VAN DER ZANDEN, Gerardus Cornelis Maria (Heideweg 21, BT Heel, NL-6097, NL)
| Claims 1. Mould for concrete floor elements which have at least one slab and at least one beam extending along said slab in a length direction, wherein the mould comprises at least a first part and a second part, which can close against each other for forming a mould cavity, wherein the first mould part has a bottom surface, preferably substantially flat for forming a first side of the slab and wherein the second mould part has a top side with a beam forming profile for forming at least part of the at least one beam, wherein the bottom surface extends at an acute angle a to a horizontal plane and the length direction is substantially horizontal and wherein at least one opening is provided, forming a filling and/or aeration opening. 2. Mould according to claim 1, wherein the at least one profiling comprises a part for forming a side of the at least one beam which faces up in the mould, which part has a main plane which encloses an angle 6 with the horizontal plane, such that a side of said plane near the first part of the mould lies at least partly higher than the opposite end. 3. Mould according to claim 1 or 2, wherein the acute angle a is between 60° and 90°, preferably between 75 and 89° and more preferably between 80 and 89°. 4. Mould according to claim 2 and 3, wherein the angle 6 is the same as or larger than 90° minus the acute angle α (6 > 90° - a). 5. Mould according to any one of the previous claims, wherein the at least one opening is provided near a top end of the mould cavity. 6. Mould according to any one of the previous claims, wherein at least one beam forming profile is provided near the top end of the mould cavity, wherein the at least one opening is provided in a top surface of that beam forming profile. 7. Mould according to claim 6, wherein a side of the slab forming portion of the mould facing upward substantially extends at a level below the at least one opening. 8. Mould according to any one of the previous claims, wherein the mould comprises at least two, preferably at least three beam forming portions, extending substantially parallel above each other. 9. Mould according to any one of the previous claims, wherein at least the second mould part comprises a number of modules. 10. Series of moulds, each mould according to any one of the previous claims, wherein at least two of the moulds in the series differ in the number of beams and/or the distance between at least two beams, wherein they preferably at least have the same length in the length direction, and wherein elements from the different moulds are connectable to each other by sides parallel to the length direction. 11. Method for forming a prefab concrete floor element comprising a slab and at least one beam extending along said slab in a length direction, wherein a mould for forming such elements is placed with beam forming parts extending with said length direction horizontally, wherein concrete is poured into the mould for forming said element, forcing air from the mould upward, out of the mould, whereby the mould is angled at an acute angle relative to a horizontal plane, at least during pouring of the concrete, such that an upper part of each beam forming part of the mould slopes at least partly upward towards a slab forming part of the mould. 12. Method according to claim 11, wherein a series of moulds is positioned in a carousel system. 13. Method according to claim 11 or 12, wherein the floor element is made of concrete, preferably self- compacting concrete, wherein cross beams can be provided, and wherein preferably at least one edge portion of the slab and/or beams is made of a material softer and/or more brittle than the concrete. 14. Prefab concrete floor element, preferably made in a mould according to any one of claims 1 - 9 or one of a series of moulds according to claim 10 and/or with a method according to any one of claims 11 - 13, wherein the floor element has a slab defining a first, lower side of the element and a number of beams extending in a length direction on the opposite second, upper side of the slab, wherein the beams have a substantially flat or stepped top surface area along substantially their entire length, and a sloping side surface at at least one side or each beam, preferably the same sides of each beam, wherein at least two beams are provided along opposite longitudinal sides of said slab, said sloping surfaces connected, preferably directly, to straight side surfaces of the slab extending along said longitudinal sides, such that the said straight sides of two such slabs can be joined together, said sloping faces connected to said straight sides sloping away from each other. 15. Prefab element according to claim 14, wherein it has been mould formed, with a pouring mark on one of said sloping surfaces. 16. Assembly of a mould according to any one of claims 1 - 9 or an assembly of moulds according to claim 10 and a filling device for filling the mould at least partly through at least one filling opening, wherein at least one aeration opening is provided substantially at the highest level of the mould cavity. 17. Assembly according to claim 16, wherein at least a part of the mould cavity adjacent the at least one opening is empty, to be filled by the filling device, said part preferably comprising at least a beam forming portion and part of an adjacent slab forming portion. 18. Series of moulds according to claim 10, wherein the moulds are of modular build, wherein at least two of the moulds in the series differ in the number of beams and/or the distance between at least two beams by having a different number of modules comprising each at least one beam forming profile. 19. Method according to any one of claims 11 - 13, wherein the concrete is poured into the mould cavity such that it fills the cavity substantially in a bottom up direction, wherein the concrete is: poured into the mould cavity through an opening at a top of the cavity, such that the concrete flows down in the mould cavity substantially along a wall of the slab forming portion, or poured into the cavity through an opening at a lower part of the mould cavity, the air forced upward in the mould cavity by the concrete, wherein the opening is preferably provided in a wall of the slab forming portion. |
The invention relates to moulds for forming concrete prefab floor elements. The invention further relates to a method for forming such elements. Moreover the invention relates to prefab floor elements as such.
Concrete wall elements are known to be moulded in moulds. Such moulds comprise a first and second mould part, which when closed against each other form a mould cavity. A pouring opening is provided at an upper side of the mould for pouring concrete into the mould cavity and letting air out of the mould cavity at the same time. The first and second part comprise side walls which are vertical and parallel, defining an interspace as the mould cavity. The upper side of the mould forms the pouring opening. This means that this end will be rough and the dimensions in the vertical direction are unspecified, in the sense that the dimensions are not stable. Different elements can thus have different heights.
Concrete floor elements are commonly moulded in horizontal position, for example in a carousel system. In such mould a lower part is placed on a transport element, where after end pieces of metal are placed between fixed upper and lower side profiles, defining a square mould cavity part with a flat bottom. The end pieces can be placed in the mould by robots, but still will have a relative high imprecision in their relative positions, for example ± 27 mm. The floor element is then formed by pouring concrete into the cavity and let it set. Due to the pouring from the open upper side and the imprecision of the position of the end pieces only the side facing the bottom surface of the mould and the opposite sides of the element formed against the fixed side profiles will be both relatively smooth and define dimensional stability. This means that one face of the element and the two opposite length sides of the floor element will be well defined, whereas the length can vary between elements, as can the thickness of the floor element. DE2253706 discloses a forming device for forming concrete, prefab elements, which aims and combining advantages of flat forming and vertical forming methods. The device comprises a mould with a lower mould part and an upper mould part, as well as foil providing means for lining the mould prior to molding the elements, including an aeration and de-aeration device. The mould is held in a horizontal position during forcing of the concrete into the mould cavity, a slab forming portion at the top of the mould and a profile forming portion facing down. The mould is vibrated after filling, and slowly brought into an upright position, at the same time forcing the concrete further into the mould cavity by using a piston, compensating for the repacking of the concrete. This forming device is complicated in construction and use, is expensive and stationary.
An object of the present invention is to provide an alternative mould and method for forming concrete prefab floor elements. Another object can be to provide a mould and/or method for forming prefab floor elements which are more form and dimensional stable. A still other object of the present invention can be to provide a method and/or mould for forming concrete prefab floor elements that need relatively little or substantially no finishing after setting of the concrete. Another object of the present invention can be to provide a mould or a series of moulds for forming different floor elements which can be coupled to form a floor.
At least on of these or other objects can be obtained with methods, moulds and/or elements according to the present invention.
In a first aspect a mould according to this description can be designed for concrete floor elements which have at least one slab and at least one beam extending along said slab in a length direction. The mould can comprise at least a first part and a second part, which can close against each other for forming a mould cavity. The first mould part has a bottom surface for forming a first side of the slab, which preferably is substantially flat. The second mould part has a top side with a beam forming profile for forming at least part of the at least one beam. The bottom surface extends at an acute angle a to a horizontal plane and the length direction is substantially horizontal. At least one opening is provided at a level at or above the at least one beam forming profile, forming a filling and/or aeration opening.
In a second aspect a series of moulds can comprise at least two moulds in the series which differ in the number of beams and/or the distance between at least two beams. They preferably have at least the same length in the length direction, and wherein elements formed in the different moulds are connectable to each other by sides parallel to the length direction.
In a third aspect a method for forming a prefab concrete floor element, which comprises a slab and at least one beam extending along said slab in a length direction, can comprise placing a mould for forming such elements with beam forming parts extending with said length direction horizontally. Concrete is poured into the mould for forming said element, forcing air from the mould upward, out of the mould. The mould is angled at an acute angle relative to a horizontal plane, at least during pouring of the concrete, such that an upper part of each beam forming part of the mould slopes at least partly upward towards a slab forming part of the mould.
The invention shall be elucidated hereafter, with reference to the drawings. These drawings and description are given by way of example only and should by no means be considered as limiting the scope of the invention as defined by the claims. These drawings show in:
Fig. 1 schematically a concrete prefab floor element;
Fig. 1A in cross section part of a floor element of fig. 1, comprising part of the slab, two beams and part of a covering element, and schematically an adjoining floor element;
Fig. IB in cross section part of a floor element of fig. 1, comprising part of the slab and a beam, in an alternative embodiment;
Fig. 1C in cross sectional view a cross beam and slab part, with a filler element along part of the cross beam; Fig. 2 schematically in cross section a mould for forming such element, in a first embodiment;
Fig. 3 schematically in cross section a mould of fig. 2, showing different levels in the mould;
Fig. 4 schematically the assembly of a mould;
Fig. 5 schematically in cross section an alternative mould assembly; Fig. 6 schematically three mould assemblies in a series of moulds; Fig. 7 schematically in frontal view part of a mould, with partly broken away a second part of the mould;
Fig. 8 schematically in top view a carousel for manufacturing floor elements;
Fig. 9 schematically an alternative embodiment; and
Fig. 10 part of a mould in an alternative embodiment.
In this description embodiments of floor elements, moulds and methods, as well as building parts formed therewith are disclosed and described by way of examples only. These embodiments are not to be considered as limiting the scope of the present invention. In these
embodiments the same or similar elements have the same or similar reference signs. In this description words like substantially and about are to be considered as meaning for the most part, mostly, or similar meaning, and should be considered as at least encompassing deviations from a given value of 15% or 10% and preferably within 5%.
In this description reference is made to slabs and beams. In the embodiments disclosed the floor elements comprising slabs and beams are made integrally by mould forming. The slabs and beams are therefore parts of the same, integral element. However, beams or a slab could be placed in a mould as inserts, forming the other of the slab and beams against the insert or inserts in the mould. A mould according to the present disclosure preferably has a substantially reusable configuration. However, the mould can also be made of disposable material. A mould according to the present invention is set at the indicated acute angle during the pouring of the element forming material, especially concrete into the mould cavity through an opening, such that it can flow into and fill the mould cavity. In embodiments this can be done primarily by gravity, for forming the element. In other embodiments the material can be forced into the mould from an opening near a lower end of the mould. A filling device is or can be used that extends above said opening, or the material can be brought to the said opening through appropriate feeding means connected to the opening, which can be referred to as a filling device extending above said opening too, even though part of the device can be positioned differently, for example next to the mould or well spaced apart from the mould.
In production of the floor elements preferably a slab forming portion of the mould is at a side facing at least partly downward, beam forming portions at a side facing at least partly upward. Air inside the mould cavity will therefore rise at least partly into said beam forming portions, to be driven out by the material filled into the cavity. The material will advantageously flow at least along the wall of the slab forming portion, without significant interference of the beam forming portions, because of the acute angle.
In a general way a method according to the description can be described as including the steps of:
a- forming a mould comprising a mould cavity, wherein beam forming portions have a longitudinal direction extending substantially horizontally, and a slab forming portion having a wall opposite the beam forming portion or portions extending at an acute angle relative to a horizontal plane, and having at least one aeration and/or filling opening at the top of the mould cavity;
b- filling the mould cavity with a forming material, especially concrete, such that the mould cavity is essentially filled from a lower end upward, forcing air from the mould cavity through at least the at least one opening at the top; c- having the material set, at least partly in the mould cavity;
d- removing the element from the thus mould cavity.
In embodiments in step a the mould can be formed by integral first and second mould parts. In alternative embodiments at least one of the mould parts, especially the part comprising the one or more beam forming portions can be made from modules.
In embodiment in step b the mould can be filled through at least one opening at the top of the mould cavity, wherein preferably the material flows along a bottom of the slab forming part of the mould cavity, towards the lower part of the mould cavity, to fill the cavity. The at least one opening at the top can in such embodiments be both filling opening and aeration opening for letting air escape from the mould cavity, at least during filling. In other embodiments the material can be inserted into the mould cavity through an opening near the lower side of the mould cavity. Preferably the material is fed into the mould cavity such that each beam forming portion is filled
substantially evenly over its entire length. Preferably of each beam forming portion an upper wall part slopes up towards the slab forming portion, such that when the beam forming portion is filled with the material, air will flow along said upper surface, which forms a side face of a beam, into the slab forming portion to be driven out.
It should be noted that for forming a concrete prefab element it is very important that as little air as possible, and preferably no air is trapped inside the cavity, since this will influence the appearance, durability and bearing capacity of the finished element. In this description pouring of concrete can be understood as but is not limited to gravity feeding and/or force feeding of concrete into the mould.
In fig. 1 a floor element 1 is shown, comprising a slab 2, four parallel beams 3 extending in a length direction LI on a top side 4 of the slab 2. The slab 2 is in this example substantially square, having a length L and a width W. A first beam 3A and a second beam 3B extend along longitudinal sides 5A, 5B of the slab 2. On opposite ends 6A, 6B of the slab 2 two cross beams 7 A, 7B are provided, between the ends of the beams 3A, B, connecting these beams 3A, B. The third longitudinal beams 3C extends in between the first and second beam 3A, 3B and are connected at opposite ends to the cross beams 7 A, B. A series of first openings 8 is provided in the first and second longitudinal beams 3A, B, such that two elements 1 can be placed side by side and be connected to each other by connecting means (not shown) extending through said openings 8, for example but not limited to nuts and bolts, screws, chemical anchors, rivets and the like known connecting means. A second series of openings 9 can be provided, extending through the first, second and third longitudinal beams 3A, B, C, wherein preferably openings 9 in adjacent beams 3 are in line with each other, such that long elements (not shown) such as but not limited to pipes, hoses, lines and the like can easily be fed through said openings 9, in a direction substantially cross to the longitudinal direction LI of the beams 3. The openings 9 can be larger than the openings 8. The openings 9 can have a lower side substantially flush with the top side 4 of the slab 2. The cross beams 7 are preferably without openings 8 or 9.
In fig. 1A in cross section part of an element 1 is shown, showing a beam 3, especially an outer first or second beam 3A, B, and the slab 2, with a side 5 of the slab 2. As can be seen the openings 8 and 9 can extend
substantially parallel to each other across the beam 3. The beam 3 has a height H above the top side 4 of the slab 2. The slab 2 has a thickness t between the top side 4 and the opposite lower or bottom side 10. The bottom side 10 can during use for example form a ceiling of a space SB below the floor element 1 or of a crawl space. The beam 3 has, in this example, a substantially flat top side 11 and two opposite side surfaces 12, 13, which slope at an angle γ relative to the top surface 4 of the slab 2. In the embodiments shown the top surface 4 of the slab 2 extends, during use, substantially horizontally, meaning that in these embodiments the top surface can for practical purposes be referred to as a horizontal surface. Obviously an element 1 could be positioned at an angle, having the surface 4 sloping in one or two directions. In the embodiment shown the angle γ can be the same for both or all sloping surfaces 12, 13 of the same or all beams 3. In the embodiment shown the edge 5 of the slab 2 is defined substantially by a substantially straight, flat side surface 14, extending substantially perpendicular to the top surface 4. The sloping surface 12 of the beam is connected to the sloping side surface 12 of the beam, in this embodiment directly, that is without an intervening part of the top surface or beam. In fig. 1A in dotted lines a second element 1A is shown, the side surface 14 thereof positioned against the side surface 14 of the element 1. A stripe- dotted line 15 shows schematically a connecting element extending through openings 8 in line with each other for connecting the elements 1, 1A. As can be seen in fig. 1 the beam 3 can have a substantially trapezoid cross section, wherein the top surface 11 has a width Wl and the base, near the top surface 4 of the slab 2 has a width W2. As can be seen in fig. 1A the longitudinal outer beams 3A, B can have a cross sectional area Al which is smaller than the corresponding cross sectional area A2 of the beam or beams 3C in between. The area's Al, A2 can be chosen such that when two outer beams 3 of two adjacent elements 1, 1A are properly connected by the connecting means 15, the load capacity of two joined beams 3A, B of such elements 1, 1A is about the same as the load capacity of the or any of the intermediate beams 3C. This can for example be achieved by the widths Wl, W2 of the outer beams 3A, B being about half the widths Wl, W2 of the or any intermediate beam(s) 3C.
Between the beams 3 above the top surface 4 of the slab 2 pockets 16 are provided, in which utility lines such as water mains, gas, electricity, data and the like can be positioned, fed through the openings 9 and/or the slab 2 and/or a cover element 17 and/or in any other suitable way. A top floor element or elements 17 can be placed on the top surfaces 11 of the beams, for forming a floor 18 and for closing off the pockets 16. Openings 19 can be provided in the top floor elements 17 for feeding utility lines into or from the pockets 16 from or to a space 20 above the floor 18. Similarly openings 21 can be provided in the slab 2 for feeding utility lines into or from the pockets 16 from or to a space SB below the slab 2. Isolating material 23, especially but not limited to acoustically isolating elements such as rubber, elastomeric, plastic and/or foam strips can be placed between the beams 3, 7 and the top floor elements 17.
In fig. IB a partial cross section of an element 1 is shown, in an alternative embodiment, in which a beam 3C is shown on the slab 2. The beam 3C has a stepped top surface 11, such that on two opposite, longitudinal sides a shoulder 24 is formed on which an edge of the top floor element 17 can be placed. This will allow a smaller overall height Ht of the element 1 with top floor elements 17, whereas about the same load capacity can be obtained with similar width beams 3 as in an embodiment of fig. 1A. In this embodiment a series of top floor elements 17 is provided, allowing access to individual pockets 16 more easily. Isolating elements 23 are provided between top floor elements 17 and shoulders 24. Similarly longitudinal first and second beams 3A, B and cross beams 7 A, B could be provided with a stepped upper surface 11, at the side facing the adjacent pocket 16, as schematically indicated in fig. IB by the vertical line 14A.
Fig. 1C shows part of an element 1, showing a cross beam 7 and slab 2. At the top of the beam 7, at a side facing the pocket 16 an edge portion 26 is made of a material different from the concrete from which the slab and beams are formed. The material of the edge portion 26 can for example be softer and/or more brittle than the concrete. During use a wall element 27, for example but not limited to a prefab concrete element or a brick wall, can be placed on top of the top surface 11 of the cross beam 7, as for example schematically shown in fig. 1C in broken lines. The edge portion 26 allows easy access into said wall element 27, easier than when part of the concrete of the beam has to be removed, for example for cables or pipes, as schematically indicated by striped line 22. Obviously the same way different parts of for example an edge of a beam 3, 7 or a slab 2 can be made of the same or similar material, for the same or similar purpose. Openings such as 8, 9, 19, 21 can also be made by providing such material in a position in which an opening could be advantageous, such that during use the opening can easily be created by removing part or all of said material.
An element 1 can be made of concrete, preferably compacted concrete. In advantageous embodiments the element 1 can be made of self compacting concrete, foaming concrete or the like. Self compacting concrete will easily allow forming the element in a substantially closed mould cavity, as will be described here below.
In fig. 2 and 3 in cross section schematically a mould 30 is shown, for forming a floor element 1, such as for example but not necessarily limited to embodiments as disclosed here before. The mould 30 comprises a first part 31 and a second part 32 and is placed on a support structure 50. The support structure can for example be part of a carousel system for in a (semi) continuous process forming floor elements 1. As can be seen in fig. 2 and 3, the first mould part 31 is placed with a bottom part 34 against an upstanding part 51 of the support structure 50, and can be resting on a lower part 52 of said structure 50. In the carousel system, as will be discussed later on, the moulds can circulate through different stages of casting the elements 1.
In fig. 2 - 4 a mould 30 is shown for a floor element 1 having four longitudinal beams 3: two outer beams 3A, B near opposite longitudinal sides 5 and two intermediate beams 3C in between. The mould 30 can have at least two parts 31, 32. Fig 7 shows inter alia a part of the mould 30 for forming a cross beam 7 at opposite ends 6 of the element 1. In embodiments cross beam 7 forming elements can be left out, for casting elements 1 without such cross beams 7. In the embodiment shown in fig. 2 - 4 the mould 30 is designed for casting the floor element 1 with a side edge 5B facing down, wherein the longitudinal direction LI of the beams 5 is substantially horizontal. In fig. 2 and 7 the horizontal plane Hp is indicated, whereas vertical planes obviously extend perpendicular to said horizontal plane. The first mould part 31 has a bottom forming part or surface 37 for forming a bottom side 10 of the element 1, especially of the slab 2. The second mould part 32 in this embodiment has a profiling 38 for forming the
longitudinal beams 3A - C and the top surface 4 of the slab 2 in between the longitudinal beams 3 and the cross beams 7, if available. In embodiments the bottom surface 37 can be profiled, for example ribbed or can have another pattern in relief, for example as decoration, for fitting wall elements, guides and the like, and/or for strengthening the element 1. Still an actual or virtual main plane P of the said surface 37 can be defined by for example the opposite side edges or end edges of the slab 2 to be formed. The bottom surface 37 or plane P encloses an angle a with a horizontal plane or surface Hp. The angle a can be acute. The angle a can be between 60° and 120°. In embodiments the angle a can be between 60° and 90°, preferably between 75° and 89°, more preferably between 80° and 89°. In an embodiment the angle a can be about 82.5°.
The profiling 38 comprises parts 39 for forming a sloping side of a beam 3, especially at a side of the beams 3 facing upward. In the embodiment shown parts 39 are provided on both sides of a space for forming a beam 3, such that a cross section of the beam defining an area Al, A2 is substantially symmetric about a plane PI perpendicular to the bottom surface 37 or plane P. The part 39 for forming a sloping side of a beam 3 facing upward, when in the position in the mould as shown, includes an angle 6 with the horizontal surface or plane Hp. The angle 6 is such that the side 39A of the part 39 facing the bottom surface 37 is positioned at a level higher than the opposite side 39B of said part 39, at least over a part of the length of said part 39, preferably over substantially its entire length L2. This means that any air inside the beam 3 forming space 40 can escape easily when filling a mould cavity 41 formed between the first and second mould part 31, 32. The angle 6 preferably is such that β > 90° - a. The bottom surface 37 is preferably tilted from a vertical position backward, such that the bottom surface 37 is exposed upward, as for example shown in fig. 2. As can be seen in fig. 2 for each of the upper parts 39 for forming the beams 3 the angle 6 is about the same. The angle 6 can however be different for different beams of an element 1 and/or for different sides of the beams.
At the upper side 42 of the mould 30 an opening 43 is provided, for example extending along a part, most or substantially all of the length LI of the beam forming space 40 adjacent said side 42. Next to the opening 43, connected to the bottom surface 37, is a side edge surface 14 of an element 1 forming portion 44 of the mould 30 provided, extending at substantially right angles to the bottom surface 37 or plane P. Due to the angles a and β the opening 43 will be substantially at the highest level of the mould cavity 41, thus preventing the entrapment of air when filling the mould cavity 41. By having the element 1 formed on a longitudinal side 5 the length of the element can be large, for example 5 meters or more, without having the problem of the filling opening being high above the ground. Moreover, this can enable more easy stability for the mould 30. The mould 30 can rest on a carrier 50 with which the mould 30 can be moved through a factory or plant for manufacturing the elements 1. A possible lay out of such plant 70 is schematically shown in fig. 8, by way of example only. This will be discussed further on.
In the embodiment of fig. 2 - 4 and later to be described
embodiments of fig. 5 and 6 and 10 a filling device 80 is shown, schematically, for bringing the material, especially concrete into the mould cavity. In the embodiments of fig. 2 - 6 the device 80 is connected to the opening 43, such that material can flow into the mould cavity through the opening 43 which can thus perform the function of filling opening as well as aeration opening.
Aeration opening has to be understood as meaning that air can enter and/or leave the mould cavity through said opening. In embodiment such as shown in fig. 10 the device 80 is connected to the opening 43A near a lower side of the mould 30. Initially the filling device 80 is connected to the cavity through an opening 43, 43A, the cavity or at least a part thereof adjacent the opening 43, 43A being substantially empty, i.e. free of the filling material such as concrete.
In fig. 3 schematically different steps in filling the mould cavity 41 are shown. First the lowest longitudinal space 40 is filled, pushing air upward in the mould cavity, to the first level Fl. The material can then easily fill the mould cavity upward, towards the second and third spaces 40 for forming the intermediate longitudinal beams 3C. As is shown for the upper one of these two intermediate beam forming spaces the material will gradually fill the space 40 from the lower level F2 to the upper level F3, pushing again the air from the space 40 upward. At the highest space 40 the filling opening 43 is substantially the highest point. Therefore air will escape there from easily.
Fig. 4 schematically shows assembling a mould 30, in which first a first mould part 31 is placed on a carrier 50, such that the back of the bottom forming surface 37 rests against a first carrier surface 51, angled relative to the vertical plane and the horizontal plane Hp. The side of the longitudinal beam 5B forming part can rest on a bottom part 52 of the carrier or can be suspended just above it. As can be seen from fig. 4 and 7, sides 53 can be provided to the first mould part 31, defining the overall length LI of the element 1 to be formed. One or both of the sides 53 can be formed by elements such ass but not limited to beams or profiled plate elements which can be attached to the mould 30, the carrier 50 or both, such that they form at least part of a wall of the mould cavity, especially part of or entirely the spaces 54 for forming a cross beam 7. In another embodiment the sides 53 can be integral parts of one or both of the mould parts 31, 32. As can be seen in fig. 7 inserts 55 can be provided in and/or on the mould 30 or mould cavity 41, for example for forming the openings 8, 9 and/or for forming openings 21 and/or 19, or for providing parts made of different materials, such as but not limited to the elements 26. These inserts 55 can be elements that can be removed from the element 1 after casting, or can be elements that remain in the element 1 after casting and can for example provide an area for fastening, an area for easy access of the pockets 16 and/or walls 27, reinforcements such as metal or plastic rods, wickerwork or the same, as known for reinforcing concrete.
After the optional placement of inserts 55 and side elements 53, the second mould part 32 can be placed against and/or over the first part 31, in order to close the mould and form the mould cavity 41 with spaces 40, 54. Then concrete or another settable and/or curable constructional material can be poured into the mould cavity 41, filling the cavity 41 with spaces 40 and 53, forming the element 1. After setting and/or curing the mould 30 can be opened and the element can be removed from the mould 30. The mould 30 can then be reused.
Fig. 5 shows three embodiments of a mould 30A, suitable for forming elements 1. These moulds 30A are similar to the moulds 30 as described here before, using the same or similar reference signs, for forming elements IB similar to the elements 1, 1A described before. However, in these embodiments elements IB with different widths W2, W3 and W4 can be made, whereas the elements IB can have the same or different lengths Li. One or more of the elements IB made with the moulds 30A as disclosed in fig. 5 can for example be used with elements 1, 1A made in the mould of fig. 2 - 4 and/or as discussed with reference to fig. 1, for example as fitting elements in order to fill the end portions of a floor, seen in a direction of the widths W of the elements 1, 1A, IB. This enables forming floors having substantially any length, the length Li of the elements 1, 1A, IB defining the width of the floor, for example starting with an element 1 in a position remote from either longitudinal end of the floor, wherein at the longitudinal end or ends, or somewhere else in the floor at least one element IB can be used, made with a mould 30A according to fig. 5, when the length of the floor is not equal to N times the width Wi of an elements of fig. 1 - 4 or at least the floor cannot be formed with such elements 1 entirely, N being a real number.
As can be seen in fig. 5 the moulds 30A can be such that an element IB formed therewith has at least two longitudinal beams 3A, 3B. In fig. 5 and six the parts of the element are shown in the mould as if the mould has been filled with such element formed therein. The distance Dl between these beams, measure hart-to-hart, can be similar to the distance Dl between two adjacent beams 3 of an element 1 of fig. 1 - 4, or N*D1, wherein N is a natural, real number, or can be different, for example larger. In fig. 5 three moulds 30A are shown, respectively having, left to right in the drawing:
- two longitudinal beams 3A, B only;
- two longitudinal beams 3A, 3B and one intermediate beam 3C; and
- two longitudinal beams 3A, 3B and two intermediate beams 3C. wherein
- in an element IB formed with the left hand mould 30A the distance Dl is equal to the distance Dl between two adjacent beams 3 of an element 1 ;
- in an element IB formed with the middle mould 30A the distance Dl between the first outer beam 3A and the intermediate beam 3C is equal to the distance Dl between two adjacent beams 3 of an element 1, and the distance D2 between the intermediate beam 3C and the second outer beam 3B is smaller than Dl; and
- in an element IB formed with the right hand mould 30A the distance Dl between the first outer beam 3A and the intermediate beam 3C and between the two intermediate beams is equal to the distance Dl between two adjacent beams 3 of an element 1, and the distance D2 between the second outer beam 3B and the adjacent intermediate beam 3C is smaller than Dl.
and wherein it should be clear that in alternative embodiments of elements IB the distances D between adjacent beams can be chosen differently, for example such that the beams 3A, B, C are equally spaced. In fig. 5 the moulds 30A can generally have a construction similar to that of fig. 2 - 4. The first ad second mould parts 31, 32 for forming these moulds 30A can have fixed dimensions.
In fig. 6 an alternative construction of a mould 30, 30A is disclosed schematically, which is especially but not exclusively suitable for forming moulds 30A having varying widths W. In fig. 6 again three moulds 30A are shown, similar to the embodiments of fig. 5, by way of example only. In these three moulds a first mould part 31A is used, having a flat bottom forming surface 37A and having a first part 56 for forming a first longitudinal beam 3A, which will be the same for each mould 30A. This first part 56 can be an integral part of the first mould part 31A or can be a separate part. Then in these embodiments a second part 57 is provided, comprising a forming part 58 for forming the other longitudinal beam 3B and comprising the filling opening 43. From the forming part 58 a cover part 59 extends, in use substantially parallel to the bottom forming surface 37A. The cover part 59 has a height Z, measured in the direction of the width W of the element, i.e. substantially perpendicular to the length L of the beams 3, which can be chosen based on the desired total width W of the element to be formed. To this end a series of such second parts 57 can be provided, varying in said height Z, or the cover part 58 can be made such that said height Z can be adjusted, for example telescopically or by adding segments to a minimal sized cover part 58. Furthermore a third part 60 can be provided, having a forming part 61 for forming an intermediate longitudinal beam 3C and a cover part 62 for forming the slab 2 between two adjacent longitudinal beams 3. To that end the cover part 62 can have a height Zi such that when connected to a similar part 60 or to a first part 56 the distance Dl between two forming parts 56, 58 for two longitudinal beams 3A, B, C is as desired and preferably as discussed before. The distance Dl shall preferably be larger than the height of the cover part 58 of the second part 57.
With a set of a first mould part 31, a first and second part 56, 57 and preferable one or two third parts 60 different elements 1, 1A, IB can be provided, differing in overall widths W. It shall be clear that the parts 56, 57, 60 can be connected to each other and/or to the further mould parts 31, 53 that a substantially closed mould cavity 41 is obtained, except at least for the filling opening 43. In fig. 6 the different parts are shown separated from each other for clarity purpose only.
In fig. 8 schematically the lay out of a moulding process and/or assembly is shown. Such system and process are known and for example described by De Hoop Pekso, The Netherlands, and as shown on their website www.dehoop-pekso.nl. In this known process and assembly floor elements and wall elements are manufactured in a horizontal orientation. According to the present disclosure the elements 1 are preferably manufactured in a position in which the longitudinal beams extend substantially horizontally and the slabs 2 have an angled position relative to the horizontal positions. This saves space and makes handling of the elements 1, moulds and filling and manufacturing equipment more easily possible.
In a process of fig. 8, also known as a carrousel process comprises basically the steps of cleaning a mould 30, 30A or parts thereof in a first station 71. Then the side elements 53 can be placed in a second station 72, defining the length of the elements 1, which is normally done after a plotter has been used for plotting the positions of for example inserts 55, the desired width W of the element 1, IB to be formed, the number and positions of the longitudinal beams 3 and the like. In a third station 73 inserts can be provided. In a fourth station 74 the mould parts can be oiled, waxed or greased, or otherwise be provided with a release agent. Then in a fifth station 75 the reinforcements can be provided on the relevant part of the mould. Then in a sixth station 76 the or each second mould part 32 or the first 56, second 57 and when desired third parts 59 for forming the cover of the mould cavity can be placed, in the appropriate order. Thus the mould 30, 30A is ready for forming the element. In a seventh station 77 the material is poured or injected into the mould cavity 41, using a filling device 80, for example from the opening 43 at the top of the mould 30, 30A filling the cavity 41 up, including the spaces 40, 54. Preferably a self compacting material such as self compacting concrete is used for these elements 1, 1A, IB. This can have the advantage that for example vibrating the moulds is not necessary, whereas a complete filling of the mould cavity 41 can easily be obtained. An element 1, 1A, lb formed shall have the right density. The material can be chosen such that it slightly foams or at least slightly expands during setting and/or curing, in order to prevent undesired voids in the material.
After pouring the material the moulds 30, 30A are placed in or moved through an eight station 78, comprising or formed by a dryer, to allow the material to cure and/or set at least sufficiently for the element to be form stable. Then in a ninth station 79 the moulds 30, 30A are opened and the element 1,, 1A, IB can be removed from the mould, substantially ready for use. The mould parts are returned to storage and/or the first station for reuse.
In the known method as described here above the floor elements are manufactured horizontally, with the ceiling forming side facing down. The reinforcements are placed such that they extend above the upper surface of the elements. In a method of the present disclosure the beams can be moulded integrally with the slab, preferably fully enclosing the reinforcements if available. Therefore the process is uncomplicated and provides for beams suitable for carrying the cover elements. The beams further strengthen the elements 1 and provide for the pockets in between the beams. The openings 8, 9 are preferably provided at or close to a neutral line of the element.
In the embodiment discussed here above the mould can be brought and held in the angled position during the entire process of preparing the mould and forming the elements therein. In alternative embodiments the mould van be moved between different angled positions during the process. For example the mould can be in a substantially horizontal opposition, such that the back surface 37 of the mould is substantially horizontal or at least at a shallow angle relative to the horizontal plane Hp, during for example cleaning, mounting inserts 55 and/or end portions 53, and/or during plotting and or during closure and/or assembly of the mould, whereas for example during filling of the mould 30 the mould is brought in the acute angled position, in which the back surface 37 extends at said acute angle, as discussed before. When the filling and/or aeration opening 43 can be closed, for example by a lid or valve, the mould can be brought back to a substantially horizontal position after filling too.
Fig. 9 schematically shows a mould 30 mounted on tracks 60 by rollers 61, such that the mould can be moved along the tracks 60 in any suitable way. The tracks can extend through part of or, preferably, the entire plant 70, such that the moulds 30 can pass through the different stations, guided by the tracks 60. The tracks can be bent such that the moulds 30 are forced into different positions in and/or between different stations 71 - 79. In an embodiment the position of the tracks can be amended in one or more of the stations, for example in order to amend the angled position of the moulds in the relevant station. In another embodiment there can be one or more switches in the tracks, for choosing specific positions of the moulds, for example depending on the angles of the sides of the beams.
In fig. 10 schematically part of a further embodiment of a mould 30 is shown, in which the material of which the elements 1 are to be made can be injected into the mould cavity 41, for example using a pump 81 and a valve 63 near a lower side of the mould 30, as part of a filling device 80. The valve 63 can for example be provided in the first part 31 of the mould 30, for example in the bottom surface 37 thereof. The valve can for example be but is not limited to a butterfly valve. Valves for use in apparatus for forwarding settable and/or curable materials such as concrete are well known in the art. In such embodiment the material can be forced into the mould cavity from a point of entry spaced apart from the opening 43, which can then be used as an aeration opening only and can be relatively small compared to the size when the opening 43 is also used as a filling opening.
In fig. 1 schematically a pouring mark 82 is shown, on a sloping side surface of a beam 3A. The mark 82 can for example extend over substantially the full length L of the element 1 and can be an imprint of a filling and/or aeration opening 43. The shape and size can be different, depending on inter alia the opening 43 used.
The invention is by no means limited to the embodiments discussed and shown in the drawings, which are shown by way of examples only. Many variations are possible with in the scope of the invention as claimed.
For example a different number of beams can be provided, whereas at least one of the outer longitudinal beams and/or the cross beams can be provided spaced apart from a longitudinal or transverse side edge respectively. The beams can have different cross shapes, sections or lengths, and can be placed differently then all parallel. For example one or more of the beams could be diagonal or at least could enclose an angle different from 90 degrees with the transverse edges of the element. In embodiments one or both of the transverse edges and/or longitudinal edges could slope or be other than straight. The element can for example be trapezoid, triangular, curved at a side or otherwise different from rectangular. The openings 8 and/or 9 could be omitted in some or all of the beams. The carrier can be different, for example having perpendicular supporting surfaces or otherwise angled surfaces or only one supporting surface to which at least one of the mould parts 31, 32 is directly mounted.
These and many other variations, including combinations of parts of the elements or methods disclosed are considered to have been disclosed herein too.