Supporting vertical precast concrete part and method for the horizontal production of a supporting vertical precast concrete part

Abstract

Method for the horizontal production of a load-bearing, vertical precast concrete element (5) comprising the following steps: a) providing a substantially horizontally oriented formwork panel with formwork fixed to the formwork panel and projecting from a plane of the formwork panel, wherein the formwork panel and the formwork define an interior area to be filled with concrete and the formwork comprises at least one formwork element (1) comprising: - a base body (2) with a first contact surface (21) facing the interior area for the concrete to be poured and a second contact surface (22) facing an outside of the formwork for the subsequent connection of a horizontal building element (6), in particular a basement ceiling or a floor slab, and - at least one force transmission element (31, 32, 33),which traverses the base body (2) from the first support surface (21) to the second support surface (22) and extends beyond the first support surface (21) and the second support surface (22), b) laying reinforcement in the interior area, c) pouring liquid concrete into the interior area, d) compacting the liquid and reinforced concrete, e) hardening the compacted, liquid and reinforced concrete, and f) stripping the hardened, compacted and reinforced concrete, wherein at least one formwork element (1) remains on the hardened concrete as permanent formwork; and a load-bearing, vertical precast concrete element (5).

Description

[0001] The present invention relates to a method for the horizontal production of a load-bearing, vertical precast concrete element according to the preamble of claim 1, in particular a building wall or a column, as well as a load-bearing, vertical precast concrete element.

[0002] US 5,491,948 A describes the horizontal production of a wall element for prefabricated houses according to the preamble of claim 1. A wooden beam with continuous reinforcement is provided as the upper end, which is connected to vertical reinforcement bars cast inside. The protruding ends are provided with threads, through which the wall elements can later be screwed to a wooden roof structure. During production, the wooden beam with the continuous reinforcement is inserted into the formwork and poured with concrete.

[0003] EP 0 338 972 describes a cantilever slab connection element with an insulating body through which reinforcing bars pass. The reinforcing bars are concreted into the cantilever slab on one side and into the floor slabs on the other. A formwork element as permanent formwork for the production of a precast concrete element, in which reinforcement elements can be passed through the formwork element, is known from DE 200 20 504 U1.

[0004] DE 100 28 514 C1 describes a formwork unit for edge formwork with a formwork element and reinforcement, wherein the reinforcement is formed on both sides of the formwork element, for concreting projecting components such as bridge ceilings, balcony slabs or the like, to which a cap, an upstand, a parapet or the like is to be attached.

[0005] Load-bearing, vertical precast concrete elements are used primarily as building walls and vertical columns. These precast concrete elements can be produced in a precast concrete plant, then transported to the construction site and assembled on site with the other building components to form the finished building. Precast concrete elements are manufactured in a precast concrete plant with the precast concrete element to be manufactured in a lying or horizontal state. For this purpose, formwork elements are fixed to a lying or horizontally aligned formwork panel to form a lateral formwork for the precast concrete element to be manufactured. This lateral formwork protrudes essentially perpendicularly from a slab level of the formwork panel and, together with the formwork panel, defines an interior area. Reinforcement is laid in this interior area to give the precast concrete element the necessary resistance to, among other things, tensile forces.Concrete is then poured into the interior, compacted, and then cured. Once the concrete has hardened, the formwork elements can be removed, and the precast concrete element can be transferred from its horizontal position on the formwork panel to a horizontal transport position. The precast concrete element is then ready for installation in a building.

[0006] When the precast concrete element is connected to a horizontally aligned basement ceiling below or a horizontally aligned floor ceiling above, a so-called bond joint is formed between the precast concrete element and the basement ceiling or between the precast concrete element and the floor ceiling.

[0007] In order for the precast concrete element to be positively connected to the basement ceiling or floor slab in the area of the composite joint, suitable force transmission elements are required, among other things. These protrude from the precast concrete element, cross the composite joint, and can be connected to the basement ceiling or floor slab. The force transmission elements must be able to absorb and transmit the shear forces occurring in the area of the composite joint. Rod-shaped reinforcement elements, for example, can be used for this purpose. In the area of the composite joint, thermally induced shear forces also occur. These are caused by the temperature difference and the associated different thermal expansion of the building parts adjacent to one another in the area of the composite joint, i.e. between the load-bearing, vertical precast concrete element and the basement ceiling or floor slab. These can, for example, lead to cracking in the concrete in the area of the composite joint.

[0008] During the horizontal production of precast concrete elements, especially in precast concrete plants, it becomes difficult when force-transmitting elements, such as rod-shaped reinforcement elements, have to be inserted through the formwork elements of the lateral formwork. The subsequent installation of force-transmitting elements on site is time-consuming and therefore costly.

[0009] The present invention is therefore based on the object of providing a method for the horizontal production of a load-bearing, vertical precast concrete element and such a precast concrete element, which are characterized by an easier introduction of force transmission elements and the associated improved force transmission in the bond joint between the precast concrete element and a horizontal building part to be connected to it.

[0010] This object is achieved according to the invention by a method for the horizontal production of a load-bearing, vertical precast concrete element having the features of claim 1 and a load-bearing, vertical precast concrete element having the features of claim 13. Advantageous embodiments and further developments of the invention are the subject of claims 2 to 12.

[0011] A method for the horizontal production of a load-bearing, vertical precast concrete element, in particular a building wall or a column, comprises the following steps: In a first method step (a), a substantially horizontally aligned formwork panel is provided with a formwork fixed to the formwork panel and protruding from a panel plane of the formwork panel, wherein the formwork panel and the formwork define an interior area to be filled with concrete.The formwork has at least one formwork element which comprises a base body with a first contact surface facing the interior for the concrete to be poured in and a second contact surface facing an outside of the formwork for the subsequent connection of a horizontal building part, in particular a basement ceiling or a floor ceiling, and at least one force transmission element which traverses the base body from the first contact surface to the second contact surface and extends beyond the first contact surface and the second contact surface.

[0012] In a second method step (b), reinforcement is installed in the interior area. This reinforcement can be made of reinforcing steel and / or glass fiber-reinforced plastic in the form of bars, mats, and / or stirrups. The reinforcement can overlap in the interior area with the at least one force transmission element extending beyond the first contact surface.

[0013] Subsequently, liquid concrete is poured into the interior in a third process step (c). The liquid concrete can be evenly distributed within the formwork and partially or completely cover the reinforcement installed inside. Furthermore, the first contact surface of the formwork element now rests against the poured concrete, so that at least one force transmission element extending beyond the first contact surface is also immersed in the liquid concrete. For example, normal concrete can be used as the concrete.

[0014] In a fourth process step (d), the liquid and reinforced concrete is compacted, i.e. the air content in the still liquid concrete is reduced. This compacted and still liquid concrete then hardens in a fifth process step (e). The hydration that takes place during hardening is a chemical reaction between cement and water and / or aggregates, which can last from several hours to days. In process step (e), this hardening can take place passively, i.e. essentially without additional heating. In this case, it is necessary to wait several hours to days until the compacted and liquid concrete has essentially hardened on its own. However, it is also within the scope of the invention for the hardening to be carried out actively by heating the compacted and liquid concrete. The heating can be carried out in a climatic chamber.Heating can shorten the hydration reaction time and thus accelerate hardening. In a further process step (f), the hardened, compacted, and reinforced concrete is removed from the formwork, with at least one formwork element remaining on the concrete, i.e., the precast concrete element, as permanent formwork. In other words, other formwork elements of the provided formwork that do not serve as permanent formwork are removed from the precast concrete element.

[0015] The base body of the formwork element can be cuboid-shaped, with the first contact surface and the second contact surface arranged on two opposite side surfaces and parallel to a longitudinal axis of the base body. The force transmission element traversing the base body is force-fitted to the hardened concrete on the side of the base body facing the hardened concrete. On the side of the base body facing away from the hardened concrete, the force transmission element extends beyond the second contact surface and serves as so-called connecting reinforcement for the horizontal building section to be connected. It is within the scope of the invention that several force transmission elements can traverse the base body.

[0016] This process enables the production of a load-bearing, vertical precast concrete element with integrated connecting reinforcement in the form of at least one force-transmitting element extending beyond the second contact surface of the formwork element's base body. This avoids the subsequent and time-consuming insertion of a force-transmitting element. Since the formwork element serves as permanent formwork and thus remains an integral part of the precast concrete element, it constrains the precast concrete element on one side. This eliminates the need for complex formwork elements with additional force-transmitting elements. This leads to time savings in the production of the precast concrete element and its subsequent installation in a building.

[0017] As mentioned previously, the precast concrete element can be a building wall or column. In this case, the formwork element is positioned at the top or bottom of the building wall or column. This allows the building wall or column to be rigidly connected either to an overlying floor or to a basement ceiling below.

[0018] In order to reduce heat conduction from, for example, the basement ceiling into an underlying load-bearing, vertical precast concrete element of a building's basement for energy reasons, these building elements are generally provided with externally applied thermal insulation on the basement side in the prior art. However, this externally applied thermal insulation cannot prevent heat conduction from the basement ceiling into the underlying load-bearing, vertical precast concrete element through the bonding joint, i.e. through the concrete of the adjacent building elements. In the method according to the invention, the base body therefore has, at least in sections, a layered structure made up of heat-insulating and / or compressive force-transmitting layers. This can reduce or even completely prevent heat conduction from, for example, a basement ceiling into the underlying basement walls.According to the invention, the layered structure comprises at least one core layer made of heat-insulating or heat-insulating and compressive force-transmitting material and at least two outer layers made of compressive force-transmitting material, each bordering the core layer on one side. The layered structure is thus designed as a so-called sandwich construction.

[0019] The term "section-wise" means that the base body has sections without a layered structure and sections with a layered structure along its longitudinal extension or longitudinal axis. The formwork element, which serves as a permanent formwork, can be adapted to the requirements of the precast concrete element's subsequent installation in the building. Furthermore, the entire base body can also have a layered structure along its longitudinal axis. The individual layers of the layered structure preferably run essentially parallel to the first contact surface and the second contact surface.

[0020] In an advantageous embodiment of the method according to the invention, the core layer is introduced between the outer layers in a process step (i). This process step (i) can be carried out before process step (a), between two of the process steps (a) to (f), or after process step (e).

[0021] For example, for process step (a), a formwork element can be provided that has two spaced-apart outer layers traversed by one or more force-transmitting elements. Between process steps (a) and (b), in process step (i), the thermally insulating or thermally insulating and force-transmitting material is then inserted as a core layer between the two outer layers. This allows the formwork element to be mass-produced without a core layer and stored in the precast concrete plant. Its thermally insulating and / or compressive force-transmitting properties are only determined during production of the precast concrete element.

[0022] A further advantageous embodiment of the method according to the invention provides that the core layer is made of lightweight concrete and / or the outer layers are made of fine-grained concrete. Lightweight concrete is a compressive force-transmitting and heat-insulating material. According to current regulations, this is defined as concrete with a dry bulk density of a maximum of 2,000 kg / m 3 . The low density compared to normal concrete is achieved through appropriate manufacturing processes and different lightweight concrete grain sizes, preferably grain sizes with grain porosity such as expanded clay. Lightweight concrete in the composition used here preferably has a dry bulk density of 1,000 kg / m 3 to 2,000 kg / m 3 , more preferably of 1,100 kg / m 3 to 1,800 kg / m 3 , and particularly preferably of 1,200 kg / m 3 to 1,650 kg / m 3 .For smaller buildings and lower loads, bulk densities in the range of 1200 to 1350 kg / m 3 are preferred, while for larger buildings and higher loads, bulk densities in the range of 1350 kg / m 3 to 1650 kg / m 3 are used. This low bulk density leads to a reduced thermal conductivity λ 10,tr of the dry or hardened lightweight concrete compared to normal concrete. The thermal conductivity λ 10,tr is usually measured at an average temperature of 10 °C and after drying to constant weight. The lightweight concrete preferably has a thermal conductivity λ 10,tr in the dry or hardened state of essentially 0.25 W / (m K) to 0.60 W / (m K). The following table shows exemplary values for the thermal conductivity λ 10,tr of the dry and hardened lightweight concrete for two different dry density ranges: . dry bulk density [kg / m 3< ] of the lightweight concrete Thermal conductivity λ 10,tr [W / (m·K)] of lightweight concrete 1.350 - 1.650 0,40 - 0,60 1.200 - 1.350 0,25 - 0,40

[0023] The modulus of elasticity (E-modulus) of lightweight concrete is between approximately 6,000 and 22,000 N / mm 2< , preferably between 8,000 and 16,000 N / mm 2< , most preferably between 11,000 and 15,000 N / mm 2< .

[0024] Fine-grained concrete is a type of concrete with a maximum grain diameter of 8 mm, but preferably also includes the group of mortars, which by definition have a maximum grain diameter of 4 mm. Fine-grained concrete can contain fibers to improve its mechanical and fire-protection properties. These fibers can be made of carbon, steel, plastic, glass, basalt, other rock fibers, and / or a combination thereof.

[0025] Thermally induced shear forces occur in the area of the bond joint between the precast concrete element and the horizontal building section. To absorb these shear forces, a further advantageous embodiment of the method according to the invention uses a base body whose first contact surface has a first surface profile and / or whose second contact surface has a second surface profile. Due to the respective surface profile, the first and / or the second contact surface are rough and, depending on the extent of the surface profile, therefore have a higher shear friction value compared to an unprofiled and thus smooth contact surface. This creates a stronger interlock between the load-bearing, vertical precast concrete element and the horizontal building section.

[0026] In general, construction joints, which in this case are formed by the second contact surface of the base body of the formwork element, are differentiated by their roughness. According to current regulations, four standard roughness categories are distinguished: a construction joint is classified as "very smooth" if the concrete element was cast against a smooth, untreated surface using highly fluid concrete. A construction joint is considered "smooth" if the concrete surface has been leveled after the concrete was poured and compacted. A construction joint is classified as "rough" if it has a roughness of at least 3 mm, resulting from exposed aggregate in the concrete. A construction joint is considered "interlocked" if it has at least 6 mm of exposed aggregate with a minimum concrete grain size of > 16 mm.The greater the roughness of the surface of the second contact surface of the base body of the formwork element, the stronger the interlocking between the load-bearing, vertical precast concrete element and the horizontal building part and the higher the shear forces that can be transmitted in the area of the composite joint.

[0027] In a further advantageous embodiment of the method according to the invention, the first surface profiling and the second surface profiling are formed independently of one another as projections projecting substantially vertically from the respective contact surface or as a surface roughness. The term "surface roughness" refers to the unevenness of a surface. The projections can, in particular, be ribs or cams. The first and / or second surface profiling can be formed as transverse ribbing along the longitudinal axis of the base body.

[0028] A further advantageous embodiment of the method according to the invention provides that the projections of the first contact surface and the projections of the second contact surface are arranged substantially in alignment with one another. At least one force transmission element can traverse the base body in the region between the respective projections of the first contact surface and the second contact surface, which are arranged in alignment with one another. In other words, the projections of the first contact surface and the projections of the second contact surface are arranged between the force transmission elements extending beyond the first contact surface and the second contact surface.

[0029] Alternatively, in a further advantageous embodiment of the method according to the invention, the projections of the first contact surface and the projections of the second contact surface are arranged offset from one another.

[0030] In a further advantageous embodiment of the method according to the invention, the projections have a flank in the transition area between their outer projection top side and the respective inner contact surface, the angle of inclination α of which is less than or equal to 90°. If the projections are designed as ribs, these ribs have a rib flank in the transition area between their outer rib apex area and the respective inner contact surface, which can also be referred to as the rib base. The angle of inclination α of the flank can be selected such that optimal shear force transmission can take place in the area of the bond joint, i.e. between the load-bearing, vertical precast concrete element and the horizontal building part to be connected to it, in particular the basement or floor slab.The angle of inclination α of the flank of the projections or the ribs preferably has a value of 45° to 90°, more preferably of 45° to 85° and particularly preferably of 60° to 75°.

[0031] For optimal transmission of the occurring shear forces, a further advantageous embodiment of the method according to the invention provides that the angle of inclination α 1 of the flank of the projections of the first contact surface and the angle of inclination α 2 of the flank of the projections of the second contact surface are identical or different from one another. For example, the angle of inclination α 1 of the flank of the projections of the first contact surface can be smaller than the angle of inclination α 2 of the flank of the projections of the second contact surface. The resulting different shear force transmission preferably allows the targeted determination of a joint that will fail first. By determining the joint that will fail first, force control can be achieved.

[0032] Furthermore, the transmission of shear force in the bond joint between the precast concrete element and the horizontal building part to be connected to it, in particular the basement or floor slab, can also be improved by using, in a further advantageous embodiment of the method according to the invention, a formwork element in which the projections of the first contact surface and the projections of the second contact surface have an identical or different projection height h. If the projections are designed as ribs, then the ribs of the first contact surface and the projections of the second contact surface have an identical or different rib height h. It is also within the scope of the invention that a formwork element can be used in this method in which the projections of the first contact surface and the projections of the second contact surface have an identical or different rib pitch T.If the projections are designed as ribs, the ribs of the first contact surface and the ribs of the second contact surface have an identical or different rib pitch T.

[0033] In a further advantageous embodiment of the method according to the invention, the at least one force transmission element is connected to the base body in a force-locking manner. If only a heat-insulating material, and thus a non-compressive force-transmitting material, is inserted between the outer layers as the core layer, the force transmission element can also be connected to the two outer layers in a force-locking manner.

[0034] In a further advantageous embodiment of the method according to the invention, the force transmission element is a rod-shaped shear force transmission element, preferably made of glass fiber reinforced plastic (GRP) or stainless steel. The use of GRP or stainless steel further improves the thermal insulation properties of the formwork element. The rod-shaped shear force transmission element can have a surface profile at least partially along its longitudinal axis. This surface profile of the rod-shaped shear force transmission element improves the transmission of the shear forces occurring in the area of the composite joint. This surface profile of the rod-shaped shear force transmission element can be designed, in particular, as ribs or knobs.The ribs can, for example, run obliquely to the longitudinal axis or radially or helically around the longitudinal axis of the rod-shaped shear force transmission element and can be formed either continuously or as non-continuous individual ribs. The studs can have the shape of a polyhedron, cone, or cylinder.

[0035] A second aspect of the invention provides a load-bearing, vertical precast concrete element, in particular a building wall or a column. This precast concrete element is obtainable by the method claimed in claim 1 or by one of its advantageous embodiments. As a result, in its simplest embodiment, produced according to the method claimed in claim 1, it comprises a base body with a first contact surface for the hardened concrete and a second contact surface for the subsequent connection of a horizontal building part, in particular a basement ceiling or a floor ceiling, and at least one force transmission element which traverses the base body from the first contact surface to the second contact surface and extends beyond the first contact surface and the second contact surface.

[0036] As mentioned previously, the load-bearing, vertical precast concrete element can be a building wall or column. In this case, the formwork element is located at the top or bottom of the building wall or column. This allows the building wall or column to be rigidly connected either to an overlying floor or to a basement floor below.

[0037] In contrast to this precast concrete element according to the invention, precast concrete elements that are constructed vertically and are intended to have force transmission elements for connection to an overlying floor slab or to a basement slab below can only be manufactured in a multi-stage and therefore time-consuming process. The term "multi-stage" means that in a vertically aligned formwork First, the lower section of the component is made of reinforced normal concrete, force transmission elements are inserted into this lower section and then an upper section of the component is made of lightweight concrete above the lower section, which is crossed by the force transmission elements and, when installed, rests against the floor slab above.

[0038] Such a multi-stage process is more time-consuming and therefore more costly than the process according to the invention.

[0039] As an alternative to this multi-stage process, for vertical production of the precast concrete element, concrete could also be poured from below against the formwork element. However, this would result in air pockets forming between the formwork element and the reinforced concrete and / or a weak layer due to rising water, which would impede the necessary force transmission in the bond joint. While this weak layer that forms does not pose a problem on open surfaces, as the water on the surface simply dries off and the non-load-bearing, weak top layer can be brushed off with a wire brush, for example, this weak layer leads to a greater problem on surfaces that are closed at the top, as once the water dries off, a gap forms between the formwork element and the freshly concreted area. Furthermore, the weak layer can no longer be accessed mechanically (e.g. with a wire brush or similar).This can lead to undesirable cracking in the area of the composite joint. The precast concrete element produced using the method according to the invention exhibits little to no air pockets or weakened areas between the formwork element and the hardened, compacted, and reinforced concrete. This results in improved force transmission in the area of the composite joint.

[0040] An exemplary embodiment of the method according to the invention, several exemplary embodiments of the precast concrete element, and an exemplary embodiment of a building section comprising the precast concrete element are described and explained in more detail with reference to the accompanying drawings. Fig. 1 shows a first embodiment of a formwork element in side view; Fig. 2 shows the first embodiment of Figure 1in a perspective view; Fig. 3 a second embodiment of the formwork element in side view; Fig. 4 the second embodiment of Figure 3 in a perspective view; Fig. 5 a third embodiment of the formwork element in a side view; Fig. 6 the third embodiment of the formwork element from Figure 5 in perspective view; Fig. 7 a fourth embodiment of the formwork element in side view; Fig. 8 the fourth embodiment of the formwork element from Figure 7 in perspective view; Fig. 9 a fifth embodiment of the formwork element in side view; Fig. 10 the fifth embodiment of Figure 9in a perspective view; Fig. 11 a sixth embodiment of the formwork element in side view; Fig. 12 an embodiment of a method according to the invention for the horizontal production of a load-bearing, vertical precast concrete element; Fig. 13 an embodiment of a precast concrete element 5 after its production in front view; Fig. 14 a cross-sectional view of a building section in which the precast concrete element is installed.

[0041] Figure 1 shows a first embodiment of a formwork element 1 in side view, not according to the invention. This formwork element 1 has a base body 2 with a first contact surface 21 and a second contact surface 22 opposite the first contact surface 21.

[0042] During the horizontal production of a precast concrete element, the formwork element 1 serves as a component of a formwork that is fixed to a horizontally aligned formwork panel and protrudes from a panel plane of the formwork panel. The formwork element 1 and the formwork panel define an interior area to be filled with concrete. The first contact surface 21 faces this interior area during the process and therefore serves as a contact surface for the concrete to be poured. If the precast concrete element is installed as part of a building after its production, the second contact surface 22 serves for the subsequent connection of a horizontal building section, in particular a basement or floor slab.

[0043] The base body 2 has a plurality of force transmission elements 31, 32, 33 designed as rod-shaped shear force transmission elements. The shear force transmission elements 31, 32, 33 traverse the base body 2 from the first contact surface 21 to the second contact surface 22 and extend beyond the first contact surface 21 and the second contact surface 22. They serve to transmit shear forces in the area of the composite joint during the installation of the precast concrete element to be manufactured. In the present exemplary embodiment, the base body 2 is cuboid-shaped and made of high-compression-resistant fine-grain concrete. The shear force transmission elements 31, 32, 33 traverse the base body 2 perpendicular to its longitudinal axis. To reduce the thermal conductivity of the formwork element, the shear force transmission elements 31, 32, 33 are made of GRP. Figure 2 shows the non-inventive embodiment of Figure 1 in a perspective view. As can be seen from this Figure 2As can be seen, the formwork element 1 has two rows of shear force transmission elements 31, 32, 33 running parallel to each other along the longitudinal axis of the base body. The number and arrangement of the shear force transmission elements 31, 32, 33 depends on the requirements of the formwork element 1 in its later installed state in the building.

[0044] Figure 3 shows a second embodiment of the formwork element 1 in side view. This second embodiment differs from the one shown in the Figures 1 and 2 The first embodiment shown is characterized in that the first contact surface 21 has a first surface profile 211 and the second contact surface 22 has a second surface profile 221. In the present second embodiment, the surface profiles 211, 221 are designed as ribs 212, 222. The ribs 221, 222 enable improved thrust absorption and transmission. Figure 4shows a perspective view of this second embodiment of the connecting element 1. In this Figure 4 It can be seen that the ribs 212 on the first contact surface 21 form a transverse ribbing along the longitudinal axis of the base body 2. The same applies to the Figure 4 invisible ribs 222 on the second contact surface 22.

[0045] Figure 5shows a third embodiment of the formwork element 1 in a side view. In this third embodiment of the formwork element 1, the projections 212 of the first contact surface 21 and the projections 222 of the second contact surface 22 are arranged in alignment with one another. The region of the projections 212, 222 arranged in alignment with one another has a layered structure 4. This layered structure 4 comprises a core layer 41 made of heat-insulating and compressive force-transmitting lightweight concrete and two outer layers 42, 43, each delimiting the core layer 41 on one side. The outer layers 42, 43 are made of high-compression-resistant fine-grain concrete. Thus, the base body 2 has a so-called sandwich construction in the region of the layered structure 4. The three layers 41, 42, 43 run parallel to the first contact surface 21 and the second contact surface 22, as well as to the longitudinal axis of the base body 2.The transverse force transmission elements 31, 32, 33 pass through the base body 2 in the region between the projections 212, 222 of the first contact surface 21 and the second contact surface 22, respectively. Thus, the layer structure 4 is located between the transverse force transmission elements 31, 32, 33. Figure 6 shows the third embodiment of the formwork element 1 from Figure 5 in perspective view.

[0046] Figure 7shows a fourth embodiment of the formwork element 1 in side view. This fourth embodiment of the formwork element 1 differs from the third embodiment of the formwork element 1 in that the entire base body 2 has the layer structure 4 along its longitudinal axis. In this case, the shear force transmission elements 31, 32, 33, as they pass through the base body 2 from the first contact surface 21 to the second contact surface 22, first traverse the first outer layer 42 made of fine-cage concrete, then the core layer 41 made of lightweight concrete, and finally the second outer layer 43 made of fine-cage concrete. Figure 8 shows a perspective view of the fourth embodiment from Figure 7 Due to the lack of surface profiling, the two contact surfaces 21, 22 have a smooth surface or a construction joint classified as "smooth".

[0047] Figure 9shows a fifth embodiment of the formwork element 1 in side view. This fifth embodiment of the formwork element 1 differs from the fourth embodiment in that both the first contact surface 21, which is formed by the first outer layer 42, and the second contact surface 22, which is formed by the second outer layer, have projections 212, 222 in the form of ribs. In this fifth embodiment of the formwork element 1, the ribs 212 of the first contact surface 21 and the ribs 222 of the second contact surface 22 are arranged offset from one another. Figure 10 shows the fifth embodiment from Figure 9 in a perspective view.

[0048] Figure 11shows a sixth embodiment of the formwork element 1 in side view. This sixth embodiment differs from the fifth embodiment in that an inclination angle α 1 of the flank of the ribs 212 of the first contact surface 21 is smaller compared to the inclination angle α 2 of the flank of the ribs 222 of the second contact surface 22. Furthermore, the ribs 212 of the first contact surface 21 have a larger rib pitch T 1 compared to the rib pitch T 2 of the ribs 222 of the second contact surface 22. In a building wall that has such a formwork element 1 on its upper side, a different interlocking effect results between the ribs 222 of the second contact surface 22 and an overlying and connected floor or basement ceiling than between the ribs 212 of the first contact surface 21 and a wall section of the building wall made of reinforced concrete that bears against the first contact surface 21.

[0049] The six previously explained embodiments of the formwork element 1, which are shown in the Figures 1 to 11 can be used in the method described below for the horizontal production of a load-bearing, vertical precast concrete element, in particular a building wall or a column.

[0050] Figure 12 shows an embodiment of a method according to the invention for the horizontal production of a precast concrete element. In a first method step (a), an aligned formwork panel is provided with a formwork fixed to the formwork panel and protruding from a panel plane of the formwork panel, wherein the formwork panel and the formwork define an interior area to be filled with concrete. The formwork comprises one of the six previously described embodiments of the formwork element 1.

[0051] In a second process step (b), reinforcement is installed in the interior area. In the present embodiment, this reinforcement comprises reinforcing steel in the form of bars, mats, and stirrups. It overlaps the rod-shaped shear force transmission elements 31, 32, 33 of formwork element 1 in the interior area.

[0052] In a third process step (c), the interior is filled with concrete. In order to reduce the air content in the concrete, the concrete is compacted in a process step (d). In the present embodiment, this compaction is carried out by vibrating. The compacted, liquid, and reinforced concrete then hardens in a fifth process step (e). This hardening takes place passively, i.e., without additional heating of the compacted, liquid, and reinforced concrete. In other words, several hours are waited for the compacted, liquid, and reinforced concrete to harden before the next process step (f). In the further process step (f), the hardened, compacted, and reinforced concrete is stripped, with the formwork element 1 remaining on the concrete, i.e., the precast concrete element, as permanent formwork. The precast concrete element is then transferred from its horizontal position to a vertical position and transported to the construction site.

[0053] Figure 13 shows an embodiment of a precast concrete element 5 after its manufacture in a front view. This precast concrete element 5 is designed as a building wall. It has a wall section 51 made of reinforced concrete. On the top side of the wall section 21, the previously explained and in the Figures 7 and 8 The fourth embodiment of the formwork element 1 shown is connected as a permanent formwork. Due to the manufacturing process described above, there are no disturbing air inclusions between the formwork element 1 and the wall section 51. For this reason Figure 13 It can be seen that the first contact surface 21 of the base body 2 of the formwork element 1 rests against the reinforced concrete 512 of the wall section 51. The shear force transmission elements 31, 32, 33 traversing the base body 2 are connected to the wall section 51, ie they extend into the reinforced concrete.

[0054] Figure 14shows a cross-sectional view of a building section 6, in which a Figure 13 shown precast concrete element 5 is installed. Figure 14 It can be seen that the shear force transmission element 31, which passes through the base body 2, is also connected to a floor slab 7 arranged above the precast concrete element 5 designed as a building wall. Since the base body 2 has a layered structure 4 comprising a core layer 41 made of heat-insulating and compressive force-transmitting lightweight concrete and two outer sides 42, 43 made of compressive force-transmitting fine-grained concrete, each of which borders the core layer 41 on one side, only a small amount of heat is dissipated from the floor slab 7 into the underlying building wall.

Claims

1. Method for the horizontal production of a supporting vertical precast concrete part (5), in particular a building wall or a column, comprising the following steps: a) providing a substantially horizontally aligned formwork panel with a formwork fixed on the formwork panel and projecting from a panel plane of the formwork panel, wherein the formwork panel and the formwork define an inner region to be filled with concrete and the formwork has at least one formwork element (1) which comprises - a base body (2) with a first contact surface (21) facing the inner region for the concrete to be filled in and a second contact surface (22) facing an outer side of the formwork for the subsequent connection of a horizontal building part (6), in particular a basement ceiling or a floor ceiling, and - at least one force-transmitting element (31, 32, 33) which passes through the base body (2) from the first contact surface (21) to the second contact surface (22) and extends beyond the first contact surface (21) and the second contact surface (22), b) laying a reinforcement in the inner region, c) pouring liquid concrete into the inner region, d) compacting the liquid and reinforced concrete, e) hardening the compacted, liquid and reinforced concrete, and f) stripping the hardened, compacted and reinforced concrete, wherein the at least one formwork element (1) remains as permanent formwork on the hardened concrete; characterized in that the base body (2) has, at least in sections, a layered structure (4) of thermally insulating and / or compressive force-transmitting layers and the layered structure (4) comprises at least one core layer (41) of thermally insulating or thermally insulating and compressive force-transmitting material and at least two outer layers (42, 43) of compressive force-transmitting material, each of which bounds the core layer (41) on one side.

2. Method according to claim 1, in which the core layer (41) is introduced between the outer layers (42, 43) in a method step (i), wherein the method step (i) is carried out either - before the method step (a), - between two of the method steps (a) to (f) or - after the method step (e).

3. Method according to claim 1 or 2, in which the core layer (41) is made of lightweight concrete and / or the outer layers (42, 43) are made of fine-grain concrete.

4. Method according to any one of the preceding claims, in which the first contact surface (21) has a first surface profile (211) and / or the second contact surface (22) has a second surface profile (221).

5. Method according to claim 4, in which the first surface profile (211) and the second surface profile (221) are formed independently of one another as substantially vertically projecting protrusions (212, 222), in particular ribs or cams, or as a surface roughness.

6. Method according to claim 5, in which the protrusions (212) of the first contact surface (21) and the protrusions (222) of the second contact surface (22) are arranged substantially flush with one another and preferably at least one force-transmitting element (31, 32, 33) passes through the base body (2) in the region between the respective protrusions (212, 222) of the first contact surface (21) and the second contact surface (22).

7. Method according to claim 5, in which the protrusions (212) of the first contact surface (21) and the protrusions (22) of the second contact surface (222) are arranged offset from one another.

8. Method according to any one of claims 5 to 7, in which the protrusions (212, 222) have, in the transition region between their outer protrusion upper side and the respective inner contact surface, a flank whose angle of inclination α is less than or equal to 90°.

9. Method according to claim 8, in which the angle of inclination α1 of the flank of the protrusions (212) of the first contact surface (21) and the angle of inclination α2 of the flank of the protrusions (222) of the second contact surface (22) are identical or different from one another.

10. Method according to any one of claims 5 to 8, in which the protrusions (212) of the first contact surface (21) and the protrusions (222) of the second contact surface (22) have an identical or different protrusion height h and / or rib pitch T.

11. Method according to any one of the preceding claims, in which the at least one force-transmitting element (31, 32, 33) is frictionally connected to the base body (2).

12. Method according to any one of the preceding claims, in which the force-transmitting element (31, 32, 33) is a rod-shaped transverse force-transmitting element preferably glass-fiber-reinforced plastic or stainless steel.

13. Supporting vertical precast concrete part (5) made of hardened, compacted and reinforced concrete, in particular a building wall or a column, having at least one formwork element (1) remaining in the hardened concrete as permanent formwork, wherein the formwork element (1) comprises a base body (2) with a first contact surface (21) for the hardened, compacted and reinforced concrete and a second contact surface (22) for the subsequent connection of a horizontal building part (6), in particular a basement ceiling or a floor ceiling, and comprises at least one force-transmitting element (31, 32, 33) which passes through the base body (2) from the first contact surface (21) to the second contact surface (22) and extends beyond the first contact surface (21) and the second contact surface (22), characterized in that the base body (2) has, at least in sections, a layered structure (4) of thermally insulating and / or compressive force-transmitting layers and the layered structure (4) comprises at least one core layer (41) of thermally insulating and / or compressive force-transmitting material and at least two outer layers (42, 43) of thermally insulating and / or compressive force-transmitting material, each of which bounds the core layer (41) on one side.

Images