AT13501U1 - Method for producing a concrete panel covered with cladding elements - Google Patents

Abstract

A process for producing a concrete slab (2) covered with cladding elements (1), wherein the cladding elements (1) are placed with intervening joints (3) on a support (4) and cast with at least one concrete layer (5a, 5b), the concrete slab (2) after curing of the concrete layer (5a, 5b) is removed from the base (4), wherein on the base (4) at least in the region of the joints (3) between the cladding elements (1) delaying the concrete curing or preventing retardant (6) is applied before the entering into the joints (3) concrete layer (5a) is poured.

Description

Austrian Patent Office AT13 501 U1 2014-01-15

Description: The invention relates to a method for producing a concrete panel covered with cladding elements, wherein the cladding elements are placed with intervening joints on a substrate and cast with at least one concrete layer, wherein the concrete slab is removed after curing of the concrete layer of the substrate.

Process for the production of concrete elements occupied with cladding elements are already known in the art. Cladding elements such as tiles, slabs or stones may be applied directly to a construction site after placing a concrete element (e.g. However, this is associated with a very high cost. In addition, the achievement of a desired joint pattern and a joint closure, so that no water can penetrate behind the tile, difficult. Furthermore, it is known to prefabricate occupied with cladding concrete panels as precast elements by the cladding elements such as tiles or plates are arranged using a template or die in a formwork and poured with concrete. However, such a stencil or die must be made specifically for each precast element and for each type of cladding elements, as well as for any desired joint depth, making this manufacturing process is not only very expensive and expensive, but also produces a lot of waste. In another known method, the cladding elements are placed on a sand bed introduced into the formwork. After pouring the cladding elements in concrete and curing the concrete layer, the sand is removed from the joints after demoulding and the joints are manually closed with mortar. This method also presents some difficulties, such as e.g. the orders of the sand to achieve a uniform sand bed. Due to the deformability of the sand, it is also difficult to achieve a desired uniform joint pattern.

The object of the invention is to avoid the disadvantages described above and to provide a comparison with the prior art improved method for producing a occupied with cladding elements concrete slab. In particular, a fixation of the applied cladding elements during concreting and compacting and an exact and straight joint formation in width, straightness and depth are to be made possible. In addition, it should be possible to provide different joint depths and to be able to achieve a good joint closure, e.g. to prevent the ingress of water behind the cladding elements and a possibly associated falling of the cladding elements.

This object is achieved by the features of claim 1. Advantageous embodiments of the invention are specified in the dependent claims.

According to the invention it is thus provided that the concrete hardening delaying or preventing retardant is applied to the substrate at least in the joints between the cladding elements, before the entering into the joints concrete layer is poured.

Through the use of a concrete curing retarding or preventing retardant at least in the joints, the setting or hardening of the concrete is delayed or prevented. Depending on the choice of delay agent used, the penetration depth of the deceleration effect can be determined and thus the joint depth to be achieved can be determined. For example, the joint depth to be achieved may be about 1 mm to about 7 mm, preferably about 2 mm to about 3 mm.

The delaying means may be e.g. to act a relatively thin lacquer layer or a correspondingly equipped with a retarder paper, wherein preferably the retarder is applied prior to placing the cladding elements on the substrate. The retarding agent may also have an adhesive effect for the cladding elements to be arranged thereon, as a result of which the cladding elements can be fixed in a stable position by the delay means for the subsequent step of pouring into concrete.

Suitable delay agents are already known per se. They are also referred to as Entak-tivierer and are for example available from the company HEBAU GmbH (company website: http://www.hebau.de/). Thus, for example, With a CSE® 25 deactivator from HEBAU, it is possible to achieve a discharge depth of approx. 2 mm with a CSE® 130 deactivator from HEBAU and a joint depth of approx. 4 mm. With respect to papers coated with a corresponding retarder, e.g. with a WB paper "yellow " from HEBAU Weighing depths or joint depths of about 2 mm and with a WB paper "green " from HEBAU achieve joint depths of about 3 mm to about 5 mm.

According to a particularly preferred embodiment it can be provided that the cladding elements are placed with substantially uniformly wide joints between adjacent cladding elements. As a result, a particularly regular joint pattern can be generated. In general, however, any joint images are possible, especially when the laying of the cladding elements on the delay means is automated, such as. By data processing controlled robot arms.

According to the desired joint image may preferably be provided that the retarder applied substantially strip-shaped on the substrate, preferably sprayed, is. Preferably, the retarder can be applied substantially only in the region of the desired joints between the cladding elements and thus a particularly low consumption of the retarder can be achieved. In general, however, the retarder can also be applied substantially over the whole area to the substrate.

As a protection for the pad and / or to be able to remove the concrete slab after curing of the concrete layer easier from the pad, may preferably be provided that a protective layer is applied to the pad before applying the retarder. It has proven to be particularly advantageous if a film, preferably a plastic film, is applied as the protective layer.

In a further preferred embodiment of the invention can be provided that before applying the cladding elements, a backing paper is applied to the substrate, wherein on a side facing away from the pad or after placing the cladding elements facing the cladding elements first side of the backing paper, the delay means is applied. In particular, when a movable pallet is used as a base, wherein preferably the pallet has a metal surface, it can preferably be provided that a rust-preventive agent is applied to a second side of the backing paper facing the base. Overall, so that the backing paper can also be regarded as a protective layer for the pad.

According to a particularly preferred embodiment, it may be provided that the surfaces of the cladding elements facing the base are formed substantially flat, preferably as tiles elements, tiles or stones are placed. After the concrete has hardened and the concrete slab has been removed from the base, it is thus possible to produce an already tiled prefabricated concrete wall.

In general, it can be provided that substantially cuboid cladding elements are used, each having a height, a length and a width, wherein the height of a cladding element less than 1/5, preferably less than 1/10, the length and / or the Width of a trim element is.

After placing the cladding elements may be provided in a preferred embodiment of the invention that the cladding elements are poured with a, preferably fine-grained, first concrete layer, preferably after pouring the first concrete layer, a second concrete layer is poured. This first concrete patent is AT 11 501 Ul 2014-01-15

Layer may be formed as a mortar with a small aggregate grain size or as so-called cement slurry, so that a good bond with the cladding elements and a complete filling of the joints can be achieved. In general, the at least one concrete layer or the first concrete layer may also be colored, in order to achieve particular aesthetic effects, in particular in connection with the lining elements used.

After pouring the cladding elements with this first concrete layer, which can also be referred to as joint concrete, a second concrete layer can be applied and compacted with a correspondingly predetermined layer thickness. This second concrete layer can be steel-reinforced as needed.

Protection is also desired for a device for producing a concrete slab occupied with cladding elements, wherein a moving means for moving pallets, an applicator for automated application of a retarding agent on the pallets, a lay-up device for correct placement of the cladding elements with a predefined joint image on the Pallets and at least one Eingießeinrichtung for automated pouring of the cladding elements are provided with at least one concrete layer.

In a preferred embodiment it can be provided that the applicator has a, preferably data processing controlled, spray head, wherein the delay means according to the predefined joint image can be applied to a pallet with the spray head.

A particular embodiment provides that a further device is provided, wherein with the further device a protective layer, preferably a plastic film, can be applied to a pallet, wherein preferably the protective layer is substantially over the entire surface applied to the pallet.

Preferably, the production of a concrete panels occupied with cladding elements in an automated process as possible, particularly preferably in a fully automatic process, take place. The individual devices (for example moving device, applicator, laying device, pouring devices, etc.) can be designed to be data-processing-controlled.

In general, the manufacturing process may comprise the following steps: cleaning of the base or pallet, application of a rustproofing agent or a carrier paper and / or a protective layer (eg plastic film) to the pallet, [0024 [0029] Placing the formwork, Laying the formwork elements, Laying the lining elements in, Casting a thin first layer of concrete (eg cement slurry or joint clay), Introducing a reinforcement, [0029 ] · Pouring in a second concrete layer.

Further details and advantages of the present invention will be explained with reference to the following description of the figures. 1a to 5b show an embodiment variant of a proposed method for the production of a concrete slab covered with cladding elements, [0032] FIG. 6a shows a plan view of a concrete slab, AT13 501 U1 2014-01-15 Fig. 6b is a cross-sectional view taken along section line AA of Fig. 6a; Figs. 7a to 10b show another embodiment of a proposed method for

Fig. 11a Fig. 11b Fig. 12b Fig. 12b is a plan view of a concrete slab, a cross-sectional view taken along section line AA of Fig. 11a, showing a plan view of the concrete slab a cladding element and a perspective view of the cladding element of Fig. 12a.

1a shows a plan view of a formed as a movable pallet base 4 and Figure 1b shows a non-scale partial cross-section along section line AA of Figure 1a. To protect the pad 4, a protective layer 7 in the form of a plastic film is applied substantially over the entire surface of the pad.

2a shows a plan view of the pad 4 according to Figure 1a and Figure 2b shows a not to scale partial cross section along section line AA of Figure 2a. Corresponding to the desired joint pattern of the concrete slab 2 to be produced, which is covered with cladding elements 1, joints 3 being arranged between the cladding elements 1 (see FIG. 6a), a delaying agent 6 retarding or preventing concrete hardening was applied to the protective layer 7 in a substantially strip-shaped manner. This application of the delay means 6 can be accomplished, for example, by a data processing-controlled spray head which sprays a delay lacquer.

3a shows a plan view of the pad 4 according to Figure 2a and Figure 3b shows a non-scale partial cross section along section line AA of Figure 3a. The underlay 4 was shut down accordingly with a shuttering 13, in order to provide a boundary for the laying of the cladding elements 1 and the pouring of the concrete layers 5a, 5b. In a further step, cladding elements 1 in the form of tiles with their essentially flat surfaces 1a have now been placed on the protective layer 7 or the delaying means 6. The width of the strips of the retarder 6 is in this example slightly larger than the width of the joints 3, so that the cladding elements 1 come to lie in the region of their outer edges on the retarder 6. The retarding means 6 acts in this sense as an adhesive, so that the cladding elements 1 can be fixed in a stable position for the subsequent pouring concrete.

FIG. 4a shows a top view of the base 4 according to FIG. 3a, and FIG. 4b shows a partial cross-section, not to scale, along the section line AA of FIG. 4a. The cladding elements 1 are cast in this step with a first concrete layer 5a designed as a cement slurry. This cement slurry has a small aggregate aggregate, so that a good bond with the cladding elements 1 and a complete filling of the joints 3 can be achieved. Due to the fact that the strip-like applied retarding means 6 extends beyond the width of the joints 3, it can furthermore be achieved that a cement slurry which may penetrate in the edge regions of a lining element 1 between the surface 1a of the lining element 1 and the retarding means 6 also cures with delay or does not harden at all. As a result, contamination of the surfaces 1 a of the cladding elements 1 can be reduced or prevented.

FIG. 5a shows a top view of the base 4 according to FIG. 4a, and FIG. 5b shows a partial cross-section, not to scale, along the section line AA of FIG. 5a. In this step, a second concrete layer 5b was applied to the first concrete layer 5a (cement slurry). In this example, the second concrete layer 5b is provided with a steel reinforcement 12.

Figure 6a shows a plan view of a ready-made, occupied with cladding elements 1 concrete slab 2 and Figure 6b shows a non-scale partial cross-section along section line AA of Figure 6a. After curing of the first concrete layer 5a (cement slurry) and the second concrete layer 5b, the concrete slab 2 can be dismantled and removed from the base 4 4/11 Austrian Patent Office AT 13 501 Ul 2014-01-15. The formerly the pad 4 facing side of the concrete slab 2 can be washed with water afterwards. By the delay means 6 soiling on the surfaces 1a of the cladding elements 1 and the uncured parts of the cement slurry can be washed out of the joints 3 and thus the desired joint depth can be achieved. According to the choice of the delay means 6, the Auswaschtiefe the cement slurry or the at least one concrete layer 5a and thus the joint depth can be set.

FIGS. 7a to 10b show a further variant of a production method for producing a concrete slab 2 covered with cladding elements 1, similar to the method according to FIGS. 1a to 5b, with the difference that instead of a protective layer 7 with delay means 6 applied thereon, a carrier paper 8 for Use comes. On a side facing away from the base 4 first side 9 of the backing paper 8, a retarder 6 is applied and on a pad 4 facing the second side 10 of the backing paper 8, a rust inhibitor 11 is applied. The carrier paper 8 also serves as a protective layer 7 for the pad 4 and reduces or prevents rusting from occurring in the event that the pad 4 is formed as a pallet with a metal surface. The steps according to FIGS. 8a to 10b correspond to the steps of FIGS. 3a to 5b.

Figure 11a shows a plan view of a concrete slab 2, which was prepared by the method according to Figures 7a to 10b. FIG. 11b shows a partial cross-section, not to scale, along section line AA of FIG. 11a. The concrete slab 2 corresponds to the concrete slab 2 according to FIG. 6a with the difference that the layer thickness of the second concrete slab 5b is slightly lower.

FIG. 12a shows a top view of a cladding element 1, and FIG. 12b shows a perspective top view of the cladding element 1 of FIG. 12a. The cladding element 1 is in this example a substantially parallelepiped-shaped tile with a height H, a length L and a width B. The height H of the cladding element 1 is less than one fifth of the length L of the cladding element 1. 5/11

Claims (16)

Austrian Patent Office AT 13 501 Ul 2014-01-15 Claims 1. A method for producing a concrete slab (2) occupied by cladding elements (1), wherein the cladding elements (1) with intervening joints (3) are placed on a base (4) and with at least one concrete layer (5a, 5b) are poured, wherein the concrete slab (2) after curing of the concrete layer (5a, 5b) is removed from the base (4), characterized in that on the base (4) at least in the region Grouts (3) between the cladding elements (1) a delaying or preventing concrete hardening delay means (6) is applied before the in the joints (3) entering concrete layer (5a) is poured. 2. The method according to claim 1, characterized in that the delay means (6) before applying the cladding elements (1) on the pad (4) is applied. 3. The method according to claim 1 or 2, characterized in that the cladding elements (1) with substantially uniformly wide joints (3) between adjacent cladding elements (1) are placed. 4. The method according to any one of claims 1 to 3, characterized in that the retarder (6) is applied substantially strip-shaped on the substrate (4), preferably sprayed, is. 5. The method according to any one of claims 1 to 4, characterized in that as protection for the pad (4) prior to the application of the delay means (6), a protective layer (7) on the pad (4) is applied. 6. The method according to claim 5, characterized in that as a protective layer (7) a film, preferably a plastic film is applied. 7. The method according to any one of claims 1 to 6, characterized in that prior to placing the cladding elements (1) a carrier paper (8) on the substrate (4) is applied, facing away on one of the pad (4) or after the Laying on the lining elements (1) the lining elements (1) facing the first side (9) of the backing paper (8), the delay means (6) is applied. 8. The method according to claim 7, characterized in that on one of the pad (4) facing the second side (10) of the carrier paper (8), a rust inhibitor (11) is applied. 9. The method according to any one of claims 1 to 8, characterized in that the pad (4) facing surfaces (1a) of the cladding elements (1) are substantially planar. 10. The method according to any one of claims 1 to 9, characterized in that as cladding elements (1) tiles, plates or stones are placed. 11. The method according to any one of claims 1 to 10, characterized in that substantially cuboid cladding elements (1) each having a height (H), a length (L) and a width (B) are used, wherein the height (H) a cladding element (1) is less than 1/5, preferably less than 1/10, the length (L) and / or the width (B) of a cladding element (1). 12. The method according to any one of claims 1 to 11, characterized in that the cladding elements (1) with a, preferably fine-grained, first concrete layer (5a) are poured, preferably after pouring the first concrete layer (5a) a second concrete layer (5b ) is poured. 13. The method according to any one of claims 1 to 12, characterized in that a movable pallet is used as a base (4), wherein preferably the pallet has a metal surface. 6/11 Austrian Patent Office AT13 501 U1 2014-01-15 14. Apparatus for producing a concrete panel (2) occupied by cladding elements (1), in particular by a method according to one of claims 1 to 13, characterized by a movement device for moving pallets (4), an application device for the automated application of a deceleration means (6 ) on the pallets (4), a laying device for the correct placement of the cladding elements (1) with a predefined joint pattern on the pallets (4) and by at least one pouring device for automated pouring of the cladding elements (1) with at least one concrete layer (5a, 5b) , 15. The apparatus according to claim 14, characterized in that the application device has a, preferably data processing controlled, spray head, wherein the spray means the delay means (6) corresponding to the predefined joint image on a pallet (4) can be applied. 16. The apparatus of claim 14 or 15, characterized in that a further device is provided, wherein the further device a protective layer (7), preferably a plastic film on a pallet (4) can be applied, wherein preferably the protective layer (7) essentially over the entire surface of the pallet (4) can be applied. 4 sheets of drawings 7/11