METHOD FOR PRODUCING A REINFORCED CONCRETE COMPONENT, REINFORCED CONCRETE COMPONENT AND PRODUCTION SYSTEM

Abstract

The invention relates to a method for manufacturing a reinforced concrete component (1, 1′), in particular a generatively produced reinforced concrete component (1, 1′), a reinforced concrete component and a manufacturing system for manufacturing a reinforced concrete component. In particular, the invention relates to a method for manufacturing a reinforced concrete component (1, 1′), comprising: creating a first concrete layer (20) and a second concrete layer (22) with a generative method, preferably with a shotcrete method, arranging a positioning element (100, 102, 104, 110, 120, 122, 124, 126, 128, 130) for fixing a reinforcement unit (200), wherein the positioning element is arranged with a supporting section (106) between the first concrete layer (20) and the second concrete layer (22) and protrudes with a fastening section (108) from the first concrete layer and from the second concrete layer (22), arranging at least one reinforcement unit (200) for reinforcing the concrete component (1, 1′) on the positioning element.

Claims

1. A method of manufacturing a reinforced concrete component, comprising: manufacturing a first concrete layer and a second concrete layer using a generative process, arranging a positioning member for arranging a reinforcement unit, wherein the positioning member is arranged with a supporting section between the first concrete layer and the second concrete layer and protrudes with a fastening section from the first concrete layer and from the second concrete layer, arranging the reinforcement unit for reinforcing the concrete component on the positioning element, and creating a concrete cover layer on the first concrete layer and the second concrete layer such that the reinforcement unit is substantially covered with concrete.

2. The method according to claim 1, wherein first the first concrete layer is produced, the positioning element is arranged on the first concrete layer, and the second concrete layer is produced on the first concrete layer and on the positioning element such that the positioning element is arranged between the first concrete layer and the second concrete layer.

3. The method according to claim 1, wherein the reinforcement unit is provided as a prefabricated reinforcement unit having a plurality of interconnected reinforcement elements.

4. The method according to claim 1, wherein a composite layer is applied to the first concrete layer and the second concrete layer such that the reinforcement unit is positioned at least in sections by way of the composite layer.

5. The method according to claim 1, the reinforcement unit having a vertical reinforcement element, the method comprising: arranging the vertical reinforcement element with a coupling section on the positioning element, and/or wherein the reinforcement unit comprises a horizontal reinforcement element, the method comprising the step of: arranging the horizontal reinforcement element on the positioning element, preferably in a vertical direction on the positioning element, and wherein first the vertical reinforcement element is arranged on the positioning element and subsequently the horizontal reinforcement element is arranged on the positioning element in such a way that the vertical reinforcement element is arranged at least in sections, in particular with the coupling section, between the horizontal reinforcement element and the first concrete layer and/or the second concrete layer and/or the composite layer.

6. The method according to claim 1, wherein the reinforcement unit comprises a corner reinforcement element, the method comprising: arranging the corner reinforcement element in a corner area adjacent to a corner of the concrete component such that a first section of the corner reinforcement element is arranged on a first side of the concrete component at a first positioning element, and in that a second section of the corner reinforcement element is arranged on a second positioning element on a second side of the concrete component, which second side is different from and adjacent to the first side.

7. The method according to claim 1, comprising: contour-matching preforming the horizontal reinforcement element and/or the vertical reinforcement element, the horizontal reinforcement element and/or the vertical reinforcement element having a radius by the contour-matching preforming.

8. The method according to claim 1, comprising: finishing the concrete cover layer for smoothing and/or structuring.

9. A reinforced concrete component, comprising a first concrete layer and a second concrete layer produced by a generative method, a positioning member for arranging a reinforcement unit, which is arranged with a supporting section between the first concrete layer and the second concrete layer and which protrudes with a fastening section from the first concrete layer and from the second concrete layer, the reinforcement unit arranged on the positioning element for reinforcing the concrete component, and a concrete cover layer arranged on the first concrete layer and the second concrete layer such that the reinforcement unit is substantially covered by the concrete cover layer.

10. The reinforced concrete component according to claim 9, wherein the reinforcement unit comprises a horizontal reinforcement element resting in a vertical direction on the positioning element, and/or wherein the reinforcement unit comprises a vertical reinforcement element which is arranged with a coupling section, comprising a fastening hook, on the positioning element, and/or wherein preferably the vertical reinforcement element is arranged at least in sections between the first concrete layer and/or the second concrete layer and/or a composite layer and the horizontal reinforcement element, wherein further the positioning element, the vertical reinforcement element and the horizontal reinforcement element are arranged and formed in such a way that a clamping acts between them.

11. The reinforced concrete component according to claim 9, wherein the reinforcement unit comprises a corner reinforcement element, wherein the corner reinforcement element is arranged in a corner area adjacent to a corner of the concrete component such that a first section of the corner reinforcement element is arranged on a first side of the concrete component at a first positioning element, and in that a second section of the corner reinforcement element is arranged at a second positioning element on a second side of the concrete component, which side is different from and adjacent to the first side.

12. The reinforced concrete component according to claim 9, wherein. the fastening section of the positioning element is hook-shaped and/or loop-shaped, and/or the positioning element protrudes with a first fastening section on a first side of the concrete component and with a second fastening section on a second side of the concrete component opposite to the first side, and/or the positioning element has a main extension direction which is oriented substantially orthogonally to a layer thickness of the first concrete layer and/or the second concrete layer.

13. The reinforced concrete component according to any one of the preceding claims claim 9, wherein the horizontal reinforcement element and/or the vertical reinforcement element is or are designed to match the contour and has or have a curved course, and/or wherein the horizontal reinforcement element and/or the vertical reinforcement element is/are bar-shaped and preferably consists of steel or comprises steel.

14. A reinforcing structure for a reinforced concrete component, comprising a positioning element for arranging a reinforcement unit, which is with a supporting section disposable between a first concrete layer and a second concrete layer produced by a generative method, and protrudes from the first concrete layer and from the second concrete layer by way of a fastening section, and a reinforcement unit arranged on the positioning element for reinforcing the concrete component.

15. The reinforcement structure according to claim 14, wherein. the reinforcement unit comprises a horizontal reinforcement element which rests in a vertical direction on the positioning element, and/or the reinforcement unit comprises a vertical reinforcement element which is arranged with a coupling section, comprising a fastening hook, on the positioning element, and/or the vertical reinforcement element is arranged at least in sections between the first concrete layer and/or the second concrete layer and/or a composite layer and the horizontal reinforcement element, wherein furthermore the positioning element, the vertical reinforcement element and the horizontal reinforcement element are arranged and formed in such a way that a clamping acts or can act between them.

16. A manufacturing system for manufacturing a reinforced concrete component, comprising means, including a shotcrete nozzle, for manufacturing a first concrete layer and a second concrete layer using a generative method, a handling system arranged and configured, to arrange a positioning element for fixing a reinforcement unit between the first concrete layer and the second concrete layer, to arrange a reinforcement unit on the positioning element, and the means, including the shotcrete nozzle, are adapted to produce a concrete cover layer on the first concrete layer and the second concrete layer such that the reinforcement unit is substantially covered with concrete.

17. The manufacturing system according to claim 16, wherein the handling system comprises a first handling unit and a second handling unit, wherein the first handling unit comprises the means, including the shotcrete nozzle, for manufacturing the first concrete layer, the second concrete layer and/or the concrete cover layer, and the second handling unit is configured to arrange the positioning element and/or the reinforcement unit, and comprises a handling tool.

18. The manufacturing system according to claim 16, comprising a processing machine for contour-matching preforming and/or for dimensioning vertical reinforcement elements and/or horizontal reinforcement elements.

19. The method according to claim 1, wherein the generative process comprises a shotcrete process.

20. The reinforced concrete component according to claim 9, wherein the first concrete layer and the second concrete layer are produced by a shotcrete method.

Description

[0059] Preferred embodiments are explained by way of example with reference to the accompanying figures. They show:

[0060] FIG. 1: a schematic, three-dimensional view of an exemplary embodiment of a reinforced concrete component;

[0061] FIG. 2: a schematic, three-dimensional view of a manufacturing step of the reinforced concrete component;

[0062] FIG. 3: a schematic, three-dimensional view of the concrete component with a reinforcement unit;

[0063] FIG. 4: a schematic, three-dimensional view of a manufacturing step of the reinforced concrete component;

[0064] FIG. 5: a schematic, three-dimensional view of a corner area of the reinforced concrete component;

[0065] FIG. 6: a schematic, three-dimensional view of a manufacturing step of the reinforced concrete component;

[0066] FIG. 7: another schematic, three-dimensional view of a manufacturing step of the reinforced concrete component;

[0067] FIG. 8: a schematic, three-dimensional detailed view of a reinforced concrete component;

[0068] FIG. 9: another schematic, three-dimensional detailed view of the reinforced concrete component;

[0069] FIG. 10: another schematic, three-dimensional view of a reinforced concrete component with a shear reinforcement;

[0070] FIG. 11: a schematic process for the production of a reinforced concrete component;

[0071] FIG. 12: a schematic view of a detail of the process shown in FIG. 11; and

[0072] FIG. 13: a preferred embodiment of the process shown in FIG. 11.

[0073] In the figures, identical or essentially functionally identical or-similar elements are designated with the same reference signs.

[0074] FIG. 1 shows an intermediate step in the production of a reinforced concrete component 1. The reinforced concrete component 1 comprises a plurality of layers arranged one above the other. The concrete component 1 extends from a bottom side 2 to a top side 4, from a first front side 6 to a second front side 8, and from a first side surface 10 to a second side surface not shown, which is arranged opposite the first side surface 10.

[0075] Adjacent to the top side 4, the concrete component has a first concrete layer 20 and a not yet finished second concrete layer 22. Furthermore, positioning elements are arranged between the existing concrete layers at regular intervals spaced apart in the horizontal and vertical directions. The concrete component 1 has, among other things, the first positioning element 100, the second positioning element 102 and the third positioning element 104.

[0076] With reference to the third positioning element 104, a preferred geometry of the positioning elements is explained. The third positioning element 104 has a supporting section 106. The supporting section 106 is the section of the third positioning element 104 that is located between two adjacent layers of the concrete component 1. In addition to the supporting section 106, the third positioning element 104 comprises the fastening section 108. The fastening section 108 is to be distinguished from the supporting section 106 in that the fastening section 108 protrudes from the concrete layers. The positioning elements 100, 102, 104 are arranged and formed in particular in such a way that a reinforcement unit, explained in more detail below, can be arranged thereon.

[0077] In FIG. 2, the completion of the second concrete layer 22 is shown. Furthermore, the arrangement of a positioning element 110 is shown. By means of a handling tool 116, the fourth positioning element 110 is arranged on the first concrete layer 20. Subsequently, shotcrete 114 is applied to the first concrete layer 20 by means of the shotcrete nozzle 112. The shotcrete 114 forms the second concrete layer 22. As a result, the fourth positioning element 110 is located between the first concrete layer 20 and the second concrete layer 22.

[0078] FIG. 3 then shows the reinforcement step, namely that the reinforcement unit 200 is arranged with vertical reinforcement struts 202 and horizontal reinforcement struts 204 on the positioning elements. In particular, it is preferred that the reinforcement unit 200 is hooked to the uppermost row of positioning elements, which are thus adjacent to the upper side 4 in the vertical direction.

[0079] After the reinforcement unit has been arranged on the positioning elements 110, a concrete cover layer 24 can be applied with the shotcrete nozzle 112, as shown in FIG. 4. For this purpose, shotcrete 114 is applied in layers next to each other or over a wide area. Thus, the reinforcement unit 200 is embedded in concrete and can act as reinforcement and thus as a strengthening component of the concrete component.

[0080] FIG. 5 shows a reinforcement unit for a corner area. The corner area includes the first side 16 and the second side 18. The first side 16 and the second side 18 abut at the corner 14. On the first side 16, a fifth positioning element 120 and a sixth positioning element 122 are horizontally spaced apart, equally arranged in vertical height. The second side 18 has analogously arranged positioning elements 124, 126.

[0081] A corner reinforcement element 206 is disposed on the positioning members 120, 122, 124, 126. In particular, the corner reinforcement element 206 rests on the positioning elements 120, 122, 124, 126. This arrangement of the positioning elements and the corner reinforcement element in the corner area allows for automated reinforcement of corner areas.

[0082] FIGS. 6 to 9 show an addition or alternative to the reinforcement unit 200 shown in FIGS. 3 and 4. The reinforcement unit shown in FIGS. 3 and 4 is suitable for simple geometries to enable a cost-effective reinforcement strategy that can be easily automated. However, more complexly designed components in particular require a more flexible reinforcement concept.

[0083] In FIG. 6, it is shown that a first vertical reinforcement element 150, a second vertical reinforcement element 154 and a third vertical reinforcement element 158 are arranged at the positioning elements. For this arrangement of the vertical reinforcement members 150, 154, 158, the vertical reinforcement members each have a coupling section 152, 156. The coupling section 152, 156 each has a hook-shaped end. With this hook-shaped end, the vertical reinforcement elements 150, 154, 158 are arranged, in particular hooked, to the positioning elements 128, 130.

[0084] In FIG. 7, it is shown that a plurality of horizontal reinforcement elements 180, 182 are arranged next to the vertical reinforcement elements 150, 152, 158, 160, 162. In particular, it is preferred that the vertical reinforcement elements 150-162 are arranged first at the positioning elements and then the horizontal reinforcement elements 180, 182. Due to this sequence, the vertical reinforcement elements 150-162 are pressed against the concrete layers or in the direction of the concrete layers and the horizontal reinforcement elements 180, 182 can be clamped behind the hook-shaped end of the positioning elements. Thus, the vertical reinforcement elements 150-162 are also clamped. As a result, a reinforcement unit can be built up automatically, without manual effort, by means of vertical reinforcement elements and horizontal reinforcement elements, which furthermore is substantially positionally rigid due to the clamping effect and is substantially not moved by the creation of the concrete cover layer.

[0085] In FIG. 8, a detailed view of the reinforced concrete component 1 is shown. In particular, the positioning element 128 with two fastening sections 128 A, 128 B is shown here. The fastening sections 128a, 128b protrude from the concrete layers 20, 22 on opposite side surfaces 10. As a result, a reinforcement unit can be arranged on both side surfaces of the concrete component. In this case, the reinforcement unit is formed by the vertical reinforcement elements 160, 162 as well as the horizontal reinforcement elements 180, 182 and other reinforcement elements.

[0086] FIG. 9 shows a geometrically more complex concrete component 1′. The concrete component 1′ has a reinforcement unit 200 analogous to the component described in the previous, which is formed by means of horizontal and vertical reinforcement elements. The vertical reinforcement elements are substantially the same in this embodiment. If the concrete component 1′ has a more complex geometry, the vertical reinforcement elements may also differ. The horizontal reinforcement elements, on the other hand, are not straight bars, but are curved and, in particular, preformed. The horizontal reinforcement elements 184, 186 have a radius, wherein the radius can also change along the extension of the horizontal reinforcement element. It is particularly preferred that the preformed horizontal reinforcement elements 184, 186 are preformed to fit the contour in a previous process step. This upstream process step can also take place within the manufacturing system in which the concrete component 1′ is produced.

[0087] FIG. 10 shows another schematic, three-dimensional view of a reinforced concrete component 1,1′ with a shear reinforcement. The concrete component 1,1′ comprises a plurality of positioning elements which are designed as described above. In the present case, the shear reinforcement is formed as a strap reinforcement 208. The strap reinforcement 208 comprises a plurality of first straps 210 and a plurality of second straps 212. The straps 210, 212 have a U-shape. The first straps 210 have a vertically downward opening 211. The second straps 212 have a vertically upward opening. The straps 210, 212 enclose the core of the concrete component 1, 1′. A respective first strap 210 and a respective second strap 212 are arranged at a substantially equal position of the concrete component 1, 1′. The legs of the straps 210, 212 overlap at substantially the same position. The structural member shown in FIG. 10 preferably comprises one or more of the further reinforcements described in the foregoing.

[0088] FIG. 11 shows a schematic method for manufacturing a reinforced concrete component 1, 1′. In step 300, a first concrete layer 20 and a second concrete layer 22 are produced using a generative process, preferably a shotcrete process, in particular a shotcrete process.

[0089] In step 302, a positioning member 100, 102, 104, 110, 120, 122, 124, 126, 128, 130 is arranged for fixing a reinforcement unit 200, wherein the positioning member 100, 102, 104, 110, 120, 122, 124, 126, 128, 130 is arranged with a supporting section 106 between the first concrete layer 20 and the second concrete layer 22 and protrudes from the first concrete layer 20 and from the second concrete layer 22 with a fastening section 108. In particular, it is preferred that the step 302 occurs between the creation of the first concrete layer 20 and the creation of the second concrete layer 22.

[0090] In step 304, at least one reinforcement unit 200 for reinforcing the concrete component 1, 1′ is arranged on the positioning element 100, 102, 104, 110, 120, 122, 124, 126, 128, 130.

[0091] In step 306, a concrete cover layer 24 is created at the first concrete layer 20 and the second concrete layer 22 such that the reinforcement unit 200 is substantially covered with concrete.

[0092] Preferably, step 304 comprises substeps 3041, 3042 shown in FIG. 12. In step 3041, a vertical reinforcement element 150-166 having a coupling section 152, 156 is arranged on the positioning element. In step 3042, a horizontal reinforcement element 180, 182, 184, 186 is arranged on the positioning element 100, 102, 104, 110, 120, 122, 124, 126, 128, 130. In particular, it is preferred that step 3041 is performed before step 3042 so that the vertical reinforcement elements 150-166 are clamped between the concrete layers 20, 22 and the horizontal reinforcement elements 180, 182, 184, 186 so that a prestressed reinforcement unit 200 is formed.

[0093] FIG. 13 shows a preferred embodiment of the method shown in FIG. 11. In particular, in step 308, a composite layer is applied to the first concrete layer 20 and the second concrete layer 22 in such a way that the reinforcement unit 200 is positioned at least in sections by means of the composite layer. This positioning is to be understood in particular relative to the concrete layers 20, 22. The composite layer is preferably created, in particular applied, before the concrete cover layer 24 is created.

[0094] In step 310, a horizontal reinforcement element 180-186 and/or a vertical reinforcement element 150-166 is preformed to match the contour, so that these preferably correspond to a concrete component contour. In particular, step 310 is performed before step 304, preferably before step 300.

REFERENCE SIGNS

[0095] 1, 1′ Concrete component [0096] 2 bottom side [0097] 4 top side [0098] 6 first front side [0099] 8 second front side [0100] 10 side surface [0101] 14 corner [0102] 16 first side [0103] 18 second side [0104] 20 first concrete layer [0105] 22 second concrete layer [0106] 24 concrete cover layer [0107] 100 first positioning element [0108] 102 second positioning element [0109] 104 third positioning element [0110] 106 supporting section [0111] 108 fastening section [0112] 110 fourth positioning element [0113] 112 shotcrete nozzle [0114] 114 sprayed concrete [0115] 116 handling tool [0116] 120 fifth positioning element [0117] 122 sixth positioning element [0118] 124 seventh positioning element [0119] 126 eighth positioning element [0120] 128 ninth positioning element [0121] 130 tenth positioning element [0122] 132 eleventh positioning element [0123] 150 first vertical reinforcement element [0124] 152 first coupling section [0125] 154 second vertical reinforcement element [0126] 156 second coupling section [0127] 158 third vertical reinforcement element [0128] 160 fourth vertical reinforcement element [0129] 162 fifth vertical reinforcement element [0130] 164 sixth vertical reinforcement element [0131] 166 seventh vertical reinforcement element [0132] 180 first horizontal reinforcement element [0133] 182 second horizontal reinforcement element [0134] 184 third horizontal reinforcement element [0135] 186 fourth horizontal reinforcement element [0136] 200 reinforcement unit [0137] 202 vertical reinforcement strut [0138] 204 horizontal reinforcement strut [0139] 206 corner reinforcement element [0140] 208 strap reinforcement [0141] 210 first strap [0142] 211 opening [0143] 212 second strap