EP0893554A1 - Method and arrangement for realising a horizontal filling- layer - Google Patents

Abstract

The method involves concealing shuttering (4) and not removing mortar after hardening. Liquid mortar is used, which takes 6 to 8 hours to harden. In its hardened state, it has a pressure strength of 8.5 to 45 N/mm<2>. Two shuttering components (4) are used for casting flowing mortar and are positioned in the base (6) limited by them. They are made of styropor or similar material. The two shuttering components (4), prior to the casting of the mortar (3), are fitted on the limited surface of the base (6), and have two location components (10), which afford a defined location on the base. At least one distance holder (9) connects the two shuttering components.

Description

The invention relates to a method for producing a rear layer for building a wall made of flat blocks or elements using the thin-bed mortar process. Furthermore, the invention relates to a device for producing a chime layer.

In contrast to conventional masonry blocks, facing blocks or elements have high dimensional accuracy with regard to the stone or element dimensions (in the range of approx. 1 mm). The one in the walling of plan blocks, i.e. when creating masonry with such stones or elements, usual The gap between the individual stones is therefore much smaller: While at usual bricks joint widths, which are filled by the masonry mortar, of 1 to 2 cm are common - which also compensates for inaccuracies in the Millimeter range is possible - is this gap in the walling of facing blocks or elements usually only 1 to 3 mm (thin-bed mortar method).

If, for example, on a cast concrete ceiling, a wall made of facing blocks or elements should be created, it is usually the case that the Flatness of the concrete layer is not sufficient to create the wall directly afterwards to start. Rather, a so-called overlay must first be placed on the cast concrete surface be applied, which has a horizontal and plane surface and compensates for the unevenness of the concrete layer.

This chime layer is usually created by conventional handwork, i.e. a bricklayer builds up the overlay. Because of the high dimensional accuracy of the facing blocks this element is designed to meet high requirements difficult.

To facilitate this work and to increase the accuracy of the overlay Mortar applicators have become known, which are an exact production of the Monitor the bilge layer with the help of a laser beam.

The disadvantage of this solution is that the mechanical effort is very high, which the Creation of an overhang layer makes it very expensive. On the other hand, the use of known mortar applicators that enough space is available for them stands. This is often not the case if e.g. stones standing around or Scaffolds prevented free access to all required places.

The invention is therefore based on the object of a method and an associated one To create device with which it is possible to easily a to generate high-precision overlay. This is supposed to be both inexpensive creation the overlap layer as well as a simple implementation of the method, so that it is not necessary to employ qualified personnel.

The solution to this problem by the invention is characterized in that a flowing mortar (3) approximately the width (b) of the stones or elements (2) pours between a formwork (4) such that the flowing mortar (3) has a flat plane and forms a horizontal surface (5) and allows it to harden.

The basic idea of the invention is therefore that a suitable flowing mortar with low viscosity is poured onto a surface, so that a creates a flat surface with a high surface quality.

Suitable products for the leveling layer according to the invention are known. They depend on the amount of potting.
Self-leveling, quick-hardening floor leveling compounds are suitable for casting heights of up to 2 cm, for example as Ardurit K 15 from Ardurit, as leveling putty NSP or leveling compound FAM from Sakret or as Schönox 2000 from Schönox in. Also suitable is a quick-hardening grout with a grain size of 0 to 2 mm in the form of the commercial products Tricofast 0 to 2 mm, from Tricosal in Illertissen or Topulit Fix from P & T in Neuss.
For pouring heights from 0 to 4 cm, a self-leveling, fast-hardening thin-flowing screed, e.g. the thin-flowing screed Sakret DFE from the company Sakret or fast-hardening grouting mortar, 0 to 4 mm grain in the form of the commercial product Tricofast, 0 to 4 mm from the company Tricosal, Illertissen, can be used .

For grouting heights from 0 to 8 cm, a quick-hardening grout, 0 to 8 mm grit, in the form of Tricofast 0 to 8 mm, from Tricosal, Illertissen can be used.
The formation of the flat and horizontal surface can be facilitated and supported in that the flowing mortar (3) is buffed with a bar device.

For the process according to the invention, a previously hardening, self-leveling grouting or poured concrete, in short flowing mortar, was specially developed, for which the following formulation example can be given up to 4 cm high:

R" der VICAT Produits Industriel. Ein geeigneter Füller außer Kalksteinmehl ist auch Flugasche. Beispiele für Fließmittel sind die Produkte Melment F 4000 und Ligninsulfonat der Fa. Lignotech, Naphthalinsulfonat, z.B Galoryl P 220 der Fa. CFPI oder Melment F 10 der Fa. SKW.
Beispiele geeigneter Entschäumer sind die Handelsprodukte Agitan P 803 der Fa. Münzing Chemie und Bevaloid 6352DD der Fa. Erbslöh. Als Verzögerer kommen insbesondere Weinsäure, Zitronensäure und Natriumgluconat in Frage. Als Beschleuniger in der erfindungsgemäßen Mischung eignen sich Lithiumcarbonat, Lithiumnitrat oder Branntkalk.Examples of suitable quick-setting cements are Lafarge or Secur 51 from Lafarge and Alpenstein

R "from VICAT Produits Industriel. A suitable filler besides limestone powder is also fly ash. Examples of flow agents are the products Melment F 4000 and lignin sulfonate from Lignotech, naphthalene sulfonate, for example Galoryl P 220 from CFPI or Melment F 10 from SKW .
Examples of suitable defoamers are the commercial products Agitan P 803 from Münzing Chemie and Bevaloid 6352DD from Erbslöh. Tartaric acid, citric acid and sodium gluconate are particularly suitable as retarders. Lithium carbonate, lithium nitrate or quicklime are suitable as accelerators in the mixture according to the invention.

Flowing mortar with a water solids value of 12 to 14% is made from the dry mix with water. The processing time is set to 30 to 60 minutes and the flow behavior is set to that of grouting mortar, i.e. to a slump over 30 cm and a flow channel over 55 cm (see leaflet grouting mortar, leaflet for the use of mixed grouting mortar, version September 1990, editorial) revised 1996) .

The formwork (4), which defines the area to be cast, can both be a lost formwork and therefore after the flowing mortar has hardened (3) remain in the fillet as well as after the flowing mortar has hardened (3) removed and reused.

A flow mortar (3) is advantageously used, which after 6 to 8 hours in is essentially hardened. Then after one night or after one Layer work on the wall to be built can be started.

According to a further development it is provided that the flowing mortar (3) is a concrete flowing mortar. But it can also be a screed flow mortar. Depending on the wall to be created and the load on it, the mortar must have an appropriate strength, which is why it is further provided that the flow mortar (3) has a compressive strength of 2.5 to 45 N / mm ² in the hardened state.

The device for producing a chow layer (1) for building a wall Flat blocks or elements (2) in the thin-bed mortar process, in particular is used to carry out the method is characterized by at least one, preferably two, formwork elements (4) before the casting of flowing mortar (3) into the area delimited by the formwork elements (4) the bottom (6) are placed. It is particularly thought that the Formwork elements (4) have an adhesive side and with this before casting of flowing mortar (3) into the area delimited by the formwork elements (4) be glued to the floor (6).

The formwork elements (4) can be made of foam, a similar plastic material, Wood or other suitable materials.

If an overlay is to be applied to the edge of a concrete floor, there may be problems with attaching the formwork elements to this edge There is often no edge area of the soil layer through Formwork element to be 'given away'. According to a further development, that at least one formwork element (4) from a straight bank element (7) is the one that limits the pouring of flowing mortar (3) Boundary surface defined, and of several in the direction of the overhang layer (1) extending, lateral retaining webs (8). The bank element then protrudes unsupported beyond the edge of the concrete floor; however, it becomes by the side extending support bars worn.

It is then advantageously provided that at least one spacer (9) is present that connects at least two formwork elements (4) to one another, these keeps at a defined distance and keeps parallel to each other. The spacer (9) is preferably detachably connected to the formwork elements (4).

An alternative device for producing a chewing layer (1) is identified through two formwork elements (4), which are poured before pouring flowing mortar (3) in the area delimited by the formwork elements (4) on the floor (6) the formwork elements (4) each have at least two support elements Have (10) placed on the floor (6) to achieve a defined support be, and at least one spacer (9), the two formwork elements (4) connects them, keeps them at a defined distance and keeps parallel to each other.

It is advantageously provided that the spacer (9) essentially consists of two plate elements (11) arranged in parallel, through a central part (12) are kept at a defined distance, with the plate elements (11) on the side facing the overlap layer to be produced in each case at least one height stop (13) is arranged.

The two parallel plate elements (11) of the spacer (9) can also be moved in terms of their distance (a) on the central part (12) be arranged. This allows the spacers for different wall widths be used. So that this also applies to different heel layer heights applies, it is also provided that the height stops (13) on the respective plate elements (11) are slidably arranged with respect to the stop height (h).

The formwork elements (4) and / or the spacer (9) are preferably made made of wood or light metal.

With the solution proposed according to the invention, it is possible in a simple manner Way to create a high-precision overlay that forms the basis for the masonry is a wall made of facing blocks or elements. Because of the simple On the one hand, expensive machines can be dispensed with; on the other hand, the Kimmschicht also be made by only trained workers, i.e. It is not highly qualified construction workers required for this.

Fig. 1

zeigt schematisch den Aufbau einer Wand aus Planblocksteinen,

Fig. 2

stellt eine erste Ausführungsform der erfindungsgemäßen Vorrichtung dar, in

Fig. 3

ist eine zweite Ausführungsform der Vorrichtung zu sehen,

Fig. 4

stellt schließlich eine dritte Ausführungsform der Vorrichtung dar, die in

Fig. 5

in einer Variante dargestellt ist.

Exemplary embodiments according to the invention are shown in the drawing:

Fig. 1

shows schematically the construction of a wall from facing blocks,

Fig. 2

represents a first embodiment of the device according to the invention, in

Fig. 3

a second embodiment of the device can be seen,

Fig. 4

finally represents a third embodiment of the device, which in

Fig. 5

is shown in a variant.

In Fig. 1, a wall of facing blocks 2 can be seen. This wall has one Width b, which is defined by the very precisely manufactured stones 2. Because of the high accuracy of the stones 2, it is necessary that the first layer of stones 2 is arranged on a very precisely manufactured rear sight layer 1. I.e. the surface 5 of the leveling layer 1 is level and horizontal and offers a good level Basis for the first stone layer 2.

How this chime layer 1 is produced according to the invention can be seen in FIG. 2. First, two formwork parts 4 are placed on the floor 6. The formwork parts 4 are made of plastic (rigid foam). You will be on the floor 6 in a distance b stuck on, which is the width of the facing blocks or elements 2 corresponds. Once this has been done, flow mortar 3 is introduced into the area, which is limited by the formwork 4. Through the thin liquid of the Flow mortar 3 creates a good surface quality, i.e. the surface 5 of the Overlap 1 is level and horizontal. The amount of flowing mortar 3 in the area defined by the formwork 4 is determined by the desired height of the Kimmschicht 1, which in turn depends on how is uneven (usually cast) floor surface.

2 requires that the floor 6 is freely accessible, i.e. no restrictions on the width of the Soil 6 exist. However, this is often not the case: there is often a layer of concrete floor cast, which is not much wider than the width b of those to be built on it Plan block stones 2. The same problem arises if there is an overlay on the edge of a concrete floor. Then at least there is room for one of the two Formwork elements limited.

A solution for this case is shown in Fig. 3. Here is the case that the width of the floor 6 is the same as the desired width of the overlap. For structural reasons, it is not possible to remove the formwork elements 4 Fig. 2 easy to attach to the edges of the bottom 6 in Fig. 3. Because by that a not inconsiderable part of the soil would remain unused, whatever is not responsible from a static point of view.

Now that there is no more space available for attaching the formwork 4 stands, formwork elements are used, as can be seen in Fig. 3. The formwork 4 consist of bank elements 7, which are essentially the Set limits for the flowing mortar. The boundary edge of the bank elements are, however, set to the edge of the bottom 6. So that the bank element - due to lack of support - does not fall off, are firmly connected to the bank elements 7 Retaining webs 8 are provided. The bank element and retaining webs are preferably in one piece educated.

The holding webs 8 can be glued to the bottom 6 with their underside, whereby they hold the bank elements 7 in the desired position. For improvement the two formworks 4 can be fastened by a spacer 9 to be connected to one another: As can be seen schematically in FIG one or more spacers 9 (e.g. with metal clips at the end) the formwork 4 is pushed, making it parallel and in a fixed predetermined Distance can be fixed. The composite, consisting of formwork elements 4 and Spacers 9 is stable and allows due to the design that the flowing mortar when pouring to the edges (or at least to one edge) of the Soil 6 can flow. Only a small area - namely that of the Retaining webs 8 is covered - falls out as a wing for the plan block wall.

If the overlap is to be produced at the edge of the floor 6, however, in itself is arbitrarily wide, there is also a combination of the solutions from FIGS. 2 and 3 reasonable: A formwork element 4 according to FIG. 3 is provided on the edge another limitation is a formwork element 4, as can be seen in FIG. 2 is made.

An alternative to the solution shown in FIG. 3 is shown in FIG. 4. If the The height of the rear sight layer increases (especially over 5 to 6 cm), so do the Compressive forces on the formwork 4 too. If the solution according to FIG. 3 is not sufficient If the stability is greater, the use of formwork elements is recommended according to FIG. 4. Here too, the overlap can extend to the edge of the floor 6 be poured.

Formwork 4 which has support elements 10 is used for this purpose. It is about here in the case shown about angle iron, which on the one hand on the formwork 4 are attached and on the other hand are placed on the floor 6. The lower one Floor surface of the formwork 4 is free beyond the edge of the floor 6.

The formwork 4 on both sides is guided through a spacer 9 and held. The spacer 9 consists of two plate elements 11, the one Middle part 12 are connected and are thus guided plane-parallel. The spacer is simply placed on the aligned formwork 4. Height stops 13, which are attached to the plate elements 11, define an edition of the Spacers 9 on the formwork 4. For the two formworks 4 are mostly at least two spacers are provided, although for reasons of clarity only one is shown in FIG. 4. The support elements 10 form in cooperation with the height stops 13 and the side plate elements 11 of the spacer 9 - although not further connected - one stable bond that stabilizes even further after pouring the flowing mortar becomes.

So that the system according to the invention for all occurring wall widths and for a wide variety of ground topographies can be used is recommended the use of a device as shown in Fig. 5.

The spacer 9 again consists of the two side plate elements 11, which are connected to one another via the central part 12. So different Distances of the plate elements 11 can be set consists in the shown The middle part 12 essentially consists of two connecting rods, on the one hand are welded to an element 11, but on the other hand through holes are guided in the other element 11. Different distances a be set, d. H. the device for the manufacture of different widths Overlay layers are used. It would of course also be possible in the same way To produce the middle part 12 from telescopically interacting tubes.

Finally, formwork 4 of different heights with the spacers can be kept well, it is provided that the height stops 13 on the plate elements are arranged, are height adjustable. in the shown case is determined by screw-nut connections. Alternatively thumbscrews (not shown) are also recommended, for the purpose of fixing the height can be tightened by hand.

For all solutions shown applies that in the event that the chime layer a Must have 90 ° corner, the elements described adapted accordingly 2 and 3 are the polystyrene formwork elements cut accordingly so that the corner results. Analogous the lengths of the formwork 4 are cut in the solution according to FIGS. 4 and 5. With these solutions, a missing piece of formwork can also be used, for example by attaching an extension piece. Such However, concepts lie in the creative ability of the expert.

After pouring flowing mortar 3 into the area delimited by the formwork 4, a horizontal and plane surface results due to the low viscosity of the flowing mortar. This can be supported by spreading and spreading the still liquid mortar using a slide ( Buffing "); this also removes air bubbles from the mortar 3.

After the flowing mortar has hardened, the formwork according to FIGS. 4 and 5 can be easily dismantled and reused: The spacers 9 are deducted. The formwork elements 4, which are now only on the support elements 10 connected to the rear sight layer are pulled out to the side. Back there are only minimal recesses that the support elements in the overlay have left, but are statically meaningless.

As already stated, the solutions according to FIGS. 2 to 5 can also be combined become. This is interesting if the overlay is on the edge of a Base plate must be applied and therefore space problems only on one side exist, on the other hand there is plenty of space, e.g. for sticking on of polystyrene formwork, is available.

example

100 kg dieser Mischung wurden mit 13 l Wasser versetzt. Dieser selbstverlaufende Fließbeton hatte eine Verarbeitungszeit von 45 Minuten, eine Abbindezeit von 2 Stunden, ein Ausbreitmaß von 30 cm und eine Fließrinne von 60 cm. Der Fließmörtel 3 wurde in einer Höhe von etwa 3 mm zwischen die Schalungselemente gegossen und mit einer Stangenvorrichtung geschwabbelt. Nach wenigen Minuten wurde eine planebene, völlig waagerechte Kimmschicht einer Dicke von 1 bis 3 cm erhalten. Diese war nach 8 Stunden völlig ausgehärtet, und darauf konnte am folgenden Tag die Mauer aus Planblocksteinen errichtet werden. To carry out the process according to the invention, a dry concrete mix of the following composition is first prepared:

100 kg of this mixture were mixed with 13 l of water. This self-leveling flow concrete had a processing time of 45 minutes, a setting time of 2 hours, a spread of 30 cm and a flow channel of 60 cm. The flow mortar 3 was poured between the formwork elements at a height of about 3 mm and buffed with a bar device. After a few minutes, a flat, completely horizontal overlap with a thickness of 1 to 3 cm was obtained. It was completely hardened after 8 hours, and the following day, the wall could be built from stone blocks.

Reference symbol list:

1

Overlay

2nd

Map blocks or map block elements

3rd

Flowing mortar

4th

formwork

5

Surface of the overlay

6

ground

7

Bank element

8th

Landing stage

9

Spacers

10th

Support element

11

Plate element

12th

Middle section

13

Height stop

a

Distance of the plate elements

b

Width of the map blocks or map block elements

H

Stop height

Claims (20)

Method for producing a chipping layer (1) for building up a wall from flat block bricks or elements (2) using the thin-bed mortar method,
characterized,
that you pour a flowing mortar (3) approximately in the width (b) of the stones or elements (2) between a formwork (4) such that the flowing mortar (3) forms a flat and horizontal surface (5), and allows it to harden . A method according to claim 1, characterized in that the training the flat and horizontal surface (5) of the flowing mortar (3) is supported by spreading with a slider. A method according to claim 1 or 2, characterized in that the Formwork (4) is a lost formwork and therefore after hardening the mortar (3) is not removed. A method according to claim 1 or 2, characterized in that the Formwork (4) is removed after the flowing mortar (3) has hardened. Method according to one of claims 1 to 4, characterized in that a flow mortar (3) is used, which after 6 to 8 hours essentially is cured. Method according to one of claims 1 to 5, characterized in that the flow mortar (3) is a concrete flow mortar. Method according to one of claims 1 to 5, characterized in that the flowing mortar (3) is a screed flowing mortar. Method according to one of claims 1 to 7, characterized in that the flowing mortar (3) has a compressive strength of 2.5 to 45 N / mm ² in the hardened state. Device for producing an overlay layer (1) for building up a wall from flat block bricks or elements (2) using the thin-bed mortar method, in particular for carrying out the method according to claims 1 to 8,
marked by
at least one, preferably two, formwork elements (4) which are placed on the floor (6) before the pouring of flowing mortar (3) into the area delimited by the formwork elements (4). Device according to claim 9, characterized in that the formwork elements (4) have an adhesive side and with this before Pouring flowing mortar (3) into the formwork elements (4) limited area can be glued to the floor (6). Apparatus according to claim 9 or 10, characterized in that the Formwork elements (4) made of polystyrene or a similar plastic material consist. Device according to one of claims 9 to 11, characterized in that that the at least one formwork element (4) from a straight bank element (7), which is the limit for the pouring of flowing mortar (3) Boundary surface defined, and made up of several towards the overlay (1) extending lateral retaining webs (8). Device according to one of claims 9 to 12, characterized by at least one spacer (9), the at least two formwork elements (4) connects them at a defined distance holds and keeps parallel to each other. Device according to claim 13, characterized in that the spacer (9) is detachably connected to the formwork elements (4). Device for producing an overlay layer (1) for building up a wall from flat block bricks or elements (2) in the thin-bed mortar method, in particular for carrying out the method according to claims 1 to 9,
marked by
two formwork elements (4), which are placed in the area delimited by the formwork elements (4) on the floor (6) before the pouring of flowing mortar (3), the formwork elements (4) each having at least two support elements (10) which are used for Achieving a defined circulation on the floor (6), and
at least one spacer (9) which connects the two formwork elements (4) to one another, keeps them at a defined distance and holds them in parallel alignment. Device according to claim 15, characterized in that the spacer (9) essentially from two parallel plate elements (11) consists of a central part (12) at a defined distance are held, on the plate elements (11) on the one to be produced At least one height stop on the side facing the lower layer (13) is arranged. Device according to one of claims 15 or 16, characterized in that that the two parallel plate elements (11) of the Spacers (9) with regard to their distance (a) on the middle part (12) are slidably arranged. Device according to one of claims 15 to 17, characterized in that that the height stops (13) on the respective plate elements (11) are slidably arranged with respect to the stop height (h). Device according to one of claims 15 to 18, characterized in that that the formwork elements (4) and / or the spacer (9) made of wood or light metal. Early hardening self-leveling flow concrete for carrying out the method according to one of claims 1 to 8, characterized by the following composition:

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