U.S. patent application number 13/256530 was filed with the patent office on 2012-05-17 for apparatus and method for casting concrete wall elements.
This patent application is currently assigned to MT-ENERGIE GMBH. Invention is credited to Peter Maack, Christoph Martens.
Application Number | 20120117907 13/256530 |
Document ID | / |
Family ID | 40719813 |
Filed Date | 2012-05-17 |
United States Patent
Application |
20120117907 |
Kind Code |
A1 |
Maack; Peter ; et
al. |
May 17, 2012 |
Apparatus and Method for Casting Concrete Wall Elements
Abstract
An apparatus for casting concrete wall elements, which together
form a wall, running along a curvature at least in sections, of a
container, in particular of a fermenter for biogas plants,
comprising a horizontal foundation, to which several horizontally
extending bounding elements are attached, which between them form
fields to be cast with concrete, several formwork elements, which
are detachably secured to at least a few bounding elements, which
form formwork surfaces, which are opposite each other in a field
and which are aligned at an angle with respect to the vertical,
which in the erected state form the face side surfaces of adjacent
wall elements, that face each other, wherein the formwork elements
each have at the formwork surfaces at least one receiving device,
and wherein at least one end of at least one reinforcing element to
be cast in the concrete is secured in each receiving device of
formwork surfaces, which are opposite each other in a field.
Inventors: |
Maack; Peter; (Salzhausen,
DE) ; Martens; Christoph; (Ostereistedt (OT
Rockstedt), DE) |
Assignee: |
MT-ENERGIE GMBH
Zeven
DE
|
Family ID: |
40719813 |
Appl. No.: |
13/256530 |
Filed: |
March 15, 2010 |
PCT Filed: |
March 15, 2010 |
PCT NO: |
PCT/EP2010/001627 |
371 Date: |
December 27, 2011 |
Current U.S.
Class: |
52/425 ;
52/745.09; 52/745.21 |
Current CPC
Class: |
E04G 21/14 20130101;
B28B 7/241 20130101; B28B 23/026 20130101; B28B 7/243 20130101;
B28B 7/0014 20130101; E04G 21/16 20130101 |
Class at
Publication: |
52/425 ;
52/745.09; 52/745.21 |
International
Class: |
E04B 2/86 20060101
E04B002/86; E04B 1/41 20060101 E04B001/41; E04B 2/84 20060101
E04B002/84 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 14, 2009 |
DE |
20 2009 003 683.9 |
Claims
1. An apparatus for casting concrete wall elements (20), which
together form a wall, at least in sections running along a
curvature, of a container, in particular a fermenter for a biogas
plant, comprising: a horizontal foundation (10), on which several
horizontally extending bounding elements (12) are fastened, which
between them form fields (18) to be cast in concrete for the wall
elements (20),--several formwork elements (28) that are connected
to at least several bounding elements (12), which form formwork
surfaces (36) that are located across from each other in a field
(18) and are aligned at an angle (.alpha.) to the vertical, which
represent the face side surfaces of adjacent wall elements (20)
facing each other in the erected state, wherein the formwork
elements (28) at the formwork surfaces (36) each have at least one
receiving device (42, 46, 60), and wherein one end of at least one
reinforcing element (44, 48, 72) to be cast in concrete is fastened
in each the receiving devices (42, 46, 60) in opposing formwork
surfaces (36) in a field (18).
2. The apparatus according to claim 1, characterized in that the at
least one reinforcing element is a reinforcing rod (48) or a
reinforcing cable, or that at least one reinforcing element is a
reinforcing tube (44) for receiving a reinforcing rod or a
reinforcing cable.
3. The apparatus according to claim 1, characterized in that the
foundation (10) is the base (10) of the container.
4. The apparatus according to claim 1, characterized in that at
least one reinforcing element (44, 48, 72) runs curved between the
receiving devices (42, 46, 60) of opposing formwork surfaces
(36).
5. The apparatus according to claim 1, characterized in that at
least one of the receiving devices (42, 46, 60) has a cylindrical
or conical element (42) fastened in the formwork surface (36),
wherein the at least one reinforcing tube (44) is slid onto the at
least one cylindrical element (42).
6. The apparatus according to claim 1, characterized in that at
least one of the receiving devices (42, 46, 60) has a bore hole
(60) provided in the formwork surface (36), wherein the at least
one reinforcing rod or the at least one reinforcing tube is placed
into the at least one bore hole (60).
7. The apparatus according to claim 1, characterized in that at
least one of the receiving devices (42, 46, 60) has a sleeve (46)
fastened in the formwork surface (36), wherein the at least one
reinforcing rod or the at least one reinforcing tube is slid into
the at least one sleeve (46).
8. The apparatus according to claim 1, characterized in that the at
least one reinforcing rod (48) has at least on one end a head (50)
with a cross section expanded with respect to the reinforcing rod
(48).
9. The apparatus according to claim 1, characterized in that at
least one reinforcing rod (48) on at least one end has a head (50)
with an cross section expanded with respect to the reinforcing rod,
and at least one other reinforcing rod (48) on at least one end has
a shaped piece (64) with an undercut (66), wherein for connecting
the reinforcing rods (48) of wall elements (20) adjacent in the
erected state, the head (50) of the one reinforcing rod (48) can be
hooked in the undercut (66) of the opposing other reinforcing rod
(48).
10. The apparatus according to claim 9, characterized in that the
at least one shaped piece (64) has a keyhole opening (68), through
which the head (50) of another reinforcing rod (48) can be hooked
in the respective undercut (66).
11. The apparatus according to claim 1, characterized in that at
least one end region of the at least one reinforcing element (44,
48, 72) is surrounded at least partially by a shaped element (54),
that represents a recess at the end region in the cast concrete
wall element (20).
12. The apparatus according to claim 1, characterized in that
shaped elements (76) are disposed at least at a few of the formwork
surfaces (36), and represent the joints in the cast wall elements
(20).
13. The apparatus according to claim 1, characterized in that at
least one projection (78) is provided at least one formwork surface
(36), and on at least one other formwork surface (36), at least one
recess (80) is provided that corresponds to the at least one
projection (78).
14. The apparatus according to claim 1, characterized in that a
film (90) is provided at least in the area of contact between the
formwork elements (28) and the foundation (10) that prevents cast
concrete from penetrating underneath the formwork elements
(28).
15. The apparatus according to claim 1, characterized in that at
least one film is disposed on the foundation of at least one field
(18).
16. The apparatus according to claim 15, characterized in that the
film extends further, at least over the formwork surfaces (36) of
the at least one field (18).
17. The apparatus according to claim 1, characterized in that it
has at least one retainer (82) which holds a fastening element (86,
92) for fastening further devices to at least one wall element (20)
at least partially in a field (18) to be cast with concrete.
18. The apparatus according to claim 17, characterized in that the
fastening element (86) is an anchor element (86) for fastening a
railing to the container wall.
19. The apparatus according to claim 17, characterized in that the
fastening element (92) is a rail (92) for fastening a film of a
cover of the container.
20. The apparatus according to claim 1, characterized in that at
least one of the formwork surfaces (36) has a preferably conical
shaped element (100), which reproduces a preferably conical recess
in the associated wall element (20), and that on at least one other
formwork surface (36), a threaded connector (106) to be cast in the
concrete is provided, into which in the cast wall element (20) a
preferably conical shaped element (102) corresponding to the recess
can be screwed.
21. A method for casting concrete wall elements (20), which
together form a wall, running at least in sections, along a curve,
of a container, in particular of a fermenter for a biogas plant,
comprising the steps: casting a horizontal base (10) from concrete
for the container at the installation site of the container,
fastening several horizontally extending bounding elements (12)
onto the base (10) which between them define fields (18) for the
wall elements (20) to be cast with concrete, casting the wall
elements (20) of concrete in the fields (18), defined by the
bounding elements (12), forming the walls of the container by
erecting the wall elements (20) cast in the fields (18).
22. The method according to claim 21, characterized in that in a
first work step the first half of the wall elements (20) of the
container are cast in the fields (18), and subsequently erected,
and that in a second work step the second half of the wall elements
(20) of the container are cast in the fields (18) and subsequently
erected.
23. The method according to claim 21, characterized in that several
formwork elements (28) are detachably fastened at least to a few
bounding elements (12), which form formwork surfaces (36) that are
located across from each other in a field (18) and that are aligned
at an angle (.alpha.) to the vertical, which in the erected state
form face side surfaces of adjacent wall elements (20) facing each
other, and that the formwork elements (28) at the formwork surfaces
(36) each have at least one receiving device (42, 46, 60), and
wherein one end of at least one reinforcing element (44, 48, 72) to
be cast into the concrete is fastened in each receiving device (42,
46, 60) of formwork surfaces (36) lying opposite each other in a
field (18).
24. The method according to claim 23, characterized in that the at
least one reinforcing element is a reinforcing rod (48) or a
reinforcing cable, or that the at least one reinforcing element is
a reinforcing tube (44) for receiving a reinforcing rod or
reinforcing cable.
25. The method according to claim 23, characterized in that the at
least one reinforcing element (44, 48, 72) runs curved between the
receiving devices (42, 46, 60) of formwork surfaces (36) opposite
each other.
26. The method according to claim 23, characterized in that with at
least one of the receiving devices (42, 46, 60) a cylindrical or
conical element (42) is fastened in the formwork surface (36),
wherein the at least one reinforcing tube (44) is slid onto the at
least one cylindrical element (42).
27. The method according to claim 23, characterized in that at
least one of the receiving devices (42, 46, 60) has a bore hole
(60) provided in the formwork surface (36), wherein the at least
one reinforcing rod or the at least one reinforcing tube is slid
into the at least one bore hole (60).
28. The method according to claim 23, characterized in that at
least one of the receiving devices (42, 46, 60) has a sleeve (46)
fastened in the formwork surface (36), wherein the at least one
reinforcing rod or the at least one reinforcing tube is slid into
the at least one sleeve (46).
29. The method according to claim 23, characterized in that the at
least one reinforcing rod (48) on at least one end has a head (50)
with a cross-section expanded with respect to the reinforcing rod
(48).
30. The method according to claim 23, characterized in that at
least one reinforcing rod (48) at least one end has a head (50)
having a cross-section expanded with respect to the reinforcing
rod, and at least one other reinforcing rod (48) on least at one
end has a shaped piece (64) with an undercut (66), wherein for
connecting the reinforcing rods (48) of wall elements (20) that in
the erected state are adjacent, the head (50) of the one
reinforcing rod (48) is hooked in the undercut (66) of the other
reinforcing rod (48) lying across from it.
31. The method according to claim 30, characterized in that at
least one shaped piece (64) has a keyhole opening (68), through
which the head (50) of another reinforcing rod (48) is hooked in
the respective undercut (66).
32. The method according to claim 23, characterized in that at
least one end area of the at least one reinforcing element (44, 48,
72) is surrounded at least partially by a shaped element (54), that
forms a recess at the end region in the cast concrete wall element
(20).
33. The method according to claim 23, characterized in that shaped
elements (76) are disposed at least a few of the formwork surfaces
(36) that form joints in the cast wall elements (20).
34. The method according to claim 23, characterized in that at
least one projection (78) is provided on at least one formwork
surface (36), and at least one recess (80) corresponding to the at
least one projection (78) is provided on at least one other
formwork surface (36).
35. The method according to claim 23, characterized in that a film
(90) is provided at least in the area of contact between the
formwork elements (28) and the foundation (10) that prevents cast
concrete from penetrating underneath the formwork elements
(28).
36. The method according to claim 21, characterized in that a film
is disposed at least on the foundation of at least one field (18)
before casting the concrete wall elements.
37. The method according to claim 36, characterized in that the
film extends further at least over the formwork surfaces (36) of
the at least one field (18).
38. The method according to claim 21, characterized in that at
least one retainer (82) is provided that holds a fastening element
(86, 92) for fastening further devices to at least one wall element
(20) at least partially in a field (18) to be cast in concrete.
39. The method according to claim 38, characterized in that the
fastening element (86) is an anchor element (86) for fastening a
railing to the container wall.
40. The method according to claim 38, characterized in that the
fastening element (92) is a rail (92) for fastening a film of a
cover of the container.
41. The method according to claim 23, characterized in that at
least one of the formwork surfaces (36) has a preferably conical
shaped element (100), which forms a preferably conical recess in
the associated wall element (20), and that a threaded connector
(106) to be cast in concrete is provided on at least one other
formwork surface (36), into which, in the cast wall element (20),
preferably conical shaped element (102) corresponding to the recess
can be screwed.
Description
[0001] The invention relates to an apparatus and a method for
casting concrete wall elements, which together form a wall of a
container, in particular, among others, of a fermenter for biogas
plants, running along a curvature at least in sections. Fluids or
other substances are filled into such typically cylindrical
fermenters for fermentation in biogas plants. For constructing the
container it is typical to first cast a base of concrete on the
foundation. Then a plurality of substantially cuboidal wall
elements, likewise of cast concrete, can be erected on this base.
In the erected state, together, the wall elements form the
polygon-like container wall. Due to the container wall running
along a curvature, the wall elements for this must be provided with
angled face side wall surfaces so that adjacently erected elements
can be placed with their face surfaces next to each other without
forming a gap. To avoid forming undesired gaps, the face sides must
be precisely formed. The same is true for the remaining dimensions
of the elements because the leak tightness of the container, in
particular, is of crucial importance. In addition, adjacent wall
elements must be connected together. For this purpose, it can be
necessary to provide reinforcing rods or similar in the wall
elements, and appropriate connections in the elements so that the
reinforcing rods of adjacent elements can be connected
together.
[0002] Thus, it is necessary to produce relatively complex wall
elements with high accuracy, preferably at the installation site of
the wall.
[0003] Starting from the described prior art as a background, the
object of the present invention is therefore to provide an
apparatus and a method of the initially named type, with which the
concrete wall elements can be provided on-site in a simple and
precise manner.
[0004] The invention achieves this object by the subject matter of
claim 1 and the subject matter of claim 19. Advantageous
embodiments are found in the dependent claims, the description and
the drawings.
[0005] The invention achieves this object with an apparatus for
casting concrete wall elements of the initially named type,
comprising: [0006] a horizontal foundation, upon which several
horizontally extending bounding elements are fastened; the area
between the bounding elements forming fields for the wall elements
to be cast with concrete, [0007] several formwork elements that are
detachably fastened to at least a few bounding elements that form
formwork surfaces lying opposite each other in a field and aligned
at an angle to the vertical, and that represent face side surfaces
of adjacent wall elements that face each other in the erected
state, [0008] wherein the formwork elements at the formwork
surfaces each have at least one receiving device, and wherein one
end of at least one reinforcing element to be cast in the concrete
is fastened in receiving devices of formwork surfaces lying across
from each other in a field in each case.
[0009] The invention achieves the object also with a method for
casting concrete wall elements, which together form a wall of a
container running along a curvature at least in sections, in
particular of a fermenter for a biogas plant, comprising the steps:
[0010] casting a horizontal concrete base for the container at the
installation site of the container, [0011] fastening several
horizontally extending bounding elements to the base that bound the
fields for the wall elements to be cast with concrete, [0012]
casting the wall elements in concrete, in the fields that are
defined by the bounding elements, [0013] forming the wall of the
container by erecting the wall elements cast in the fields.
[0014] With the method according to the invention, a high-value
formwork is available at the installation site of the container due
to the bounding elements; using the formwork the wall elements of
the container can be cast with concrete. In the process, in a first
work step the first half of the wall elements of the container are
cast in the fields, and subsequently erected, and in a second work
step, the second half of the wall elements of the container are
cast in the fields and subsequently erected.
[0015] According to a further embodiment of the method it can be
provided that several formwork elements are detachably fastened at
least to a few bounding elements which form formwork surfaces that
lie opposite each other in a field and that are aligned at an angle
to the vertical, said formwork surfaces represent the face sides of
adjacent wall elements facing each other in the erected state, and
that the formwork elements at the formwork surfaces each have at
least one receiving device, and wherein one end of at least one
reinforcing element to be cast into the concrete is fastened in
receiving devices of formwork surfaces lying opposite each other in
a field.
[0016] The bounding elements run in the horizontal direction on the
level foundation and form a grid of fields to be filled with
concrete. The bounding elements can be beams, for example steel or
aluminum beams. Their position can be fixed using diagonals and/or
braces so that a dimensionally exact position is attained. A
separation layer, for instance a separation film, is provided on
the bottom of the field to prevent the poured concrete from bonding
to the foundation that also consists of concrete, for instance.
After casting, the wall elements lie on the foundation with their
front sides or back sides provided as outer or inner walls of the
container. Then, they are lifted from the foundation together with
the formwork elements, and the formwork elements are removed from
the wall elements. Next, the wall elements are set upright, and
erected for forming the container wall, wherein adjacent elements
are connected at their face side surfaces.
[0017] The formwork surfaces running in the horizontal direction
along the bounding elements form the surfaces abutting each other
at the joints between adjacent wall elements in the erected state.
The container wall can run along a circle, at least in sections. It
is then formed as a polygon due to the wall elements. The angled
formwork surfaces ensure that the joints between the side surfaces
of adjacent wall elements can be closed. The wall elements have
essentially plane parallel front and back sides, which each can be
formed essentially as rectangles. Thus, except for the angled side
surfaces, the wall elements are substantially cuboid.
[0018] Great flexibility is attained due to the detachable
fastening of the formwork elements to the bounding elements.
Therefore, for different container sizes different formwork
elements are fastened to the bounding elements which represent the
appropriate different angled face side surfaces of the wall
elements. For this purpose, chamfered flat sheets (made of steel,
aluminum or similar) can be fastened, welded on for instance, to
the bounding elements, for instance, at their bottom, laterally and
in sections, or continuously upward. The side formwork elements
then have a recess at their bottom with which they are placed on
the chamfer of the flat sheets. The formation of the recess in the
formwork elements determines the angle of the formwork surface. At
their top, the formwork elements can be fixed by the head plates
connected to the bounding elements, for example.
[0019] Because receiving devices, in which the reinforcing elements
that are necessary for the reinforcing of the wall are placed, are
already provided in the formwork elements, the reinforcing is
already prepared in a simple manner during casting. After erecting,
reinforcing elements of adjacent wall elements can then be easily
connected together.
[0020] Naturally, several receiving devices can be provided at each
formwork surface. Accordingly, several reinforcing elements then
run in a field between opposite receiving devices.
[0021] Projections (for example formed by triangular strips) can be
provided at the bottom and/or top of the formwork elements, e.g. at
the possibly provided head surfaces, which create appropriate
chamfers on the wall element. Furthermore, in addition to the
formwork elements having angled formwork surfaces, further formwork
elements that represent the top and bottom of the wall elements can
naturally be provided in a field. Depending on the desired shape,
these can form vertical formwork surfaces, in particular. In
addition, fastening elements that are also cast and allow receiving
the cast wall elements while erecting the wall, can be disposed in
the fields of the apparatus. It is also possible to dispose
elements in the fields to be cast with concrete that represent
openings in the wall elements to be produced, for example for
hatches, safety flaps, etc.
[0022] Using the apparatus according to the invention and the
method according to the invention it is possible to produce wall
elements in a simple and flexible manner, and to form the container
walls at the installation site of the container. In the process, it
is guaranteed that precise quality standards are maintained during
the production of the elements.
[0023] A concrete steel reinforcement can be provided according to
applicable rules. According to one embodiment, the reinforcing
elements can be reinforcing rods or reinforcing cables. The
reinforcing elements can also be reinforcing tubes, in particular
reinforcing empty tubes or respectively jacket tubes, for
respectively receiving a reinforcing rod or reinforcing cable. The
reinforcing elements and in particular the reinforcing rods or
respectively reinforcing cables can be made of steel. The
reinforcing rods or respectively reinforcing cables of adjacent
wall elements are connected together after erecting the elements.
With the reinforcing tubes, the reinforcing rods or reinforcing
cables can be inserted before or after pouring the concrete into
the tubes. The connection, especially of reinforcing rods or
respectively reinforcing cables, can be performed by welding, for
example. Reinforcing cables that are connected to the reinforcing
rods can form loops in the face area of the wall elements. Loops of
adjacent elements can then be placed above one another and
connected together by a reinforcing rod guided through the
loops.
[0024] In a particularly practical manner, the foundation itself
can be formed by the base of the container to be erected. The
container base provides a planar foundation well suited for pouring
the concrete wall elements thereupon. The container base is
therefore, also, of concrete that is cast on site.
[0025] The reinforcing elements, in particular, the reinforcing
rods or reinforcing tubes, can run curved between the receiving
devices of opposing formwork surfaces. In this, the axis of
curvature can run in particular in the horizontal direction. They
can run in particular in a circular arc shape between the receiving
devices. The curvature required in each case is specified by an
appropriate alignment of opposing receiving devices.
[0026] According to a further embodiment, at least one of the
receiving devices, in particular a few or all of the receiving
devices located opposite each other in a field can each have a
cylindrical element fixed in the formwork surface, wherein the
reinforcing tube(s) are slipped onto the cylindrical element(s).
Recesses can then be provided in the formwork elements, and the
cylindrical element(s) are placed therein. After casting, the
formwork elements with the cylindrical elements are removed from
the wall elements. According to a further particularly simple
embodiment, at least one of the receiving devices, in particular a
few or all of the receiving devices located opposite each other in
a field can each have a bore hole provided in the respective
formwork surface, wherein the reinforcing rod(s) or reinforcing
tubes are inserted into the bore hole(s). According to an
alternative embodiment, the at least one receiving device, in
particular a few or all of the receiving devices located across
opposite other in a field can each have a sleeve fastened in the
formwork surface, wherein the receiving rod(s) or receiving tubes
are inserted into the sleeve(s). The sleeves can each have an outer
surface tapering conically starting from the formwork surface. This
facilitates removing the formwork after casting.
[0027] One or more of the reinforcing rods can have at least one,
in particular at both ends, head having an expanded cross section
with respect to the reinforcing rod. Such heads can be formed
pot-like or solid. For fastening to the formwork elements, the rods
with their heads can be inserted, e.g. in sleeves or boreholes in
the formwork elements. For connecting reinforcing rods of adjacent
wall elements, the heads can then be placed on one another, and for
example, connected together by clamping. Such clamping can be
formed, for example by two half-shells encompassing the heads that
are fixed by a ring.
[0028] According to a further embodiment, at least one reinforcing
rod can have at least one end a head having an expanded
cross-section with respect to the reinforcing rod, and at least one
other reinforcing rod can have at least at one end a shaped piece
with an undercut, wherein for connecting the reinforcing rods of
wall elements that are adjacent in the erected state, the head of
the one reinforcing rod can be hooked into the undercut of the
opposite reinforcing rod. In a particularly simple manner it is
possible to provide each reinforcing rod at one end with a head,
and with a shaped piece at the other end. However, it is also
possible to provide a few of the reinforcing rods at both ends with
a head and the other reinforcing rods at both ends with a shaped
piece. The shaped pieces can, in a particularly practical manner,
each have a keyhole opening through which the head of another
reinforcing rod can be hooked into the respective undercut. In this
manner, in the erected state, quasi-continuous rods are formed in
the walls, wherein the rods of adjacent wall elements can be hooked
into one another in a particularly simple manner. The respective
heads or shaped elements can in turn be held in sleeves and/or bore
holes in the formwork elements.
[0029] A further embodiment provides that at least one end region,
in particular both end regions, of the reinforcing elements are
encompassed in each case at least in sections, particularly
completely, by a shaped element that forms a recess in the cast
concrete wall element at the end region(s). Such shaped elements
can be composed of rigid foam, for example. Recesses formed this
way allow subsequent access in the region of the connection of two
erected wall elements for fastening the reinforcing elements
together, e.g. for a welding procedure or another type of
connection. It is also possible to dispose shaped elements at a few
or all of the formwork surfaces, which form joints in the cast wall
elements. Sealing compound can be placed in such joints. The shaped
elements can be bars for example, which are formed as half-rounds
so that a cylindrical recess forms with assembled walls.
[0030] At least at one formwork surface, in particular at several
or all, formwork surfaces, at least one projection can be provided,
and at least one, in particular at several or all, other formwork
surfaces at least one recess can be provided that corresponds to
the at least one projection. During casting, the projection forms a
recess, and the recess during casting forms the corresponding
projection. With walls put together, this projection fits in a kind
of block shear connector into the recess. This way, the walls and
for example, joints provided therein, are connected together in a
shear-resistant manner. The shape and the size of the projections
and the recesses are matched to the selected embodiment of the
formwork surfaces and reinforcing elements. To prevent poured
concrete from penetrating under the formwork elements, furthermore,
at least one film can be provided in the area of contact between
the formwork elements and the foundation. According to a further
embodiment, at least one film is disposed on the foundation of at
least one field, in particular under several or respectively all
fields. Such films are used to seal the container formed by the
wall elements. According to a further embodiment in this regard,
the film can furthermore extend at least over the formwork surfaces
of the at least one field, in particular over several or
respectively all fields. In the erected state of the wall elements,
these films cover the top and bottom sides of the wall
elements.
[0031] According to a further embodiment, the apparatus can have at
least one retainer, which holds a fastening element for fastening
further devices to at least one wall element, at least partially in
a field of concrete to be cast. The fastening element is therefore
cast at least partially in the concrete. The corresponding retainer
is fastened to the formwork elements or bounding elements before
casting the concrete. The fastening element can be, for example an
anchor element for fastening a railing to the container wall. Such
an anchor can be formed by a bolt, for example, to which a railing
is fastened or on which it is suspended. However, it is also
possible that the fastening element is a rail for fastening a film
of a cover of the container. The film of a film covering of such a
container is placed in rails having a U-shaped cross-section, for
example. Finally, they can be clamped in a known manner, for
instance by a tube placed in the rail, and thus fastened.
[0032] To precisely align the heavy and large wall elements to each
other while erecting, the apparatus can have an assembly aid. Thus,
the at least one of the formwork surfaces can preferably have a
conical shaped element, which forms a preferably conical recess in
the associated wall element, wherein at least one other formwork
surface, for example an opposite one, is provided with a threaded
connector to be cast in the concrete, in that a preferably conical
shaped element can be screwed in that corresponds to the recess in
the cast wall element. The cone can be a cone or a truncated
cone.
[0033] The invention relates also to one or more concrete wall
elements, produced with the apparatus according to the invention,
if necessary, in the erect state, connected to each other to build
a wall.
[0034] An exemplary embodiment of the invention is explained in the
following in more detail using the figures. The figures show
schematically in:
[0035] FIG. 1 a top view of an apparatus according to the invention
according to a first exemplary embodiment,
[0036] FIG. 2 a top view of an apparatus according to the invention
according to a second exemplary embodiment,
[0037] FIG. 3 a section along the line a-a in FIG. 1 according to a
further exemplary embodiment,
[0038] FIG. 4 side views of two concrete wall elements cast with
the apparatus according to the invention for illustrating a
bracing,
[0039] FIG. 5 a section along the line a-a in FIG. 1 according to a
further exemplary embodiment,
[0040] FIG. 6 a cross-sectional view of a connection of the wall
elements produced according to FIG. 5,
[0041] FIG. 7 a longitudinal sectional view of the representation
from FIG. 6,
[0042] FIG. 8 a section along the line a-a in FIG. 1 according to a
further exemplary embodiment,
[0043] FIG. 9 a connection of wall elements produced according to
FIG. 8 in a further side sectional view,
[0044] FIG. 10 a section along the line a-a in FIG. 1 according to
a further exemplary embodiment,
[0045] FIG. 11 two sectional views of a connection of the wall
elements produced according to FIG. 10,
[0046] FIG. 12 a section along the line a-a in FIG. 1 according to
a further exemplary embodiment,
[0047] FIG. 13 a section along the line a-a in FIG. 1 according to
a further exemplary embodiment,
[0048] FIG. 14 a section along the line a-a in FIG. 1 according to
a further exemplary embodiment,
[0049] FIG. 15 a section along the line a-a in FIG. 1 according to
a further exemplary embodiment,
[0050] FIG. 16 a section along the line a-a in FIG. 1 according to
a further exemplary embodiment,
[0051] FIG. 17 a section along the line a-a in FIG. 1 according to
a further exemplary embodiment,
[0052] FIG. 18 a section of a wall element according to a further
exemplary embodiment,
[0053] FIG. 19 a section for illustrating the function of the
assembly aid represented in FIG. 18, and
[0054] FIG. 20 sectional views for illustrating an assembly aid
according to a further exemplary embodiment.
[0055] The same reference numbers refer to the same objects in the
figures unless indicated otherwise. Using the apparatus according
to the invention, containers can be erected in sizes from 15 to 50
m in diameter and 5 to 12 m in height, for example. FIG. 1 shows
the base 10 that is cast in concrete at the installation site, for
a fermenter to be erected for a biogas plant. Seen in a top view,
it is circular and has a flat surface. FIG. 1 also shows several
bounding elements 12 that are beams composed of steel, aluminum or
another material in the example shown. The beams are placed in the
grid spacing and fixed by diagonals 14 and braces 16 for fastening
on the base 10 so that a dimensionally precise positioning is
attained. Next, the beams 12 are fastened on the base 10 in a
manner to be described in more detail. Fields 18 to be cast with
concrete are defined between the beams. By filling the fields 18
with concrete, wall elements for the container are produced in two
work cycles. After the first concrete pouring procedure, the first
half of the wall elements are mounted on the base, which is
schematically indicated in FIG. 1 for the wall elements 20. The
wall elements 20 form a wall of the container running in a
polygon-like manner along a circular track. Next, the second half
of the wall elements 20 are cast in the fields 18, and the wall is
correspondingly completed. FIG. 2 shows the case of a particularly
large container with very high walls. In this case, it is necessary
to enlarge the base 10 by a small area to be able to produce the
wall elements in two work steps.
[0056] The sectional view in FIG. 3 shows a first exemplary
embodiment of the apparatus according to the invention. A support
beam 12 can be seen. Beveled flat steels 22 are welded to this beam
in sections or continuously using a welding connection 24. The flat
steels 22 and with them also the beams 12 are fixed on the base 10
using dowel bars 26, merely indicated schematically in FIG. 3, and
corresponding screws. Also shown in FIG. 3 are formwork elements
28, made of wood for example, that have a machined recess 30, for
instance, on their bottom. The formwork elements 28 extend over the
entire length of each respective beam 12. The formwork elements 28
are engaged with the recesses 30 on the chamfer of the flat steels
22. The formwork elements 28 are held at their top on the entire
length using a head plate 32 supplied with trimming strips. The
head plate 32 is screwed to the beam 12 using screws 34. As a
result, the formwork elements 28 are detachably connected to the
beams 12. They form formwork surfaces 36 aligned at an angle
.alpha. to the vertical and opposite each other in a field 18.
These formwork surfaces 36 form the face side surfaces of adjacent
wall elements, that face each other in the erected state of the
wall elements. With the polygon-like set-up of the wall elements 20
shown in FIG. 1, it is assured due to their angled formation that
the gap between adjacent wall elements 20 can be closed. Because
the corresponding required inclination of the face sides depends on
the diameter of the container, the formwork elements 28 are adapted
to the respective required inclination by different machining at
their foot. In addition, in the represented example, a triangular
strip 38 that creates a chamfer in the concrete, is fastened in
each case to the formwork elements 28 at the lower end. A
corresponding chamfer is formed in the upper region of the field 38
by projections 40 of the head plate 32.
[0057] As receiving devices, the formwork elements 28, shown in
FIG. 3, have at their formwork surfaces 36 cylindrical elements 42
inserted in a recess. In the example shown, an end of a reinforcing
tube 44 to be cast in concrete, in the represented example a jacket
tube 44, of steel, plastic or aluminum for example, is fastened in
the receiving devices of formwork surfaces 36 located opposite each
other in a field 18. An appropriate alignment of the cylinder
elements 42 guarantees that the jacket tubes 44 run along a
circular arc in a field 18. Here, the circular axis runs in the
horizontal direction. This is shown in the upper part of FIG. 4 as
an example. The cast wall element 20 is shown in a side view and
the jacket tube 44 cast therein is shown with dotted lines. Here, a
plurality of such jacket tubes 44 or other reinforcing elements can
be disposed in the described manner in a field 18 for casting in
concrete. The tubes 44 are already cut precisely to length at the
factory. Before the installation of the tubes 44, the lower
reinforcement that is required for the respective wall elements 20
is installed at the construction site.
[0058] After casting of the wall elements in the fields 18, the
head plates 32 are released and the wall elements together with the
formwork elements 28 and the receiving devices 42 are lifted
upwards out of the fields 18. Next, the formwork elements 28 are
pulled laterally from the wall elements 20. Afterwards, reinforcing
rods for example, composed of steel for instance, can be guided
through the reinforcing tubes 44. For fastening reinforcing rods of
adjacent wall elements 20, it can be necessary to guide these out
of the wall elements 20, as shown in the lower section of FIG. 4.
In the regions marked with the arrows, adjacent reinforcing rods
can be connected, as will be explained below in more detail using
an example. The lower part of FIG. 4 shows a particular connection
wall element 20' to be cast using the apparatus according to the
invention for clamping the elements 20 shown in the upper part of
FIG. 4. Two such opposite connection wall elements 20' can be
supplied in a container wall, for example. The jacket tubes 44',
shown with dotted lines, can be cast into the wall. Now, if
reinforcing rods are guided through the jacket tubes 44 of the
elements 20 in the erected state, that end in the connection
element 20' and are guided laterally out of it through the jacket
tubes 44', as shown at the bottom in FIG. 4, then a clamping of the
reinforcing rods, and therefore the entire container wall can take
place, in that the rods at their exits from the connection elements
20' are subjected to an appropriate tractive force.
[0059] FIG. 5 shown an alternative embodiment to the representation
in FIG. 3. In contrast to the representation in FIG. 3, the
formwork elements 28 have ring shaped sleeves 46 as receiving
devices that are held in appropriate recesses of the formwork
elements 28. Starting from the formwork surfaces 36, the sleeves 46
have a conically tapering outer surface. This simplifies the
removal of the formwork. In the example shown, steel reinforcing
rods 48 are inserted in the sleeves 46. The reinforcing rods 48 are
welded to a pot-like head 50 via a steel disk 52 with a larger
diameter. The reinforcing rods 48 are placed with their heads 50
into the sleeves 46, and thus in turn, are placed circular arc-like
in the fields 18. For connecting the reinforcing rods 48 with the
erected wall elements 20, that is still to be explained, a recess
is required that in the example shown is formed by a shaped element
54 composed of rigid foam in the concrete. The shaped elements 54
extend beyond the entire height of the wall elements. This does not
have to be case. The shaped elements 54 are released after casting
the concrete, thereby leaving a recess. FIGS. 6 and 7 show the
connection of the heads 50 of the reinforcing rods 48, shown in
FIG. 5. For this purpose, the wall elements 20 are placed together
so that the heads 50 of the reinforcing rods 48 of opposite wall
elements abut each other. Then, half shells 56 are placed over the
heads 50 and securely fixed using a ring 58.
[0060] FIG. 8 shows a section of a further embodiment of the
apparatus according to the invention. In contrast to the exemplary
embodiment shown in FIG. 5 for instance, the reinforcing rods 48,
in the example shown on the left in FIG. 8, are inserted without a
head into a sleeve 46 of the formwork elements 28. The sleeve 46 in
turn, has a conical tapering outer shape, thereby making it easier
to remove the formwork from the concrete. The right part of FIG. 8
shows an even simpler embodiment, in which the reinforcing rods 48
are inserted directly into a recess 60 in the formwork elements 28.
These boreholes 60 each extend only approximately halfway through
the thickness of the formwork elements 28. In addition, also shown
in FIG. 8 are, in turn, the shaped elements 54 which in the region
of the ends of the reinforcing rods 48 form a recess in the
concrete. In the example shown, these do not extend over the total
height of the wall elements to be cast. FIG. 9 shows a possible
connection of the reinforcing rods 48 of adjacent wall elements 20
produced according to FIG. 8. In the end region of the reinforcing
rods 48 that are freely accessible due to the shaped elements 54,
round steel rods 62 are applied to the reinforcing rods 48 as a
typical welding joint according to DIN, and welded as a grouting.
Subsequently, the joint left by the shaped element can be closed
using grout, for example or similar.
[0061] FIG. 10 shows a further alternative of the apparatus
according to the invention. In contrast to the embodiment shown in
FIG. 5 for instance, the end of one of the reinforcing rods 48 has
a solid head 50 with which it is seated in a corresponding recess
60 and the associated formwork element 28. It can be seen here that
the recess 60 has a greater depth than the thickness of the head
50. With the head 50 completely inserted into the recess 60, a part
of the recess 60 remains free on the side facing away from the end
of the reinforcing rod 48. This in turn, is filled with a
releasable shaped element 54, of rigid foam for example, which
leaves behind a corresponding recess behind the head 50 in the cast
wall element. At its opposite end, the reinforcing rod 48, as shown
in FIG. 10 in the right part, for another reinforcing rod 48, has a
shaped piece 64, which is welded to the reinforcing rod 48. The
shaped piece 64 has a cavity 66 that is formed as an undercut, as
shown by the dotted lines in FIG. 10. With the shaped piece 64, the
reinforcing rod 48, in turn, is seated in a sleeve 46 in the
formwork element 28. After casting the wall elements in the fields
18 and removing the formwork, the reinforcing rods 48 are connected
together using their head pieces 50 and shaped pieces 64, as shown
in FIG. 11. The left part of FIG. 11 shows a cross section of the
erected wall element 20 in the area of the wall connection. The
right part of FIG. 11 shows a view along the line a-a in the left
part, wherein only the rear wall element 20 is shown. It can be
seen here that the shaped element 64 has a keyhole opening 68,
through which the adjacent reinforcing rod 48 with its head 50 can
be inserted into the cavity 66, and can be lowered into the
undercut so that the reinforcing rods 48 are quasi-continuous.
[0062] In the further example shown in FIG. 12, in contrast to the
example shown for instance in FIG. 8, shaped elements, conventional
galvanized sheet steel boxes 70 in the example shown, are fastened
on the formwork surfaces 36, for example by bonding or tacking. In
this example, reinforcing cables 72 which have loops 74 disposed in
the boxes 70, are welded to reinforcing rods, for example. When
casting the fields 18 with concrete, cavities are formed due to the
boxes 70 that can extend, in particular, over the entire height of
the wall elements 20. For connecting adjacent wall elements 20, the
loops 74 are placed above one another and a reinforcing rod, not
shown in detail in FIG. 12, is guided through the loops. Next, the
joints formed by the boxes 70 can be filled with concrete.
[0063] FIG. 13 shows additions which can be necessary in the joint
during the production of the plates. Shown as an example are formed
half round strips 76 at the formwork surfaces 36 which, when the
assembled wall elements 20 are assembled, form corresponding
cylindrical joints, in which sealing material can be inserted
before the final assembly. The strips can extend for example over
the total height of the erected wall elements. To attain a
shear-resistant connection of adjacent wall elements 20, the
formwork elements 28 can further be provided with projections in
the shape of block shear connectors 78 that typically do not extend
over the entire height of the erected wall elements. When casting
the fields 18, these form a corresponding recess. In the wall
element that is opposite in the erected state, a projection
corresponding to the recess can be formed, in that a recess 80 is
provided in the formwork elements 28 as represented in the right
part in FIG. 13.
[0064] FIG. 14 further shows a retainer 82 that is removed after
casting the fields 18. The retainer 82 is connected to the formwork
element 28 using screws 84. It supports a bolt 86 that is cast in
the concrete as an anchor for connecting a railing of the container
for example. The formation and function of such bolts 86 as
anchors, for railing parts for example, is known. The right part of
FIG. 14 shows the device for forming a bottom of the wall elements
20. The formwork element 28 has a corresponding vertically aligned
formwork surface 36. The formwork element 28 is secured by a spacer
88. Because the cast concrete wall parts 20 are lifted out of the
fields 18 perpendicular to the base 10, low friction of the spacer
88 with respect to the formwork beams 12 must be attained. Because
concrete can run beneath the formwork beams 12 due to unevenness of
the base 10, in the example shown in FIG. 14, film strips 90 are
bonded to the base 10 on one side and to the formwork elements 28
on the other. Such films can also be provided on the entire base
10, and naturally also with the other exemplary embodiments. Films
can be provided that in the erected state of a wall element cover
in particular the top and/or bottom of the wall elements. Such
films can be used later in particular also for sealing the
container.
[0065] FIG. 15 shows a section along the line c-c from FIG. 1. The
formwork surfaces 36 in this example form the top side of the wall
elements 20. In the example shown, these are also formed at an
angle. Rails 92 for example can be seen here fastened to the
formwork elements 28, for the known connection of film coverings of
such fermenters. Furthermore the left part of FIG. 15 shows that
the film cover 90 covers the entire area of the wall elements 20.
It can be detachably bonded to the formwork element 28, and can be
anchored to the edges 94 using any type of connection that is
appropriate for film. FIG. 15 further shows in more detail the
connection 26 of the flat steels 22, and with it the beams 12, to
the base 10. A tube 98 provided with an inner thread is welded to a
disk 96. This tube 98 is adjustably guided in an inner thread of
the flat steels 22. After precise alignment of the beams 12 on the
base 10, an dowel bar 26 is anchored through the tube 98 into the
concrete, thereby securing the position of the beams 12. The flat
steels 22 can be provided with several holes next to each other
with inner threads for the tube 98, in order to avoid possible
difficulties arising during boring due to the cast and abraded
base, for instance reinforcements or larger stones.
[0066] The FIGS. 16 and 17 each show an assembly aid for the
apparatus with which the large and heavy concrete wall parts 20 can
be safely guided up to the connection at the joint. One of the two
represented formwork surfaces 36 has a shaped element 100 that
extends tapering starting from the formwork surface 36. The shaped
element 100 is hollow and is composed of metal or plastic for
example, and is mounted on the formwork surface 36. In addition, a
shaped element 102 correspondingly adapted to the shaped element
100 is screwed onto the formwork surface 36 along the axis 104. On
the other formwork surface 36, in the erected state forming the
opposite face side surface of the wall element 20, a corresponding
threaded connection 106 is fixed via a screw 108 guided through the
formwork element 28, and cast in the concrete. After casting and
removing the formwork of the wall elements 20, conical recesses
remain in the wall elements 20 corresponding to the conical form
element 100. The shaped piece 102, after removing the formwork, is
screwed into the threaded connection 106 of an opposing wall
element, as is shown for example in FIG. 18 for the assembly aid
from FIG. 17. For assembly, the shaped piece 102 can now be
inserted into the corresponding conical recess in the opposing wall
element 20. With this, a precise alignment of the walls is attained
in a simple manner.
[0067] The embodiment shown in FIG. 17 corresponds largely to the
embodiment according to FIG. 16. Here, however, in contrast a plate
shaped spacer 110 is disposed between the conical elements 100, 102
in the formwork surface 36. The spacer plate 110 can be joined to
the formwork element 28 by means of screws 112. The spacer 110
forms a shoulder 114 as is shown in FIG. 18. Due to the elongated
shape of the recesses formed by the shaped element 100 and the
spacer 110, this assembly aid can also be used for the wall
connection shown in the FIGS. 10 and 11. The shoulder 114 at the
assembly cone 102 shown in FIG. 18, permits in particular an
insertion of the assembly cone 102 into a correspondingly shaped
element 100, and subsequently a shifting of the assembly cone 102
into the shaped element 100 so that the wall connection according
to the FIGS. 10 and 11 can also be produced without damage. This is
illustrated in FIG. 19 by the arrow 120. Next, the required
tolerances are to be adjusted for the individual parts. The shaped
element 100 can be implemented for this purpose also in a simple
shape for inserting an assembly cone, as is shown in FIG. 20. The
right part of FIG. 20 shows a section along the line a-a of the
left part of FIG. 20.
[0068] The embodiments according to the invention of the receiving
devices and the other elements, including the assembly aids, can
each be provided on a few or all formwork elements, and combined
with each other in any arbitrary manner. The same is true for the
embodiments according to the invention of the ends of the
reinforcing elements. With receiving devices corresponding to each
other, assembly aids or reinforcing elements, as shown for instance
in FIGS. 10, 11, and 16 to 20, can have formwork elements opposing
in a field for each of the corresponding receiving elements or
respectively assembly aids. Correspondingly, the reinforcing
elements running in the field can each be provided at their ends
with the appropriately corresponding shapes.
[0069] The apparatus according to the invention permits a simple
and flexible production of wall elements 20, even in inaccessible
areas, and correspondingly, erecting the container walls
on-site.
* * * * *