SK508388A3 - Method of making form elements - 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

Technical field

I

The invention relates to a method for producing formwork elements for producing concrete sheathing with walls and concrete-based fasteners, wherein the fasteners are in the form of a bar with two flanges disposed on opposite walls and a spacer.

BACKGROUND OF THE INVENTION

For concrete cladding systems, large format formwork elements made of rigid cellular material are used, which are provided with a groove and tongue at their edges for interlocking and which have connecting elements inside the side walls which are designed to absorb the forces arising during the concrete filling. Such formwork elements are known, for example, in DE-AS 26 18 125 and DE-OS 34 05 736. As connecting elements there are also bar-shaped concrete elements which are provided with two opposing flanges and a spacer between them, which are grooved and with the tongue on the free flange surfaces insert into corresponding grooves and lips on the inside of the formwork elements. When the formwork elements are poured in concrete, the joining elements are connected homogeneously with filled concrete.

Unlike metal fasteners, there are no thermal bridges. Compared to solid lightweight fasteners, such as are formed with one-piece walls, the sound bridges and the possibility of a fire in the fastener area are completely eliminated. In addition, the relatively heavy fasteners made of concrete or the like prevent the formwork elements from being filled with light concrete. sailing. The contact pressure of the superimposed shuttering elements, which is achieved by the weight of the fasteners, ensures the sealing of the joints so that the cement milk, which is important for binding, cannot escape. In addition, the weight of the fasteners ensures high reliability of their position, for example in a storm.

Known fasteners, which are made of concrete and have the shape of a dumbbell, are individually cast separately from the formwork elements made of rigid lightweight mass and are later inserted or snapped into the internal grooves in the walls of the formwork elements or bonded with them . In addition, it is known to manufacture dumbbell-shaped fasteners by separately casting them into two halves, which are then later joined by means of spacers in the form of eyelets, hooks, rods, wires or screws (German Patent Application Publication No. 36 01 878).

The shuttering elements of the type described have proven themselves. However, their production is relatively expensive and requires a lot of space and time due to the time required to cure the concrete parts of the fasteners.

SUMMARY OF THE INVENTION

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method of manufacturing shuttering elements for sheathing of the type mentioned above, which makes it possible to reduce production costs and which makes the shuttering element more expensive for larger loads.

When the fasteners according to the invention are cast directly on the formwork walls, they are not produced separately. The use of a liquid mortar with an adhesive means allows an extremely good and durable and tensile connection to the formwork walls. The adhesive can be easily added to the liquid mortar. However, it is also possible to apply the adhesive, at least in the region of the holes of the template, to the walls, for example by spraying or painting in the form of a coating. Finally, the adhesive may also be applied by dipping the walls into the bath. In this case, it is particularly advantageous for the outer surface to be overlaid by the simultaneous addition of paint, which is particularly advantageous for the snow-white surface of a rigid cellular mass. Dazzling white appearance, especially in sunlight, very disturbing and leads to similar difficulties as the known snow blindness. The casting of flanges of concrete or similar material is considerably easier, since the concrete can be filled into relatively large openings from above, thus defining the later connecting surface of the fastener to its associated wall. The molds can be reused and the templates ensure very good adherence to the dimensions and reproducible formwork elements. According to a further preferred embodiment of the invention, freshly made concrete hardening and storage walls can be stacked on top of each other, thereby substantially reducing production and storage space. For this purpose, the walls produced are laid with their flanges upwardly in a single layer on a flat surface, then an intermediate layer of thin boards, for example a plywood board, is placed, which is placed on the flanges and finally an additional layer of walls is laid. In this way, stacks of several meters can be created. After each layer has been laid, the concrete of the fasteners at the beginning of the layer should be allowed to solidify to such a degree that no deformation of the fasteners occurs when the next layer is applied to thin plates. The stacked layers must be of sufficient length to allow sufficient time for the next layer to be laid. Before stacking the walls, the free ends of the flanges are expediently adjusted by a template, for example of a bridge shape, to a predetermined height by expansion or slight compression. The later formwork elements then have very precise external and internal dimensions.

A particular advantage of the formwork elements according to the invention is that smooth, cut walls without grooves or other cuts or recesses can be used from one block, preferably from a rigid cellular mass. On the whole, the use of expensive injection molds is eliminated. Such formwork elements are therefore very inexpensive and can be used, for example, as a bundle of hollow block elements. The relatively high self-weight of the concrete fasteners ensures sufficient stability even for single-floor walls that are then filled with normal or lightweight concrete. For the same reason, the weight of the concrete fasteners prevents the formwork from flooding when filled with lightweight concrete. In order to provide additional protection against the effects of wind or storm, the formwork elements seated on top of each other can be joined together by gluing until the concrete is filled.

According to a further embodiment of the invention, there are many possibilities for providing the connecting elements according to point 1 and other points. The flanges are preferably in the form of a circle but may also be oval, rectangular or square. The molds into which the concrete is poured can be bell-shaped by connecting the shaft flange with the flange. The free ends of the shafts are then glued together to join two walls in one formwork element. By means of a simple device, it can be ensured that the ends of the shanks fit precisely to each other. Prior to curing, at least one groove indentation may be formed at the transition between the flange and the shank, which may be used later as a bearing for the Monier rod, for example by impressing such a Monier rod.

However, the mold for producing flanges can also be designed such that a disc flange is formed. This can be provided with a central, preferably circular cylindrical recess, and for joining two walls to one formwork element, more precisely, into one formwork element, the shaft-shaped intermediate pieces are then glued between the bottoms of two mutually opposed recesses. By varying the length of the shaft-shaped intermediate pieces, the internal dimension of the formwork elements can be adjusted and thus the thickness of the later wall. The shaft-shaped spacer can conveniently be made of concrete using a cylindrical hollow mold. In this case, before curing, the groove indentation can be provided in the region of both ends as a later fit for the Monier rods.

According to a further advantageous embodiment of the invention, it is envisaged that further fastening means such as Monier rods, hooks, eyelets, screws, wires, sheet metal tapes and the like are anchored in the flange or in the subsequent shank adapter before curing. In the same way, openings can also be provided for later adaptation of the downstream fastening means, for example by means of dowels.

The template ensures that the fasteners are evenly spaced, creating for example a grid size of 25 cm. At the construction site, the formwork elements can then be cut between the connecting elements distributed on the scale of the grid. However, this cannot be done without further action in the area of the connecting barriers. According to a further advantageous embodiment of the invention, this limitation is overcome by inserting into the molds for the production of flanges and possibly shank spacers, intermediate separating plates which are arranged to extend through the axis of the connecting elements and in the direction of the formwork elements. Then the finished formwork element can be cut in parallel and in the extension of the separating plates so that it is also possible to work with half the size of the grid. Since it is generally necessary to carry out the separation only in the region of the ends of the shuttering elements, the separating plates are expediently used only for flanges or shaft-shaped intermediate pieces which are adjacent to both ends of the walls.

A further embodiment of the method according to the preamble of point 1 of the definition of the subject matter of the invention is shown in point 16. According to it, the bar-shaped fasteners are produced by means of half molds whose inner contour corresponds to half of the axially slit fastener. After filling the two mold halves, either filling the mold half with concrete can be immediately placed on top of each other so that the concrete fillings are firmly connected to each other or a separating means, for example a foil, can be inserted to form two halves of the fastener. These can be used to produce the formwork elements either separately, laid on top of each other or also glued to each other. Concrete filling can be done either manually or by machine pouring, pouring, squeezing or shaking. Depending on the filling method used, the concrete is expediently moist to liquid.

I

An additional solution of the method according to the preamble of point 1 of the definition of the subject matter of the invention is given in point 19. Here again, two axially divided mold halves of the type described above are used but which are laid together and firmly connected to each other before filling, for example by clamps one form. The additional edge connection can be improved by creating a groove and tongue. The concrete can be filled again by pouring, shaking or injecting, both from above and below.

In the case of the two fasteners described in the previous production methods, reinforcing wires can be inserted into the mold or into the mold half in an approximately axial position. This results in a substantial increase in the tensile strength, especially if the wires are profiled and have a thickened or welded reinforcement at their ends or if they are at least bent. Even if, for example, the connecting elements break off during transport, the tensile connection between the walls of the formwork element is maintained.

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

In the case of formwork elements which are produced by the method according to the invention, generally both walls and, if available, end walls, if any, f.

made of rigid cellular matter. However, according to another embodiment of the invention, one wall may also be made of gypsum, cellular gypsum, gypsum concrete, clay or the like. This wall then forms the inner wall of the wall later, thereby preventing unwanted transmission of noise through the wall. Furthermore, when knocking on such a wall, it does not disturb any transmitted hollow sound.

The methods according to the invention thus make it possible to manufacture formwork elements from smooth slabs cut from one block. However, these formwork elements may also be provided with a grooved profile on the inside of the walls in order to improve the coherence between the flanges of the connecting elements and the walls, the grooves being provided with additional undercuts for better anchoring. The transverse shape of the grooves can be arbitrarily chosen so that, for example, they may be in the form of a dovetail, open semicircle or solid circle, or otherwise. Likewise, the walls on the top and on the front sides can be provided with snap grooves.

The fastening wires may be embedded in the flanges, as already described in the description of a further preferred embodiment of the method according to claim 1. These wires can then be pulled from both sides by a tubular spacer which has marginal recesses or openings at both ends. Through these holes the wires are led out and then twisted under tension. Thus, the formwork elements on the construction site can be easily folded off as required. Different wall thicknesses can be achieved using adapters of different lengths.

The end pieces for closing the shuttering elements at the end of the wall or in the corner region are expediently glued to the end faces or between the ends of the shuttering element walls. In order to achieve greater stability, especially in the area of windows and doors, the end pieces of a plurality of formwork elements arranged one above the other may form a common passage plate.

In order to ensure a firm connection between the flanges and the walls, the walls can be provided with a top-down groove at least in the region of the flange. Its width may be roughly half the diameter of the flange. The groove, which can possibly also be cut later on site, ensures that the concrete joins without interruption in the wall connection area or in the corner joints and passes through the wall of rigid cellular material. This will increase strength and remove fire breakthroughs and sound bridges.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained in more detail below with reference to the drawing.

In FIG. 1 schematically illustrates the production of a formwork wall according to the invention according to claim 1.

Fig. 2 schematically represents the individual operations of the method according to item 1.

In FIG. 3 shows stacking of the formwork walls which were produced by the method of FIG. 1 and 2.

In FIG. 4 shows a side view of an exemplary embodiment of a crimping element according to the invention.

Fig. 5 is a side view of another exemplary embodiment of a formwork element according to the invention.

In FIG. 6 is a cross-sectional view of a split mold for a flange of a fastener according to the method of the invention in accordance with claim 1 of the claims.

In FIG. 7 schematically illustrates the possibility of splitting a formwork element in a half module.

In FIG. 8 shows a side view of another exemplary embodiment of a formwork element according to the invention.

Fig. 9 shows a side view of an exemplary embodiment of a formwork element according to the invention.

In FIG. 10 shows a corner connection with a continuous concrete connection.

Fig. 11 shows the connection of walls with a continuous concrete connection.

DETAILED DESCRIPTION OF THE INVENTION

Fig. 1 and 2 illustrate the method of claim 1 in its individual steps. On the wall 1 of one of the two walls which form the formwork element, a template 2, which is made, for example, of plastic or sheet metal, is laid, the centering pins 3 ensuring a precisely defined position of both parts, for example on a work table. The wall 1 is made, for example, of a rigid cellular mass. In contrast to FIG. 1 has a wall 1 according to FIG. 2 shows a groove profile 4 of a dovetail cross-section, which, however, is, as already explained, only another preferred embodiment of the invention.

The template 2 is provided with circular openings 5, which are arranged in mutually equal, module determining spacing. However, they may also have a different shape, may be irregularly spaced and may be arranged centered. After placing the template 2 on the wall 1, a cross-section is formed in the region of the opening 5, which is shown in FIG. 2a. The liquid mortar 6 provided with the adhesive is then filled into the openings 5 and smoothly leveled. The adhesive may also be applied to the wall 1 as a coating, for example by staining it, or it may also be colored. Then, FIG. 2b and both right holes 5 in FIG. First

Subsequent to or in conjunction with this method operation, the wet concrete 8 is filled with a mold 7 which is substantially bell-shaped. The mold 7 is directed upwards through its large opening, that is to say, it has an inverted position than that shown in FIG. 2d, which allows a comfortable filling of the wet concrete 8.

Then the mold 7 with the still wet concrete 8 is placed on the liquid mortar and 6, the edge of the mold 7 being gripped by the openings 5, thus creating an accurate centering, as shown in FIG. 2c. Then, the molds 7, possibly with a slight shaking, can be pulled off and later the template 2 can be removed (see FIG. 2d).

The walls 1 with molded halves 10 of the fastener, which are made of concrete 8 and liquid mortar 6, are then schematically shown in FIG. 3, are placed side by side on a flat surface, for example on a concrete floor of a hall, in a length between 10 m to 30 m or more. When a single layer is deposited, thin boards 11 of plywood or other material, for example having dimensions of 100 x 200 x 0.3 cm, are laid on this layer to protect fresh halves 10 of the fasteners. A further layer of halves 10 of the fasteners can then be deposited. In this way stacks with a total height of 2 m to 3 m can be stacked. However, it is always necessary to allow sufficient time for the concrete 8 of the halves 10 of the fasteners to solidify to the extent that they will be able to bear the respective loads.

In FIG. 4 is a diagrammatic illustration of how the two walls 1 with the halves 10 of the fastener are later joined together by face gluing into one formwork. By means of a simple device (not shown), it is ensured that the faces of the coupling element halves 10 are brought exactly one on top of the other. This results in connecting elements 20 which are formed of two halves 10 of a connecting element which are in the form of a bar and which are each provided with two flanges 12 and one connecting spacer 13, which in this case is in the form of a shank.

In the embodiment of FIG. 5, a mold not shown in the drawing, which differs from the mold 7 of FIG. 2d. This mold has the shape of a flat key, so that only flanges 22 having a central recess 14 are formed. When the two walls 1 are joined to the flanges 22, the shank 14 is glued to the recess 14. In both embodiments of FIG. 4 and 5, the intermediate pieces 13 and 23, in the region of their passage to the flange 12 and 22, respectively, are provided with crease indentations 15, which serve as bearing points for the Monier rods (not shown), before curing.

Fig. 6 shows a molding means 17 which substantially corresponds to the mold 7 of FIG. 2d, but additionally it is provided with a more central separating plate 16. By this means the mold half 17 made of connecting elements have the same shape as the ^pole: CE connection element 10, but is divided into two parts, so that the formwork element can be at this point then separated by sawing as shown schematically in FIG. 7 in addition to the separation between the fasteners 20 in the region of the dashed line 19, and thus a predetermined module having a value of, for example, 25 cm, can be performed in half-module separation, allowing easy adaptation to the actual situation on site.

Fig. 8 shows a further embodiment of the formwork element according to the invention. Again, in accordance with FIG. 5, flanges 22 with central recesses 14 are poured onto the walls 1. Anchored additional wires 24. Due to the interconnection of the two walls A with the flanges 22, a tubular spacer 33, which can also be made of concrete, serves. The wires 24 are guided from both sides by a tubular spacer 33, they are pulled outwards and then twisted at each other under tension. The peripheral recesses 25 at the edge of the intermediate pieces 33 allow good conducting of the wires 24.

In the embodiment of FIG. 9, the metal strips 26 are anchored in the flanges 26. The two walls 1 and the flanges 22 are then joined together by means of the metal strips 26, whereby either the screws or wires are guided through the bores 27 or a spot welding connection can be made. Increasing the spacing and hence the clear distance of the formwork element can be accomplished by means of an extension piece 28 which also has a bore

27th

Fig. 10 schematically illustrates an embodiment of a corner joint, with the first layer 10a and the subsequent odd layers shown in the left portion 10a and the second layer and the subsequent even formwork layers in the right portion 10b. In FIG. 10a, the inner wall 1 in the region of the left connecting element 20 is provided with a groove 29 which extends to the bottom of the flange 12. Upon subsequent filling with concrete, the filled concrete is formed at a given location with the flange 12 thereby creating a continuous concrete wall extending over the corner. which has no interruption by the rigid cellular mass of the walls 1 and can therefore serve as a fire wall. The same applies to the next layer of FIG. 10b, wherein the groove 29 also allows a through concrete connection.

In FIG. 11 shows a wall connection with the alternate layers of FIG. 11a and 11b, respectively. Here, the brackets 29 or cut-outs of the continuous continuous concrete wall also provide here. Such a through concrete core not only prevents the formation of fire breakthroughs and sound bridges, but can also be subjected to high static loads.

In FIG. 10a, an end piece 30 is also shown which is glued between the walls A and closes the formwork element externally.

Claims (20)

Method for producing formwork elements for the production of concrete sheathing with walls (1) and fasteners (20) based on concrete, wherein the fasteners (20) are formed in the form of a letter I with two flanges (12) disposed on mutually opposite walls ( 1) and an intermediate piece (13, 23, 33), characterized in that a template (2) having holes (5) corresponding to the shape of the flange (12) is placed on the inside of the wall (1) into the holes (5) the liquid mortar (6) is filled and smoothly leveled, whereby an adhesive corresponding to the wall material (1) is applied to join the liquid mortar (6) and the wall (1) therebetween, the molds (7) corresponding to the shape of the flanges (12) ), arranged with their larger aperture upwards filled with damp concrete which is leveled on the surface, then the molds (7) are laid with their larger aperture into the apertures (5) in ¹ template (2) on the liquid mortar (6), ) and the templates (2) are removed for reuse and two walls each y (1) after hardening is joined with intermediate pieces (13, 23, 33). Method according to claim 1, characterized in that the adhesive is admixed with the liquid mortar (6). Method according to claim 1, characterized in that the adhesive is applied to the wall (1) at least in the region of the openings (5) in the template (2) as a coating. Method according to claim 3, characterized in that the adhesive is applied by dipping the wall (1). Method according to claim 4, characterized in that the adhesive is mixed with the paint. v838 / 93H - 4.9.1998 Method according to one of claims 1 to 5, characterized in that the walls (1) are arranged at least once with each other before the walls (1) are joined by means of spacers (13, 23, 33), wherein the walls (1) formed are laid in one layer on a flat surface with its flange (12, 22) up, on the flanges (12, 22) an intermediate layer of thin plates (11) is laid, then on the thin plates (11) another layer of walls (1). Method according to one of Claims 1 to 6, characterized in that, after removal of the molds (7), the free ends of the flanges (12) are adjusted to a predetermined height by an adjustment template. Method according to one of Claims 1 to 7, characterized in that the spacer (13) is formed by gluing the free ends of the webs connected to the flange (12) formed in the form of a bell (7). Method according to claim 8, characterized in that at least one groove (15) is formed at the transition between the flange (12) and the web before the hardening, in order to receive the Monier rod. . ^? Method according to one of Claims 1 to 7, characterized in that the flange (22) is formed by means of a disc-shaped mold (7) with a central, preferably cylindrical recess (14), whereby the bottom of the recess is bonded to the columnar spacer (23). ). Method according to claim 10, characterized in that the columnar spacer (23) is formed from concrete by means of a cylindrical hollow mold and is provided with a groove (15) for receiving the Monier rod in the region of its two ends before hardening. Method according to one of Claims 1 to 9, characterized in that fastening means, such as Monier rods, hooks, eyes, screws, wires (24), are inserted into the flange (22) or the associated columnar spacer (23) before hardening. ) and metal strips. V838 / 93H-4.9.1998 Method according to claim 12, characterized in that the holes for receiving the fastening means are embossed in the flange (22) or in the associated columnar spacer (23) before hardening. Method according to one of claims 1 to 11, characterized in that the mold (7) is formed by an external molding means for casting (17) to form a flange (12) and optionally a columnar spacer (23), which is provided with a central separating plate. (16), located in the axis of the connecting element (20) and parallel to the height of the formwork element, wherein the formwork elements are divided in an extension of the separating plate (16). Method according to claim 14, characterized in that the separating plates (16) are inserted into the flanges (12) and possibly a columnar spacer at both ends of the walls (1). Method according to the preamble of claim 1, characterized in that the mold halves corresponding to their surface formwork The I halves of the axially cut fastener (20) in the I-shaped cross-section, are filled with concrete and leveled in the cutting plane, after which the two mold halves are stacked with their cutting planes. (20) bonding to two opposing walls by means of adhesives (1). Method according to claim 16, characterized in that a separating plate (16) is placed between the two mold halves before the two mold halves are laid on each other. Method according to claim 16, characterized in that a reinforcing wire is inserted into one of the two mold halves along the axis of the connecting element (20) before the two mold halves are laid on each other. A method according to claim 1, characterized in that two mold halves whose formwork surface corresponds to the surface of half of the axially cut I-shaped connecting element (20) are laid on the V838 / 93H - 4.9.1998 along the cutting plane, flush with each other and firmly joined together to form a mold, the mold is positioned vertically with its axis on a planar surface and filled with concrete, after partially hardening the two mold halves and fasteners ( 20) are fastened by means of adhesive to two opposite walls (1). ' Method according to claim 19, characterized in that a reinforcing wire is inserted into the mold along the axis of the connecting element (20) before at least partially hardening.