CN1200065A - Method and apparatus for producing concrete elements - Google Patents

Abstract

The present invention relates to a method and apparatus for producing a composite structure comprising a sheet metal bottom plate (6) and a concrete layer (18). The upper surface of the bottom plate (6) is provided with anchors (15) for anchorage to the overlying concrete, and the concrete layer (18) is cast over the bottom plate (6), and the concrete layer (18) is shaped by taking it through a bordered casting space (1, 5, 10, 13) and compacting it by virtue of a vibrating motion applied on at least one form wall of the casting space, said movement providing a vibrating area (7, 8) on said casting space.

Description

Produce the method and apparatus of concrete component

The present invention relates to a kind of method according to claim 1 production hollow steel bar as described in the preamble prefabricated board or similar slab concrete member.

The invention still further relates to a kind of equipment that is used to realize said method.

Many different pouring procedures are arranged in the production of tabular precast concrete.In these methods, plate by one movably the continuous pouring machine be cast in and fixedly water on the bed, perhaps, water bed and can below fixing casting machine, move.Usually, concrete mix is sent into mould, utilize various types of vibrators then its compacting from the feed hopper that is arranged in the casting machine top.General compacting mode is to utilize a trowel or oscillating plate, and they form the end face or the side of member.In the production of cored slab, by in the cast step, core being put into concrete mix, obtain the hollow cavity of mix inside, and these cores often are designed to pass through vibration or vertically move back and forth the form of handling, so just provide consolidation effect, and described vibration or reciprocating effect are the concrete mixs that compacting is poured into a mould as the floating effect in outside.Required reinforcing bar is sent into the mix from drum in casting process, and perhaps, required reinforcing bar is arranged in pre-stressed state and waters on the bed.Usually, once-cast can be made very long plank, can be cut into Len req with the diamond cutter blade saw after the maintenance (curing).

Except continuous pouring, board member also can be made by the mode that mix is poured in the mould by fixing or adjustable size.When producing cored slab, usually mix is not poured in the mould, just must be inserted by the chipware that light filler is made in the concrete mix because will obtain the core chamber in this way, a shortcoming of these continuous pourings and fixed die pouring procedure is exactly to need a large amount of working space, templates and water bed.Because the cast member just can be moved after the maintenance that must carry out certain hour after the cast on watering bed, in addition, the cutting of the scale of plate also is an expensive time-consuming job again.On the other hand, when producing with method for continuous casting, it is open that the core chamber of cored slab termination keeps, and it is blocked also is to take a lot of work very much this.If the plate end is subjected to the effect of a high compression forces, then the bearing capacity of plate is subjected to the restriction of the maximum allowable load of core chamber openend.Though the pouring length of plate is designed to the multiple near prefabricated board length, some termination of downcutting always from the casting plate end, they are without any use.Because the cement after the maintenance can't reclaim again, these waste materials can only be outwelled, and have caused complete unnecessary extra charge and significant loss.In addition, it also is very time-consuming and trouble finished product being divided the bundle transportation.

The workload of compacting below mould and vibration produce and the restriction of time loss are further dismantled/are installed in cast in fixed die, this vibration does not resemble that works in method for continuous casting acts on concrete mix inside effectively, and this has just caused the low-density and the low-intensity of product.

Purpose of the present invention is exactly to realize a kind of method and apparatus that can overcome the prior art shortcoming, and is suitable for comprising by size production the composite plate member of metal sheet and concrete slab.

The objective of the invention is by on the metal sheet that plate is cast in the member of formation lower surface, and realize the end, front and back that utilizes mold walls to limit member in the cast traveling process of pouring piece by the continuous pouring machine by certain size cutting.

According to a preferred embodiment of the present invention, concrete mix was poured into a mould by two steps.At first, the mix with bottom is cast in the lower part that is positioned at the plate of below, core chamber on the thin metal base plate with formation; Subsequently, remaining concrete mix is poured into a mould in main cast operation.

In addition, according to the present invention, the end with cored slab in main cast operation seals up.Core is extracted out from the core chamber, and plate stays 10～30cm in end, core chamber and does not pour into a mould, this space is filled with concrete mix, and by bottom vibrating compacting to obtain the solid end of plate.

More specifically, the principal character of the inventive method is described at the characteristic of claim 1.

In addition, the feature of present device is described at the characteristic of claim 8.

The present invention has outstanding advantage.

But the hollow and solid slab of method production fixed length of the present invention.

After the cast operation is finished, can immediately casting plate be walked from watering bed, in the maintenance operation, manufactured goods can be piled up storage.Therefore, the maintenance operation of plate can be finished in a quite little space, preferably its temperature is improved so that the maintenance of accelerate concrete.Because member can be removed from watering bed at once, can begin to pour into a mould new member immediately with the same bed that waters after cast.Like this, required cast place is just less than conventional method.Because the termination of cored slab can seal by casting complete, therefore do not need the high independent obstruction operation of cost, can in an operation, finish member production.Significant loss is reduced to minimum, because member directly can be pressed the certain-length cast, eliminated waste material, and the high sawing operation of cost has not needed yet.

Member length can be selected continuously, and bottom surface, the top curvature of required plate also can realize by the automatic controls of equipment respectively.Can produce with half-dried concrete mix, thereby maintenance processes is faster, the water that oozes out from mix when vibration also still less.

Thin metal base plate has multiple advantages, and particularly the basal surface quality is more smooth than prestressed slab, and prefabricated curvature is subjected to good control.This is to obtain by the vertical anchoring piece on the thin metal base plate that is used as the reinforcement that bears tension, and it has substituted employed prestressed cable in traditional prestressing force prefabricated component.New-type prestressed slab often is subjected to the obstruction of " spirality " dimensional distortion distortion, and this makes to install and become complicated that composite construction of the present invention has been avoided above-mentioned this shortcoming fully.

Present invention is described by accompanying drawing below, wherein:

Fig. 1 is the side view of present device;

Fig. 2 is the cutaway view along the plane A-A of equipment shown in Figure 1;

Fig. 3 is the amplification cross-sectional view of equipment shown in Figure 1;

Fig. 4 is the cross-sectional view according to the hollow compound structural of the inventive method making; And

Fig. 5 is the perspective view of the partly cut-away of structure shown in Figure 4.

In equipment of the present invention, cast is to carry out formed the watering on the bed 1 of the endless-belt that moves on two guide rollers by one.In the direction of watering above the bed 1, carrying out along cast, at first arranged an apparatus for pouring that is used to pour into a mould the bottom concrete mix, this apparatus for pouring comprises feeding belt 2, wears thereafter to be useful on the link mandrel 15 that the shop is sent the feed hopper 4 of bottom concrete mix and is used for forming bottom.Near bottom concrete mix apparatus for pouring be a main casting machine, actual member casting process just carries out herein.Casting space is sealed by watering bed 1 and being positioned at its side walls 13, the top of casting space is made of belt 10 and floating/oscillating plate 8, belt 10 is advanced by triangular paths on three guide rollers 9 continuously, and in the length range at casting space top, belt 10 is across two guide rollers 9, thereby runs parallel with the end face of casting space basically.Between these two rollers, place floating/oscillating plate 8, thereby compress belt 10 from above.Belt 10 and floating/oscillating plate 8 are little downward-sloping along the cast travel direction, so just make casting space slightly tapered on this direction, thereby have increased compaction.

One side of the triangular paths of belt 10 has constituted one side of feed hopper 5.Feed hopper 5 is in the back discharging of floating/oscillating plate 8, and concrete mix is sent in this feed hopper by conveyer 3.Below watering bed 1, vibrator 7 is installed, thereby base plate can slide thereon when cast.First vibrator roughly is placed under the discharge port of feed hopper 5, and second vibrator then is provided with near it along the cast travel direction.These vibrators form a vibration area on the cast passage, concrete mix is able to compacting in this zone.In order to form the leading section of cast member, be placed with the shaping sidewall 11 of member leading section in position near main casting machine, can move described sidewall by driver 22, the other end of member with one movably rear wall 12 limit, core shaping core 14 passes this rear wall 12.

When beginning cast is transported to the base plate 6 of member earlier and waters on the bed 1, and with the feed hopper 4 correct centerings of bottom concrete mix.Base plate 6 is to form like this, and metal sheet or a stainless sheet steel are made the plate with folding spine 15, and wherein spine is used as plate and the fixing anchoring piece of cast concrete.With base plate 6 after appropriate location below the feed hopper 4, just begin the cast of bottom concrete mix 21.Concrete mix that bottom is used 21 is sent into feed hopper 4 after through feed appliances 2 meterings, flows into space between the link mandrel 15 again from feed hopper, flows into again then in the space of its below.Utilize the shake table of arranging near link mandrel can increase flowing of concrete mix.Adjust the flow velocity of concrete mix so that it matches with poring rate, after first road cast operation, the base plate 6 that will be covered by bottom concrete mix 21 send main casting machine to along watering bed 1.

In main casting machine, the termination of base plate 6 stops at the below of concrete conveyer 3 ends and feed hopper 5 discharge ports.The die wall 11 of shaping front end is moved to the end of base plate 6, can begin the metering and the cast of top layer concrete mix 18 like this.Utilize 3 pairs of mixs 18 of conveyer to measure, this conveyer can be a belt conveyor or any other suitable pay-off.Preferably mix is poured into a mould, therefore with of the conveying of belt conveyor ratio with conveying worm or the easier realization mix of similar means with half-dried denseness.In main cast operation, antetheca 11 is fed a little from mix and is moved backward, the rear wall 12 that can move back and forth simultaneously at the belt 10 of floating/oscillating plate 8 below with the mix compacting, in the time need sealing by the core chamber of cast member, mobile antetheca 11 and base plate 6 so just form a space between the end of core 14 and antetheca 11.In this space, at first fill up concrete mix, and then the actual main preceding shifting movement of pouring into a mould operation and base plate 6 of beginning.

By regulating the compaction force that rear wall 12 is applied, can the pressure of control action on the concrete of pouring into a mould, act on the vibrational energy that waters in the material feeding by regulating the input power of vibrator 7 and 8, can changing.In addition, shaping core 14 can be provided with vibrator, perhaps is provided with according to the mode that can move back and forth.By movable belt 10 is pressed against water material feeding lip-deep floating/oscillating plate 8, can the upper surface of concrete mix of cast be formed.Belt 10 is designed to and pouring piece constant speed movement movably, so just provides a upper surface that level is smooth for pouring piece.Also reduced the wearing and tearing of floating/oscillating plate 8 in addition, because avoided plate to contact with the direct of concrete mix, and the latter is the most effective abrasive material.In addition, belt 10 has increased the feed effect of concrete mix through feed hopper 5, prevented mix in feed hopper obstruction and reduced the dynamic flow resistance of mix in casting space.

When cast, the shaping sidewall 11 of leading section can rise this wall then along with the cast operation is passed through main casting machine.Shaping core 14 moves with pouring piece, arrives the concrete mixing material conveyer until them.Core 14 must extend sufficient lengths, and is excessive to avoid not having, be delivered to by the vibrational energy that vibrator 7 and 8 were produced and be shaped and no longer by the core cavity region of described core supporting.

The plate that is used for floor and ceiling structure or similar applications all has the amount of deflection precompensation, and in other words, plate is poured into slight fovea superior, thereby it can present maximum level after being in place.By the cast operation in vertical mobile feed hopper 5 of a kind of control mode and vibrating device 8,9 and 10, can realize this precompensation.So, the discharge port of feed hopper 5 at first forms the top surface of member, vibrator 8 accurately with surface finish to design height.The motion of the core of core shaping at this moment 14 also is suitable for carrying out along the precompensation shape of member top surface.

As shown in Figure 3, core shaping core 14 comprises the vertical stacked relatively channel in two edges, they can stretch mode along vertically vertically together nestable slidably mutually, this configuration becomes easily height (and cross section) adjustment in core chamber 19, so that satisfy various application in the best way.

In the casting process of member rearward end, be shaped core 14 of core is extracted from core chamber 19 by the mould rear wall, thereby behind the extraction core, just in the cast concrete mix, formed opening.Now, component ends terminates under the discharge port of main casting machine feed hopper 5, and core chamber opening is then sealed by concrete mix.In addition, utilize the end of core 14 mix to be pressed in the end in core chamber, so further the compacting mix.When with behind the concrete mix 20 noggin piece ends, the end was pushed away casting machine, thereby finished compacting concrete mix by floating/oscillating plate 8 and shake table 7.Core shaping core 14 and rear wall 12 pass through main casting machine with the cast member.When by behind the casting machine, member is prepared to be transported to the maintenance operation, and the cast of new structural member can begin immediately.

With reference to figure 4 and Fig. 5, the composite component of the final formation shown in it has comprised thin metal base plate 6, it has in order to the anchoring vertical anchoring ridge 15 on the bottom concrete mix 21 of institute's lay thereon, on bottom concrete mix 21, be the remainder of concrete layer 18, be provided with longitudinal reinforcement 16, transverse steel 17 and core chamber 19 in it.Shown in Fig. 5 is the hermetic terminal 20 in core chamber 19.

Except the above embodiments, the present invention also can be by other scheme implementations.For example, floating belt can substitute with a floating beam that acts directly on the concrete layer end face.Except base plate, member can also adopt such as the bar-mat reinforcement or the reinforcing rod that are placed in the member body and be used as other reinforcement.Except the carrying hollow unit, this method also can be used for producing the product of other class, for example, and carrier bar and solid slab.By using alternative structure, dissimilar concrete conveyer for example, each parts of equipment are variable.In the above-described embodiments, casting machine is fixed, and also can consider another kind of the layout, and it has a fixing bed that waters, and casting machine is then made corresponding mobile thereon.Yet such embodiment needs a bigger place, and makes structure become more complicated.Because the steel-sheet cost is low, base plate is made by it traditionally.Be shaped on suitable rise crest on this sheet metal, it has constituted the used anchoring piece of cast concrete.Obviously, for the requirement of specific use, can adopt other any material that under tension, has sufficient intensity and rigidity to make the member base plate.

Except with the vibrator, concrete also can utilize such as the suitable modes such as motion of hammer or parts and come compacting.Be skewed by regulating the relative angle of antetheca and/or the end wall and the product longitudinal axis, the end of product can being made.This adjustment can be by realizing according to the hydraulic cylinder that plate is moved be provided with at an easy rate.Concrete bottom and top can have bar-mat reinforcement, utilize the extracting and the positioner that are arranged in the machine can automatically this net be arranged on a suitable height.

It is to be noted that especially method and apparatus of the present invention also can be used for production hollow and solid beam, post and wall body construction.

Claims (14)

1. A method of producing a composite structure comprising a thin metal base plate (6) and a concrete layer (18), in which method: - The top surface of the bottom plate (6) has an anchor (5) for anchoring the concrete laid thereon; - the concrete layer (18) is poured on the base plate (6); and - passing the concrete layer (18) through a delimited pouring space (1, 5, 10, 13) and compacting it by means of a compacting motion acting on at least one forming wall of the pouring space, thereby forming the concrete layer (18), the compaction movement forms a compacted area (2-10) in the pouring space; It is characterized by: --In the pouring process, the bottom plate (6) whose size is consistent with the design size of the composite structure to be manufactured is supported by a movable pouring bed (1) through the above-mentioned pouring space (2-10), thereby - at least at the beginning of the pouring process, by placing the front end of the above-mentioned concrete layer (18) on the front end of the base plate (6) and defining the front end of the concrete layer (18), the front wall (11) can be followed by moving together with the movement of the base plate (6) and at least partially through the confines of said compaction zones (7, 8); and - the rear end of the concrete layer (18) is shaped by means of the rear wall (12) delimiting the rear end of the pouring space (2-10), said rear wall being movable with the movement of the base plate (6) and at least partially ground through the extent of the compaction zone (7, 8). 2. A method according to claim 1, characterized in that the concrete is formed by placing a core forming core (14) for each core cavity (19) to be formed in the pouring area (7, 8). At least one core cavity (19) is formed in the layer (18), the core being movable through the rear wall (12) in the pouring direction during the pouring process. 3. The method according to claim 2, characterized in that: the concrete mixture is poured in two steps, first pouring the bottom concrete mixture (21) on the base plate (6), passing through a movable core The core (15) is formed so that the top surface of the mixture conforms to the shape of the lower surface of said core; in a next step, a second layer of concrete is poured on top of the concrete layer (21) already poured on the base plate (6), This layer comprises the top portion and core cavity of the composite structure. 4. The method according to any one of claims 1 to 3, characterized in that during the pouring of the front edge of the concrete layer (18), the core forming core (14) is not driven to the front wall ( 11) in contact but at a certain distance from the front wall (11), so that the front edge of the concrete layer (18) will become a solid part (20), accordingly, the core (14) ) is extracted and leaves the poured concrete layer (18) flush with the rear wall (12), so that the rear end of said concrete layer (18) will also become a solid part (20). 5. A method according to any one of claims 1 to 4, characterized in that the movable surface is formed by moving a belt (10) supported by a vibrator (8) parallel to the concrete surface, using The movable surface applies vibrations to at least one surface, preferably the top surface, of said concrete layer (18). 6. The method according to any one of claims 1 to 4, characterized in that the bending precompensation of the top surface of the component is formed on the concrete layer (18) by varying its pouring thickness along the length of the concrete layer . 7. A method according to any one of claims 1 to 6, characterized in that at least one side wall (11, 12) forming the end of the composite structure is arranged obliquely with respect to the longitudinal axis of the component. 8. A plant for the production of composite elements comprising a metal base plate (6) with anchors thereon and a concrete layer (18), the plant comprising: - pouring space (1, 10, 13) bounded at least by its upright sides; - fixtures (3, 5) for feeding concrete mix into said pouring space (1, 10, 13); and - at least one vibrator (7, 8) for vibrating one of the sides delimiting said pouring space and forming a vibrating zone within said vibrating space; It is characterized by: - having means for conveying said base plate (6) through the pouring space; - a movable front wall (11) at the front end of the base plate (6) for delimiting the front boundary of the poured concrete layer, at least at the beginning of the pouring process; - means (22) for conveying said front wall (11) along the direction of movement of the base plate (6) and at least partially through the range of said vibration zones (7, 8); - a rear wall (12) that delimits the rear end of the pouring space and thus forms the rear end of said concrete layer (18), and - means for conveying said rear wall (12) in the direction of movement of the base plate (6) and at least partially through the extent of said vibration zones (7, 8). 9. Apparatus according to claim 8, characterized in that during the casting process at least one core-forming core (14) can be moved through the rear wall (12) and into the casting space (1, 10, 13). 10. The apparatus of claim 9, wherein: - having means (2, 4) for pouring the first layer of concrete onto said cut-to-length floor (6); - means (15), for example, a movable core forming core for compacting the surface of the first layer of concrete (21) poured on the base plate (6), and for shaping the upper surface of said layer of concrete Consistent with the shape of the lower surface of the core forming core (14). 11. The device according to any one of claims 8-10, characterized in that it has a smoothing/vibration assembly comprising: - an endless belt (10) that goes around the guide rollers (9) so that its outer surface constitutes a side of the pouring space; - a vibrator (8) built into the inner surface of the belt (10) in the region forming one side of the pouring space, in order to vibrate the concrete mixture located under the belt (10); - Means for driving said belt (10). 12. Apparatus according to claim 11, characterized in that the belt (10) runs in the direction in which the pouring takes place. 13. Apparatus according to any one of claims 8 to 12, characterized in that there are means for controlling the height of the parts (5, 8, 10) to form the upper surface of the cast component. 14. The apparatus according to any one of claims 9-13, characterized in that the core-forming core (14) comprises two vertically oppositely stacked trough-shaped pieces which can slide vertically in a telescopic manner nested together in order to adjust the height of the core forming core (14).

Images