inventors: Werner Simon
Original assignee: Werner Simon
Priority date: 2007-08-24
Filing date: 2008-08-22
Publication date: 2009-03-05
Also published as: DE102007040263B3; WO2009027352A3; EP2183083A2

Abstract

The invention relates to a method for the production of a concrete ceiling element, wherein a concrete formliner (3a) is equipped with rigid carrier elements (3b), using the following steps: providing an underlayment (1) for the production of the concrete formliner (3a), placing concrete reinforcement frameworks (2) into the form for the carrier elements (3b) such that the concrete reinforcement frameworks (2) are aligned parallel to each other in a first horizontal direction, and that passage surfaces are disposed therein in alignment, inserting molds (4a, 4b) through the passage surfaces in a second horizontal direction extending transverse to the first horizontal direction, placing mold elements (8) into the intermediate spaces formed between the concrete reinforcement frameworks (2), and pouring of concrete into the elongated mold hollow spaces formed between the mold elements (8).

Description

Method and device for producing a concrete ceiling element

The invention relates to a method and an apparatus for producing a concrete ceiling element.

From EP 1 146 180 Al a method for producing a concrete ceiling element with rigid support elements is known. Initially, the rigid support elements are produced by casting a reinforcing framework with concrete. Breakthroughs in the support element are formed by the retraction and subsequent extraction of mandrels. On a support elements produced in this way a concrete formwork panel is then cast. - The known method is relatively expensive. To produce the concrete ceiling element, the prefabricated support elements must be used in parallel alignment in a formwork. When casting the concrete formwork panel can lead to a misalignment of the support elements.

The object of the invention is to provide a method and a device with which the disadvantages of the prior art are eliminated. In particular, a method for the fastest possible and efficient production of rigid concrete ceiling elements is to be specified, with which a unterjochungsfreie production of concrete ceilings is possible.

This object is solved by the features of claims 1 and 13. Advantageous embodiments emerge from the features of claims 2 to 12 and 14 to 23. According to the invention, a method for producing a concrete ceiling element is provided, in which a concrete formwork panel is provided with rigid support elements, with the following steps:

Providing a base suitable for producing the concrete shuttering panel,

Placing reinforcement frames for the support elements on the base, so that the reinforcement frames are aligned parallel to one another in a first horizontal direction and passage areas provided therein are aligned,

Retracting cores in a transversely to the first horizontal direction extending second horizontal direction through the passage areas,

Arranging of form elements in spaces formed between the Armierungsgerüsten and

Potting concrete in elongated mold cavities formed between the mold elements.

The proposed method can be carried out easily and inexpensively. It can be assumed that a conventional base or a formwork table for producing a concrete formwork panel. In contrast to the prior art, reinforcing frameworks for the carrier elements are placed on the substrate in such a way that penetration areas formed therein are arranged in alignment, so that shaped cores can be driven through the penetration areas. Forming elements are also arranged between the reinforcing frames. Subsequently, for the production Concrete concrete ceiling element concrete poured into the formed between the mold elements elongated mold cavities. The cast-in concrete spreads over the base and forms the concrete shuttering panel as well as the support elements. The process does not require a lot of time. It can be done relatively inexpensively.

Advantageously, a reinforcement for the concrete shuttering panel is placed on the base prior to placing the Armierungsgerüste. This makes it possible to produce a completely reinforced concrete ceiling element in one step.

According to a further embodiment, the concrete formwork panel is cast before arranging the mold elements. In particular, when providing a reinforcement that allows a particularly fast and uniform distribution of the concrete on the substrate. The production of concrete ceiling element can be accelerated again.

According to a further embodiment, the mandrels are retracted from two opposite sides of the mold by the passage areas. This allows in particular pulling the mandrels in opposite directions. This facilitates demolding. This is especially true when retracted from opposite sides

Form cores are arranged offset, so that two adjacent mandrels can be pulled in each case in the opposite direction.

It has proven to be expedient that the mold elements are placed on the retracted mandrels. The form elements can be lowered for example with a crane on the mandrels. Advantageously, the mold elements are placed on the mandrels that the profile the mold cores corresponding recesses on the underside facing the pad lie positively on the mold cores. Thus, both the form elements and the mandrels are forced into a proper arrangement. This makes it possible in a simple manner, a particularly accurate production of concrete ceiling elements.

According to a further embodiment, excess concrete is drawn off on a peel surface formed by an upper side of the mold elements. Thus, the top of the support elements can be given a desired contour. In particular, the Abziehfläche may have arranged at regular intervals recesses. Such recesses can be used to insert a reinforcing grid.

To remove mold cores are suitably pulled and shaken at the same time. If the mandrels are arranged on two opposite sides of the base, the mandrels are pulled in opposite directions with simultaneous shaking.

To be particularly advantageous, it has been found that during the drawing of the mandrels and the mold elements removed from the pad, preferably lifted, are. The fact is used that the shaking movement of the mandrels acts on the poured concrete and thus facilitates removal of the mold elements. In a separate shaking of the mold elements can be dispensed with in this case.

According to another aspect of the invention, an apparatus for producing a concrete ceiling element is provided in which a concrete formwork panel is provided with rigid support members, with a substrate suitable for the production of the concrete shuttering panel,

in which on at least one side a device for driving in parallel aligned mandrels is provided in a plane parallel to the base plane, and

wherein means are provided for arranging parallel aligned form elements transversely of the mandrels.

The proposed device enables a simplified and efficient production of rigid concrete ceiling elements. The proposed device is simple. It can be realized by simple extensions of conventional formwork tables for the production of concrete formwork panels.

According to an advantageous embodiment, a first and on the opposite other side of the pad, a second means for moving mandrels is provided on one side of the pad. In this case, the mandrels are advantageously arranged so that in the retracted state in each case a mandrel of the first device is arranged adjacent to a mandrel of the second device. As a result, each adjacent mandrels are in opposite

Direction over the pad moves. Advantages arise in particular when pulling the mandrels. It does not come to a deformation of the support elements.

Conveniently, the mandrels are mounted in a horizontal plane. Ie they are at the same height above the surface. According to a further advantageous embodiment, the form elements are formed like a bar. They extend over the entire length of the Armierungsgerüste. The mold elements may have recesses for engagement with the mold cores corresponding to a profile of the mold cores on an underside facing the base. The recesses may be V-shaped, for example. Furthermore, the mold elements may have recesses provided at regular intervals at an upper side facing away from the mold. Such recesses are used to make recesses in the support elements, which serve for inserting reinforcing bars.

According to a particularly advantageous embodiment, the mold elements have at their ends from the bottom extending extensions, so that thus a concrete ceiling element can be produced, in which the support elements extend beyond a side wall of the concrete formwork panel addition. The supernatant of the carrier elements is expediently 2 to 10 cm, preferably 3 to 8 cm.

According to a further embodiment, a device for shaking the mandrels is provided. This allows easier demolding. Furthermore, a device for automatically performing a pulling movement of the mold cores and a simultaneous movement, preferably lifting movement, of the mold elements can be provided. A simultaneous and automatically coordinated movement of the mandrels and the form elements allows a particularly gentle demolding. An undesirable deformation, in particular of the carrier elements, is avoided.

According to a further embodiment, a device for filling the elongated formed between the mold elements is provided. Stretched interspaces with concrete provided. With such a device, the entire required for the production of concrete ceiling element concrete can be cast. But it is also possible to first cast the concrete formwork panel with this device and then to produce the intermediate spaces with concrete to produce the support elements.

Furthermore, means for removing excess concrete may be provided on a peel surface formed by the tops of the mold elements. Such a device allows the introduction of predetermined contours in the top of the support elements.

An embodiment of the invention will be explained in more detail with reference to the drawing. Show it:

1 is a first side view of the device,

2 is a second side view of FIG. 1,

Fig. 3 is a plan view of the device, wherein the reinforcement has been omitted and

Fig. 4 is a side view of a formula element.

In the apparatus shown in Figs. 1 to 3 is denoted by 1 a base or a formwork table for producing a concrete formwork panel 3a with it cast support elements 3b. In Figs. 1 and 2 Armierungsgerüste 2 are supported on the substrate 1 for the support elements 3b.

Lancet-shaped mandrels 4, which preferably have a triangular profile, are mounted on horizontally movable carriage 5. Each of the mandrels 4 is connected to a vibrator 6. In the apparatus shown in FIGS. 1 to 3, a plurality of first mandrels 4a are provided on one side of the base 1 side by side, and a plurality of second mandrels 4b are provided on an opposite other side of the base 1. The first 4a and the second mandrels 4b are formed approximately the same length. Its length corresponds approximately to a width B of the base 1. The first 4a and the second mandrels 4b are arranged offset, so that the first mandrels 4a are retractable into the gaps formed between the second mandrels 4b. The offset corresponds in each case to half the distance A between the first 4a or the second mandrel 4b.

As can be seen in particular from FIG. 1, the carriages 5 accommodating the first 4a and the second mandrels 4b are connected via a circulating chain or the like. 7 kinematically connected to one another such that the first 4a and the second mandrels 4b are each movable in the opposite direction. For this purpose, the first carriages 5a receiving the first forming cores 5a are fastened to an upper run of the chain 7 and the second carriages 5b accommodating the second forming cores 4b are fastened to a lower run of the chain 7.

The reference numeral 8 designates bar-like shaped elements, which are attached to a support frame 9. The support frame 9 is vertically movable by means of a crane 10. With 11 with respect to the pad 1 horizontally movable concrete feeding device is called. This may be a conventional concrete feeder 11 for the production of concrete formwork panels (3a). In Fig. 4, a mold element 8 is shown in detail. The mold element 8 has V-shaped recesses 12, which correspond to the shape of the mold cores 4a and 4b, on a lower side U facing the underlay 1. On an upper side O opposite the underside U, recesses 13 are provided, which serve to produce corresponding recesses 13 in the carrier elements 3b. Such recesses 13 serve in the support elements 3b for receiving reinforcing gratings. Furthermore, the form elements 8 have on their side walls as well as on the upper side O a corrugation 14, which serves for an intimate connection with an in-situ concrete layer to be poured onto the concrete ceiling element. At the ends extending from the bottom U extensions 15 serve to realize a supernatant of the carrier elements to be produced 3b on a side wall of the concrete shuttering panel 3a addition. For the production of the further recesses 16 shown in FIG. 4, further mold cores may be provided in a manner similar to the mold cores 4a and 4b.

The function of the device is as follows:

First, a reinforcement for the concrete shuttering panel 3a is placed on the base 1 in a conventional manner. Arming scaffolds 2 for the carrier elements 3b are then placed on the reinforcement in a parallel arrangement and parallel to a longitudinal side of the base 1. The Armierungsgerüste 2 are formed for example of an upper and two lower chords, which are interconnected by V-shaped diagonals. The lower chords and the diagonals form triangular penetration areas. The Armierungsgerüste 2 are arranged on the base 1, that the passage areas are in alignment with the direction of movement of the mandrels 4a and 4b. After a first variant of the method, after placing the reinforcement and the Armierungsgerüste 2 on the base 1 by means of the concrete feeder 11, first the concrete formwork panel 3a is poured. Subsequently, the first 4a and the second mandrels 4b are then retracted in a plane parallel to the base 1 by an opposite movement of the first 5a and second carriages 5b. In this case, the mandrels 4a and 4b pass through the passage areas of all reinforcing frameworks 2 arranged parallel next to one another. Subsequently, by means of the crane 10, the shaped elements 8 are lowered into the intermediate spaces remaining between the reinforcing frameworks 2. The recesses 12 engage in the mandrels 4a and 4b. As a result of the positive connection between the recesses 12 and the profile of the mandrels 4a and 4b, the mandrels 4a and 4b and the mold elements 8 are aligned at right angles to each other. Subsequently, concrete is filled into the elongated intermediate spaces formed between the mold elements 8 by means of the concrete feeding device 11. Excess concrete is drawn off on the upper sides O shaped elements 8 by means of a pull-off device (not shown here). As a result, the surface contour formed on the upper surface O of the mold members 8 is transferred to the surface O of the support members 3b.

After a second variant of the method, it is also possible, after supporting the reinforcement and the Armierungsgerüste 2 first retract the first 4a and the second mandrels 4b on the pad 1 and then lower the mold elements 8 thereafter. Subsequently, concrete can then be filled into the intermediate spaces formed between the shaped elements 8 by means of the concrete feeding device 11. In this case, the consistency of the concrete should be adjusted to ensure that all mold cavities are filled. After casting and partial solidification of the concrete, the vibrators 6 are put into operation and the first 4a and the second mandrels 4b are simultaneously pulled horizontally away from the base 1 in opposite directions. The coupled into the partially solidified concrete ceiling element vibration is advantageously used simultaneously to lift the mold elements 8. In this way, removal of the mandrels 4a and 4b and of the shaped elements 8 can be carried out quickly and simply without deformation of the concrete ceiling element.

The proposed method makes it possible to produce rigid concrete ceiling elements in a quick and simple manner. The proposed concrete ceiling elements can be used without the provision of Unterjochung for the production of concrete floors. Spans of up to 8.50 m can be bridged.

Reference numeral

1 pad

2 reinforcing framework

3a concrete formwork panel

3b carrier element

4, 4a, 4b mold core, first mold core, second mold core

5, 5a, 5b carriages, first carriage, second carriage

6 vibrating device

7 chain

8 mold element

9 support frame

10 crane

11 concrete feeder

12 recess

13 recess

14 curl

15 extension

16 more recess

U bottom

O top

A distance

B width

Claims

claims

1. A method for producing a concrete ceiling element, in which a concrete shuttering panel (3a) is provided with rigid support elements (3b), comprising the following steps:

Providing a base (1) suitable for producing the concrete shuttering panel (3a),

Laying Armierungsgerusten (2) for the support elements

(3b) on the base (1), so that the Armierungsgeruste (2) are aligned parallel to each other in a first horizontal direction and provided therein Durchgriffsflachen in alignment,

Retracting cores (4a, 4b) in a transversely to the first horizontal direction extending second horizontal direction through the passage surfaces,

Arranging mold elements (8) in between the Armierungsgerusten (2) formed spaces and

Pouring concrete in between the mold elements (8) formed elongated mold cavities.

2. The method of claim 1, wherein prior to placing the Armierungsgeruste (2) a reinforcement for the concrete formwork panel (3a) in the pad (1) is inserted.

3. The method according to any one of the preceding claims, wherein prior to arranging the mold elements (8), the concrete formwork panel (3a) is poured. 2

4. The method according to any one of the preceding claims, wherein the mandrels (4a, 4b) of two opposite sides of the pad (1) are retracted by the Durchgriffsflachen.

5. The method according to any one of the preceding claims, wherein first mandrels (4a) in gaps between second mandrels

(4b) are moved.

6. The method according to any one of the preceding claims, wherein the mold elements (8) on the retracted mandrels (4a, 4b) are placed.

7. The method according to any one of the preceding claims, wherein the mold elements (8) are placed on the mandrels (4a, 4b), that the profile of the mandrels (4a, 4b) corresponding recesses (12) to the pad (1) facing Bottom sides (U) form-fitting on the mold cores (4a, 4b) rest.

8. The method according to any one of the preceding claims, wherein excess concrete is peeled off on a by a top (O) of the mold elements (8) Abziehflache.

9. The method according to any one of the preceding claims, wherein the Abziehflache arranged at regular intervals recesses (13).

10. The method according to any one of the preceding claims, wherein for demolding the mandrels (4a, 4b) are pulled and jogged simultaneously. 3

11. The method according to any one of the preceding claims, wherein in the retracted state adjacent first (4a) and second mandrels (4b) are pulled in opposite directions.

12. The method according to any one of the preceding claims, wherein during the drawing of the mandrels (4a, 4b), the mold elements (8) from the pad (1) removed, preferably lifted.

13. An apparatus for producing a concrete ceiling element, in which a concrete formwork panel (3a) is provided with rigid support elements (3b), with

a substrate (1) suitable for producing the concrete shuttering panel (3a),

in which at least one side of a device for moving parallel aligned mandrels (4a, 4b) in a direction parallel to the substrate (1) extending plane is provided and

wherein means for arranging parallel aligned mold elements (8) transversely to the mold cores (4a, 4b) is provided.

14. The apparatus of claim 13, wherein on one side of the pad (1) has a first (5a) and on the opposite other side of the pad (1) a second device

(5b) for moving mold cores (4a, 4b) is provided.

15. The apparatus of claim 13 or 14, wherein the mandrels (4a, 4b) are mounted in a horizontal plane.

16. Device according to one of claims 13 to 15, wherein the mold elements (8) are formed like a bar.

17. Device according to one of claims 13 to 16, wherein the mold elements (8) on one of the pad (1) facing bottom (U) to the profile of the mandrels (4a, 4b) corresponding recesses (12) for engagement in the mandrels (4a , 4b).

18. Device according to one of claims 13 to 17, wherein the mold elements (8) on one of the pad (1) facing away from the top (O) provided at regular intervals recesses (13).

19. Device according to one of claims 13 to 18, wherein the shaped elements (8) at their ends from the underside (U) extending extensions (15), so that carrier elements produced therewith (3b) over a side wall of the concrete shuttering panel (3a).

20. Device according to one of claims 13 to 19, wherein means (6) for shaking the mandrels (4a, 4b) is provided.

21. Device according to one of claims 13 to 20, wherein a device for automatically carrying out a pulling movement of the mandrels (4a, 4b) and a simultaneous movement, preferably lift-off, the mold elements (8) is provided.

22. Device according to one of claims 13 to 21, wherein means (11) for filling the between the mold elements (8) formed elongated spaces is provided with concrete.

23. Device according to one of claims 13 to 22, wherein means for removing excess concrete on a by the upper sides (O) of the mold elements (8) formed Abziehhflache is provided.