Method for producing a concrete component, prefabricated structural element of a concrete component, and concrete component

Abstract

The present invention relates to a method of producing a concrete component (15), to a prefabricated structural element (3), which serves as a semi-finished product for the production of the concrete component (15) made in this way, and to a corresponding concrete component (15). The method claimed involves the following steps: producing a prefabricated structural element (3) comprising first reinforcement structures (18), which feature textile reinforcement structures, and first thermal insulation elements (6), pouring concrete into a shell mold (13) to form a first concrete layer (11), lowering the prefabricated structural element (3) onto the first concrete layer (11).

Claims

1. A method of producing a concrete component, the method comprising: producing a prefabricated structural element (3), including: bending a generally flat textile grid into a non-flat orientation with a first portion of the textile grid extending transversely to a second portion thereof; joining the first portion of the bent textile grid with a generally flat grid to form a first reinforcement structure (18), and introducing a first thermal insulation element (6) to the first reinforcement structure, pouring concrete into a shell mould (13) to form a first concrete layer (11), lowering the prefabricated structural element (3) onto the first concrete layer (11), orienting the prefabricated structural element such that the generally flat grid and the first portion of the bent textile grid is embedded within the first concrete layer.

2. The method according to claim 1, further comprising applying a second concrete layer (14) onto the prefabricated structural element (3).

3. The method according to claim 2, wherein bending the generally flat textile grid into the non-flat orientation comprises bending the textile grid into a U-shaped configuration having a recess between the first portion, second portion, and a third portion of the textile grid that extends generally parallel to one of the first and second portions thereof and transversely to another of the first and second portions; the method further comprising during production of the prefabricated structural element (3), introducing the first insulation element (6) into the recess (8) in the first textile reinforcement structure (18), which at least partially embraces the first insulation element therein.

4. The method according to claim 3, wherein the first insulation element comprises a panel-shaped portion, further comprising introducing the panel-shaped portion of the first insulation element (6) into the recess of the first textile reinforcement structure.

5. The method according to claim 1, further comprising during production of the prefabricated structural element (3), introducing the first thermal insulation element (6), in a liquid or foam form, into an area of the first reinforcement structure (18).

6. The method according to claim 5, further comprising equipping the prefabricated structural element (3) with connectors (19), which (19) are already part of the first reinforcement structure (18), or are firmly connected to the first reinforcement structure (18), at a time at which the liquid or foam is introduced into the area of the first reinforcement structure (18), and which (19) extend beyond the area which becomes filled with the foam or liquid, and which (19) extend into a layer (16) of soft, powdered and/or viscous moulding material while the foam or liquid is curing.

7. The method according to claim 1, further comprising forming at least the first concrete layer (11) in a shell mould (13) and that, on being lowered onto the first concrete layer (11), the prefabricated structural element (3) fits into the shell mould.

8. A prefabricated structural element for a concrete component, the element comprising: first reinforcement structures (18), which feature a generally flat grid and three-dimensional textile reinforcement structures connected thereto, wherein individual ones of the textile reinforcement structures include a unitary textile grid that is formed into a U-shape via bending, wherein a first portion of the textile grid is connected to the generally flat grid and both the first portion of the textile grid and the generally flat grid are configured to be embedded in a first layer of concrete, a second portion of the textile grid connected to the first portion that extends generally orthogonally from the first portion, and a third portion of the textile grid connected to the second portion that extends generally orthogonally from the second portion, the third portion configured to be embedded in a second layer of concrete, and first thermal insulation elements (6), wherein individual ones of the first thermal insulation elements are disposed between individual ones of the textile reinforcement structures with a portion of the individual ones of the first thermal insulation elements disposed within a void formed by one of the adjacent U-shaped textile reinforcement structures.

9. The prefabricated structural element according to claim 8, further comprising connectors (19), which (19) are part of the first reinforcement structures (18) or are connected firmly to the first reinforcement structures (18), which (19) extend beyond the first insulation elements (6), and which (19) are configured to connect to second reinforcement structures (12) and/or be permanently embedded in a concrete matrix.

10. The prefabricated structural element according to claim 8, wherein the structural element is panel-shaped, such that a length (l) and breadth (b) of the structural element is a multiple of the structural element's depth (t).

11. The prefabricated structural element according to claim 10, wherein the first reinforcement structures (18) and the first insulation elements (6) fill a majority of the prefabricated structural element (3).

12. The prefabricated structural element according to claim 8, wherein the insulation elements (6) define a plane that is not pierced by a metal or concrete material.

13. The prefabricated structural element according to claim 8, wherein the first thermal insulation elements (6) comprise foam insulation materials.

14. A concrete component comprising a prefabricated structural element (3) comprising: first reinforcement structures (18), which feature a generally flat grid and three-dimensional textile reinforcement structures connected thereto, wherein individual ones of the textile reinforcement structures include a unitary textile grid that is formed into a U-shape via bending, wherein the generally flat grid and a first portion of the textile grid is embedded in a first layer of concrete, a second portion of the textile grid connected to the first portion extends generally orthogonally from the first portion, and a third portion of the textile grid connected to the second portion extends generally orthogonally from the second portion, the third portion embedded in a second layer of concrete, such that each unitary U-shaped textile grid is firmly embedded in both first and second layers of concrete; and first thermal insulation elements (6), wherein a portion of individual ones of the first thermal insulation elements are disposed within individual ones of the U-shaped textile reinforcement structures.

15. A method of producing a prefabricated structural element for use in forming a concrete component, the method comprising: bending a generally flat first textile grid into a U-shaped configuration with a first portion of the first textile grid extending transversely to a second portion thereof and a third portion that extends generally parallel to the first portion to form at least a portion of a first textile reinforcement structure having a void between the first, second, and third portions; introducing at least a portion of a first insulation element into the void of the first textile reinforcement structure.

16. The method according to claim 15, wherein the first insulation element is a solid panel-shaped element and introducing the first insulation element into the void includes inserting an end of the first insulation element into the void.

17. The method according to claim 15, further comprising introducing the first thermal insulation element in a liquid or foam form into the void of the first textile reinforcement structure.

18. The method according to claim 15, further comprising bending a generally flat second textile grid into a non-flat orientation with a first portion of the second textile grid extending transversely to a second portion thereof; joining the second textile grid with the first textile grid to form the first textile reinforcement structure.

19. The method according to claim 18, wherein joining the second textile grid with the first textile grid includes joining the second portion of the first textile grid to the second portion of the second textile grid such that the respective first portions of the first and second textile grids extend generally along the same reference plane.

20. The method according to claim 15, further comprising joining the first textile reinforcement structure to a generally flat grid.

21. The method according to claim 15, further comprising bending a generally flat third textile grid into a U-shaped configuration with a first portion of the third textile grid extending transversely to a second portion thereof and a third portion that extends generally parallel to the first portion to form at least a portion of a second textile reinforcement structure having a void between the first, second, and third portions; joining the first and second textile reinforcement structures to a generally flat fourth textile grid at spaced apart locations, introducing the first insulation element into the void of the first textile reinforcement structure and between the first and second textile reinforcement structures.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a side view of a prefabricated structural element in the process of being assembled.

(2) FIG. 2 shows a top view of the prefabricated structural element of FIG. 1.

(3) FIG. 3 shows a side view of the prefabricated structural element of FIG. 1, to which first thermal insulation elements have just been added.

(4) FIG. 4 shows a modification of the prefabricated structural element of FIG. 3 from the side.

(5) FIG. 5 shows a development of the prefabricated structural element of FIG. 4 from the side.

(6) FIG. 6 shows a first concrete layer in a shell mould.

(7) FIG. 7 shows the prefabricated structural element of FIG. 5 in a shell mould and with a first and a second concrete layer.

(8) FIG. 8 shows a production stage of another prefabricated structural element.

(9) FIG. 9 shows the finished prefabricated structural element of FIG. 8 as part of a concrete component.

(10) FIG. 10 is an exploded diagram showing the parts of a spacer of the kind depicted in FIGS. 1 to 7.

(11) FIG. 11 shows a development of the concrete component of FIG. 9.

(12) FIG. 12 shows a further embodiment of a concrete component.

DETAILED DESCRIPTION

(13) FIG. 1 shows a textile grid 1 lying flat on the floor, with a spacer 2 placed upon it. For purposes of assembling the prefabricated structural element 3, the spacer may be fixed in place on the textile grid 1 with a suitable adhesive. The spacer may be configured as a three-dimensional textile grid structure. In this case it may be produced by bending textile grids. For example, two U-shaped grid constituents 4 and 5 may be formed and assembled to create a T-shaped entity (FIG. 10). The bond between the two grid constituents 4 and 5 may also be created with an adhesive. It remains to be mentioned that the drawings show the radii at the connection between the legs 7 of the spacer 2 and its transverse connection 21 to be very small. As a rule, these radii will be considerably larger.

(14) In FIG. 1, the textile grid 1 and the spacer 2 already constitute part of the first reinforcement structures 18.

(15) FIG. 2 shows a top view of the same structural element 3 at the same production stage. The hatching indicates that the fibre strands of the textile grid 1 are oriented at 90 and 180, respectively, relative to the edges of the textile grid 1. The orientation of the fibre strands of which the spacer 2 consists has been rotated by 45 relative to that of the fibre strands of the textile grid 1, which has advantages. However, depending on the case in question, other angles, such as 0 or 30, are also possible.

(16) FIG. 3 shows a somewhat more advanced production stage of the same structural element 3. The insulation elements 6 have already been inserted into the structural element. It becomes clear from FIGS. 3 and 10 that the spacer 2 and its constituents have several functions:

(17) The legs 7 of the spacer 2 embrace the ends of the insulation elements 6, which are panel-shaped. The legs 7 thus define the recesses 8, into which the insulation elements 6 are inserted.

(18) The prefabricated structural element 3 in FIG. 4 contains, in addition to the features shown in FIG. 3, distance-keeping elements 9. These ensure that a space is maintained between the insulation elements 6 and the legs 7 of the spacer 2. The distance element 10 maintains the distance between the textile grid 1 and the insulation element 6. The point of this measure becomes clear from FIG. 7:

(19) The textile grid and the legs 7 of the spacer 2 reach deep into the concrete matrix of the first concrete layer 11, so that here, the leg 7 also serves as a connector 19 as defined in this publication.

(20) The assembly of the prefabricated structural element 3 in FIG. 5 corresponds in the first instance with what has already been said in connection with FIG. 4, with the upper spacers 9 defining a somewhat greater distance than do the corresponding spacers 9 in FIG. 4. In FIG. 5, however, another, second reinforcement structure 12 is already visible, which has been added. In the embodiment of FIG. 5, this reinforcement structure consists of metal. It may be added in the customary manner to the prefabricated structural element, which is delivered free of metal, in a precast concrete works or at a construction site. Binding wire, for example, may be used for this purpose.

(21) FIG. 6 shows a shell mould 13 containing a first concrete layer 11. A prefabricated structural element 3 may be lowered into a shell mould 13 of this kind. It is to advantage if the precision with which a prefabricated structural element 3 fits into the shell mould 13 is within the tolerances customary in the branch (meant here, in particular, are the tolerances in the l/b plane).

(22) FIG. 7 shows a situation in which the prefabricated structural element of FIG. 5 has been lowered into the shell mould of FIG. 6, which already contained a first concrete layer 11. FIG. 7 also shows that a second concrete layer 14 has been poured on top of the prefabricated structural element. This second concrete layer is reinforced by the second reinforcement structure 12. Once the concrete layers 11 and 14 have set and hardened, a finished concrete component 15 may be removed from the shell mould 13.

(23) FIG. 8 shows a production stage of another prefabricated structural element 3 featuring three-dimensional textile reinforcement structures which, in FIG. 8, have a sinusoidal cross section. Reinforcement structures of this kind, too, may be obtained by subjecting textile grids, like the textile grid 1, to a forming process. Particularly in the case of complex textile structures of the kind shown, it is to advantage if insulation elements 6 are combined in the viscous state with the first reinforcing members. The layer of moulding material 16 is shown at the lower edge of FIG. 8. A layer of this kind may consist of sand, for example, or of a heavy medium. The first reinforcement structures 18 have, as mentioned, a sinusoidal cross section. The layer of moulding material 16 has been covered with viscous insulation material 17, which cures with time to form first insulation elements 6. As a rule, the layer of moulding material 16 may be used to produce a plurality of prefabricated structural elements 3. If the layer of moulding material 16 consists of a granular or powdered material, the surface of the layer may be smoothened before a new prefabricated structural element 3 is processed further with the same layer of moulding material. The new prefabricated structural element 3 is then pressed into the mould layer 16 in such manner that a portion of the connecting members 19 dip into this layer 16, preventing them from being surrounded by viscous insulation material 17.

(24) If a heavy liquidon which a preferably foam-like layer of viscous insulation material floatsis used as the layer of moulding material 16, active smoothing of the surface of the layer 16 is likely to be superfluous.

(25) FIG. 9 shows a prefabricated structural element 3 that was produced in the described manner. The first thermal insulation elements 6 have already cured. The first and second concrete layers 11, 14 are already in place, so that one can speak of a concrete componenthere a sandwich component.

(26) Yet to be mentioned is the horizontal reinforcing member 20 shown in FIGS. 8 and 9, which improves the anchorage of the first reinforcement structures 18 in the second concrete layer 14.

(27) It is generally to advantage if the insulation elements (6) in prefabricated structural elements (15) are not penetrated by materials that conduct heat well, such as metal or concrete.

(28) The drawings described above show panel-shaped prefabricated structural elements 3 and concrete components 15, which, in turn, contain predominantly panel-shaped insulation elements (6). Panel-shaped in this connection means that the depth t of these bodies is substantially less than their length l or breadth b. Particularly in the case of components 15 of such kind, it is to advantage if the insulation elements define a plane (here in the l and b directions), which is not penetrated by materials that conduct heat well.

(29) It is also to advantage if concrete components 15 feature a plurality of grid-like reinforcement structures (some of them made of arbitrarily selected material), which run in the l and b directions.

(30) FIG. 11 shows a concrete component based on FIG. 9. In addition to the features of the concrete component 15 shown there, FIG. 11 shows cross-sectional surfaces of the transverse rods 22, which are secured in form-locking manner in the first reinforcement structures 18. The transverse rods, too, substantially improve the anchorage of the first reinforcement structures 18 and of the entire prefabricated structural element 3 in the first concrete layer 11. The transverse rods may be made of metal or of a textile reinforcing material.

(31) FIG. 12 shows an embodiment of a further structural element 3. This structural element has two relatively thin concrete layers 11 and 14, which are advantageously configured such as to be of approximately equal thickness. Both concrete layers may be made of fair-faced concrete and thus serve, for instance, as exposed walls, e.g. in garage construction.

(32) With some of the concrete components 15 shown, it is to advantage to remove the component 15 from the shell mould 13 after the first concrete layer 11 has set and to turn it over. The second concrete layer 14 can then be poured in the same or another shell mould 13. This is done in a manner analogous to the production of the first concrete layer 11, with the second concrete layer 14 being formed in the shell mould 13 and the rest of the later component lowered onto the second concrete layer.

(33) In connection with the insulation materials already mentioned above, it must be added that their mechanical properties may also play a major role. In the case of suitable expanded materials, a distinction is often made between flexible and rigid foams.

(34) Among the problems of processing textile reinforcing materials is the fact that the reinforcement structures are unsuitable for walking on. However, particularly through use of rigid insulation materialssuch as rigid foamas a constituent of the prefabricated structural elements 3, it is possible to create zones, at least, that can be walked on before the concrete layers concerned have set and hardened.

(35) As already mentioned earlier, the first reinforcement structures 18 contain textile reinforcement structures. In all of the embodiments of the invention, it has proved additionally advantageous to also provide the reinforcements of the concrete layersthat is, maybe that of the first 11 and/or of the second concrete layer 14with textile reinforcement structures. This may be undertaken to such an extent as to render one, or even both, of these concrete layers 11 and 14 free of steel. The entire concrete component may then, if desired, be configured free of steel and free of metal constituents.

(36) Use of the aforementioned measures is particularly advantageous in connection with the last embodiment of a concrete component and its production, which were explained against the background of FIG. 12.

(37) TABLE-US-00001 List of reference numerals 1 Textile grid 2 Spacer 3 Structural element 4 U-shaped grid constituent 5 U-shaped grid constituent 6 Insulation elements 7 Leg (of the spacer 2) 8 Recess (in the spacer 2) 9 Distance element 10 Distance element 11 First concrete layer 12 Second reinforcement structure 13 Shell mould 14 Second concrete layer 15 Concrete component 16 Layer of moulding material 17 Viscous insulation material 18 First reinforcement structures 19 Connectors 20 Horizontal reinforcing member 21 Transverse connection 21 of the spacer 2 22 Transverse rod