EP3299524B1 - Wall made of prefabricated products and method for manufacturing the same - Google Patents

Description

The invention relates to a prefabricated wall with a reinforced prefabricated wall on a strip foundation with reinforcement according to the preamble of claim 1, as well as a method for producing the prefabricated wall.

Many types of prefabricated walls are already known from the prior art. These can be designed in the manner of a retaining wall as a partial component of a building or also free-standing, individually or modularly. In contrast to the common methods of erecting concrete walls by pouring the concrete on site, which require an elaborate construction of formwork, reinforcements and supporting devices, the erection of precast walls is based on the use of industrially prefabricated reinforced concrete walls, which are then placed at the Construction must be connected to the foundation layers previously anchored in the ground, so that these are supported by the foundation in a stable manner. The erection of prefabricated walls is much more economical than pouring the concrete on site and means significant cost and time savings.

This is how the EP 2 535 463 A1 a modular prefabricated retaining wall, which comprises at least one vertically mountable reinforced wall-shaped wall element, which can be connected to at least one wall holding element that can be vertically arranged perpendicularly to this wall element. Each wall element has In particular, connecting reinforcement elements protruding from the flat side assigned to the wall mounting element and each wall mounting element has a central cavity which can be filled with in-situ concrete, as well as at least one passage opening connected to the cavity for the connecting reinforcement elements of the wall elements after the cavity has been filled are embedded in the in-situ concrete.

For the state of the art, refer to the publications U.S. 5,697,736 A and DE 23 65 376 A1 referenced.

The U.S. 5,697,736 A discloses a bank protection wall or a bulkhead wall made of several prefabricated L-structural elements, which have the shape of a modified letter "L", with a vertical wall section, a horizontal foot section with a vertical nose area protruding below the foot section and an angular wave striking plate protruding therefrom, which directly opposite the foot section this is arranged extending, the L-links are connected to each other at the ends by connecting means, and wherein the vertical nose areas are set in the bank floor and the horizontal foot sections are dug in the bank floor or in a bank embankment and are held so and the angular Wave impact plates extend in the direction of the water and sit deep enough next to the wall to withstand erosion. The wave striking plates are in particular covered with a protective layer of stones.

The DE 23 65 376 A1 teaches a wall element made of opposing concrete shells, each of which contains a structural steel mesh mat as surface reinforcement and which are connected to one another by spacers, with four connected concrete shells forming a rectangular jacket and recesses in the concrete layer for inserting connecting anchors in the area of connection surfaces. In this case, passages for inserting clamping devices are provided in the area of the connection surfaces. A prefabricated wall according to the preamble of claim 1 is also in the document DE 34 085 46 A described.

The invention is therefore based on the object of improving the aforementioned prior art in such a way that the manufacturing process for the manufacture of prefabricated walls is optimized and the duration of the manufacturing process is reduced.

This object is achieved according to the invention by a prefabricated wall with the features of claim 1 and a method for producing such a prefabricated wall with the features of claim 6. Further advantageous refinements can be found in the respective back-referenced subclaims.

In the prefabricated wall according to the invention, the at least two support elements are cuboid and each have at least one passage opening, the at least two support elements being arranged such that the passage openings run in the longitudinal direction of the strip foundation. The prefabricated wall can be designed as a hollow or solid wall and made of concrete or another suitable material. Furthermore, the prefabricated wall can be partially or completely layered from a composite material and have facings made of sandstone, for example. Typically, the precast wall is tabular and has a straight or stepped underside which is delimited by the side edges at right angles and / or at an angle deviating therefrom. The top is shaped as desired. The U-shaped reinforcement elements are integrated into the underside of the precast wall in such a way that the two free ends of the U-shape are completely enclosed by the material of the precast wall and the remaining curved area protrudes from the precast wall. The U-shaped reinforcement elements are arranged in parallel so that, viewed in the longitudinal direction of the precast wall, the U-shape is visible as such. The reinforcement elements are made of steel or another suitable material. After the foundation has been completely manufactured, the cuboid support elements can be enclosed in the foundation and not visible from the outside due to the length of the wall of a strip foundation in the present case. Likewise, the material of the support elements is chosen so as to absorb the load of the precast wall in a non-destructive manner, at least until the foundation is completely made. The passage openings should be designed in a straight line and thus penetrate two opposite side surfaces of the respective support element. The passage opening can be implemented by an inserted tubular sleeve in the support element. By arranging several support elements of the same type or at least essentially the same type of features along the longitudinal axis of the strip foundation and the support of the precast wall in the same direction, a stable support over the entire length of the precast wall is achieved. When the support elements are placed on the strip foundation, the at least one passage opening is aligned in such a way that the axis of the passage opening points in the longitudinal direction of the strip foundation and, after the precast wall has been placed on the support elements, reinforcement bars are inserted into the U-shaped reinforcement elements in the area between the Permits support elements by means of passing through the at least one passage opening.

The prefabricated wall according to the invention consists of a reinforced panel-shaped prefabricated wall element with U-shaped reinforcement elements that protrude on the bottom and are arranged in parallel. This prefabricated wall element can already be made of solid concrete, so that no further rework is required. This prefabricated wall element can also contain optical elements such as clinker bricks, facings of any kind or trellises and the like on the visible side.

The parallel U-shaped reinforcement elements can be essentially equally spaced. The distance between two adjacently arranged U-shaped reinforcement elements is generally the same. The distance between the parallel U-shaped reinforcement elements can vary according to the number of support elements. In the area of positioning the support elements for carrying the precast wall on a foundation, the distance between the adjacent reinforcement elements, between which the support element is to be received, is selected so that the support element has a contact surface with the lower edge of the precast wall and fits between them. In addition, additional reinforcement elements can be added in the area of these reinforcement elements Reinforcement elements be arranged so that the distance between the reinforcement elements is compressed in the immediate vicinity of the support elements.

The cuboid shape of the support element offers at least two parallel opposing surfaces, with one serving as the contact surface on the ground to the strip foundation and the other side providing the supporting surface for the prefabricated wall resting on it. The opening cross section of the at least one passage opening must be selected so that it is larger than the cross section of the reinforcing bars used, wherein the at least one passage opening can be formed by an inserted tubular sleeve.

The prefabricated wall preferably has reinforcing rods which run in the intermediate space between the support elements in the longitudinal direction of the prefabricated wall in the reinforcement of the strip foundation and are arranged within the U-shaped reinforcement elements. The straight and parallel arrangement of the U-shaped reinforcement elements enables the reinforcement bars to be passed through and the stable arrangement of the reinforcement bars within the U-shape of the reinforcement elements, the reinforcement bars being introduced through the at least one opening in the at least two support elements. This can be done from one side as well as from the other side of the strip foundation, the length of the reinforcing bars for the space corresponding at most to the distance between the support elements. It is also possible to introduce reinforcing bars from both sides, the total length of which corresponds to the distance between the support elements or which are longer. After the reinforcement bars have been inserted, they are then fixed in the desired position on the U-shaped reinforcement elements in a known manner.

Appropriately, reinforcing bars are also arranged outside the space between the support elements in the longitudinal direction of the prefabricated wall and inside the reinforcement of the strip foundation. These are also pushed into the U-shaped reinforcement elements at the front and fixed to them accordingly. The number of rebars inside and outside of the gap depends on the stability requirements required for the size of the precast wall.

So that the at least two support elements have a stable support, it is expedient to provide a concrete layer for this in the form of a concreted blinding layer. For the later concreting of the strip foundation with in-situ concrete, shuttering is required in a known manner. In a particularly advantageous embodiment, the strip foundation in the non-concreted state has a concreted blinding layer on the bottom side and formwork walls that extend in the longitudinal direction of the foundation and are connected to the bleaching layer via connecting irons, the reinforcement being arranged between the formwork walls and the at least two support elements on the blending layer between the reinforcement are. First, the formwork walls are made over the length of the strip foundation in a known manner and provided with connecting iron to connect with the blinding layer. This means that these formwork walls can stand stable for the strip foundation and can be used to attach supports to support the prefabricated wall directly after it has been placed on the support elements. These formwork walls then later serve as formwork for concreting the space provided with reinforcement within the concrete formwork elements. On the front side, the formwork can usually be done with formwork panels.

The strip foundation is advantageously concreted with in-situ concrete. The concreting is necessary to complete the precast wall and serves on the one hand to provide a stable and stable connection between the precast wall and the foundation and on the other hand to ensure that the load-bearing capacity of the precast wall is evenly distributed over the entire foundation.

1. (a) Vorsehen einer bodenseitigen Sauberkeitsschicht für ein Streifenfundament;
2. (b) Herstellen der Bewehrung für das Streifenfundament auf der Sauberkeitsschicht;
3. (c) Einsetzen von mindestens zwei, mindestens eine Durchtrittsöffnung aufweisenden, quaderförmigen Stützelementen in die Bewehrung, wobei die Stützelemente auf der Sauberkeitsschicht aufliegen, parallel zueinander angeordnet sind und die Achsen der Durchtrittsöffnungen in Längsrichtung des Streifenfundaments verlaufen;
4. (d) Aufsetzen eine Fertigteilwand mit parallel angeordneten, U-förmigen, aus der Fertigteilwand herausragenden Bewehrungselementen auf die Stützelemente, wobei die Bewehrungselemente in die Bewehrung des Streifenfundaments hineinragen;
5. (e) Einbringen von Bewehrungsstäben in die Bewehrung des Streifenfundaments in und außerhalb des Zwischenraums zwischen den Stützelementen, wobei die Bewehrungsstäbe mit einer Länge, die maximal dem Abstand der Stützelemente entspricht, durch die jeweils mindestens eine Durchtrittsöffnung der Stützelemente durchgesteckt werden;
6. (f) Anordnen der Bewehrungsstäbe und Verbinden der Bewehrungsstäbe mit den U-förmigen Bewehrungselementen der Fertigteilwand; und
7. (g) Betonieren des Streifenfundaments mit Ortbeton.

The object is also achieved by a method for producing a prefabricated wall, which comprises the following steps:

1. (a) providing a bottom blinding layer for a strip foundation;
2. (b) producing the reinforcement for the strip foundation on the blinding layer;
3. (c) Insertion of at least two cuboid support elements having at least one passage opening into the reinforcement, the support elements resting on the blinding layer, being arranged parallel to one another and the axes of the passage openings extending in the longitudinal direction of the strip foundation;
4. (d) placing a precast wall with parallel, U-shaped reinforcement elements protruding from the precast wall onto the support elements, the reinforcement elements protruding into the reinforcement of the strip foundation;
5. (e) Introducing reinforcing bars into the reinforcement of the strip foundation in and outside the space between the support elements, the reinforcing bars being pushed through each of the at least one passage opening of the support elements with a length that corresponds at most to the distance between the support elements;
6. (f) arranging the reinforcing bars and connecting the reinforcing bars to the U-shaped reinforcing elements of the precast wall; and
7. (g) Concreting the strip foundation with in-situ concrete.

For concreting the strip foundation, it is of course necessary to strip it beforehand. This can be done at the beginning before steps (a) or (b) or after the reinforcement of the strip foundation and the connection with the U-shaped reinforcement elements have been completed before step (g). The shuttering for concreting can be done in the usual way by means of shuttering panels and timber, which are removed again after the in-situ concrete has hardened. All of this can be superfluous if that Foundation is arranged in a corresponding trench in the ground, which then forms the lateral boundary of the concrete foundation.

In a preferred embodiment it is provided that before process step (a) vertical formwork walls are concreted with connecting iron for the blinding layer. The formwork walls are positioned vertically along the longitudinal axis of the strip foundation and anchored in the blinding layer, which is subsequently created, using connecting irons. The formwork walls can be poured from concrete or consist of another suitable material and are held stable in their vertical position by being anchored to the blinding layer. During the final concreting of the strip foundation, all that is required is an end panel in the usual manner by means of formwork panels or the like, which are removed after the concrete has solidified. The formwork walls then form part of the strip foundation.

It is also expediently provided that after method step (d) the prefabricated wall is supported on at least one formwork wall by means of inclined supports. The formwork wall is therefore used to achieve a stable positioning of the precast wall on the support elements, which is secured against shear forces, and a lateral support of the precast wall. In addition to the inclined supports connected to the formwork wall, other support structures are also conceivable, which are either formed by temporarily installable and removable external scaffolding or implemented with solutions integrated in the prefabricated wall.

Compared to the state of the art, the prefabricated wall according to the invention is produced in such a way that the reinforcement does not protrude from the foundation and is then connected to the prefabricated wall by concreting, but conversely, the prefabricated wall has protruding reinforcement elements that are inserted into the reinforcement of the not yet concreted strip foundation be introduced. The advantages of the invention lie in the cost-effective industrial prefabrication of the wall elements, with the on-site Reinforcement elements of the wall elements are connected to the reinforcement with reinforcing bars that was previously produced at the same time as the production of the wall elements on the strip foundation. This means that it is only necessary to pour the foundation with in-situ concrete at the installation site. This considerably reduces the time required for erection due to the simultaneous production of the wall element and the foundation layers with reinforcement. A prefabricated wall produced in this way can be combined with other prefabricated walls of the same type to form an inexpensive retaining wall of considerable length for roads.

Figur 1

eine schematische Darstellung eines Querschnitts der Fertigteilmauer,

Figur 2

eine schematische Darstellung der Fertigteilmauer entlang der Schnittebene A-A aus Figur 1.

The invention is explained using an exemplary embodiment shown in the figures. Further features emerge from the following description of the exemplary embodiment of the invention in conjunction with the claims and the attached figures. The individual features of the invention can be implemented individually or in groups in different embodiments of the prefabricated wall, prefabricated wall, support element and manufacturing method according to the invention. Show it

Figure 1

a schematic representation of a cross section of the precast wall,

Figure 2

a schematic representation of the prefabricated wall along the section plane AA Figure 1 .

The Figure 1 shows a schematic cross section orthogonal to the longitudinal axis of a precast wall 1 according to the invention in the non-concreted state with a precast wall 2 and a concrete foundation designed as a strip foundation 7. A panel-shaped prefabricated wall 2 has a prefabricated wall element 3 made of concrete with a wall reinforcement 15, as well as a plurality of U-shaped reinforcement elements 4, which are completely embedded and anchored in the prefabricated wall element 3 with their open ends. The lower closed part of the U-shaped reinforcement elements 4 protrudes from the prefabricated wall element 3 from the side facing the strip foundation 7. The strip foundation 7 has a cleanliness layer 8, which are delimited along the longitudinal axis of the prefabricated wall 1 by two vertically arranged formwork walls 12. For fixed positioning, the formwork walls 12 are each anchored via at least one connecting iron 13 embedded in the blinding layer 8. A reinforcement 9 of the strip foundation 7 made of steel is arranged on the blinding layer 8, the reinforcement 9 forming an essentially uniform grid of a basic shape useful for the strip foundation 7. A support element 5 with a passage opening 6 is arranged in the area of the reinforcement 9. With its side facing the ground, the support element 5 rests completely on the blinding layer 8, so that any load on the supporting element 5 is transferred to the blinding layer 8 and no partial load is transferred to the reinforcement. Usually, at least two support elements 5 are arranged in parallel, aligned in the plane of the drawing, in order to sensibly support the prefabricated wall 2 mounted thereon along the longitudinal axis of the prefabricated wall element 3. The U-shaped reinforcement elements 4 of the prefabricated wall 2 protruding from the prefabricated wall element 3 are arranged in such a way that they engage in the reinforcement 9 of the strip foundation 7 and the load of the prefabricated wall element 3 is transferred to the support elements 5. A stable anchoring connection is established between the U-shaped reinforcement elements 4 and the reinforcement 9 of the strip foundation 7. For this purpose the passage opening 6 of the support element 5 is used, which provides access to the area enclosed by the U-shaped reinforcement elements 4 in an intermediate space 10 (not shown here) ( Figure 2 ) between two support elements 5 allows. Reinforcing bars 11 are passed through these passage openings 6 into the space 10. The reinforcing bars 11 have a maximum length of the distance between the support elements 5. The reinforcing bars 11 introduced in this way are positioned accordingly and connected to the U-shaped reinforcing elements 4. In addition, they can also be connected to the reinforcement 9 of the strip foundation 7 as in the exemplary embodiment. In order to secure the precast wall 2 mounted on the support elements 5 against laterally acting forces and prevent the precast wall 2 from tipping over prevent a schematically indicated conventional inclined support 14 can be arranged, which is detachably connected at one end to the prefabricated wall element 3 of the prefabricated wall 2 and at the opposite end to one of the vertical formwork walls 12.

How out Figure 2 As can be seen, the U-shaped reinforcement elements 4 are largely evenly spaced and aligned with one another so that their openings are congruent in the direction of the longitudinal axis of the prefabricated wall 1 and form an elongated cavity with the passage openings 6 of the support elements 5. The reinforcing rods 11 are introduced into this cavity, both in the intermediate space 10 delimited by the support elements 5 and in the outer areas which are delimited only on one side by a support element 5 in each case. The passage openings 6 each serve as access to the space 10. The shape of the reinforcement 9 of the strip foundation 7 is chosen so that the U-shaped reinforcement elements 4 of the precast wall 2 are each arranged close to the reinforcement 9 and facilitate simple anchoring among one another. Both the reinforcement 9 of the strip foundation 7 and the U-shaped reinforcement elements 4 of the precast wall 2 have free areas that are sufficiently dimensioned to be able to position a support element 5 standing on the blinding layer 8. In addition, these free areas are limited by a locally compacted sequence of U-shaped reinforcement elements 4 on both sides. As a result, additional points of intersection for anchoring with the reinforcing bars 11 are realized.

Claims (8)

1. Prefabricated wall structure (1) comprising a reinforced prefabricated wall (2) on a strip foundation (7) having reinforcement (9), parallel U-shaped reinforcement elements (4) projecting from the prefabricated wall (2) on the side facing the strip foundation (7) and the prefabricated wall (2) resting on at least two support elements (5) arranged in the strip foundation (7) in the non-concreted state, the support elements (5) being between the reinforcement elements (4) and the U-shaped reinforcement elements (4) projecting into the reinforcement (9) of the strip foundation (7), characterised in that the at least two support elements (5) are cuboid and each have at least one through-opening (6), the at least two support elements (5) being arranged such that the through-openings (6) extend in the longitudinal direction of the strip foundation (7).
2. Prefabricated wall structure (1) according to claim 1, characterised in that, in the space (10) between the support elements (5), reinforcement bars (11) that extend in the longitudinal direction of the prefabricated wall (2) in the reinforcement (9) of the strip foundation (7) are arranged within the U-shaped reinforcement elements (4).
3. Prefabricated wall structure (1) according to claim 2, characterised in that reinforcement bars (11) are arranged outside the space (10) between the support elements (5) in the longitudinal direction of the prefabricated wall (2) and inside the reinforcement (9) of the strip foundation (7).
4. Prefabricated wall structure (1) according to any of the preceding claims, characterised in that the strip foundation (7) has, in the non-concreted state, a concreted blinding layer (8) on the ground and formwork walls (12) which extend in the longitudinal direction of the foundation and are connected to the blinding layer (8) by means of connecting bars (13), the reinforcement (9) being arranged on the blinding layer (8) between the formwork walls (12) and the at least two support elements (5) being arranged on the blinding layer inside the reinforcement (9).
5. Prefabricated wall structure (1) according to any of the preceding claims, characterised in that the strip foundation (7) is concreted.
6. Method for producing a prefabricated wall structure (1) according to any of claims 1 to 5, characterised by

   (a) providing a ground blinding layer (8) for a strip foundation (7);

   (b) forming the reinforcement (9) for the strip foundation (7) on the blinding layer (8);

   (c) inserting at least two cuboid support elements (5), each having at least one through-opening (6), into the reinforcement (9), the support elements (5) resting on the blinding layer (8) and being arranged in parallel with one another, and the axes of the through-openings (6) extending in the longitudinal direction of the strip foundation (7);

   (d) placing a prefabricated wall (2) comprising parallel U-shaped reinforcement elements (4) projecting from the prefabricated wall (2) on the support elements (5), the reinforcement elements (4) projecting into the reinforcement (9) of the strip foundation (7);

   (e) introducing reinforcement bars (11) into the reinforcement (9) of the strip foundation (7) inside and outside the space (10) between the support elements (5), the reinforcement bars (11) being pushed through the at least one through-opening (6) of the respective support elements (5) by a length corresponding at most to the distance between the support elements (5);

   (f) arranging the reinforcement bars (11) and connecting the reinforcement bars (11) to the U-shaped reinforcement elements (4) of the prefabricated wall (2); and

   (g) concreting the strip foundation (7).
7. Method according to claim 6, characterised in that, before method step (a), vertical formwork walls (12) having connecting bars (13) for the blinding layer (8) are concreted.
8. Method according to claim 7, characterised in that, after method step (d), the prefabricated wall (2) is supported against at least one formwork wall (12) by means of inclined supports (14).

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