Sealing system for openings in molds or formwork for the production of prestressed concrete components reinforced with textile structures

Abstract

In the sealing system, which can be used at openings in molds or formwork for the production of textile structures formed with textile fibers, in particular carbon fiber reinforced prestressed concrete components, textile fibers (8) of a textile structure (10), which are oriented in the direction of a tensile force that acts on these textile fibers (8) during production, can be guided in at least one plane within the mold (1) or the formwork through an opening (3).Each sealing plate (5) is supported on the wall of the mold (1) or the formwork next to an opening (3) formed therein and can be arranged in a plane vertically above and below the plane in which the textile fibers (8) of a textile structure (10), on which a tensile force acts, are such that in the area of ​​the textile fibers (8) on which the tensile force acts, end faces of the corresponding sealing plates (5) are in contact with each other and with the textile fibers (8) on which the tensile force acts, and a sealing effect can be achieved.

Description

[0001] The invention relates to a sealing system for openings in mold tools or formwork for the production of prestressed concrete components which are reinforced with textile structures made of textile fibers, in particular those made of carbon fibers.

[0002] In recent years, concrete components reinforced with textile structures instead of steel reinforcement have become increasingly prevalent. These components require significantly less concrete and therefore avoid large quantities of CO2 released during concrete production.

[0003] Concrete components reinforced with textiles require different manufacturing measures because the textiles have different properties compared to the previously used steel bars. In particular, their flexible deformability, even when used as reinforcement in the form of textiles, must be taken into account. Textiles are also considerably more susceptible to mechanical damage than steel bars, so precautions must be taken to ensure that the textiles are not adversely affected during the manufacturing process and beyond.

[0004] Especially with concrete components reinforced with textile structures, it has been shown that their performance characteristics can be significantly improved if they are prestressed during manufacturing. Textile reinforcements are subjected to tensile force, similar to conventional steel elements, before or while they are encased in concrete. These tensile forces must be maintained until the concrete has sufficiently hardened. To achieve these effects, methods must be available to apply the necessary tensile forces to the reinforcement during production.

[0005] Reinforcement is typically inserted into a forming tool or surrounded by formwork. To exert tensile force on the reinforcement, suitable devices must be present outside the respective forming tool or formwork. The reinforcement must extend beyond the forming tool or formwork, for which purpose openings are provided in suitable forming tools or formwork through which at least one corresponding reinforcement made of textile structures is guided. Anchor elements attached to the textile structures outside the forming tool or formwork can then be used to apply the desired tensile force.

[0006] For many concrete components, it is necessary to use reinforcements formed with several textile structures, which in turn are arranged in several levels above each other and at intervals to achieve sufficient strength of the concrete component to be manufactured.

[0007] It is obvious that the openings in the wall of a mold or formwork must be sealed, at least during the concrete pouring process until sufficient hardening is achieved. With conventional steel reinforcement, this could easily be accomplished by means of simple openings through which the steel bars could be inserted.

[0008] However, reinforcements formed with textile structures are susceptible to damage that can negatively impact the strength of the finished concrete component. It is also problematic that, at least until sufficiently large tensile forces are exerted, the textile structures used to form the reinforcement are mechanically quite fragile, meaning that conventionally designed sealing systems, such as those commonly used with steel, cannot be used without drawbacks.

[0009] For cost-effective production, larger production volumes are also beneficial, which necessitate frequent assembly and disassembly of seals when a finished component has been demolded and preparations are made for the production of a new concrete component. A suitable seal should therefore be simple in design and easy to handle.

[0010] The invention therefore aims to demonstrate ways in which improved sealing can be achieved in the production of prestressed concrete components reinforced with textile structures, while simultaneously requiring moderate assembly effort.

[0011] According to the invention, this problem is solved with a sealing system having the features of claim 1. Advantageous embodiments and further developments of the invention can be realized with features specified in dependent claims.

[0012] Suitable molds or formworks have openings in their walls, usually on two diametrically opposed sides. At least one textile structure is placed in the mold or formwork so that the interior is filled and an outer edge protrudes through the opening. Tensile forces can act and exert their prestressing force in these protruding areas.

[0013] Typically, a textile structure is arranged in a plane, preferably horizontally oriented. When the respective mold or formwork is filled with fresh, uncured concrete, one, or usually several, textile structures arranged in different, superimposed planes are encased in concrete, so that all textile structures within the mold or formwork are embedded in the concrete. During this time, tensile forces act on the textile fibers oriented in the same direction, which then act upon the textile structure(s).

[0014] Textile fibers of a textile structure, which are aligned in the direction of a tensile force acting on these textile fibers during manufacturing, are guided in at least one plane within the mold or formwork and through an opening to the outside.

[0015] Each sealing plate is supported against the wall of the mold or formwork next to an opening formed within it. It is arranged vertically in a plane above and below the plane in which the textile structures subjected to tensile force are positioned such that, in the area of ​​the textile fibers subjected to the tensile force, the end faces of the corresponding sealing plates are in contact with each other and with the textile fibers subjected to the tensile force. This creates a sealing effect that prevents a significant quantity of concrete from escaping from a mold or formwork before it has hardened sufficiently to prevent escape.

[0016] As previously mentioned, several textile structures are typically arranged in a mold or formwork on multiple levels and at intervals. In these cases, a sealing plate is placed between each pair of textile structures. It can be inserted from a free end face until it provides support against the wall of the mold or formwork next to the opening. When inserting the sealing plate into the gap between two textile structures that form the reinforcement of a concrete component, it can be rotated so that it is oriented at an oblique angle to the plane in which the nearest textile structure is located. This significantly facilitates insertion.

[0017] When inserting a sealing plate, if the wall of the mold or formwork is reached and it is possible to support it, the corresponding sealing plate is then rotated so that it is aligned parallel to the wall of the mold or formwork and perpendicular to the acting tensile force, thus providing the largest possible sealing surface.

[0018] In a sealing system according to the invention, at least two sealing plates are provided, which are aligned on a wall of a mold or formwork, one above and one below a textile structure, perpendicular to the plane in which the textile structure is arranged. If several textile structures are provided in several planes in a concrete component, one sealing plate should be able to be arranged above and one sealing plate below each textile structure, in contact with the textile fibers on which tensile forces act.

[0019] The sealing plates should make contact with their respective end faces over as large an area as possible, so that the greatest possible sealing effect can be achieved solely through this means.

[0020] The installation of the sealing panels in relation to the respective wall and the textile structure(s) can be automated, which, in addition to the multiple reusability of sealing panels, can also have a positive impact on costs.

[0021] The sealing plates should preferably be made of a plastically or at least partially elastically deformable material. In addition, or alone, depressions can be formed in the end faces that can be brought into contact with the textile fibers on which the tensile force acts; the cross-sectional area of ​​these depressions should be at least nearly complementary to the outer dimensions of the textile structures on which the tensile force acts.

[0022] Textile structures can be enclosed by recesses between two adjacent sealing plates.

[0023] Textile structures, in their simplest form, can be bundles of parallel textile fibers. These bundles of fibers in a single plane do not necessarily need to be connected. However, textile structures can also be advantageously woven or knitted fabrics, in which a large number of fibers are aligned parallel to each other and in the same direction, for example, as warp threads, so that they run precisely in the direction of the tensile forces acting during prestressing. Additionally, these aligned fiber strands can be connected to predominantly perpendicular textile fibers, for example, as weft threads. This can increase the strength against shear forces acting on concrete components.

[0024] To improve the sealing effect, elastically deformable sealing elements can also be arranged on the end faces of the sealing plates, which can be brought into contact with the textile fibers on which the tensile force acts.

[0025] It is particularly advantageous if at least one support element can be arranged between the wall of the mold or formwork and the sealing plates, on which a support effect on the sealing plates can be achieved in surface areas where none of the textile fibers on which the tensile force acts, if a support element has been positioned accordingly and fixed in position.

[0026] One or more support elements can be positioned accordingly using a suitable mechanism and braced against the wall of the respective mold or formwork next to the opening. Alternatively, they can be designed in such a way that sufficient support for sealing plates is provided even without additional support against a wall of the mold or formwork.

[0027] After sufficient setting of the concrete in the mold or formwork and demolding, the support element(s) can be removed and the mold or formwork prepared for reuse by inserting new textile structures into the mold or formwork and prestressing them.

[0028] Once this has been done, the support element(s) and the sealing plates can be rearranged so that a seal to the mold or formwork can be achieved with support against a wall of the mold or formwork.

[0029] The support element(s) should be dimensioned and designed so that the entire free area of ​​the respective opening in the wall of the mold or formwork can be covered and the sealing plates receive sufficient support to prevent bending or slippage.

[0030] Preferably, at least one longitudinally oriented slot extending from an end face is formed on a support element, into which the textile structures on which the tensile force acts can be inserted by moving the support element in the direction of these textile structures. This makes it possible to achieve a corresponding support effect on sealing plates with a support element over larger surface areas between the textile structures oriented in this direction.

[0031] If textile structures are arranged in different planes, in which textile fibers subjected to tensile forces are arranged in an offset arrangement relative to each other, i.e., not vertically one above the other, at least one longitudinal slot on a support element can also be aligned in one plane so that these offset textile fibers subjected to tensile forces can be inserted into the correspondingly aligned longitudinal slot when the respective support element has been positioned in relation to sealing plates in order to support the sealing plates when concrete is poured into the respective mold or formwork.

[0032] Accordingly, longitudinal slots can be aligned not only vertically but also, for example, at an angle of 30°, 40° or 60° to the vertical, if they have been positioned in relation to sealing plates according to their function to be fulfilled.

[0033] Even better are several longitudinal slots aligned parallel to each other on a support element, into which appropriately aligned textile structures on which tensile forces act can be inserted, when a correspondingly designed support element is positioned for the performance of its function in relation to a mold or formwork and the correspondingly aligned textile fibers.

[0034] It is also possible to temporarily fix one or more support elements to a wall of a mold or formwork using fasteners, so that removal after demolding a finished concrete component is easy. Fasteners can be, for example, simple clamping elements that can grip a wall securely. This should also allow for easy disassembly of such a connection. Alternatively, one or more support elements can be temporarily attached using screws.

[0035] The sealing plates can be made from various materials; preferably, simple, prefabricated injection-molded plates made of soft PVC or a plastic with similar properties can be used, which can either be reused or recycled after use. Alternatively, other flat-coated materials or hybrids thereof can also be used.

[0036] The surfaces can be designed as a functional surface in the direction of the later precast concrete element (material-contacting side) or modified to facilitate separation during demolding or shell removal.

[0037] The design and material selection of the sealing plates should be such that the textile fibers and their sizing cannot be damaged during installation and positioning. Therefore, hard materials and sharp edges should be avoided in particular.

[0038] The support elements can be made of different materials than the sealing plates, for example metal, and can have different thicknesses or profiles to provide optimal support for the sealing plates.

[0039] The tolerances resulting from the manufacturing of the structures and anchor bodies should be taken into account in the design of the support elements and sealing plates. The sealing plates can also be curved on one side or made flexible to facilitate their insertion between the textile structures.

[0040] Both the version with only a sealing plate and the version with a sealing plate and support element(s) function in industrial applications. Omitting support elements saves material and a few seconds of assembly time, but places very high demands on the form and positional tolerances of the textile structures to be enclosed by the sealing plates. Using support elements allows for greater tolerances with only slightly more assembly effort.

[0041] The present invention enables a highly productive and sustainable sealing process in industrial production in precast concrete plants, but also directly on a construction site during the production of prestressed carbon concrete components.

[0042] The invention will be explained in more detail below by way of example.

[0043] This shows: Fig. 1 In schematic representation an example of a possible use of an example of a sealing system according to the invention on a wall of a molding tool for sealing a perforation in the wall of the molding tool.

[0044] In Fig. 1 are several textile structures 10 that have been inserted into a mold 1 at several levels and at intervals from each other. The textile structures 10 are guided through openings 3 in the wall of a mold 1, which in Fig. 1 is shown only by the example of a penetration 3 in a wall.

[0045] The textile structures 10 have textile fibers 8 on which the tensile forces act to prestress. The orientation of these textile fibers 8 and that of the acting tensile forces are identical.

[0046] In this example, the textile fibers 8 of a textile structure 10, on which the tensile forces act, are each connected to textile fibers 9, which in this case are oriented perpendicular to the textile fibers 8. However, other angles between 0° and 90° for the orientation of the textile fibers 9 relative to the textile fibers 8 are possible.

[0047] Theoretically, the interior of the mold tool 1 could be used in the representation of Fig.The opening 3 can be arranged both in front of and behind the wall of the forming tool 1. On the opposite side, in relation to the wall in which the opening 3 is formed, the device for applying the tensile forces acting on the textile fibers 8 is located. Anchor elements are also typically arranged on and connected to the textile structures 10 at this location.

[0048] Sealing plates 5 are provided to seal the opening 3. These plates are aligned parallel to each other and to planes in which textile structures 10 are arranged. They are arranged such that one sealing plate 5 is positioned above and one sealing plate 5 below each textile structure 10, with their opposing end faces in contact. The textile fibers 8 are also arranged between these end faces of the respective sealing plates 5.

[0049] In this example, a single support element 4 has been positioned between the sealing plates 5 and the wall of the mold 1, against which the sealing plates 5 can be supported in the area of ​​the opening 3. The support of the sealing plates 5 by the support element 4 takes place in surface areas where no textile fibers 8 and 9 are arranged.

[0050] Since only one support element 4 is provided here, with which the sealing plates 5 are to be supported, longitudinal sections 4.1 are formed in the support element 4, into which the textile fibers 8, on which the tensile forces act, are inserted when the support element 4 has been positioned accordingly to support the sealing plates 5.

[0051] In this example, semicircular recesses 6 are formed on the end faces of the sealing plates 5, which are brought into contact for sealing, at the positions where textile fibers 8 are arranged. These recesses encircle the textile fibers 8, on which tensile forces act, so that improved sealing can be achieved, but mechanical damage to the textile fibers 8 can be largely avoided.

[0052] In a form not shown, the textile structures 10 could each be arranged offset from one another, so that the textile fibers 8, on which the tensile forces act, could be arranged not vertically but laterally offset from one another in the individual planes, should the longitudinal slots 4.1 not be oriented vertically as shown here but at a correspondingly inclined angle, so that an unproblematic insertion into longitudinal slots 4.1 of a support element 4 is possible when positioning in relation to the sealing plates 5.

Claims

[1] Sealing system for openings in molds or formwork for the production of textile structures formed with textile fibers, in particular carbon fiber reinforced prestressed concrete components, wherein through a perforation (3) textile fibers (8) of a textile structure (10), which are oriented in the direction of a tensile force that acts on these textile fibers (8) during manufacturing, can be guided in at least one plane within the mold (1) or the formwork and each a sealing plate (5) which is supported on the wall of the molding tool (1) or the formwork next to an opening (3) formed therein , in a plane vertically above and below the plane in which the textile fibers (8) of a textile structure (10), on which a tensile force acts, can be arranged such that in the area of ​​the textile fibers (8) on which the tensile force acts, end faces of the corresponding sealing plates (5) are in contact with each other and with the textile fibers (8) on which the tensile force acts, and a sealing effect can be achieved. [2] Sealing system according to claim 1, characterized by , that the sealing plates (5) are made of a plastically or at least partially elastically deformable material and / or have recesses (6) in end faces which can be brought into contact with the textile fibers (8) on which the tensile force acts, the cross-sectional area of ​​which is at least nearly complementary to the outer dimensions of the textile fibers (8) on which the tensile force acts. [3] Sealing system according to one of the preceding claims, characterized by, that at least one support element (4) can be arranged between the wall of the molding tool (1) or the formwork and the sealing plates (5), on which a support effect of the sealing plates (5) can be achieved in surface areas where none of the textile fibers (8) on which the tensile force acts. [4] Sealing system according to one of the preceding claims, characterized by , that at least one longitudinal section (4.1) is formed on a support element (4) into which, when the support element (4) is positioned in relation to at least one sealing plate (5), textile fibers (8) of at least one textile structure on which tensile forces act can be inserted. [5] Sealing system according to any one of the preceding claims, characterized by , that on a support element (4) at least one in a vertical direction or in the direction of a plane in which textile fibers (8) of several textile structures (10) are arranged one above the other in different planes and on which tensile forces act, an aligned longitudinal slot (4.1) is formed starting from an end face, into which the textile fibers (8), on which the tensile force acts, can be inserted by means of a movement of the support element (4) in a vertical direction. [6] Sealing system according to one of the preceding claims, characterized by , that several longitudinal slots (4.1) aligned parallel to each other are formed on a support element (4). [7] Sealing system according to one of the preceding claims, characterized by , that elastically deformable sealing elements are arranged on the end faces of the sealing plates (5) which can be brought into contact with the textile fibers (8) on which the tensile force acts. [8] Sealing system according to one of the preceding claims, characterized by, that the sealing plates (5) and / or the support element(s) (4) can be arranged to support themselves against the wall of the molding tool (1) or the formwork. [9] Sealing system according to any one of the preceding claims, characterized by that sealing and / or support plates are temporarily and securely connected to each other and / or to the mold or formwork by suitable means to prevent displacement during filling and movement of the mold or formwork. Suitable measures include, for example, clips, adhesives, magnets, or positive locking mechanisms on the relevant elements of the formwork, the mold, the support plates, and the sealing plates. Such positive locking mechanisms can be achieved, for example, by tongue and groove, pin connections, or other suitable contours and / or fasteners. [10] Sealing system according to any one of the preceding claims, characterized by, that after the finished part has hardened, the plates can be easily removed and separated from the finished part without damaging it. [11] Sealing system according to one of the preceding claims, characterized by The aim is to minimize post-processing at the penetration points of the textile structures by the formwork or molding tool to such an extent that the material-contacting side of the finished part in the area of ​​the formwork or molding tool requires no further post-processing. In addition to demolding, the textile structure extending beyond the formwork or molding tool is cut off close to the support plate; subsequently, the support and sealing plates can be removed without requiring any further post-processing in the penetration area. [12] Sealing system according to one of the preceding claims, characterized byThe sealing plates are made of various materials, preferably simple, prefabricated injection-molded sheets of soft PVC or a plastic with similar properties. Alternatively, other flat-coated materials with a sealing effect on the end faces or laminates can be used. Such laminates can be designed so that one undersized layer provides the necessary mechanical properties, particularly resistance to deflection due to back pressure when filling the mold or die, while the second, soft layer softly seals the undersized gaps between the harder base plate and the textile structure. [13] Sealing system according to one of the preceding claims, characterized by, that sealing plates and / or support plates can have complementary shapes to the formwork or molding tool in order to produce flat component surfaces without disruptive steps and impressions from the sealing system without rework in the area of ​​penetration, in the case of high surface requirements on the precast concrete element. [14] Sealing system according to one of the preceding claims, characterized by that the surfaces of the sealing plates are designed as a functional surface in the direction of the later precast concrete element (material-contacting side) or are modified before, during or after the installation of the sealing system in such a way as to facilitate the separation between the precast concrete element and the sealing system during demolding or stripping.

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