Method and device for producing a concrete component, and concrete component produced according to the method

Abstract

The subject matter of the invention is a method for producing a concrete component (1), wherein a plurality of layers of a dry mixture consisting of at least one silicate former and one hydraulic binder are deposited one atop another on a base (7), wherein after applying each layer the respective layer is mixed with water, wherein the contour of the area that is mixed with water correlates with the desired shape of the concrete component (1) at the level of the respective layer to be applied.

Claims

1. A method for manufacturing a reinforced concrete component, comprising: depositing a plurality of layers of a dry mixture above one another on a base, the dry mixture including at least one silicate former and a hydraulic binder; after application of each layer of the dry mixture, mixing at least a portion of the respective layer with water, the portion of the respective layer that is mixed with water is a contour correlated to a desired shape of a concrete component, the concrete component having one or more recesses; introducing a liquid or paste-like hardenable mass into the one or more recesses, the liquid or paste-like hardenable mass being a plastic or a metal; and hardening the liquid or paste-like hardenable mass into a hardened state, the mass in the hardened state protruding from the one or more recesses and forming a reinforcement of the reinforced concrete component.

2. A method in accordance with claim 1, wherein the plurality of layers are applied onto each other in determined time intervals, the time intervals depending on the progress of the setting process of a respective lower layer.

3. A method in accordance with claim 1, wherein the layers have a thickness in the range of 0.05 to 5 mm.

4. A method in accordance with claim 3, wherein the layers have a thickness of 0.1 mm.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1 is a perspective view of a concrete component of the type according to the invention;

(2) FIG. 2 is a top view of the concrete component according to FIG. 1;

(3) FIG. 2a is a cross sectional view of the hollow space the concrete part taken along line IIa/IIa in FIG. 1;

(4) FIG. 2b shows a view from above onto a concrete component with a mass in a hardened state protruding from a recess.

(5) FIG. 3 is a perspective view of a device for manufacturing a concrete component; and

(6) FIG. 4 is a lateral view of FIG. 3;

DETAILED DESCRIPTION OF THE INVENTION

(7) In accordance with the representation of FIG. 1, the concrete component is labeled 1. The concrete component 1 shows three superimposed recesses 2 that serve to receive a reinforcement. One recess extends in three spatial directions in order to show the possibilities offered by the method according to the invention.

(8) FIG. 2 and FIG. 2a show the structure in the area of the top and middle recess 2, which runs obliquely in the concrete component. The individual layers 5 of the concrete component in the area of the recess 2 are visibly configured in such a manner that they are discontinued stepwise toward the outside, and then converge again toward the top after reaching the lateral apex of the approximately circular recess. As has already been explained, manufacture of the recess 2 occurs by depositing the individual layers of the dry mixture above one another. The layers are only wetted with water in those places where the layer must set in order to form the concrete component. In this respect, layers of the dry mixture are also located in the hollow space to be formed, the layers above the horizontal apex of a substantially circular recess being supported by the underlying layers that have not been sprayed with water. The dry mixture in the recess that has not set trickles out of the recess when the component is picked up from the base or is blown out.

(9) The device according to FIG. 3 is characterized by a discharge head 10 that is displaceable in three spatial directions and is configured as a discharge channel and is disposed on a crossbeam 21. The crossbeam 21 is held by two supports 22, which are displaceable on rails 23 in the direction of the arrow 25. The crossbeam 21 is held by the supports 22 so that it is vertically movable (arrow 35). Together with the rails 23 and the supports 22, the crossbeam 21 forms the frame 20. Another discharge head 27 configured as a spray head, which serves to discharge water, is located on the discharge head 10.

(10) The discharge channel is disposed on the crossbeam so that it is movable in the direction of the arrow 30 and the discharge head 27 is configured as a spray head and is attached to the discharge channel. The channel and head are therefore displaceable in three spatial directions.

(11) On its bottom side, the discharge head 10 configured as a discharge channel comprises a slot-like discharge opening 11 for the mixture of the hydraulic binder and the silicate former, e.g. sand. The spray head serves for sharply contoured spraying of water.

(12) The procedure for manufacturing a structured concrete component can be described as follows: first a layer of the mixture of the hydraulic binder and the silicate former is applied onto the base 7 by the discharge head 10 configured as a discharge channel. In a top view, the layer has for example a rectangular shape. The layer is then sprayed with water in accordance with the desired contour. Once the layer has set or at least partially set to the extent that it has become stiff, a layer of the dry mixture is again applied onto the first layer in a rectangular shape. This layer is then also sprayed with water in accordance with the desired contour of that layer. The entire procedure is continued on a layer-by-layer basis until the body of the concrete part is completed. The concrete part is then lifted off the base. The non-set mixture detaches itself from the concrete part or concrete body; hollow spaces in the concrete part can be emptied with pressurized air.

(13) As shown in FIG. 2b, a hardenable mass 9 can be introduced into the hollow spaces 2, which is able to absorb tensile forces once it has hardened. The hardened mass can be for example a plastic, for example a synthetic resin.