Method and facility for cutting concrete product

Abstract

Method and facility or apparatus for cutting a slipform cast hollow-core concrete product with water jet cutting, wherein in the outer surface of the fresh cast hollow-core concrete product is formed depressions or grooves in the areas to be cut with water jet cutting before curing of the hollow-core concrete product, which depressions or grooves extend in the area of the hollow-cores of the concrete product.

Claims

1. A method for cutting a slipform cast hollow-core concrete product with water jet cutting, wherein the hollow-core concrete product comprises an upper surface, a lower surface, two side surfaces and multiple hollow-cores and wherein the side surfaces and the hollow-cores are laterally arranged in between the upper surface and the lower surface, the method comprises the steps: forming depressions, or grooves, or both, in the upper surface of the fresh cast hollow-core concrete product before curing of the hollow-core concrete product in one or more areas to be cut with water jet cutting, which depressions or grooves extend to at least some of the hollow-cores of the concrete product, wherein the forming of depressions, or grooves, or both is implemented at a casting place, curing the hollow-core concrete product, and transferring the cured hollow-core concrete product from the casting place to a separate workstation for the water jet cutting.

2. The method according to claim 1, wherein the formed depressions, or grooves, or both, in the concrete hollow-core product are large enough to contain the nozzle of a water jet cutting device.

3. The method according to claim 1, wherein the water jet cutting is implemented from the opposite side of the hollow-core concrete product from the side where the forming of the depressions, or grooves, or both has occurred.

4. An apparatus for cutting a slipform cast hollow-core concrete product with water jet cutting, which facility comprises: one or more devices for slipform casting a hollow-core concrete product, wherein the hollow-core concrete product comprises an upper surface, a lower surface, two side surfaces and multiple hollow-cores and wherein the sides surfaces and the hollow-cores are laterally arranged in between the upper surface and the lower surface, a water jet cutting device, a device for forming depressions and grooves in the upper surface of a fresh cast hollow-core concrete product before curing of the hollow-core concrete product in one or more areas to be cut with water jet cutting, wherein said depressions and grooves extend to at least some of the hollow-cores of the concrete product; and further comprising a separate workstation for water jet cutting of a cured hollow-core concrete product.

5. The apparatus according to claim 4, wherein the device for forming depressions and grooves comprises a movable rotary elongate milling tool for milling the surface of the fresh cast hollow-core concrete product.

6. The apparatus according to claim 4, further comprising devices for transferring the cured hollow-core concrete product to the separate workstation for water jet cutting.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Exemplifying embodiments of the invention and its various advantages are explained in greater detail below in the sense of example and with reference to accompanying drawings, where

(2) FIG. 1 shows schematically a layout of a manufacturing facility according to an embodiment of the invention,

(3) FIGS. 2A, 2B, and 2C show schematically an embodiment of the phases of the invention for creating a lead-through in a hollow-core concrete product as cross-sectional views, and

(4) FIGS. 3A, 3B, and 3C show schematically an embodiment of the phases of the invention for cutting a hollow-core concrete product as side views.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

(5) The manufacturing facility 1 for casting and cutting slipform cast hollow-core concrete products shown in FIG. 1 comprises a plurality of slipform casting beds 2, a plurality of transfer beds 3 for moving cut hollow-core concrete products to a storage area, a storage area 4, bridge cranes 5, 6, 7 for lifting and transferring cast concrete products and casting equipment, and water jet cutting station 8.

(6) In the embodiment of FIG. 1, the slipform cast hollow-core concrete products are first cast as continuous slipform casting on the casting bed 2. After the casting, or during the casting process, depressions and/or grooves are formed on the top surface of the hollow-core concrete product at the predefined locations where lead-throughs or parts need to be cut away, or where other cuttings needs to be made.

(7) The depressions and/or grooves are formed on the top surface of the fresh cast concrete product preferably with a separate slab processing machine moving on the same rails as the slipform casting machine. The slab processing machine preferably comprises a movable rotary elongate milling tool for forming the depressions and/or grooves to the fresh concrete product.

(8) After the casting process and the formation of the depressions and/or grooves is done, the cast continuous hollow-core concrete product is left to cure on the casting bed 2. After curing, the continuous hollow-core concrete product is cut to predefined lengths with suitable machinery, such as a diamond bladed saw, on the casting bed 2, and the cut concrete products are transferred to the water jet cutting station 8 with bridge cranes 5 and 6.

(9) In the water jet cutting station 8, the required lead-throughs and other cuttings are carried out with a water jet cutting device, in the areas of the formed depressions and grooves. The water jet cutting can be carried out to the hollow-core concrete product from the same side as the formation of the grooves and depressions, or the hollow-core concrete product can be turned around so that the water jet cutting is carried out from opposite side of the concrete product.

(10) Once the required water jet cuttings are done, the ready hollow-core product is lifted on to transfer beds 3 and moved to a storage area 4.

(11) FIGS. 2A-2B show schematically an embodiment of the phases of the invention for creating a lead-through in a hollow-core concrete product 21 as cross-sectional views.

(12) FIG. 2A shows a cross-section of the fresh slipform cast hollow-core concrete product 21 comprising cavities 22 and reinforcing wires 23.

(13) After the slipform cast hollow-core concrete product 21 is cast, at the upper surface of the concrete product is formed transverse grooves 24 and longitudinal grooves 25, 25, which grooves restrict a rectangular area within the concrete product, as shown in FIG. 2B. The grooves 24, 25, 25 extend at least in the area where the cavities 22 are located, and preferable even deeper, but still above the reinforcing wires 23.

(14) The width of the grooves 24, 25, 25 is such, that a nozzle of a water jet cutting device can be placed within the grooves.

(15) Once the hollow-core concrete product 21 is cured, the area of the concrete product defined by the grooves 24, 25, 25 is cut from the concrete product with water jet cutting. The final hollow-core concrete product after water jet cutting is shown in FIG. 2C.

(16) The water jet is strong enough to cut through the concrete as well as the reinforcing wires 23, but the cutting speed needs generally be slowed down for cutting of the reinforcing wires.

(17) FIGS. 3A-3C show schematically an embodiment of the phases of the present invention for cutting a hollow-core concrete product 21 as side views.

(18) In the fresh cast hollow-core concrete product 21 (FIG. 3A) is first milled a transverse groove 24 from the top surface of the product (FIG. 3B), and once the concrete product has cured, the rest of the concrete product is cut with a water jet cutting (FIG. 3C).

(19) Since the groove 24 is wide enough for inserting the nozzle of the water jet cutting device in the groove, the water jet cutting may be carried out either through the groove 24 or from opposite side of the concrete product at the location of the groove.

(20) The specific exemplifying embodiments of the invention shown in figures and discussed above should not be construed as limiting. A person skilled in the art can amend and modify the embodiments in many evident ways within the scope of the attached claims. Thus the invention is not limited merely to the embodiments described above.