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EP2767373A1 - Procédé de fabrication d'un élément en béton armé multicouche - Google Patents

Procédé de fabrication d'un élément en béton armé multicouche Download PDF

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Publication number
EP2767373A1
EP2767373A1 EP13155444.6A EP13155444A EP2767373A1 EP 2767373 A1 EP2767373 A1 EP 2767373A1 EP 13155444 A EP13155444 A EP 13155444A EP 2767373 A1 EP2767373 A1 EP 2767373A1
Authority
EP
European Patent Office
Prior art keywords
concrete wall
concrete
insulating layer
reinforcing body
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13155444.6A
Other languages
German (de)
English (en)
Inventor
Rolf Dr. Roers
Haval Khaffaf
Michael LOOF
Achim Symannek
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Covestro Deutschland AG
Original Assignee
Bayer MaterialScience AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bayer MaterialScience AG filed Critical Bayer MaterialScience AG
Priority to EP13155444.6A priority Critical patent/EP2767373A1/fr
Priority to RU2015139040A priority patent/RU2015139040A/ru
Priority to PCT/EP2014/052500 priority patent/WO2014124886A1/fr
Priority to CN201480008971.9A priority patent/CN104981330B/zh
Priority to US14/766,148 priority patent/US20150368902A1/en
Priority to MX2015010227A priority patent/MX2015010227A/es
Priority to EP14705737.6A priority patent/EP2956283B1/fr
Publication of EP2767373A1 publication Critical patent/EP2767373A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342—Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/042—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/028—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members for double - wall articles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/08—Members specially adapted to be used in prestressed constructions
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/02—Conveying or working-up concrete or similar masses able to be heaped or cast

Definitions

  • the invention relates to a method for producing a multilayer, reinforced concrete element, wherein the multilayer, reinforced concrete element comprises at least a first concrete wall in combination with a reinforcing body, wherein the concrete element comprises an at least indirectly applied to the first concrete wall insulating layer and wherein the reinforcing body at least partially the first concrete wall protruding and the insulating layer is formed penetrating.
  • Precast concrete plays an important role in the construction industry.
  • precast concrete elements have been fitted with integrated insulation layers at the factory for some years, in particular reinforced concrete walls and ceilings with core insulation.
  • insulation boards in particular of mineral wool and polystyrene, are introduced by hand.
  • the EP 1 010 828 B1 shows a further production of a wall panel with an inner shell and an outer shell made of concrete, which are connected to one another via carriers of a reinforcing body.
  • PU foam is applied to the inner side of the foam, which faces upward to apply the PU foam.
  • the complementary concrete shell is then produced by immersion in a concrete bed and subsequent curing. A defined cavity for the PU foam body is not created, and a subsequent pouring with more concrete takes place on an undefined PU insulating layer surface.
  • the not yet cured PU foam body, which is applied as a reaction mixture, is distributed by means of a stream of air.
  • the height of the cured foam results from the applied height of the reaction mixture, the height of which is again determined by the speed of the application for a given reaction time and has an irregular topography.
  • a structural geometric limitation of the cavity is therefore not created, so that disadvantageously no insulating layer of a defined thickness can be formed.
  • a similar method discloses the EP 1 106 745 A2 ,
  • a method for producing a prefabricated ceiling element is described as a prefabricated component, wherein two sheets of reinforced concrete by a plurality of lattice girder are spaced from each other, and wherein the lattice girders are embedded in the respective disc and wherein the end sections comprise at least the longitudinal bars with welded strut knot, and wherein the space between the panes is completely filled with foamed polyurethane.
  • the resulting between the two discs cavity is filled with polyurethane foam during production already.
  • the hardened polyurethane layer should support the structural-technical function of the lattice girders and the concrete slabs.
  • the object of the present invention is to provide an improved method for producing a multi-layer, reinforced concrete element, and in particular, the object of the invention is to be able to flexibly form the insulating layer of a PU foam, preferably with different thicknesses.
  • a method for producing a multi-layer reinforced concrete element comprising a first concrete wall in conjunction with a reinforcing body and having an at least indirectly adjacent to the first concrete wall insulating layer, wherein the first concrete wall via a reinforcing body, in particular a steel reinforcing body, with the insulating layer and in particular connected to a second concrete wall.
  • the method according to the invention comprises the following steps: As a first step, the provision of the first concrete wall can be carried out with a reinforcing body, wherein the reinforcing body is partially cast in the first concrete wall.
  • the step of arranging the first concrete wall and the reinforcing body arranged thereon follows with a vertical distance of the underside of the first concrete wall above a bed, in particular of quartz sand, which has been previously introduced into a bed and, for example, shaken or smoothed.
  • the projecting portion is arranged on the underside of the first concrete wall and immersed in the bed, the bed can be shaken in particular subsequently.
  • a predefined free space remains between the surface of the bed and the underside of the first concrete wall. This is followed by the filling of the free space with a reaction mixture to form polyurethane foam, which forms an insulating layer. This is followed by the step of curing the insulation layer. In a final step, the concrete wall can be removed from the bed with the reinforcing body and cured on this composite insulating polyurethane layer and in particular be freed from the material of the bed.
  • the essence of the invention consists in particular in that the concrete wall provided with the reinforcing body, for example with integrated metallic lattice girders or fiberglass anchors for forming the reinforcement body, is placed upside down, ie pointing downwards with the reinforcement body, above a preferably vibratable bedding container or the like, in which the bed of flowable solids is provided, in particular granules of fine granules such as quartz sand.
  • the filling height of the bed or the height at which the concrete wall is held above the surface of the bed can be set arbitrarily.
  • the insulating layer can be formed highly flexible with different thicknesses.
  • the thickness of the insulating layer may for example be a value of 2cm to 40cm, preferably for example from 5cm to 30cm and more preferably for example from 10cm to 25cm, as these thicknesses can be foamed particularly well with a reaction mixture.
  • Reaction mixtures of polyol and isocyanate are particularly suitable for the production of polyurethane insulating layers, but the insulating layer may comprise any further insulating material, for example also a phenolic resin foam.
  • the reinforcement body need not be made in one piece and it may, for example, individual, preferably glass fiber reinforced polymer rods or baskets form the reinforcing body. Also known as shear mandrels are known, so that the reinforcing body can in particular also be constructed from a Schubdornsystem consisting of steel elements or fiber-reinforced polymer elements that form the shear mandrels.
  • Filling the clearance with the reaction mixture may be accomplished by a flexible casting system, such as a sprue system, a rigid or oscillating casting head, or a casting mandrel designed to exist between the concrete element and the bed surface despite the presence of the reinforcement body can be moved.
  • a flexible casting system such as a sprue system, a rigid or oscillating casting head, or a casting mandrel designed to exist between the concrete element and the bed surface despite the presence of the reinforcement body can be moved.
  • the casting can also be done from the side, and the reaction mixture can enter the free space.
  • the term casting also encompasses any type of spraying or spraying of the reaction mixture.
  • the bed can in principle be formed by any type of flowable solids and may also comprise mixtures of different solids.
  • the bed should be suitable to form a barrier to the reaction mixture so as to form forming, wherein the reaction mixture, which comprises in particular the components polyol and isocyanate, in the approximately horizontally flat réellerechenden space with vertically defined height can foam.
  • the thus created cavity forms a defined cavity with a substantially flat, parallel to the first concrete wall extending extension between the surface of the bed as the lower boundary and the bottom of the first concrete wall as the upper boundary, and this cavity can in particular by means of a distribution system over the entire surface with flowable Reaction mixture or another at least phased flowable mixture are filled to form the insulating layer after curing.
  • the second concrete wall can be cast onto the produced element, so that the end component is a reinforced concrete sandwich element with two concrete walls and the intermediate insulating layer, in particular a PU hard foam core insulation.
  • the following process step takes place after curing of the insulating layer: Insertion of the first concrete wall with the reinforcing body in a casting mold, wherein the protruding portion and the insulating layer are arranged below the first concrete wall. It can then be done filling the mold with concrete, but preferably can take place the first concrete wall in the already reinforced and freshly concreted second wall.
  • the casting of the concrete for the second wall is usually carried out so before inserting the already cured first wall.
  • the result is the second concrete wall, in which the protruding portion of the reinforcing body is at least partially also cast. In this embodiment, therefore, the projecting portion protrudes downwards.
  • the mold is delimited upwards by the concrete wall. Depending on the amount of liquid concrete, which is introduced into the mold, the free space is thus selectively filled.
  • the second concrete wall can also be formed in such a way that the second concrete wall rests against the insulating layer, at least indirectly, by completely filling the free space. So it is then in the finished product no gap between the second concrete wall and insulation layer available.
  • the free space in the casting mold between the bottom of the casting mold and the insulating layer is only partially filled with liquid concrete, so that a gap remains between the insulating layer and the second concrete wall.
  • Such a gap can be filled with concrete, for example, later on the site.
  • the composite of insulating layer and the first concrete wall is inserted with the reinforcing body in the mold, wherein the protruding portion of the reinforcing body and the insulating layer is disposed above the first concrete wall.
  • the insulating layer can form the bottom of the mold thus created.
  • the composite of the first concrete wall with the reinforcing body and the insulating layer is immersed in an already filled with concrete mold with the insulating layer facing down and the concrete is then cured for this process step. In this embodiment, no gap between the second concrete wall and insulation layer is generated.
  • An indirect concern also means a structure in which a further layer of material is provided between the concrete wall and the adjacent insulating layer, for example an insulating film.
  • a further layer of material is provided between the concrete wall and the adjacent insulating layer, for example an insulating film.
  • the two layers are no longer in contact with each other.
  • the concrete walls which may basically be plate-shaped, are oriented substantially horizontally.
  • FIG. 2c shows a finished reinforced concrete element 10, which was prepared by a method according to the invention.
  • the reinforced concrete element 10 includes an overhead arranged first concrete wall 11 and a second concrete wall spaced therefrom 12. Between the two concrete walls 11 and 12, an insulating layer 14 is provided. The insulating layer 14 is present the first concrete wall 11, and between the insulating layer 14 and the second concrete wall 12, a free gap 20 is formed.
  • Figure 3c shows an alternative reinforced concrete element 10. This corresponds largely to the structure of the reinforced concrete element after Figure 2c , wherein the free gap 22 is omitted.
  • the insulating layer 14 is now also on the second concrete wall 12.
  • plastic films or other layers of material may be arranged between the insulating layer 14 and the concrete walls adjacent thereto.
  • a reinforcing body 13 is shown in the form of a steel reinforcement basket, visible in the space 20.
  • the reinforcing body 13 is completely enclosed by concrete or the insulating layer 14 and therefore not visible.
  • FIG. 1a the reinforcing body 13 is inserted in a first mold 17.
  • the first mold 17 is now partially filled with liquid concrete 22.
  • the concrete then cures to the first concrete wall 11, see FIG. 1b ,
  • a section 13 "of the reinforcing body 13 is now cast in the first concrete wall 11.
  • Another section 13 'of the reinforcing body 13 protrudes from the first concrete wall 11.
  • first concrete wall (11) and reinforcing body (13) is reversed, so that the protruding portion 13 'is arranged on the underside of the first concrete wall 11.
  • the reinforcing body 13 is now immersed in a bed 15 of defined depth, which is entered into a bed of bulk material 23, see Figure Ic.
  • the bed 15 is formed by sand, in particular by quartz sand. But it is only the reinforcing body 13 with its protruding portion 13 'immersed in the bed 15.
  • the first concrete wall 11 remains completely above and arranged at a distance from the bed 15. There thus remains a vertical space 16 between the first concrete wall 11 and the bed 15 in the hopper 23, see Figure 1d ,
  • the bed 15 can be shaken by means of a vibrator.
  • the shaking of the bed 15 is useful so as to distribute the bed as evenly as possible and to obtain a flat surface as possible.
  • the free space 16 is now completely filled with a flowable reaction mixture, in this example PU foam of polyol and isocyanate.
  • the reaction mixture becomes solid and forms a composite of the insulating layer 14 with the first concrete wall 11 and the reinforcing body, see Figure 1e , In FIG. 1f Now, the intermediate product is shown, which comprises the first concrete wall 11, the adjacent insulating layer 14 and the reinforcing body 13.
  • FIG. 1f represent a finished reinforced concrete element.
  • the intermediate product is inserted into a second mold 18, see FIG. 3a ,
  • the reinforcing body 13 is inserted with its protruding portion 13 'down into the second mold 18.
  • Spacers not shown, can ensure that the reinforcing body 13 basically has a certain distance from the bottom 19 of the casting mold 18.
  • FIG. 2b It can be seen that now a free space 21 between the insulating layer 14 and the bottom 19 of the mold 18 is formed.
  • the protruding portion 13 'of the reinforcing body 13 is arranged.
  • This space 21 is now at least partially filled with concrete 22. There remains a gap 20, since the space 21 is only partially filled. But it is also possible that the space 21 is completely filled. So then the second concrete wall 12 is brought into contact with the insulating layer 14.
  • the intermediate product becomes FIG. 1f inserted into the second mold 18, that the protruding portion 13 'of the reinforcing body 13 facing upward and so that the first concrete wall 11 is disposed below the insulating layer 14, see FIG. 3a
  • FIG. 3b is now the intermediate after FIG. 1f shown within the second mold 18.
  • the first concrete wall 11 rests on the bottom 19 of the second casting mold 18.
  • the mold 18 is filled from above with concrete 22. Due to gravity now puts the filled concrete 22 to the insulating layer 14, so that it is not provided in this embodiment, that a gap 20 between the insulating layer and the second concrete wall 12 is formed.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
  • Producing Shaped Articles From Materials (AREA)
EP13155444.6A 2013-02-15 2013-02-15 Procédé de fabrication d'un élément en béton armé multicouche Withdrawn EP2767373A1 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
EP13155444.6A EP2767373A1 (fr) 2013-02-15 2013-02-15 Procédé de fabrication d'un élément en béton armé multicouche
RU2015139040A RU2015139040A (ru) 2013-02-15 2014-02-10 Способ изготовления многослойного армированного бетонного элемента
PCT/EP2014/052500 WO2014124886A1 (fr) 2013-02-15 2014-02-10 Procédé de fabrication d'un élément en béton armé à plusieurs couches
CN201480008971.9A CN104981330B (zh) 2013-02-15 2014-02-10 用于生产多层增强混凝土元件的方法
US14/766,148 US20150368902A1 (en) 2013-02-15 2014-02-10 Method for producing a multi-layered reinforced concrete element
MX2015010227A MX2015010227A (es) 2013-02-15 2014-02-10 Metodo para producir un elemento de hormigon armado de multiples capas.
EP14705737.6A EP2956283B1 (fr) 2013-02-15 2014-02-10 Procédé de fabrication d'un élément en béton armé multicouche

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP13155444.6A EP2767373A1 (fr) 2013-02-15 2013-02-15 Procédé de fabrication d'un élément en béton armé multicouche

Publications (1)

Publication Number Publication Date
EP2767373A1 true EP2767373A1 (fr) 2014-08-20

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Family Applications (2)

Application Number Title Priority Date Filing Date
EP13155444.6A Withdrawn EP2767373A1 (fr) 2013-02-15 2013-02-15 Procédé de fabrication d'un élément en béton armé multicouche
EP14705737.6A Not-in-force EP2956283B1 (fr) 2013-02-15 2014-02-10 Procédé de fabrication d'un élément en béton armé multicouche

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP14705737.6A Not-in-force EP2956283B1 (fr) 2013-02-15 2014-02-10 Procédé de fabrication d'un élément en béton armé multicouche

Country Status (6)

Country Link
US (1) US20150368902A1 (fr)
EP (2) EP2767373A1 (fr)
CN (1) CN104981330B (fr)
MX (1) MX2015010227A (fr)
RU (1) RU2015139040A (fr)
WO (1) WO2014124886A1 (fr)

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AU2013299323A1 (en) * 2012-08-02 2016-03-03 L. & A. Fazzini Manufacturing Pty Ltd Improved mesh, mesh panels, composite building elements and method of reinforcing and articles reinforced by the method, duct and riser walls and methods for their construction
CN104499654B (zh) * 2014-12-17 2019-04-02 张跃 一种预制装配式屋顶及其制作方法
US11072933B2 (en) * 2016-02-26 2021-07-27 Ashgrove Holdings, Inc. Panel production kits, methods, and systems
CN107553806B (zh) * 2016-07-01 2021-08-24 科思创德国股份有限公司 聚氨酯混凝土夹芯元件及其制法
CN109176867A (zh) * 2018-09-14 2019-01-11 西安建工绿色建筑集团有限公司 一种预制ptw墙板生产定位装置及预制ptw墙板生产方法
CN110219417B (zh) * 2019-05-05 2021-02-12 江苏建筑职业技术学院 一种高粘结性钢骨及生产工艺
US12258760B1 (en) * 2023-10-13 2025-03-25 King Saud University Linkage for increasing the ductility of fiber reinforced polymer bars

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US20150368902A1 (en) 2015-12-24
CN104981330B (zh) 2017-09-01
RU2015139040A (ru) 2017-03-22
EP2956283B1 (fr) 2017-02-01
WO2014124886A1 (fr) 2014-08-21
CN104981330A (zh) 2015-10-14
EP2956283A1 (fr) 2015-12-23

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