METHOD FOR THE MANUFACTURE OF CONCRETE FLOOR COVERING ELEMENTS AND CONCRETE FLOOR COVERING ELEMENT

Description

Technical field

[0001] The invention relates to a method for producing floor covering elements made of concrete, in particular concrete blocks and / or concrete slabs, which are suitable for creating a surface covering, and further to a floor covering element made of concrete. State of the art

[0002] Concrete flooring elements, namely concrete blocks for creating surface coverings, are well known in the art. Such flooring elements, or concrete blocks, which are generally so-called pre-formed concrete blocks, are to be understood as concrete surface covering elements that, depending on the application, can be shaped like slabs or stones and are commonly referred to as concrete pavers. These concrete blocks are usually laid in a bonded pattern to create a surface covering, which is why concrete blocks of this type are often also called bonded concrete blocks or bonded pavers.

[0003] Also known are multi-layered concrete blocks and concrete paving stones, which have at least a core layer and a facing layer, whereby the core layer is usually made of core concrete and forms a core of the concrete block, and whereby the facing layer is usually made of facing concrete and forms the walkable or drivable top of the concrete block, namely its visible surface.

[0004] The production of concrete blocks is usually carried out using formwork and is done, for example, by machine; it is known to produce concrete paving stones in so-called paving stone machines or plants specifically designed for this purpose.

[0005] As a rule, the concrete paving stones are manufactured in the desired stone formats using appropriate formwork.

[0006] Not least due to landscape planning and urban development considerations, increasing attention has recently been paid to the visual design and appearance of concrete pavers of the aforementioned type. In particular, there is a growing demand for concrete pavers whose visible surface is specially structured and / or colored, thus exhibiting a specific surface texture, a desired visual and / or tactile surface effect, and / or a desired color scheme.

[0007] For example, DE 10 2011 050 974 A1 discloses a device and a method for producing multicolored concrete blocks. Furthermore, it is known from the prior art, for example, to additionally treat the facing concrete layer before hardening during the production of the concrete blocks to give it a structure, for example by embossing or molding indentations or raised areas, as is described, for example, in DE 10 2010 025 024 A1.

[0008] It is also known from the prior art to treat the facing concrete layer before hardening by adding or applying a structuring or coloring material in order to create a surface finish. For example, German patent application DE 10 2004 062 656 A1 describes a method for producing concrete blocks in which a portion of a finishing material is applied to the facing concrete layer before hardening using a specially designed application device. German patent application JP 2003 320512 A also describes the production of concrete blocks in which the facing concrete layer arranged on the top of the concrete blocks has a water-permeable and a water-impermeable surface section to make the concrete block dirt-resistant. This patent application additionally discloses a concrete floor covering element according to the preamble of claim 11.

[0009] However, a disadvantage of these known methods is that the treatment or application steps required in the manufacturing process to create the surface finish are time-consuming and therefore costly, and also place high demands on the design, as special treatment and / or application equipment is required. Therefore, there is still a need for improved methods for the production of concrete blocks. Description of the invention

[0010] The object of the present invention is therefore to provide a method for manufacturing floor covering elements that enables simple, automated, flexible, and rapid production of floor covering elements with special surface effects, and which, in particular, allows the creation of a desired surface texture. This object is achieved by the method for manufacturing floor covering elements according to claim 1. Furthermore, a floor covering element according to claim 11 is specified to achieve this object. Further advantageous aspects, details, and embodiments of the invention will become apparent from the dependent claims, the description, and the drawings.

[0011] The present invention provides a method for producing concrete flooring elements, in particular a method for producing concrete paving stones or concrete slabs using a paving stone machine. According to the invention, the flooring elements are produced as multi-layered flooring elements and comprise at least one core concrete layer made of core concrete and at least one facing concrete layer made of facing concrete. In the method, the core concrete is first poured into at least one mold and compacted. The facing concrete is then poured onto the compacted core concrete and also compacted. Finally, the core and facing concrete are cured. According to a key aspect of the present method, at least one first facing concrete mix and at least one second facing concrete mix are prepared and provided for the production of the facing concrete layer.The facing concrete used for topping the compacted core concrete comprises at least a portion of the first facing concrete mix and at least a portion of the second facing concrete mix, wherein the first facing concrete mix is ​​a dense concrete material and the second facing concrete mix is ​​a porous concrete material. The facing concrete, which is topping the compacted core concrete and comprises both the first and second facing concrete mixes, is distributed onto the core concrete layer by means of a distribution device before compaction, and the first and second facing concrete mixes are at least partially blended and / or mixed together.

[0012] The production of the concrete flooring element, which can also be understood as a concrete paving stone and is preferably a "concrete paving stone" according to DIN EN 1338, is carried out mechanically using the method according to the invention, advantageously in a paving stone machine configured for automated, preferably controlled, and in particular program-controlled production. Such a paving stone machine can also be understood as a device or system for manufacturing concrete paving stones or concrete slabs. In other words, the production process is also automated, preferably controlled, and in particular program-controlled.

[0013] The "mold" used to carry out the process can also be understood as a formwork and is preferably a mold provided on the paving machine, configured for one or more paving elements. That is, one or more paving elements can be formed in one mold, with the latter case having several recesses in a basic mold, each of which can also be understood as an individual mold. The paving elements are preferably manufactured in a desired format or final format, which in this case can also be referred to as the nominal format, nominal size, or nominal dimension.

[0014] For the purposes of the present invention, the term "facing concrete mix" refers to a concrete material used to produce the facing concrete layer, i.e., a concrete material from which the facing concrete layer is formed or has been formed. Each of the "facing concrete mixes" is a part or proportion of the concrete material used to form the facing concrete layer, which, for the purposes of the invention, is referred to as "facing concrete." According to the understanding of the present invention, the "facing concrete mix"—and consequently also the "facing concrete"—is therefore not limited to a dense concrete material, but can also be a porous or open-pore concrete material.

[0015] In the inventive method, at least a proportion of a first facing concrete mix and at least a proportion of a second facing concrete mix are used as facing concrete for producing the facing concrete layer, wherein the at least two facing concrete mixes differ from one another. The facing concrete for producing the facing concrete layer can thus also be understood as a proportional composition or combination of at least two facing concrete mixes.

[0016] The at least two facing concrete mixes are present in the facing concrete or facing concrete material either unmixed or at most partially mixed or blended, and are in particular not completely mixed, such that the facing concrete is a uniform facing concrete mix or a uniform facing concrete material. In other words, the at least two facing concrete mixes, existing side by side, together constitute the facing concrete, so that the resulting facing concrete layer has at least two facing concrete sections, each made of a different facing concrete material.

[0017] The at least two facing concrete mixtures differ from each other in preferably at least one property that affects and / or influences the optical and / or haptic surface appearance of the facing concrete layer.

[0018] The main differences between facing concrete mixes lie in the base material used to prepare each mix, such as the aggregate and / or the aggregate material used in its preparation. An advantage is that at least one distinguishing characteristic of the various facing concrete mixes is present, for example, the type of aggregate, its color, its coarseness or fineness, or its particle size distribution. Alternatively, at least one distinguishing characteristic of the various facing concrete mixes can also be the type or color of an aggregate material, or another property that influences the visual and / or tactile appearance of the facing concrete surface. Naturally, facing concrete mixes can also differ in several of the aforementioned characteristics.

[0019] For the purposes of this invention, "aggregate" refers to a granular material, in particular natural and artificial rock aggregates such as those used as a base material for concrete production. The aggregate can be in either rounded or crushed form. The aggregate used to produce the facing concrete layer can also be referred to as sand.

[0020] According to the invention, the facing concrete mixes used to produce the facing concrete layer also differ in that one of the facing concrete mixes is a dense concrete material and the other is a porous concrete material. The facing concrete mixes can differ solely in these properties, namely "dense" or "porous," or additionally in other possible distinguishing properties mentioned above.

[0021] By using the at least two facing concrete mixes according to the invention to produce the facing concrete layer, the finished floor covering elements have at least two different sections, in particular surface sections, wherein a first section essentially or mainly comprises the material of the first facing concrete mix and therefore essentially has a first optical and / or tactile surface appearance, and wherein a second section essentially or mainly comprises the material of the second facing concrete mix and therefore essentially has a different, second optical and / or tactile surface appearance. The surface sections are also referred to here as facing concrete layer sections.

[0022] The inventive method thus enables the production of floor covering elements with a special surface effect or surface play. The surface effect or surface play can, in particular, be the change or transition from the first to the second section – and vice versa - be viewed.

[0023] In particular, the present method can be used to produce concrete flooring elements where the surface formed by the facing concrete layer, which is visible when the flooring element is installed, has a natural appearance and closely resembles natural stone. This natural appearance can be further enhanced by using proportions of a dense facing concrete mix and a porous facing concrete mix. This also makes it possible, in particular, to produce concrete paving stones that look and / or feel like limestone or calcium silicate brick, for example, concrete paving stones with a travertine look, that is, concrete paving stones that resemble or are identical to natural travertine in appearance and feel.

[0024] Preferably, the first and second facing concrete mixes are each prepared and stored in separate containers. The advantage of this is that each facing concrete mix can be prepared and stored in a suitable volume with the specified or desired components and in the specified or desired composition, without the individual facing concrete mixes being prematurely mixed or partially mixed.

[0025] It is understood, however, that within the scope of the present invention it is also conceivable that the facing concrete mixtures can be introduced together into a container or a feeding device, or together into a filling device, in order to ultimately be fed into the mold. In this way, for example, a chaotic feeding of the facing concrete, consisting of components of the facing concrete mixtures, into the mold is possible.This can also create and enhance the effect that, in addition to the facing concrete layer sections that comprise only or mainly the first or second facing concrete mix, mixing sections or mixing areas are also formed that comprise both the first and second facing concrete mix to varying degrees, wherein the first and second facing concrete mix are present in different proportions in the various mixing areas, preferably mixed, for example almost completely or entirely mixed.

[0026] Preferably, the first facing concrete mix is ​​prepared with an aggregate having a first grain size distribution or average grain size, and the second facing concrete mix is ​​prepared with an aggregate having a second grain size distribution or average grain size, whereby the first and second grain size distributions or average grain sizes are different. That is, the first and second grain size distributions of the respective aggregates used to produce the first and second facing concrete mixes are chosen differently. In simpler terms, for example, sand of different fineness grades is used to produce the first and second facing concrete mixes.

[0027] This advantageously results in different surface sections within the facing concrete layer, namely at least one finer or smoother facing concrete section and at least one coarser or more porous or rougher facing concrete section. Here, the terms "facing concrete section" and "section" are used synonymously. The terms "finer" and "coarser" or "rougher" and "smoother" are to be understood as meaning that one of the at least two facing concrete sections appears "finer" or "coarser" relative to the other section. This advantageously creates a surface variation within or on the facing concrete layer, ranging from fine to coarse. vice versa.

[0028] The aggregates can be classified into so-called grain size groups and represented by so-called grading curves. For the purposes of the present invention, grain size refers to the average diameter of the rock grains in the aggregate composition or a range of rock grain diameters (including the smallest and largest grains). The aggregate can be understood as a mixture of rock grains, whereby the rock grains present in the mixture may have different diameters, but these diameters lie within a predetermined or limited range, preferably within a narrowly defined range. The rock grains present in the aggregate thus exhibit a predetermined grain size distribution, preferably within a narrow range, and form a grain size group. In this context, grain size is also to be understood as the value for the average diameter of a rock aggregate.

[0029] For example, the first particle size distribution lies in the range of 0 mm to 2 mm or 1 mm to 2 mm (this can also be referred to as particle size distribution 0 / 2 or 1 / 2). The second particle size distribution lies, for example, in the range of 2 mm to 4 mm or 3 mm to 4 mm (this can also be referred to as particle size distribution 2 / 4 or 3 / 4). The particle sizes of the aggregates used to produce the first and second facing concrete mixes thus preferably correspond to different grading curves. The resulting surface variation can also be understood as a surface variation consisting of sections with different densities, namely as an interplay between "denser" and "less dense" sections.

[0030] For example, the fine facing concrete mix contains aggregate with a grading curve of 0 to 4 mm, in particular grading curve 0 to 3 mm, preferably 0 to 2 mm. The coarse facing concrete mix preferably contains aggregate with a grading curve of 2 to 4 mm, in particular grading curve 4 to 8 mm. When using such aggregates in the facing concrete mixes, it is advantageous to create optimally blended zones between "fine" and "coarse" on the surface of the concrete paving stone.

[0031] It goes without saying that the different aggregates used to prepare the various facing concrete mixtures may differ, alternatively or in addition to their grain size distribution, also in their color and / or other optical and / or haptic properties.

[0032] According to a preferred embodiment of the present method, the first and second facing concrete mixes for topping the compacted core concrete of the core concrete layer are introduced into the mold simultaneously or in successive steps. The facing concrete mixes are preferably fed via at least one feeding device and then, for example, poured directly into the mold via the feeding device or with the interposition of a filling device.

[0033] Simultaneously filling the different facing concrete mixes speeds up the filling process and reduces the risk of unintentional mixing. This saves time and allows for the creation of a more defined or regular surface texture with sharper transitions. Conversely, sequential, step-by-step filling can produce a more random, irregular surface texture with smoother transitions. This can be advantageous in certain applications, as it makes the surface of the flooring elements appear more natural and resembles natural stone.

[0034] According to a further preferred embodiment, the first and second precast concrete mixes are fed into the mold together and preferably simultaneously by means of a feeding device designed as a common feeding device. This offers the advantage of time savings and a structurally simple design for the device used to produce floor covering elements. In particular, this also allows for chaotic filling of the mold.

[0035] Preferably, the first and second facing concrete mixtures are poured onto the compacted core concrete in such a way that the facing concrete layer extending over an upper surface of the floor covering element is formed by at least one first facing concrete layer section comprising the first facing concrete mixture and at least one second facing concrete layer section comprising the second facing concrete mixture, in particular that the facing concrete layer is formed by several different facing concrete layer sections.

[0036] According to the invention, the facing concrete, which is poured onto the compacted core concrete and comprises the first and second facing concrete mixes, is distributed onto the core concrete layer by means of a distribution device before compaction. The first and second facing concrete mixes are preferably mixed and / or partially blended, at least in sections. The distribution of the facing concrete can be achieved, for example, by spreading or troweling using a distribution device designed as a troweling and / or troweling device. Depending on the application and / or individual design, a more varied and / or random surface texture can be created, particularly through additional section-by-section mixing and / or partial blending, thereby further enhancing the natural stone-like appearance or the natural character of the flooring elements. Marble effects can also be created in this way.

[0037] According to a particularly preferred embodiment of the method, additional facing concrete mixes are prepared and provided, and the facing concrete used for topping the compacted core concrete further comprises at least a proportion of one or more of the additional facing concrete mixes. By using more than two facing concrete mixes, a varied and diverse surface texture can advantageously be created. In particular, this allows for a natural appearance of the concrete paving stones.

[0038] For example, a first facing concrete mix can be used as a coarse, especially open-pore, facing concrete mix of a first color; a second facing concrete mix as a coarse, especially open-pore, facing concrete mix of a second color; a third facing concrete mix as a fine, especially dense, facing concrete mix of the first color; and a fourth facing concrete mix as a fine, especially dense, facing concrete mix of the second color. The facing concrete layer sections created by using the four aforementioned facing concrete mixes, including the various mixing sections or areas that also result, create a surface interplay with numerous transitions, both in terms of color and in terms of the "fineness" or "density" of the surface.In particular, this can enhance the natural appearance of the concrete paving stones; for example, it can create an almost authentic travertine look.

[0039] Preferably, the facing concrete mixtures are filled into the mold in fixed or randomly selected proportions. The determination and / or selection of the proportions of the facing concrete mixtures is particularly preferably automated, in particular controlled, preferably by a program. In particular, the feeding of the proportions of the facing concrete mixtures into the mold is also preferably automated, in particular controlled, preferably by a program.

[0040] The facing concrete layer is preferably produced with a layer thickness in the range of 4 mm to 15 mm, preferably in the range of 6 mm to 12 mm and particularly preferably from 8 mm to 10 mm.

[0041] According to a particularly preferred embodiment, before the core concrete is poured into the at least one mold and / or before the facing concrete is poured onto the compacted core concrete, at least one further concrete material is poured into the mold and compacted. This creates at least one further concrete layer, wherein the further concrete layer is arranged on the side of the core concrete layer facing away from the facing concrete layer and / or wherein the further concrete layer is arranged between the core concrete layer and the facing concrete layer. Such additional concrete layers can, for example, be designed as concrete layers for regulating water permeability or water storage, or as reinforcing layers to increase compressive strength and mechanical load-bearing capacity, or they can be designed to serve as anti-displacement protection.

[0042] A device comprising at least one paving stone machine with at least one mold can be used to produce the paving elements. The device has at least one first feed hopper for holding a first facing concrete mix, at least one second feed hopper for holding a second facing concrete mix, and at least one feed device for feeding the facing concrete mixes toward the mold. The feed hoppers are equipped with a controllable, in particular steerable, outlet for the controlled dispensing of the facing concrete mixes. The feed device is designed to receive the facing concrete mixes from the feed hoppers and transport them toward the mold.

[0043] Preferably, the at least one feeding device is further designed to fill the facing concrete mixtures into the mold or to feed them to a filling device for filling into the mold.

[0044] Each storage container is preferably assigned a measuring and / or dosing device for the precise and / or metered dispensing of the facing concrete mixtures.

[0045] Particularly preferred is a control and / or regulating unit that communicates with the storage containers, with the measuring and / or dosing device and / or with the feeding device, and the feeding of the facing concrete mixtures is controlled and adjustable, in particular by program control via at least one control routine implemented in the control and / or regulating unit.

[0046] Furthermore, at least one distribution device for distributing the facing concrete in the mold is preferably provided, wherein the distribution device is preferably mounted to be movable. The present invention further relates to a concrete floor covering element, in particular a concrete paving stone or concrete slab, comprising at least one multi-layered concrete block body with at least one underside suitable for laying on a bedding layer of a substrate and an opposing upper side. The multi-layered concrete block body comprises at least one core concrete layer and at least one facing concrete layer.According to the invention, the facing concrete layer comprises at least one first facing concrete section and at least one second facing concrete section, wherein the first facing concrete section comprises a first facing concrete mix and the second facing concrete section comprises a second facing concrete mix that differs from the first facing concrete mix, wherein the floor covering element thereby has a surface play on an upper surface on the top of the concrete block, and wherein the at least one first facing concrete section comprises a porous concrete material and the at least one second facing concrete section comprises a dense concrete material, wherein the first and second facing concrete mixes are sectionally blended and / or partially mixed.

[0047] The facing concrete layer preferably has a large number of facing concrete sections, wherein the facing concrete sections are arranged randomly and irregularly across the top of the concrete block.

[0048] Further developments, advantages, and possible applications of the invention will also become apparent from the following description of exemplary embodiments and from the figures. All features described and / or illustrated are, individually or in any combination, fundamentally the subject matter of the invention, irrespective of their compilation in the claims or their cross-reference. The content of the claims is also incorporated into the description. Brief description of the drawings

[0049] The invention will be explained in more detail below with reference to exemplary embodiments in conjunction with the drawings. The drawings show... Fig. 1, in a roughly schematic and highly simplified partial sectional view, shows a section of an embodiment of a device for producing a floor covering element, in a state during the filling of facing concrete into a mold; Fig. 2, in a roughly schematic and highly simplified partial sectional view, shows a section of an embodiment of the device for producing a floor covering element, in a state during the distribution of facing concrete; Fig. 3, in a roughly schematic and highly simplified partial sectional view, shows a section of an embodiment of the device for producing a floor covering element, in a state during the compaction of the concrete; Fig. 3, in a very simplified and roughly schematic sketch, shows a section of an embodiment of the device with several feed containers and a feeding device.Figure 4 is a very simplified and roughly schematic perspective view of an embodiment of a floor covering element with surface play, and Figure 5 is a very simplified and roughly schematic perspective view of another embodiment of a floor covering element with surface play. Ways to implement the invention

[0050] Identical reference numerals are used in the figures for identical or similarly functioning elements of the invention. Furthermore, for the sake of clarity, only those reference numerals necessary for describing the respective figure are shown in the individual figures.

[0051] With regard to the Figure 1 as well as 2a and 2b, the present method for the production of floor covering elements 1 (in the Figures 1 to 2b not clearly visible; see here Figures 4, 5 ) described by way of example. The Figures 1 to 2bThe figures outline, purely as examples, selected process steps and show, in a highly simplified and only roughly schematic manner, views or partial sectional views of respective sections of a device for manufacturing the floor covering elements 1, as it can be used to carry out the process. The figures show, for example, a paving stone machine 20 encompassed by the device, as well as other associated units or equipment preferably provided in the device.

[0052] In the process, the floor covering elements 1 are produced in the paving stone machine 20 as multi-layered floor covering elements 1, each of which has at least one core concrete layer 2 made of core concrete and at least one facing concrete layer 3 made of facing concrete.

[0053] In the present method, the core concrete for the production of the paving element 1 is first poured into a mold 4 provided on the paving machine 20 and then compacted, thereby forming the core concrete layer 2. For the sake of simplicity, the mold 4 is shown in the figures as a single mold for one paving element 1, i.e., as a mold 4 with only one recess for receiving the concrete material. However, it is understood that the mold 4 can, of course, also be a mold 4 for several paving elements 1, which would then have several recesses, each recess being designed to form one paving element 1. The mold 4 can also be referred to as a formwork mold or basic formwork mold.

[0054] The step of filling the core concrete into the mold 4, which can also be understood as pouring or casting the core concrete, is not shown in detail in the figures, but it is carried out, for example, by means of a filling device 24 provided on the paving stone machine 20, via which the core concrete is taken from a corresponding storage container and fed into the mold 4, for example by means of suitable pumps or by means of other suitable conveying means known to those skilled in the art.

[0055] The filling device 24 preferably comprises a filling nozzle that extends into the mold 4, enabling the core concrete to be filled as cleanly and without splashing as possible. The filling device 24 can, for example, include a funnel-shaped filling vessel that supports the filling nozzle. The filling vessel and / or the filling nozzle can be connected, for example, via a flexible connector, such as a hose, to other units of the filling device 24 and / or, in particular, to a concrete supply. In particular, the filling nozzle or the entire filling device 24 is movable relative to the mold 4, preferably in height and also in a movable direction, specifically in both the x-direction and y-direction with respect to a plane accommodating the mold 4, so that uniform filling of the mold 4 can be facilitated or ensured.

[0056] In the next step of the manufacturing process, the core concrete filled into mold 4 is compacted. For this purpose, the paving stone machine 20 has a compaction device, for example a press or a ram 27. The compaction of the core concrete is not explicitly shown in the figures, but it can be carried out similarly to the process described in... Figure 2b This is shown, but before the facing concrete is poured into form 4. The core concrete can also be compacted by vibration.

[0057] In the next step of the process, which in the highly simplified representation of the Figure 1 As outlined, a facing concrete is poured onto the compacted core concrete, namely onto the prepared core concrete layer 2, thereby forming a facing concrete layer 3.

[0058] The facing concrete layer 3 is produced from a first facing concrete mix 3.1 and a second facing concrete mix 3.2. Each of the facing concrete mixes 3.1, 3.2 is prepared and provided in its own storage container 21, 22, namely the first facing concrete mix 3.1 in the first storage container 21 and the second facing concrete mix 3.2 in the second storage container 22. A predetermined quantity of the respective facing concrete mix 3.1, 3.2 is taken from each of these two storage containers 21, 22, fed to a feeding device 23, and conveyed via this feeding device 23 towards the mold 4.

[0059] The facing concrete used for refilling the compacted core concrete thus comprises at least a proportion of the first facing concrete mixture 3.1 and at least a proportion of the second facing concrete mixture 3.2.

[0060] The first and second facing concrete mixes 3.1 and 3.2 are different from each other. For example, the first facing concrete mix 3.1 uses an aggregate, in particular sand, with a first grain size distribution, while the second facing concrete mix 3.2 uses an aggregate, in particular sand, with a second grain size distribution. The first and second grain size distributions of the respective aggregates are selected differently.

[0061] The grain size distribution can also be understood as the mean grain size or average grain size in the aggregate. For example, the first grain size distribution lies in a range from 0 mm to 2 mm (this can also be referred to as grain group 0 / 2) and the second grain size distribution in a range from 2 mm to 4 mm (this can also be referred to as grain group 2 / 4).

[0062] In the example shown according to Figure 1The removal, dispensing, or transfer of the respective facing concrete mixtures 3.1, 3.2 from the associated storage containers 21, 22, as well as the transfer of the facing concrete mixtures 3.1, 3.2 to the feeding device 23, is carried out by means of a respective controllable, in particular controllable, outlet with which each of the storage containers 21, 22 of the exemplary embodiment is equipped and which is designed for a controlled dispensing of the facing concrete mixtures 3.1, 3.2. For a particularly precise and / or metered dispensing of the facing concrete mixtures 3.1, 3.2, the embodiment according to Figure 1 Each storage container 21, 22 or each associated outlet is assigned a measuring and / or dosing device 25.

[0063] The controllable, in particular controllable, outlet of the storage containers 21, 22 and in particular also the measuring and / or metering device 25 are, for example, in communicative communication with a control device or control unit of the device not shown in the figures, so that the controlled, in particular quantity-accurate and / or metered dispensing of the respective proportions of the facing concrete mixtures 3.1, 3.2 can be controlled by the control device or control unit.

[0064] The feeding device 23 of the illustrated example is designed as a common feeding device for both facing concrete mixtures 3.1, 3.2 and is specifically configured to receive the facing concrete mixtures 3.1, 3.2 dispensed from both storage containers 21, 22 and transport them towards the mold 4. The feeding device 23 can be a conveyor belt or another suitable conveyor.

[0065] In the example of the Figure 1 The feed device 23 is designed to interact with the movable filling device 24 described above and to feed the facing concrete mixtures 3.1, 3.2 to the filling device 24, through which the facing concrete mixtures 3.1, 3.2 are then filled into the mold 4 and thus topped up onto the compacted core concrete. Alternatively, a second filling device can be provided for the facing concrete to prevent any mixing of the core concrete and the facing concrete.

[0066] In a further alternative embodiment, the feeding device 23 can also be configured to fill the facing concrete mixtures 3.1, 3.2 directly into the mold 4, i.e., without the need for a separate filling device. In such an embodiment, not shown in the figures, the feeding device 23 has, for example, a filling section at its end facing the mold 4, through which the facing concrete mixtures 3.1, 3.2 can ultimately be introduced into the mold 4.

[0067] The first and second facing concrete mixes 3.1 and 3.2 are fed into mold 4 and poured onto the compacted core concrete in such a way that the facing concrete mixes 3.1 and 3.2 form a heterogeneous facing concrete mass throughout the entire feeding and filling process. In this mass, the two facing concrete mixes 3.1 and 3.2 are present either unmixed or at most partially blended. Thus, the two facing concrete mixes 3.1 and 3.2 are present, at least in part, as coexisting components within the heterogeneous facing concrete mass, and remain so, particularly until the final completion of the floor covering element 1.

[0068] The feeding or filling of the facing concrete mixtures 3.1, 3.2 into the mold 4 can also be carried out chaotically or randomly. In an alternative embodiment not shown, the facing concrete mixtures 3.1, 3.2 can also be provided in a common container and fed and filled from there into the mold 4.

[0069] During and / or after the filling of the facing concrete into the form 4, the facing concrete, which is poured onto the compacted core concrete and comprises the first and second facing concrete mixtures 3.1, 3.2, can optionally be distributed onto the core concrete layer 2 by means of a distribution device 26, as shown in Figure 2aAs indicated, distribution can be achieved, for example, by spreading or smoothing. During this spreading or smoothing step, depending on the application and / or individual design requirements, the first and second facing concrete mixes 3.1, 3.2 can also be mixed and / or partially blended in certain areas, for example, to create a marbled effect. The distribution device 26 includes, in particular, a suitable spreading and / or smoothing tool for spreading or smoothing.

[0070] As in Figure 2b As outlined, the facing concrete is compacted after backfilling onto the core concrete layer 2 - and, if necessary, after optional distribution - again using the press or the ram 27. Finally, the core and facing concrete are hardened.

[0071] Due to the use of the facing concrete, which consists of at least one proportion each of the first and second facing concrete mixtures 3.1, 3.2, for the production of the facing concrete layer 3, and due to the above-described supply and filling of the respective proportions of the first and second facing concrete mixtures 3.1, 3.2, the surface O on a concrete block top 1.2 (see Figures 4 and 5 ) of the floor covering element 1, the facing concrete layer 3 is formed by at least one first facing concrete layer section 6.1 comprising the first facing concrete mixture 3.1 and at least one second facing concrete layer section 6.2 comprising the second facing concrete mixture 3.2.

[0072] With regard to the Figures 4 and 5 Several exemplary floor covering elements 1, manufactured using the present method, will now be described in more detail. Figures 4 and 5Each shows a perspective view of a floor covering element 1 in a very simplified and roughly schematic representation.

[0073] As explained above in connection with the manufacturing process, the floor covering elements 1 are designed as multi-layered concrete blocks and each has a multi-layered, in the example shown in the figures essentially cuboid, concrete block body with a core concrete layer 2 and a facing concrete layer 3. The floor covering element 1, or the concrete block body, has a predetermined format with a length L and a width B and has at least one concrete block underside 1.1 suitable for laying on a bedding layer of a substrate and a concrete block topside 1.2 opposite this, along which the upper surface O of the floor covering element 1 extends.

[0074] Projections 5, for example rib-like or nose-like projections 5, can be provided on the side surfaces of the floor covering element 1 (see Figure 5 ), which serve as spacers or spacer lugs and, when laying the floor covering elements 1 in a bonded arrangement, ensure that a minimum distance is maintained between the respective adjacent floor covering elements 1 in the laid surface bond, thereby creating joints with a specified minimum width.

[0075] The upper surface O is formed by the facing concrete layer 3, which has a layer thickness d of approximately 10 mm in the examples shown. The facing concrete layer 3 comprises several facing concrete layer sections 6.1, 6.2, 6.3, 6n, which differ in their optical and / or tactile surface appearance or structure.

[0076] For the in Figure 4In the example shown, two different facing concrete mixes 3.1 and 3.2 were used to produce the facing concrete layer 3, so that the floor covering element 1 has a first and a second facing concrete layer section 6.1 and 6.2 on its concrete block top surface 1.2. The facing concrete layer sections 6.1 and 6.2 are visible on the upper surface O and thus create a surface effect or surface variation. In the example shown, the surface effect or surface variation is a transition from a finer, smoother surface to a coarser, rougher surface, caused by the respective facing concrete mixes 3.1 and 3.2 used, which are made with aggregates of different grain sizes.

[0077] At the in Figure 5In the example shown, the facing concrete layer 3 is produced using four different facing concrete mixes 3.1, 3.2, 3.3, 3.n, wherein, for the production of the exemplary floor covering element 1, the four different facing concrete mixes 3.1, 3.2, 3.3, 3.n are held in four separate storage containers 21, 22, 21', 22', as shown. Figure 3 This is shown as an example. The four facing concrete mixtures 3.1, 3.2, 3.3, 3.n can in turn be fed via a common feeding device 23 and filled into the mold 4, so that the finished floor covering element 1 has at least one first to fourth facing concrete layer section 6.1, 6.2, 6.3, 6.n on its concrete block top 1.2.

[0078] In this case too, the facing concrete layer sections 6.1-6.n are visible on the upper surface O and thus form or create a surface effect or surface play.

[0079] Depending on the method of filling the facing concrete mixtures 3.1, 3.2, 3.3, 3.n into the form 4 and depending on whether a distribution step, in particular for spreading or troweling, or partial mixing is carried out after filling, different facing concrete layer sections 6.1, 6.2, 6.3, 6.n can of course be produced when using several facing concrete mixtures 3.1, 3.2, 3.3, 3.n, which exceed the number of facing concrete mixtures 3.1, 3.2, 3.3, 3.n used.

[0080] In the process for manufacturing the floor covering elements 1, both the number of facing concrete mixes 3.1, 3.2, 3.3 - 3.n used and the desired combination of the available facing concrete mixes 3.1, 3.2, 3.3 - 3.n can be freely selected. The proportions of the respective facing concrete mixes 3.1, 3.2, 3.3 - 3.n used, i.e., their respective proportions in the facing concrete, can also be freely selected. The determination or selection of the number of facing concrete mixes 3.1, 3.2, 3.3 - 3.n, their combination, and the corresponding proportions of the respective facing concrete mixes 3.1, 3.2, 3.3 - 3.n used can be carried out in a predetermined manner according to fixed specifications or selected randomly.

[0081] The feeding, in particular the filling of the respective proportions of the facing concrete mixtures 3.1, 3.2, 3.3 - 3.n into the mold 4 can be carried out in an automated, in particular controlled manner, either simultaneously or in successive steps, depending on the application and design requirements.

[0082] The present method allows for the production of floor covering elements 1, according to requirements and individual design preferences, whose surface O has a natural stone look and, in particular, forms a true-to-life imitation of natural stone. Advantageously, floor covering elements 1 can be produced that exhibit a surface variation or effect, in which visually and / or haptically different surface sections alternate, whereby smooth transitions between individual surface sections are just as possible as sharp changes between sections. Reference symbol list

[0083] 1 Paving element 1.1 Concrete block underside 1.2 Concrete block topside 2 Core concrete layer 3 Facing concrete layer 3.1 First facing concrete mix 3.2 Second facing concrete mix 3.3, 3.n Further facing concrete mix 4 Mold 5 Projection 6.1-6.n Facing concrete layer sections 20 Paving stone machine 21, 21' Feed hopper 22, 22' Feed hopper 23 Feeding device 24 Filling device 25 Measuring and / or metering device 26 Distribution device 27 Press or ram B Width of the paving element d Layer thickness of the facing concrete layer L Length of the paving element Top surface

Claims

1. Method for producing floor covering elements (1) made of concrete, in particular for producing concrete paving stones or concrete slabs using a paving stone machine (20), wherein the floor covering elements (1) are produced as multi-layer floor covering elements (1) and comprise at least one core concrete layer (2) made from core concrete and at least one face concrete layer (3) made from face concrete, wherein, in the method, the core concrete is filled into at least one mould (4) and compacted, wherein the face concrete is then filled onto the compacted core concrete and also compacted, and wherein the core concrete and face concrete are cured, wherein at least a first face concrete mixture (3.1) and at least a second face concrete mixture (3.2) are prepared and provided for the production of the face concrete layer (3), and wherein the face concrete used for filling onto the compacted core concrete comprises at least a proportion of the first face concrete mixture (3.1) and at least a portion of the second face concrete mixture (3.2), wherein the first face concrete mixture (3.1) is a dense concrete material and the second face concrete mixture (3.2) is a porous concrete material, wherein the face concrete, being filled onto the compacted core concrete and comprising the first and second face concrete mixtures (3.1, 3.2) is distributed on the core concrete layer (2) by means of a distribution device (26) before compaction, and wherein the first and second face concrete mixtures (3.1, 3.2) are at least partially mixed and / or partially blended.

2. Method according to claim 1, characterised in that the first and second face concrete mixtures (3.1, 3.2) are each prepared and provided in an own storage container (21, 22).

3. Method according to claim 1 or 2, characterised in that the first face concrete mixture (3.1) is prepared with an aggregate having a first grain size distribution and the second face concrete mixture (3.2) is prepared with an aggregate having a second grain size distribution, wherein the first and second grain size distributions are different.

4. Method according to one of claims 1 to 3, characterised in that the first and second face concrete mixtures (3.1, 3.2) for filling onto the compacted core concrete of the core concrete layer (2) are introduced into the mould simultaneously or in successive steps (4), wherein the first and second face concrete mixtures (3.1, 3.2) for filling into the mould (4) are preferably fed via at least one feed device (23) and / or in that the face concrete mixtures (3.1, 3.2) are fed chaotically into the mould (4).

5. Method according to claim 4, characterised in that the first and second facie concrete mixtures (3.1, 3.2) for filling into the mould (4) are fed together and preferably simultaneously by means of a feed device (23) designed as a common feed device (23).

6. Method according to one of the preceding claims, characterised in that the first and second face concrete mixtures (3.1, 3.2) are filled onto the compacted core concrete in such a way that the face concrete layer (3) extending over an upper surface (O) of the floor covering element (1) is formed by at least one first face concrete layer section (6.1) comprising the first face concrete mixture (3.1) and at least one second face concrete layer section (6.2) comprising the second face concrete mixture (3.2). (3.1), in particular that the face concrete layer (3) is formed by several face concrete layer sections (6.1, 6.2 - 6.n) that differ from one another.

7. Method according to one of the preceding claims, characterised in that additional face concrete mixtures (3.3 - 3.n) are prepared and provided and that the face concrete used for filling onto the compacted core concrete also comprises at least a portion of one or more of the additional face concrete mixtures (3.3 - 3.n).

8. Method according to one of the preceding claims, characterised in that the face concrete mixtures (3.1, 3.2, 3.3 - 3.n) are filled into the mould (4) in fixed or randomly selected portions, wherein the determination and / or selection of the portions of the face concrete mixtures (3.1, 3.2, 3.3 - 3.n) and, in particular, their feeding for introduction into the mould (4) is preferably carried out in an automated manner, in particular in a controlled manner.

9. Method according to one of the preceding claims, characterised in that the face concrete layer (3) is produced with a layer thickness (d) in a range from 4 mm to 15 mm, preferably in a range from 6 mm to 12 mm and particularly preferably from 8 mm to 10 mm.

10. Method according to one of the preceding claims, characterised in that, before filling the core concrete into at least one mould (4) and / or before filling the face concrete onto the compacted core concrete, at least one further concrete material is filled into the mould and compacted, thereby producing at least one further concrete layer, wherein the further concrete layer is arranged on the side of the core concrete layer facing away from the face concrete layer (3) and / or between the core concrete layer (2) and the face concrete layer (3).

11. Floor covering element (1) made of concrete, in particular concrete paving stone or concrete slab, comprising at least one multi-layer concrete block body with at least one concrete block underside (1.1) suitable for laying on a bedding layer of a sub-base and a concrete block upper side (1.2) opposite to this, wherein the multi-layered concrete block body comprises at least one core concrete layer (2) and at least one face concrete layer (3), wherein the face concrete layer (3) comprises at least one first face concrete section (6.1) and at least one second face concrete section (6.2), wherein the first face concrete section (6.1) comprises a first face concrete mixture (3.1) and the second face concrete section (6.2) comprises a second face concrete mixture (3.1) differing from the first face concrete mixture (3.1), wherein the floor covering element (1) thereby comprises a surface effect at an upper surface (O) at the concrete block top surface (1.2) and wherein the at least one first face concrete section (6.1) comprises a porous concrete material and the at least one second face concrete section (6.2) comprises a dense concrete material, characterised in that the first and second face concrete mixtures (3.1, 3.2) are mixed in sections and / or partially blended.

12. Floor covering element (1) according to claim 11, characterised in that the face concrete layer (3) comprises a plurality of face concrete sections (6.1 - 6.n), wherein the face concrete sections (6.1 - 6.n) are arranged randomly and irregularly distributed over the concrete block upper surface (1.2).