Method of reinforcing a reinforced concrete component

Abstract

The present invention relates to a method of producing an individual reinforcement of a future reinforced concrete component (1).

Description

[0001] Method for reinforcing a reinforced concrete component

[0002] The invention relates to a method for producing individual reinforcement of a future reinforced concrete component from prefabricated reinforcement elements.

[0003] Typically, a structural engineer creates a reinforcement plan for a reinforced concrete component, ideally optimized for steel quantity and product-neutral, often already electronically in 3D using a round steel module within a CAD program. Based on this reinforcement plan, the reinforcement of the reinforced concrete component is created on-site or in the precast plant, and the component is then manufactured. Such a reinforcement plan contains the location and quantity of the reinforcing steel bars to be placed in the top and bottom planar reinforcement, as well as the additional reinforcement elements in between, such as spacers, hooks, bent bars, cages, and the like. This type of reinforcement plan, already existing in three-dimensional electronic form, is often converted into 2D drawings and printed on paper.

[0004] The practical implementation of the reinforcement plan on the construction site is essentially achieved by manually laying the individual cut and bent reinforcing steel bars, which must be connected to each other by hand using binding wire. This method is cumbersome and requires a considerable amount of working time, and is particularly uneconomical and prone to errors, especially given the increasing labor shortage. Therefore, it is generally advisable to use standardized reinforcement elements for implementing the reinforcement plan, such as stock mats, pre-made mats, mesh cages, or similar products, which can be prefabricated and stored, and thus quickly deployed on the construction site.

[0005] The applicant is also known to have individualized reinforcement elements in the form of uniaxial, rollable reinforcing steel bar mats, in which a large number of parallel reinforcing steel bars are connected to each other at several points along their length by means of non-statically acting bands and are rolled up into a roll, transported and placed into the resulting component, where they only need to be unrolled.

[0006] A disadvantage of this approach is that the individual circumstances of each construction site cannot be adequately taken into account, and therefore manual tying of steel bars is often still necessary.

[0007] It is therefore the purpose of the invention to avoid this disadvantage.

[0008] This task is solved in a method for generating individual reinforcement of a reinforced concrete component from predominantly prefabricated reinforcement elements by including at least the following steps: - Importing a first reinforcement plan of the future reinforced concrete component based on reinforcing steel bars and featuring area-based basic reinforcement; - Converting the area-based basic reinforcement into a modified basic reinforcement, which features reinforcing steel bars of unlimited length such that no overlaps of bars occur within the basic reinforcement; - Calculating a plurality of individual reinforcement elements from the modified basic reinforcement and the first reinforcement plan, also changing the individual reinforcing steel bars with regard to their number, shape, length, diameter, position, steel grade, and also specifying a laying sequence to create an individual reinforcement plan.

[0009] The transformation according to the invention is initially carried out by calculating a modified basic reinforcement of the component, in which the reinforcing steel bars specified by the designer are transformed into bars that extend continuously from one side of the future component to the opposite side. The modified basic reinforcement of the respective reinforcement layers of the future reinforced concrete component thus comprises mutually parallel reinforcing steel bars of any length without overlaps. Therefore, according to the invention, the reinforcing steel bars can also be selected to be of any length, regardless of the actual availability of such extremely long bars. The other reinforcement elements of the first reinforcement plan between the two basic reinforcements are not initially changed.In a further step, a plurality of individual reinforcement elements are calculated from this modified basic reinforcement and the additional reinforcement components of the first reinforcement plan. According to the invention, the reinforcing steel bars designated for these elements may differ from those of the first reinforcement plan with regard to number, shape, length, diameter, position, and steel grade, as well as in that a laying sequence is specified or additional or different welding points are provided. They may also include the additional reinforcement components, provided that this also results in simpler and faster installation.

[0010] The method according to the invention significantly increases the ease of reinforcement placement, albeit at the cost of potentially higher material usage. This is achieved primarily by identifying structurally undisturbed areas that are easy to reinforce and equipping these areas with reinforcement elements that are simple, quick, and as straightforward as possible to install. These reinforcement elements can be extended into the disrupted areas, potentially with additional reinforcement elements, thus increasing material usage. This method is particularly advantageous for use with so-called BIM (building information modeling) components, i.e., those that digitally represent a building or its parts. This is especially true when an IFC format is used. In other words, the invention transforms a quantity-optimized reinforcement solution into an execution-optimized reinforcement solution, albeit with computational effort.In this case, the execution-optimized reinforcement solution is implemented particularly in reinforcement bodies manufactured individually for the construction site.

[0011] The method according to the invention may include the following further steps, wherein all steps of the method are preferably carried out using a computer, provided this is practically feasible: - Minimizing the number of reinforcement elements in the individual reinforcement plan; fixing an individual reinforcement element with regard to the type and arrangement of the reinforcing steel bars in the individual reinforcement plan; - Generating a machine data set for the production of at least one calculated individual reinforcement element; - Transferring the machine data set to a production machine and producing at least one individual reinforcement element; - Producing the individual reinforcement on site at a construction site. The last three steps are not essential components of the method.A significant advantage of this method is that individual reinforcing steel bars no longer need to be laid manually and connected with binding wire. Instead, according to the invention, predominantly or exclusively prefabricated reinforcement elements can be used, each replacing a multitude of the original individual reinforcing steel bars and individually calculated for each construction site. This significantly reduces the working time required for on-site reinforcement installation. Furthermore, the probability of installation errors is greatly minimized due to the considerably smaller number of components to be laid and connected. Because of the inherent minimization of the individual reinforcement elements, their size and shape are optimized to minimize the number required. This further reduces the working time needed to connect the elements.

[0012] Preferably, the method also includes the performance of a collision check of the bars, so that changes in number, shape, length, position and laying sequence cannot lead to problems.

[0013] The process selects the type of reinforcement elements to be manufactured or used from uniaxial reinforcement mats, in particular rollable uniaxial reinforcing steel bar mats, biaxial reinforcement mats, edge cages, connection cages, welded reinforcement cages, and individual reinforcing steel bars. The use of slab reinforcement is also possible. These are static reinforcement solutions consisting of a multitude of bars of varying diameters, lengths, and spacings, grouped within a slab-like concrete encasement. Spacers and other additional reinforcement between the two primary reinforcement layers can be integrated, but this is not mandatory. In the case of uniaxial reinforcement mats, each of the upper and lower primary reinforcement layers comprises two layers of mats oriented orthogonally to each other.Biaxial or drawing mats are used if they are more advantageous for use on the respective construction site. Edge and connection cages serve to connect the individual reinforcement elements or to join slab and wall reinforcements, which offer a significant time saving compared to laying and bending individual connecting steel bars. According to the invention, these cages are not standardized, but rather individually calculated and manufactured for each construction site, optimally suited to the local connection and edge conditions. Additional reinforcement, according to the invention, includes in particular spacers, but also fixed, steel-optimized reinforcing steel bars from the original calculation.

[0014] The method according to the invention solves the problem of overlaps or collisions as described below, in particular by modifications.

[0015] These modifications include those relating to the presence, arrangement, length, and diameter of at least one reinforcing steel bar, particularly through the addition of sacrificial or supplementary material. According to the invention, the modification of the basic reinforcement for generating the individual reinforcement elements is achieved, in particular, by lengthening at least one reinforcing steel bar compared to the original reinforcement plan by adding sacrificial or purely structural supplementary material. Sacrificial material here refers to supplementary material not included in the calculations of the original reinforcement plan. Such an addition of sacrificial material, which generally increases costs and should therefore be avoided, offers particular advantages in areas with non-predominantly static loads, where welding is not permitted and, consequently, the ends of reinforcing steel bars cannot be connected to each other with straps.The invention also provides for an extension of reinforcing steel bars to connect reinforcing mats with edges or connection cages, or to extend a reinforcing steel bar to the next mounting strip or mounting bar, thus enabling attachment to at least two mounting elements without requiring additional individual connecting steel bars. Reinforcing elements that must ensure sufficient overlap of a reinforcement splice after overcoming an obstacle also feature an extension. Alternatively, such an extended reinforcing element is one that is itself the extension, i.e., connecting two individual reinforcing elements, such as uniaxial roll-up mats, which cannot be unrolled together because they are separated by an obstacle, by means of an overlap.The extension of reinforcing steel bars according to the invention beyond the originally calculated dimension required for structural analysis is indeed more expensive; however, the simpler and faster installation made possible by this method results in a significant time saving during reinforcement assembly. This is particularly advantageous since personnel costs represent a large proportion of the total costs of reinforcement assembly.

[0016] According to the invention, overlaps are provided at adjacent joints of the reinforcement elements by means of extended reinforcing steel bars of one reinforcement element. Therefore, according to the invention, the reinforcing steel bars of one reinforcement element are offset relative to those of the two adjacent reinforcement elements, and thus the position of these offset reinforcement elements deviates from the calculated modified basic reinforcement. The offset is achieved in particular by the diameter of a reinforcing steel bar, whereby two adjacent mats (reinforcement elements) can be laid overlapping without the reinforcing steel bars coming into contact with each other.In this context, it is also according to the invention to shift the strip(s) located in the subsequent overlap area as mounting elements for the bars of a mat along the longitudinal axis of the reinforcing steel bars during the production of reinforcement elements in the form of uniaxial, rollable reinforcement mats, so that a vertical collision is avoided and the plane of the reinforcement is maintained. The modifications also include the automatic repositioning of reinforcing steel bars based on machine specifications in the production process, for example, a minimum spacing of the reinforcing steel bars required by the production plant.

[0017] In addition to the modification, the process also includes the calculation and fabrication of lap reinforcement elements, particularly in the form of axially short lap mats made of parallel reinforcing steel bars, which are connected to mounting elements and are laid overlapping between adjacent, abutting reinforcement mats. Mounting elements are statically ineffective strips for uniaxial reinforcement mats, and statically effective or ineffective mounting bars for uniaxial or biaxial mats.

[0018] According to the invention, two or more reinforcement elements can also be manufactured and transported connected to each other by means of continuous assembly elements, which are only separated on site during installation, particularly at appropriately marked areas, by cutting through the assembly elements.

[0019] Particularly with regard to the reinforcement elements that form the upper layer of a basic reinforcement, the method according to the invention provides for the repositioning of reinforcing steel bars and / or the addition of additional reinforcing steel bars, possibly reducing the diameters of the affected reinforcing steel bars, if they would otherwise be too far apart for safe access by a worker, for example, during the concreting of the reinforced concrete component. In this embodiment as well, the basic principle of the invention is applied: to simplify and accelerate the placement of the reinforcement elements by using additional material and generating a placement-optimized plan from a quantity-optimized plan. This is preferably done electronically.

[0020] In one embodiment of the method according to the invention, extended reinforcing steel bars are connected in the area of ​​the sacrificial material to a mounting element, which may also be extended, such as a strap or a bar. If the original ends of the extended reinforcing steel bars are located in areas where welding is prohibited, it is not possible to weld the connecting mounting straps in the relevant area. Consequently, the ends of the reinforcing steel bars would be disadvantageously unconnected and loose. Extending the reinforcing steel bars by a purely structural length, which is not relevant to the structural analysis, enables welding in this area and thus the attachment of mounting elements that connect the reinforcing steel bars.

[0021] This results in a stabilization of the position of the reinforcing steel bars.

[0022] In a further development of the process, it is planned to create additional reinforcing bars for the edge areas of the reinforcing steel mesh in the reinforcement where the reinforcing steel bars have been shortened. In other words, if there are cutouts in the edge areas of the reinforcing mesh, the reinforcing steel bars cut by the cutout are reinforced at their ends adjacent to the cutout by additional, calculated reinforcing steel bars. This ensures the transfer of compressive and tensile forces between the shorter reinforcing steel bars and the reinforcing steel bars in the area of ​​the cutouts, without hindering or preventing the simple unrolling or laying of the reinforcing mesh beyond the cutout. This again results in a significant time saving in the assembly, which, in terms of process optimization, outweighs the additional material required.

[0023] According to the invention, the individual reinforcement elements are also calculated with recesses, whereby additional individual reinforcing steel bars are added in the calculation for the irons omitted in the area of ​​the recess. These are extended, if necessary, to be attached to two mounting elements. Recesses may be required due to holes or depressions, or wall connections projecting vertically into the reinforcement layer, or similar features. At these points, only the mounting straps are unrolled; the additional reinforcing steel bars provided according to the invention then ensure that forces are transferred around these obstacles. The required additional material is, in turn, offset by a considerable time saving during assembly.

[0024] The method according to the invention also provides that the reinforcing steel bars are calculated in such a way that reinforcing mats and edge cages can be connected by the reinforcing steel bars of the reinforcing mat overlapping into the edge cages. In this way, reinforcing mats and edge cages can be connected to each other without the need for additional reinforcing steel bars. According to the invention, when calculating the reinforcement elements from the basic reinforcement, individual additional bars for reinforcement elements are also possible, which are not integrated or integrable into them. In this way, the prefabrication of the reinforcement elements can also take place if, for production or reinforcement-related reasons, a reinforcing steel bar cannot be integrated into a prefabricated reinforcement element. The manual addition of the corresponding reinforcing steel bar still ensures the reinforcement required from a structural point of view.

[0025] The inventive method further provides that individual reinforcement elements are fixed in type, shape, position, or design during their production from the modified basic reinforcement. The actual conditions on the construction site are sometimes different from those previously calculated. The resulting need for modifications to parts of the reinforcement is addressed by reproducing the reinforcement elements from the modified basic reinforcement and the additional reinforcements of the first reinforcement plan, whereby the fixed reinforcement elements can no longer be changed. This significantly prevents changes to a large number of reinforcement elements due to a purely local modification.

[0026] One embodiment of the invention is discussed below with reference to several figures, the figures showing in detail:

[0027] Fig. 1: in three sub-figures a), b) and c) a schematic

[0028] Reinforcement plan before and after application of the inventive method and

[0029] Figs. 2a-d: Details of redesigned individual reinforcement elements. Fig. 1 schematically shows in three partial figures a reinforcement plan for a component before and after application of the method according to the invention.

[0030] Part a) shows the original reinforcement plan, provided by the structural engineer, preferably quantity-optimized and product-neutral, for a reinforced concrete component 1 indicated in outline. This plan is based on reinforcing steel bars 3 and features a series of overlaps 6. These overlaps are arranged arbitrarily depending on the length of the underlying reinforcing steel bars 2. Spacers and other parts of the reinforcement located below or above the plane of the drawing are not shown.

[0031] Only one layer of the planar basic reinforcement is shown, which is often modified to a greater extent by the inventive method than the aforementioned, not shown parts of the reinforcement.

[0032] Part b) shows the modified basic reinforcement generated computationally from the original, first reinforcement plan in the first step of the method according to the invention, in which reinforcing steel bars of unlimited length 3 are used computationally, so that a completely overlap-free modified basic reinforcement is calculated.

[0033] Part c) schematically shows a plurality of site-specific calculated reinforcement elements generated according to the invention from the modified basic reinforcement using the method, here two reinforcement elements 4, 4 'In these cases, simpler installation is achieved in accordance with the invention, albeit at the cost of a larger quantity of material. In practice, of course, significantly more than the two reinforcement elements 4, 4 shown are required. ' calculated.

[0034] The calculated reinforcement elements 4,4' each have reinforcing steel bars 3 arranged at certain intervals and connected by mounting elements 5. To achieve sufficient structural effect despite the separation, additional material 7 in the form of extensions of the reinforcing steel bars 3 was inserted into the end regions of another reinforcement element 4' adjacent to the reinforcement element 4, creating overlaps 6 between the reinforcing steel bars of the two reinforcement elements 4,4'. The mounting straps 5 ensure a stable spacing of the reinforcing steel bars 3 of the reinforcement elements 4,4' and simultaneously prevent the ends of the reinforcing steel bars 3 from spreading apart, which would result in undesirable lateral or vertical forces. It can also be seen that the strap 5 'the first reinforcement element 4 was offset along the longitudinal axis of the reinforcing steel bars 3 away from the end area, so that no vertical stacking of the two elements 4, 4 occurred. ' This results in the following. In the example shown, the laying sequence is also determined, since element 4 is laid first. ' It must be rolled out, overlapping, followed by element 4. It can also be seen that the reinforcing steel bars 3 of element 4, compared to those of element 4, are ' The reinforcing bars were offset by one bar diameter to prevent any collision. The inventive method performs this automatically. Furthermore, it can be seen that the reinforcing steel bars 3 of element 4 were also extended to create an overlap 6. This overlap was not present in the original reinforcement plan according to partial figure a); instead of a continuous, ordered splice, there were numerous splices distributed haphazardly.

[0035] Figure 2 shows details of redesigned individual reinforcement elements in detail figures 2a) to 2d). The redesign is carried out in such a way that undisturbed spatial areas are identified from the modified basic reinforcement 2, and suitable reinforcement elements are produced for these areas. These elements can be unrolled or laid without obstruction and are supplemented with additional reinforcement elements, which are produced and laid separately, in the structurally disrupted areas.

[0036] Figure 2a schematically shows an exemplary reinforcement plan for a reinforced concrete component 1 produced using the method according to the invention. The reinforcement was implemented on the basis of a reinforcement element 4 in the form of a uniaxial reinforcement mat, which has reinforcing steel bars 3 at intervals and which are linked together by mounting straps 5. A disturbance 9 is taken into account such that a strap 5 'was shifted from an original, dashed relative position to the solid position in order to achieve the free end 3 ' The reinforcing steel bars 3 were shortened to ensure ease of installation. The two upper reinforcing steel bars 3 were also shortened to eliminate an area disrupted by section 9 and to maintain rollout capability.

[0037] Fig. 2b schematically shows another reinforcement element 4 with mounting bars 5 and reinforcing steel bars 3. The otherwise free ends 10 of shorter bars 3 are extended by the additional material 7 in order to be attached to the next mounting bar 5 and thus to at least two mounting elements 5.

[0038] Fig. 2c shows a portion of a prefabricated, rollable reinforcement element 4. The reinforcement element 4 is intended for installation in areas where welding is prohibited due to non-static loads, or where a welded reinforcing steel bar 3 is no longer considered structurally effective from the weld point onward. A weld line 11 intersects the reinforcing steel bars 3, which therefore terminate there according to the modified basic reinforcement. To allow these free ends 10 to be installed, a filler material 7, shown with dashed lines, is added to enable welding at the nearest assembly strip 5. However, this weld is not structurally relevant, as the structurally effective areas of the bars 3, shown with solid lines, are not affected. The assembly element 5 has therefore also been extended into this area.

[0039] Fig. 2d schematically depicts a section of a prefabricated reinforcement element 4, which has a recess 12 within its spanned area, for example, a ceiling opening. To allow the reinforcement element 4 to be positioned over this obstruction, the reinforcing bars 3 are shortened in this area. According to the invention, additional material 7 in the form of additional reinforcing steel bars 3' is inserted to transmit forces in the area of ​​the recess 12 and is also extended for fastening to the mounting straps 5. Thus, according to the invention, reinforcement based on a prefabricated reinforcement element 4 is again made possible by adding additional material 7.

[0040] Not shown is a reinforcement element in which the diameter of reinforcing steel bars has been reduced and their spacing decreased, nor is one in which the diameter of reinforcing steel bars has been increased and their spacing increased. Such modifications are also according to the invention, as is an adjustment of the steel grade. REFERENCE SYMBOL Reinforced concrete component Modified basic reinforcement Reinforcing steel bar ' Additional reinforcing steel bar Reinforcing element ' Further reinforcement element Mounting element (mounting strip) Lap joint Additional material Circumference Recess 0 Free end 1 Weld line 2 Cutout

Claims

PATENT CLAIMS 1. Method for producing individual reinforcement of a reinforced concrete component (1) from predominantly prefabricated reinforcement elements (4) comprising at least the following steps: - Reading in a first reinforcement plan of the future reinforced concrete component (1) based on reinforcing steel bars (3) having a planar basic reinforcement; - Conversion of the planar basic reinforcement into a modified basic reinforcement (2) which has reinforcing steel bars of unlimited length such that no overlaps of bars occur within the basic reinforcement; - Calculation of a plurality of individual reinforcement elements (4) from the modified basic reinforcement (2) and the first reinforcement plan, also with changes to the number of individual reinforcing steel bars (3), Shape, length, diameter, position, steel grade and, specifying a laying sequence, for the creation of an individual reinforcement plan; The method according to claim 1, further comprising one or more of the following steps: - Minimizing the number of reinforcement elements (4) of the individual reinforcement plan; - Fixing an individual reinforcement element (4) with regard to the type and arrangement of the reinforcing steel bars (3) in the individual reinforcement plan; - Generation of a machine data set for the production of at least one calculated individual reinforcement element (4); - Transfer of the machine data set to a manufacturing machine and production of at least one individual reinforcement element (4); - Production of individual reinforcement on site at a construction site.

2. Method according to claim 1 or 2, wherein the individual reinforcement elements (4) are selected from the uniaxial reinforcement mats, in particular the rollable uniaxial reinforcing steel bar mats, the biaxial reinforcement mats, the edge cages, the connection cages, the welded reinforcement cages and the individual reinforcing steel bars.

3. Method according to claim 1, 2 or 3, wherein at least one reinforcement element (4) is modified in comparison to the modified basic reinforcement with regard to the presence, arrangement, length and diameter of at least one reinforcing steel bar (3), in particular by adding sacrificial or additional material (7).

4. Method according to one of the preceding claims, wherein the arrangement of a mounting element (5) of the reinforcement element (4) within the reinforcement element (4) is changed.

5. Method according to one of the preceding claims, wherein the reading of the first reinforcement plan is carried out electronically, wherein this is in particular a quantity-optimized and product-neutral first reinforcement plan.

6. Method according to one of the preceding claims, wherein recesses (12) are provided within a rollable reinforcement element, wherein additional reinforcing steel bars (3') are computationally inserted in edge areas of the reinforcement mats adjacent to the recesses (12).

7. Method according to one of the preceding claims, wherein reinforcement mats and edge baskets are connected during assembly in such a way that reinforcing steel bars (3) of reinforcement mats overlap into the edge baskets.

8. Method according to one of the preceding claims, wherein mounting elements (5) of the reinforcement mats are separated at marked points during assembly.

9. Method according to one of the preceding claims, wherein additional bars are added to the basic reinforcement bars (2) that cannot be integrated into prefabricated reinforcement elements (4).