EP2418058A2 - Method for producing multi-layer concrete elements - Google Patents

Abstract

The method involves placing cladding panels (16) on a production table under release of joints arranged next to each other in a formwork frame. Edges of the panels are pressed into strips (14) on all sides to apply a concrete layer (28) on the panels. A sealing compound present in the strips is applied on the table, where a position of the compound corresponds to a pattern of the joints. An insulating layer (34) is applied on the concrete layer. Boreholes are attached to the insulating layer to insert an anchoring rod (36) into each borehole after inserting the insulating layer into the frame.

Description

The invention relates to a method for producing multilayer concrete elements, in which cladding panels are placed side by side in a formwork frame on a production table, leaving joints free, whereupon a concrete layer is applied to the cladding panels.

Multilayered concrete elements in the form of slabs are used primarily for the construction of buildings; The cladding panels serve as cladding and can be made of natural stone such as granite or marble, tiles, bricks or clinker. In addition, other weather-resistant materials come into question, such as clay, concrete, artificial stone, plastic or steel. In all cases, these cladding panels must be permanently connected to the concrete layer.

The production of multilayer concrete elements has hitherto largely been done manually. First, the required cladding panels are placed in a formwork frame on a production table, wherein the formwork frame contains matrices made of plastic or metal. For positioning the layer and for sealing the joints, alternatively, the cladding panels are often manually placed in a sand bed or on a sealing foil. In this way, the penetration of concrete water is prevented in the joints and the position of the elements are ensured.

The use of dies has the disadvantage that for each concrete element a separate die must be produced, whereby the flexibility is considerably restricted. In addition, the cost is economically justifiable only in large quantities. The Manufacturing a sand bed or applying a film seal is very time consuming and difficult to integrate into automated production.

After inserting the cladding panels then the concrete layer is applied, which also penetrates into the joints between the cladding panels. The sealing of the joints poses a major problem because the concrete and the concrete milk penetrates between the joints and undermines the cladding panels on their visible side. Such contamination must be removed consuming after completion of the multilayer concrete elements. In order to avoid this cleaning, a subsequent grouting of the elements is often performed, which requires an additional operation, which must be carried out at finishing stations.

The invention has for its object to provide a method for producing multilayer concrete elements available, which can be carried out automated using robots and the joints completes so that even without the use of matrices, a sand bed or a sealing film of the penetrating concrete effectively is held back in the joints.

To achieve this object, the invention provides that on the production table, first a potting compound is applied in strips whose position corresponds to the grid of joints, whereupon the cladding panels are inserted so that their edges impress on all sides in the existing of the potting strip, which the concrete layer is applied.

As potting compound is a material that does not connect to the joint concrete and does not adhere to the surface of the production table, so that it can be easily detached after completion of the concrete element. Possible materials here are synthetic resin, for example silicone, mineral materials or the like.

In a further development of the invention, it is provided that an existing from the potting compound strip is applied to each edge of the formwork element on the production table, on which the corresponding cladding panels are pressed. It is possible to hang the cladding panels on the strip so that the distance to the formwork frame corresponds to a joint width. In an alternative, the Cover panels are laid on the strip so that they rest on the formwork frame without clearance.

The invention opens up the possibility of automatically applying the potting compound with the aid of a robot on the surface of the production table and thereby to produce a joint grid that corresponds to the CAD planning. The potting compound applied in strips, on the one hand, compensates tolerances of the production table and, on the other hand, acts to damp vibrations, so that the lining panels are protected against damage during the subsequent compacting of the concrete layer.

In a further development of the invention, it is possible to apply an insulating layer to the concrete layer and to cover it with a further layer of concrete.

The insulating layer may consist of plates, which are supplied as well as the cladding panels by a robot and inserted. The robot picks up the insulating panels, moves them to the specified position and presses them onto the uncured concrete layer. In this case, projecting formwork parts are bypassed in a suitable manner.

Anchoring rods are used to connect the individual layers. For this purpose, bores are introduced into the insulating layer before insertion into the formwork frame; in each hole an anchor rod is inserted after insertion into the formwork frame, which engages in the not yet cured concrete layer and protrudes with its end facing away from the insulating layer; then the further concrete layer is applied to this. After curing, a solid sandwich composite is available.

• Figur 1 die schematische Darstellung beim Auftragen eines Streifens aus Vergussmasse auf einen Fertigungstisch,
• Figur 2 die Zuführung einer Verkleidungsplatte,
• Figur 3 die Figur 2 gezeigte Verkleidungsplatte nach dem Aufdrücken auf den Streifen aus Vergussmasse,
• Figur 4 eine der Figur 3 entsprechende Darstellung nach dem Aufdrücken einer zweiten Verkleidungsplatte,
• Figur 5 die schematische Darstellung eines Schalungsrahmens beim Aufbringen der Vergussmasse an dessen Rand,
• Figur 6 die Zuführung einer Verkleidungsplatte gegen den Streifen aus Vergussmasse,
• Figur 7 die Verkleidungsplatte nach dem Aufdrücken auf den Streifen ohne Abstand zum Schalungsrahmen,
• Figur 8 eine weitere Variante der Figur 7,
• Figur 9 die Draufsicht auf einen Fertigungstisch mit aufgesetztem Schalungsrahmen,
• Figur 10 den Fertigungstisch mit Schalungsrahmen nach dem Auftragen der Vergussmasse im Raster der Fugen,
• Figur 11 eine der Figur 10 entsprechende Darstellung nach dem Einlegen der Verkleidungsplatten,
• Figur 12 eine Schnittdarstellung in der Ebene A-A der Figur 11,
• Figur 13 eine vergrößerte Ausschnittsdarstellung aus Figur 12 und
• Figur 14 eine nochmals vergrößerte Ausschnittsdarstellung im Bereich XIV der Figur 13.

The invention is explained below with reference to exemplary embodiments which are illustrated in the drawing. Show it:

• FIG. 1 the schematic representation when applying a strip of potting compound on a production table,
• FIG. 2 the feeding of a panel,
• FIG. 3 the FIG. 2 shown lining panel after pressing on the strip of potting compound,
• FIG. 4 one of the FIG. 3 corresponding representation after the pressing of a second cladding panel,
• FIG. 5 the schematic representation of a formwork frame when applying the potting compound at the edge,
• FIG. 6 the feeding of a trim panel against the strip of potting compound,
• FIG. 7 the cladding plate after pressing on the strip without spacing from the formwork frame,
• FIG. 8 another variant of FIG. 7 .
• FIG. 9 the top view of a production table with attached formwork frame,
• FIG. 10 the production table with formwork frame after the application of the potting compound in the grid of the joints,
• FIG. 11 one of the FIG. 10 corresponding representation after inserting the cladding panels,
• FIG. 12 a sectional view in the plane AA the FIG. 11 .
• FIG. 13 an enlarged detail view FIG. 12 and
• FIG. 14 a further enlarged detail view in the area XIV the FIG. 13 ,

FIG. 1 schematically shows the surface of a manufacturing table 10 or a pallet, over which the discharge nozzle 12 is arranged a feed line, not shown, which in turn is connected to a reservoir which is fixed to a robot head. The nozzle 12 is movable in a horizontal direction relative to the production table 10 and serves to deliver a potting compound contained in the mentioned container, so that on the surface of the production table 10 a in FIG. 1 in cross section indicated strip 14 of this potting compound is applied. As already mentioned, the potting compound consists of a material that can be easily removed from the surface of the production table 10 after completion of the process.

In a following step, in FIG. 2 is indicated, a cladding panel 16 is supplied in the direction of arrow from above and according to FIG. 3 pressed on the strip 14 of potting compound.

As FIG. 4 shows, then another cladding panel 16 is placed on the production table 10, in such a way that its edge presses into the strip 14. In this way, the joint 18 between the two cladding panels 16 is sealed on their side opposite the production table 10 side.

In FIG. 5 the possibility is shown, the discharge nozzle 12 to move over the aforementioned robot so that it applies close to the edge of a formwork frame 20 a strip 14 of the potting compound. As FIG. 6 shows, then the cladding panel 16 is inserted, according to the FIGS. 7 and 8 There are two options. In the example of FIG. 7 the cladding panel 16 is pressed without clearance to the formwork frame 20, while in the example of the FIG. 8 with its edge has a distance a to the formwork frame 20, for example, a joint width 18 (see. FIG. 4 ) corresponds.

In all cases, the discharged from the nozzle 12 discharge amount can be controlled and adapted to the dimensions of the joint 18.

By the pressure on the cladding panel 16 is in the example of the FIG. 7 the strip 14 is pressed flat from the edge of the cladding panel 16, while in the example of the FIG. 8 in the region of the joint a seals this between the formwork frame 20 and the cladding panel 16.

FIG. 9 schematically shows the top view of the manufacturing table 10, on which by means of Abschalelementen 22 of the formwork frame 20 is formed, whose dimensions correspond to those of the concrete element to be produced. By means of a frame insert 24, the recess required for a window or the like is kept free.

In the next step, the in FIG. 10 is indicated by means of in FIG. 1 indicated discharge nozzle 12, the required strips 14 applied from the potting compound, so that a grid 26 with the size of the aufgelegenden cladding panels 28 is formed (see. FIG. 10 ). As already mentioned, the cladding panels 16 are then inserted with sufficient pressure so that their edges penetrate into the strips 14 of the potting compound.

FIG. 12 shows in enlarged scale a sectional view in the plane AA of FIG. 11 , It can be seen that a concrete layer 28 is applied to the side-by-side cladding panels 16, the joints 18 of which are sealed by the strips 14 from the potting compound down. As the FIGS. 13 and 14 show this penetrates both in the joints 18 between each two cladding panels 16 as well as in undercuts, surface roughness or recesses 30, which are incorporated in the back of the cladding panels 16. In this way, after curing of the concrete layer 28, a positive connection between this and the cladding panels 16 is produced.

The strips 14 of the potting compound ensure that between two juxtaposed cladding panels 16 no concrete and no concrete milk in the direction of the production table 10 can escape, so that after lifting the finished concrete element 32 whose visible side on the now free surface of the cladding panels 16th is free of impurities.

In a further production step, which can likewise be carried out by means of the mentioned or an additional robot, an insulating layer 34 is applied to the concrete layer 28. This can consist of appropriately cut insulating panels, which the robot feeds individually. Before inserting the insulating layer 34 are introduced into these holes, which are perpendicular in the embodiment shown. After inserting this insulating layer 34 are in these holes in FIG. 12 indicated anchoring rods 36 are used, the lower ends engage in the not yet cured concrete layer 28. A further concrete layer 28 'is finally applied to the insulating layer 34, which according to FIG. 12 is so high that it covers the upwardly projecting ends of the anchoring rods 36.

After the two concrete layers 28 and 28 'have cured, the multilayer concrete element 32 produced in the described manner can be removed from the production table 10. Thereafter, the strips 14 are peeled off the cladding panels 16. By the surface roughness, undercuts or recesses 30 in the cladding panels 16 and by the anchoring rods 36 ensures that the multi-layer concrete element 32 forms a solid bond.

Claims (8)

A process for producing multilayer concrete elements, in which cladding panels are placed side by side in a formwork frame on a production table, leaving a concrete layer applied to the cladding panels, characterized in that on the production table (10) first a potting compound in strips (14) is applied, whose position corresponds to the grid (26) of the joints (18), whereupon the cladding panels (16) are inserted so that their edges on all sides in the existing of the potting compound strip (14) press, after which the concrete layer (28) is applied. A method according to claim 1, characterized in that on each edge of the formwork frame (20) on the production table (10) from the casting compound existing strip is applied, on which the corresponding cladding panels (16) are pressed. A method according to claim 2, characterized in that the cladding panels (16) are placed on the strip (14) that the distance (a) corresponds to the shuttering frame (20) of a joint width. A method according to claim 2, characterized in that the cladding panels (16) are placed on the strip (14) that they rest without clearance on the formwork frame (20). Method according to one of the preceding claims, characterized in that the potting compound consists of one of the joint concrete and the production table (10) easily removable material. Method according to one of the preceding claims, characterized in that an insulating layer (34) is applied to the concrete layer (28). A method according to claim 6, characterized in that in the insulating layer (34) bores are introduced, whereupon after insertion of the insulating layer (34) in the Formwork frame (20) in each bore an anchoring rod (36) is inserted, which engages in the not yet cured concrete layer (28) and protrudes with its end facing away from the insulating layer (34). A method according to claim 7, characterized in that on the insulating layer (34), a further concrete layer (28 ') is applied, which covers the of the insulating layer (34) projecting ends of the anchoring rods (36).

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