PT87976B - PROCESS FOR THE MANUFACTURE OF COVERAGE ELEMENTS FOR THE CONSTRUCTION OF BETAO SURFACES AND ELEMENTS MANUFACTURED BY THESE PROCESSES - Google Patents

Abstract

In one of the methods, connecting elements made by using concrete are produced by first pouring a fluid mortar, on the inside of a wall (1), into openings (5) of a template (2), with the addition of an adhesion promoter. A bell- or disc-shaped casting mould, which is filled with earth-moist concrete and is centred by the openings, is then placed upon this fluid mortar. The form elements thus produced can be stacked for hardening, with the interposition of thin plates, and subsequently joined to form form-element halves, for example by adhesive bonding. Modified methods produce the form elements by using dumbbell-shaped connecting elements made with the aid of axially separated mould halves. Form elements produced according to the method permit numerous modifications. <IMAGE>

Description

The present invention relates to a process for the manufacture of formwork elements for the construction of concrete surfaces according to the preamble of claim 1 which reduces the cost of manufacture and, in addition, leads to a better formwork element, susceptible to suppose

higher loads and cheaper. The solution to the problem is indicated in claims 1, 16 and 19. Improved characteristics of the process, as well as the formwork elements and connecting elements manufactured by said process are the subject of the secondary claims.

When the connecting elements according to claim 1 are poured directly into the walls of the formwork elements, separate manufacture is eliminated. The use of fluid mortar with an adhesion agent makes it possible for an extraordinarily good, long-lasting and solid, tensile-resistant connection to the walls of the formwork element. The adhesion agent can be added simply to the fluid mortar. But there is also the possibility of applying the adhesion agent, at least in the area of the mold openings, for example by spraying or painting in the form of an inductance on the walls. Finally, the bonding agent can be applied by immersing the walls in a bath.

In a particularly advantageous way, it can then be used simultaneously to add a paint so that, especially in the case of rigid foam material, the snow-white exterior is covered with paint. The bright white appearance is particularly uncomfortable in the sunlight and leads to injuries similar to the well-known snow blindness. The pouring of the concrete or similar material flanges is substantially facilitated, as the concrete can be poured from above into the relatively large openings, which define the future connecting surfaces of the connecting element to the respective wall. The molds are reusable and the dies with the openings guarantee a good conservation of the dimensions and a good reproducibility of the formwork elements. In an improvement of the present invention, it is possible to stack the fresh ready-made walls, for setting the concrete, as well as for storage, so that the space required for manufacture and storage is substantially reduced. For this, the finished walls are laid on a flat surface in a position with the flanges facing upwards, and then an intermediate layer of thin plates, for example flat plywood, is placed on the flanges.

and then a new layer of walls on the plates. In this way, piles with a height of several meters can be formed.

After the placement of each layer, the concrete of the connecting elements at the beginning of the layer has solidified to the point that, when the next layer is laid on the thin plates, there is no deformation. The layers of walls colonized next to each other must therefore have a determined length, so that sufficient time elapses until the next layer is applied. Before stacking the walls, the free ends of the flanks are conveniently adjusted, by means of a template, formed, for example, as a bridge, at a predetermined level, by traction or light compressions. The subsequent formwork elements have very precise interior and exterior measurements.

A special advantage of the formwork elements manufactured according to the process of the present invention is that smooth walls cut from a block, preferably of rigid foam, can be used without grooves or other cutouts or cavities. It is not necessary to use expensive injection molds. These formwork elements are therefore very cheap and can be connected, for example, like hollow bricks. The relatively large self-weight of the concrete connecting elements contributes to sufficient stability even for floor-height walls, which can then be filled with normal concrete or lightweight concrete.

The weight of the concrete connecting elements also prevents fluctuation of the formwork elements when light concrete is poured. When additional security is desired due to the action of wind and storms, the formwork elements placed on top of each other can be bonded to each other before filling with concrete.

For the formation of the connecting elements manufactured according to the process according to claim 1 and its dependent claims, there are several possibilities, depending on the improved characteristics of the present invention. The flanges are preferably made with a cir4 configuration

but can also be oval, rectangular or square. The molds into which the concrete is poured can be made in the form of a bell, in such a way that the flanges are joined by a rod. For the connection of two walls to form a formwork element, the free ends of the rods are then glued together. With the aid of a simple device, they can then ensure that the ends of the rods touch each other precisely. Before hardening, at least in the transition between the flange and the rod, at least one groove-like depression can be placed as a further support point such as a Monier bar, for example by compression with such a Monier bar.

But the mold or die for the manufacture of the flanges can also be configured so that it results in a disk-shaped flange. This is provided with a central recess, preferably circular cylindrical and, for the connection of two walls to form a formwork element, intermediate rod-shaped pieces are then glued between the bodies of each two opposite recesses. In a similar way, holes can also be molded for the subsequent placement of additional guide fixing means, for example with the aid of dowels.

By means of a uniform distance achieved with the gauges between the connecting elements, for example 25 cm, a fixing scale is determined beforehand. The formwork elements can then be sawed between the fixing elements in accordance with this scale; but this does not happen in the area of the connecting tabs. This limitation is overcome in an improved form of the present invention in such a way that medium separator plates are inserted into the molds for the manufacture of flanges, and possibly intermediate rod-shaped parts, arranged through the axis of the connecting elements and in the direction the height of the formwork elements. The formwork element can then be cut parallel to and in the extension of the separator plates, so that it can then also be worked on the half-scale of fixation. As the cut, in most cases, is only necessary in the area of the ends of the formwork elements,

the separator plates are conveniently used only on the flanges or intermediate parts, respectively, adjacent to the two ends of the walls.

Another solution of the process according to the preamble of claim 1 is characterized in claim 16. In that case, the halter-shaped connecting elements are therefore manufactured by means of molds, whose inner contour of the halves corresponding to an axial cut of the connecting element. After filling the two mold halves with concrete, the two mold halves can be placed immediately on top of each other, so that the concrete fillers bond solidly to each other. But a separating device can also be introduced, for example a sheet so that halves of connecting elements result. These can be used separately, placed on top of each other or also glued together for the manufacture of formwork elements. The filling with concrete can be done manually or mechanically, by injection, vibration, compression or agitation Depending on the process used, the concrete then has from the consistency of the wet earth to a fluid consistency.

An additional solution for the process according to the preamble of claim 1 is indicated in claim 19. Here again, two axially divided mold halves, of the type described above, are used, but which, before filling, are solidly connected together after leaning in line, forming a mold, this connection being made for example by clamps. Additionally, the connection at the edges can be improved by forming grooves and tongues. The concrete filling can once again be done by injection, agitation or compression, more precisely from the top down.

In the dofb manufacturing processes described above for the connecting elements, reinforcement bars can be glued, more or less axially to the mold or to a half of the mold. In this way, a substantial increase in tensile strength is achieved, especially when the wagons are profiled and have expansions at the ends, for example.

repress or welded, or are simply bent. Even if the connecting elements break, for example during transport, the tensile-resistant connection between the walls of the formwork element remains.

The mold halves can be made of metal, for example steel sheet, but also of plastic material.

In the formwork elements manufactured by the process according to the present invention, in general the two walls, as well as the top walls, if any, are made of rigid foam material. But in a variant of the present invention, a wall may also be of plaster, light plaster, concrete with plaster cement, clay or similar materials. This wall then forms the inner face of the construction wall ulteriomely, thus preventing unwanted transport of the formwork along the wall. Furthermore, a hollow noise does not disturb when hitting the wall.

The processes according to the present invention actually make it possible to manufacture formwork elements from smooth plates cut from a block. However, in order to improve the retention force between the flanges of the connecting elements and the walls, the interior faces of the walls may also, in a known manner, be provided with a groove and tongue profile, the grooves being able to have, for a better anchoring, recessed cavities. The shape of the cross-section of the grooves can be chosen at will, for example the shape of a swallowtail, an open semicircle or a full circle, and it can also have other configurations. Therefore, the walls can also be provided on the top face and on the top faces of grooves in a known manner.

The flanges may, as has already been explained in the explanation of one of the process variants according to claim 1, include fastening wires. These wires can then be pulled on both sides by means of a tubular intermediate piece, placed at both ends of peripheral cavities or flares. Through these holes, these wires are carried

out and then twist with each other, under tension. In this way, it is possible, at the assembly site, to associate the formwork elements according to needs, in a simple way. Different wall thicknesses can be obtained using intermediate pieces of different lengths.

End pieces for closing the formwork elements at the end of a wall or corner are conveniently glued to the top faces or between the ends of the walls of the formwork elements. Then, in order to obtain greater stability in doors and windows as well, the end pieces of various formwork elements located above each other, can form a continuous unitary plate.

Due to the solid connection between the flanges and the walls, the walls can, at least in the area of a flange, be provided with a continuous groove from top to bottom. Its width can be in the region of half the diameter of the flange. The groove that can also be sawn afterwards at the installation site ensures that, when connecting the walls or the connections to the corners, the concrete, without interruption, passes continuously through a wall of rigid foam material.

The present invention is described below with reference to exemplary embodiments illustrated in the accompanying drawings, the figures of which represent:

Fig. 1 schematically making the wall of a formwork element according to the process according to claim 1;

Fig. 2, the various stages of the process according to fig. 1;

Fig. 3, the stacking of walls of formwork elements on top of each other, which were manufactured by the process according to figs. 1 and 2;

Fig. 4, a side view of an example of a formwork element according to the present invention;

Fig. 5, the side view of another example8

method of making a formwork element according to the present invention;

Fig. 6, in cross-section, a split casting mold for the flanges of a connecting element according to the process according to claim 1;

Fig. 7, schematically, the possibility of separating a formwork element by the midpoints of the fixation scale;

Fig. 8 is a side view of another example of a formwork element according to the present invention;

Fig. 9 is a side view of an example of a formwork element according to the present invention;

Fig. 10, a corner connection with continuous connection of the concrete; and

Fig. 11, a wall connection with continuous connection of the concrete.

Figs. 1 and 2 illustrate the process according to the present invention according to claim 1, in its various stages. In a wall (1) of a formwork element formed by two of these walls, a mold or matrix (2) is placed, for example, of plastic or sheet material, ensuring that the centering pins (3) have a perfectly defined position of the two pieces, on , for example, a work table. The plate (1) is made, for example, of rigid foam material. Unlike fig. 1, the plate (1) according to fig. 2 shows grooves (4) with a dovetail cross-section, which as mentioned above can only exist additionally in an improved variant of the present invention.

The mold (2) is provided with circular openings (5), placed at a uniform distance from each other and determining the fixation scale. But they can also have other shapes, be at irregular distances and be together.

leased. After placing the mold (2) on the wall (1), the configuration shown in section in fig. 2a. A fluid mortar (6) provided with an adhesion agent is then poured into the openings (5) and the mortar is smoothed out. The sticking agent can also be applied as an inductance to the wall, for example by immersion, if necessary colored. The situation obtained after these operations is shown in fig. 2b and the two openings on the right of fig. 1.

Then, or in parallel with this phase of the process, a pouring mold (7) is filled with the configuration of a concrete bell (8) with the consistency of wet earth. The mold then has its largest opening upwards (position opposite to that shown in Fig. 2b) so that the concrete (9) can be poured easily.

Then the mold (7) is turned, still with the wet concrete (8) on the fluid mortar (6), the mold edge (7) being received by the openings (5), so that a precise centering is obtained (fig. 2c). After that, the molds can be removed, possibly with a slight stirring and then the matrix (2) is also removed (fig. 2d).

The walls (1) with the molded connecting element halves (10), made of concrete (8) and flowable mortar (6) are - as shown schematically in fig. 3 - lined up next to each other on a flat base, for example the concrete floor, in a length between 10 and 30 m, or more. When a layer is ready, they are placed, for the protection of the media or plates of another material, for example, with the dimensions of 100 x 200 x 0.3 cm. Then the next layer of connecting element halves (10) can be placed. In this way, piles with a total height of 2 to 3 m can be formed. It is now necessary to allow sufficient time for the concrete (8) of the connecting element halves (10) to harden to a point where they can withstand bti lice loads.

Fig. 4 · shows schematically how, more

later, two walls (1) with halves of connecting elements (-10) are associated per top glue to obtain a formwork element. Using a simple device (not shown), it is then ensured that the top faces of the halves of the connecting elements (10) touch each other precisely. The result is that the connecting elements (20) in the shape of a dumbbell, formed from two halves (10), each with two flanges (12) and an intermediate connecting piece (13) which, in the present case, have the shape of a rod.

In the embodiment according to fig. 5, a mold (not shown) different from the mold (7) according to FIG. 2b, in the form of a flattened terrine, so that only the formation of the flanges (22) ',' having a central cavity (14) results. When two walls (1) are combined with flanges (22), the intermediate parts (23 / in the form of a shank in the cavities (14) are then glued together. In the two examples according to figures 4 and 5 the intermediate parts (13) or (23), respectively, were also provided in the zone of their agreement with the flanges (12) or (22), respectively, before the hardening, groove-shaped marks (15), which serve as support points for Monier bars (not shown).

Fig. 6 shows a casting mold (17) whose shape substantially corresponds to the casting mold (7) according to fig. 2b, but additionally having a separator plate (16) in the middle. The halves of the connecting elements produced with this mold have the same shape as the halves (10), but are separated into two parts, so that a formwork element can be sawn to be divided at this point, as the lines to be schematically indicate dashed line (18) in fig. 7. In addition to a separation between the connecting elements (20) in the area of the marked lines (19) and the expected fixing scale of, for example, 25 cm, they can also be cut in the middle of the referred scale, so that it is possible to easily adapt to the circumstances found at each installation site.

Fig. 8 shows another example of an embodiment for a formwork element according to the present invention. Again, flanges (22) corresponding to fig. 5, with a central cavity (14). Before hardening, additional wires are anchored to the flanges (24). To join two walls (1) with flanges (22), a tubular intermediate part (33), also made of concrete, is used. The wires (24) are introduced on both sides, through the intermediate piece (33), pulled out and then twisted with each other with a certain tension. The cavities (25) on the periphery of the intermediate piece make it possible to remove the wires (24) without difficulty.

In the embodiment according to fig. 9, plate strips (26) are attached to the flanges (22). The connection of two walls (1) with flanges (22) is then made through sheet strips (26), for example by inserting screws or wires through the holes (27), or by making a connection with welding by points. An increase in the distance, and therefore in the interior width of the formwork element, can be achieved by means of elongation pieces (28), which also have holes (27).

Fig. 10 schematically represents the embodiment of a corner connection, with the first layer and the following odd layers shown on the left and the second layer and the following even layers of formwork elements on the right. In fig. 10a, the inner wall (1) is provided, in the area of the left intermediate part (20), with a cutout (29) which is taken to the bottom of the flange (12). When filling with the following concrete, a connection of the local poured concrete results to the flange (12) and, in short, a continuous concrete wall through the corner, which is not interrupted by a layer ¹ of hardened foam. of the walls (1), thus representing a wall for the fire. The same can be said for the next layer, according to fig. 10b, in which a continuous connection of concrete through the cut (29) is possible.

Fig. 11 shows a wall connection with

> alternating layers according to fig. 11a and 11b, respectively! Here again, the cutouts (29) take care of training | of concrete walls with continuity. Such a continuous concrete core 'not only avoids fire crossing points and' sound crossing bridges, but additionally a greater static load capacity is obtained. í i

f i

Fig. 10a also shows an end piece (30) which is glued between the walls (1) and closes the formwork element outwards.

Claims (4)

- 1§ Process for the manufacture of formwork elements for the construction of concrete surfaces with walls (1) and connecting elements (20) made of concrete or similar building materials for the walls, having the connecting elements (20) the shape of a dumbbell with two flanges (12) attached to the opposite walls (1) and an intermediate piece (13,23,33), characterized by comprising the following phases: a) a matrix (1) is placed on the inner face of a wall (1) 2) which has openings (5) in the shape of flanges (12); b) the openings (5) are filled with a fluid mortar (6) and the mortar is smoothed, providing an adherent adhesion agent for the wall material (1) to promote a bonding of the fluid mortar; c) fill with concrete (8) with the consistency of wet earth molds (7) with the shape corresponding to that of the flanges (12), with the opening of the flanges facing upwards and smooth the concrete; d) the molds (7) are turned over, placing them with their flange opening on the fluid mortar and on the holes (5) of the matrix; e) the molds (7) and the matrix (2) are removed for new use; f) after hardening, two walls (1) are joined by means of the intermediate pieces (13,23,33). - 2nd - Process according to claim 1, characterized in that the adhesion agent is mixed with the fluid mortar (6). _ 3a _ The method according to claim 1, characterized in that the adhesion agent is applied as an inductant at least in the region of the openings (5) of the matrix, on the walls (1). - _ Process according to claim 3, characterized in that the adhesion agent is applied by immersing the walls (1). - 5® - Process according to claim 4, characterized in that the adhesion agent is colored. - 6δ - Process according to any of claims 1 to 5, characterized by the following stages: g) install the finished walls (1) with the flanges (12,22) facing upwards, in a layer, on a flat surface; h) an intermediate layer of thin plates (11) rests on the flanges (12,22); i) another layer of walls (1) rests on the plates (11); k) the phases (h) and (i) of the process are repeated. - 7 ^fi - Process according to one of Claims 1 to 6, characterized in that, after smoothing the molds (7) according to the process step (e), the free ends of the flanks (12) are adjusted with a template for a predetermined height. - 8 & - 1 to 7, Process according to the fact that the molds (7) according to one of the claims are bell-shaped so that a rod (13) is connected to the flanges (12) and that, for the connection of two walls (1), according to In phase (f) of the process, the free ends of the rods (13) are glued together. - ga _ Process according to claim 8, characterized in that, before hardening, it forms at least one groove-shaped cavity (15) in the transition between the flange (12) and the rod (13) as further support point for a Monier bar. - 10§ Process according to any of claims 1 to 7, characterized in that the molds have a shape that results in the formation of a flange (22) in the form of a disc, since the flange is provided with a cavity (14) centrally, preferably of a circular cylindrical shape and, for connecting two walls (1) according to the phase (f) of the process, intermediate rod-shaped pieces (23) are glued to the bottom of the cavities (14). - Process according to claim 10, characterized in that the rod-shaped intermediate part (23) is made of concrete, by means of a hollow cylindrical mold, and is provided, before hardening, in the region of its ducts. ends, of groove-shaped cavities obtained by pressure (15), as posterior support points for Monier bars. - 125 - Method according to one of Claims 1 to 9, characterized in that additional guide fastening means, such as Monier bars, hooks, eyes, screws, are embedded in the flange (22) or connected with it wires (24), plate strips (26) and the like. - 13® - Process according to any of claims 1 to 9, characterized in that holes are formed in the flange (22) or in the rod connected thereto, before hardening. - 14® - Process according to any one of claims 1 to 11, characterized in that the molds (fig.6: 17) are inserted into the molds for the manufacture of flanges (12) and, where appropriate, rod-shaped intermediate parts, medium separation plates (16), arranged through the axis of the connecting elements (20) and in the direction of the height of the formwork elements, so that the ready formwork element can be cut parallel to the separator plates (16) and in the extension of them (fig) .7). - 15® - Process according to claim 14-, characterized in that the separator plates (16) are used only on the flanges or rod-shaped intermediate parts adjacent to the ends of the walls (1). - 16§ - Process according to the preamble of claim 1, characterized in that it comprises the following steps: m) mold halves are filled with concrete, the interior contour of which corresponds to the halves of an axially shaped connecting element, cut axially, which are smoothed along the cutting plane; n) mold halves are placed on top of each other, two by two by their cutting planes; o) after at least partial hardening they are smoothed; p) the connection elements are glued using a bonding agent with two opposite walls. - 17® - Process according to claim 18, characterized in that, before step n) a separating device is placed between the two halves of the mold. - 18§ - Process according to claim 16, characterized in that, before step n), a reinforcing bar is introduced along the axis of the connecting element in one of the mold halves. - 19® Process according to the preamble of claim 1, characterized by comprising the phases: q) two mold halves are aligned, the inner contour of which corresponds to the halves of a halter-shaped connecting element, axially cut, along the cutting plane and they connect solidly to form a mold; r) the mold is placed, with the axis perpendicular to a flat surface and filled with concrete; s) after at least partial hardening, the halves of the mold are removed; t) bonding elements using a bonding agent with two opposite walls. 20. Method according to claim 19, characterized in that, before step s), a reinforcing bar is introduced along the axis of the connecting elements in the mold. 215 Formwork elements manufactured according to the process according to any of claims 1 to 20, characterized in that at least one of the walls (1) of the formwork element is made of rigid foam material. Formwork element according to claim 21, characterized in that a wall (1) of the formwork element is made of plaster, light plaster, concrete with plaster cement, clay or similar material. - 235 - Formwork element according to claim 21 or 22, characterized in that the inner face of the walls is provided, in a known manner, with a groove and tongue profile (4). - 24 ^ê - Formwork element according to claim 23, characterized in that the grooves (4) have cut-outs for the best anchoring of the flanges (12,22). - 25 ^ - Formwork element according to any of claims 21 to 24, characterized in that the flanges according to claim 12 are provided with fastening wires (24), which can be pulled on both sides, because the intermediate part (33) is provided at both ends with peripheral cavities (25) or holes, through which the wires (24) are led out and then twisted with each other with tension. - Formwork element according to one of Claims 21 to 25, characterized in that end pieces (30) are glued to the side faces of the walls (1) or between the ends of the walls (1). - 27 & - Formwork element according to claim 26, characterized in that the end pieces of several formwork elements placed on top of each other form a unitary plate. - 28 & - Formwork element according to one of claims 21 to 25, characterized in that the walls (1) are provided in the area of the flanges (12) of at least one of the connecting elements (20) with a continuous groove (29) from above down. 29 & Halter-shaped connecting element, characterized in that it is manufactured according to any of claims 16 to 20. The applicant declares that the first application for this patent was filed in the German Federal Republic on 15 July 1987, under ο N2. p 37 23 341.6, claiming the priority of this request under the provisions of Art. 32 and 4- of the Paris Union Convention, as it has an effective and not fictional establishment in Luxembourg at 15-17 Route de Grundhof, 6315 Beaufort.