CA1115072A

CA1115072A - Method of manufacturing building elements and building

Info

Publication number: CA1115072A
Application number: CA335,142A
Authority: CA
Inventors: Cornelis A. Zandbergen; Johannes T. De Heus
Original assignee: WACO BETON BV; Ballast Nedam Groep NV
Current assignee: Ballast Nedam NV; WACO BETON BV
Priority date: 1978-09-06
Filing date: 1979-09-06
Publication date: 1981-12-29
Also published as: DE2861408D1; JPS5818212B2; EP0009056B1; JPS5544895A; EP0009056A1

Abstract

ABSTRACT
In order to strip a concrete building element casting from its mould in a simple and reliable manner without damage, so that the casting mould can be rapidly used for a next manufacturing process, the upper and lower forms of the casting mould are retained against the still incompletely cured concrete mortar of the casting, whilst the casting is removed from a core and a jacket of the casting mould.

Description

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The invention relates to a method of manufacturing a tubular building element in which concrete mortar is poured and consolidated by vibrations or shocks in the cavity of a casting mould consisting of a lower profile form, a jacket, a core and an upper form and in which the upper form is connected by positioning means with the lower form and the resultant, incompletely cured casting together with the upper and lower forms intercon-nected by the positioning means is removed from the core and the jacket whilst the upper and lower forms are retained with respect to the casting and with respect to each other wi~h the aid of the positioning means. ~-Such a method is known from French patent specification 1,103,30~.
In this known method first the core is removed, whilst the upper and lower forms are interconnected by rods extending outside the jacket. In a later stage the rods extending outside the jacket are replaced by a pull rod arranged in a central recess which is made by means of the core. The upper and lower forms are interconnected by means of this pull rod in order to have the jacket removed from the casting in a yet later stage.
~ This known method is cumbersome. Moreover the risk exists that the .;
casting may be damaged in that during the connecting operation of the upper and lower forms external forces are exerted upon the still uncured casting, a whilst the casting is already arranged in an opened casting form.
The invention has for its object to avoid such damage in a simple way whilst requiring only a short time of residence in the casting mould.
The invention provides a method of manufacturing a tubular building element comprising pouring concrete mortar and consolidating it by vibrations ; or shocks in the cavity of a casting mould consisting of a lower profile form, a jacket, a core and an upper form and in which ~he upper form is con-nected by positioning means to the lower form, removing the resultant, incom-' pletely cured casting together with the upper and lower forms interconnected by the positioning means from the core and the jacket, whilst the upper and . .
lower forms are retained with respect to the casting and with respect to each other with the aid of positioning means, said poaitioning means comprising r~
~ ~ onnecting members which interconnect the upper and lower profile g~ge~ and .....

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extend through the mould cavlty across the concrete mortar.
Preferably a number of pipes each defining a passage for a connect-ing member forming part of the positioning means, are arranged in the mould cavity. These pipes can constitute passages for tensioning cables in a building structure consisting of a series of building elements.
The invention relates to and provides in addition, a method of building a structure such as a tunnel, sewer, culvert, composed of Joined building elements manufactured each by the method according to the invention.
A building structure, for example a tunnel, which is composed of a series of contiguous building elements having longitùdinal recesses for receiving tensioning cables is known per se from United States patent specification 3,548,485. The building elements of this building structure are not manufactured by applying the present invention and are not provided with pipes embedded in the concrete and defining channels for the tensioning cables.
The aforesaid and further features of the invention will be , described mors fully with reference to the drawing.
In the drawings:-Figure 1 illustrates the method in accordance with the invention, Figure 2 is an enlarged sectional view of detail II of Figure 1 in carrying out a preferred method in accordance with the invention, Figure 3 is an enlarged sectional view of detail III of Figure 1, Figure 4 shows a building structure in accordance with the inven-tion, in which the situation after a degree of settling in the ground is indicated by broken lines, Figure S shows on an enlarged scale detail V of Figure 4~ and Figure 6 is a sectional view taken on the line VI-VI in ~igure 5.
Figure 1 illustrates schematically the series of steps for the manufacture of tubular building elements 3. On a first manufacturing site 1 ~;
; 30 concrete mortar 10 is poured from a container 11 into the cavity 4 of a `

casting mould 5 consisting of a lower profile form 6, a jacket 7, a core 8 and an upper p-rofile form 9. Durîng the uniform pouring of the concrete ` 2 ~ ~' ' mortar 10 the casting mould 5 disposed on a vibrating table 12 is subjected to vibrations or shocks to consolidate the concrete mortar 10. After the mould cavity 4 is filled, the upper profile form 9 is pressed against the : :
concrete mortar 10 in the mould cavity 4, whilst the concrete mortar 10 is further consolidated by means of a vibrating device 13 arranged in the upper : form 9.
- The vibrating table 12 is disposed in a pit 14 a~ a lower level ~ ~.
than the factory floor 15 on springs 16 and provided with a vibrating devlce 17, and is guarded by means of stop bolts lô against excessive upward move-ments. The core 8 is detachably fastened by means of bolts 19 to the vibrat-ing table 12.
: A lower profile form 6 is deposited from a stack 20 around the core 8 on the vibrating table 12 and the jacket 7 is secured by bolts 21 to ~:
the lower fo~m 6. A reinforcing mesh 22 is arranged in the mould cavity 4 as well as a number of pipes 24, for example, of synthetic resin, each defin- .
ing a passage for a tie rod 23. Each tie rod 23 is screwed at its lower end .
25 into the lower form 6 and has a screwthreaded top end 26 with a square head 27, so that after the mould cavity 4 is filled and after the upper form 9 is disposed thereon the upper form 9 can be pressed home by nuts 28. The :~
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. ~ 20 tie rods 23 with the nuts 28 constitute positioning means for retaining the ~-~:~ upper form 9 with respect to the casting 33.
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The core 8 is first disengaged from the resultant, incompletely -~ cured casting 33 by pulling up the jacket 7 together with the lower form 6 ~ and the upper form 9 and the ~ie rods 23 extending through the concrete mortar lO of the casting 33, the eyelets 29 of the jacket 7 being engaged with the aid of an elevator crane 30, which conveys this assembly to a second .- manufacturing site 2 and deposits it with the lower form 6 an a floor 31.
: Then the jacket 7 is removed from the still incompletely cured casting 33 and ,:.--~-; from the lower form 6 and the upper form 9 retained therein by means of the tie rods 23 of the positioning means extending through the roncrete of the casting 33, by loosening the bolt connections 21 and by pulling up the jacket ~; 7.
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In a further stage, after disengaging the upper form 9 from the ` -;
lower form 6 by unscrewing the pull rods 23 from the lower form 6, the upper form 9 is removed. After complete curing of the concrete of the build-ing element 3 the lower form 6 is removed.
Finally, subsequent to hardening of the castings 33 for example, by means of steam in an autoclave (not shown) building elements 3 are obtained for fabricating a building structure 32 as shown in Figure 4, for ~;
example, a tunnel, a culvert, a duct or a similar structure consisting of a series of joined, tubular building elements 3.
The pipes 24 which form the passages for pull rod 23 embedded at the corners 34 of the building elements 3 (Figure 5~ can be used, in addition, -for receiving tensioning cables 35 to interconnect the building elements 3. ;
; These cables 35 are anchored under tension at both ends of the tunne]. 32 by means of cable anchors 36. The joints 37 (Figure 5) between the contiguous building elements 3 comprise a ring 38 on one building element 3 for engaging :;
a recess 39 of the other building element 3, whilst the axial gap 40 accommodates an elastic sealing ring 41. It is thus possible to deposit the building structure 32 on a weak underground 42, which tends to subside, since the building elements 3 can turn relatively to one another whilst, however, - 20 the water tightness of the joints 37 is maintained.
By using the method according to the invention it is ensured that the joint surfaces of the building elements 3 which adjoin the gap 40 maintain - their shape satisfactorily during moulding, despite the fact that the castings 3 are stripped from the core 8 and the jacket 7 at an early stage, so that ;
they can form a satisfactory joint. `~
The concrete mortar 10 of the lower end of the casting 3 is ~ ~
satisfactorily consolidated particularly by means of the vibrating device 17, ~;
whilst the vibrating device 13 particularly consolidates the upper concrete ; mortar 10 at the upper end where the effect of the vibrating device 17 is reduced.

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Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A method of manufacturing a tubular building element comprising pouring concrete mortar and consolidating it by vibrations or shocks in the cavity of a casting mould consisting of a lower profile form, a jacket, a core and an upper form and in which the upper form is connected by positioning means to the lower form, removing the resultant, incompletely cured casting together with the upper and lower forms interconnected by the positioning means from the core and the jacket, whilst the upper and lower forms are retained with respect to the casting and with respect to each other with the aid of positioning means, said positioning means comprising connecting members which interconnect the upper and lower profile forms and extend through the mould cavity across the concrete mortar.

2. A method as claimed in claim 1, wherein said positioning means comprise a plurality of pipes each defining a passage through the mould for a connecting member.

3. Method of building a structure, e.g. a tunnel, sewer or culvert from a series of contiguous tubular building elements, wherein each tubular building element is manufactured in a first step, wherein concrete mortar is poured and consolidated by vibrations or shocks in the cavity of a casting mould consisting of a lower profile form, a jacket, a core and an upper pro-file form, and in which the upper profile form is connected by positioning means with the lower profile form and the resultant, incompletely cured cast-ing together with the upper and lower forms interconnected by the positioning means, is removed from the core and the jacket, whilst the upper and lower profile forms are retained with respect to the casting and with respect to each other with the aid of the positioning means, characterized in that the positioning means comprises connecting members which interconnect the upper and lower profile forms and extend through the mould cavity across the con-crete casting, and in that the incompletely cured casting together with the upper and lower profile forms interconnected by the connecting members is removed from the core and the jacket, in which first step a number of pipes each forming a passage for a tie rod forming part of the connecting members are arranged in the mould cavity, and wherein in a second step the sequence of contiguous tubular building elements is assembled with said passages of the building elements brought in line with one another and, said elements being interconnected in said second step by tensioning cables passing through the aligned passages thereof.