• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Method and tooling for the production by molding of pre-stressed concrete elements. The method and tooling includes the assembly of a rebar 20 outside a mold 10, in which prestressing cables 30 are fixed fixed in a position coinciding or close to their definitive position with respect to the rebar 20, subsequently said rebar is introduced. With cables in a mold, the cables being extended along the mold and leaving two grip portions 31 of each cable protruding from the mold 10 through two opposite faces 11 of the mold 10, then the gripping portions are introduced into elongated openings defined by spaces of separation between parallel and facing walls 42 integrating at least two prestressing masts 40, proceeding to the tensioning of the cables and the concreting and setting of the concrete element to be manufactured. (Machine-translation by Google Translate, not legally binding)
    公开号:ES2593933A1
    申请号:ES201530805
    申请日:2015-06-09
    公开日:2016-12-14
    发明作者:Manuel Cidoncha Escobar；Francisco Javier Martínez De Castañeda
    申请人:Pacadar SA；
    IPC主号:
    专利说明:

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    DESCRIPTION
    METHOD AND TOOL FOR MANUFACTURING BY MOLDING OF ELEMENTS OF
    PRETENSED CONCRETE
    Technical field
    The present invention concerns in general a method and tooling for the fabrication by molding of prestressed concrete elements, in particular flat or elongated elements, such as beams, capable of withstanding the stresses of the prestressing, and in particular a method and tooling which allows an accelerated manufacture of concrete elements by preassembly of the ferralla outside the mold, and the inclusion and fixation of the prestressing cables in a position close to or coinciding with its final position with respect to the ferralla before its transfer and placement inside of the mold, where grip portions of the cables protruding from both the ferralla and the mold can be attached to a prestressing masts accelerated by a middle region of the grip portion, away from the end of the cable.
    State of the art
    In the field of the manufacture of prestressed concrete elements, the use of a mold, arranged on a bench, in which a ferrule composed of a plurality of bent and joined corrugated steel bars is introduced in a precise arrangement intended to constitute a passive reinforcement once embedded in the concrete.
    Typically after the deposition of the ferralla inside the mold, prestress cables are placed that run along the entire mold, through the ferralla, with two cable grip portions protruding from two opposite ends of said mold, passing through the cables of two opposite faces of the mold. Said gripping portions are threaded into circular openings provided in fixing anchors that are firmly anchored to the bed and arranged on opposite sides of the mold.
    The operation of extending the cables along the mold in their desired final position between the prefabricated ferrule and extracting the two gripping portions of the same wire through two opposite faces of the mold and threading the ends of said gripping portions through the corresponding circular openings of the fixing anchors located at opposite ends of the mold is a tedious and complicated operation that is time-consuming, and that has to be repeated multiple times until the placement of all the
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    cables provided in the same precast concrete element, during which time the mold and the bench are occupied and therefore cannot be used in the manufacture of other additional prestressed concrete elements, limiting the productivity of the plant.
    This manufacturing process and its tools are described, for example, in documents US4149306A, US5766648 or US2005017403.
    Brief Description of the Invention
    The present invention concerns a method for manufacturing by molding prestressed concrete elements, in which the following known tools are used:
    • at least one mold, opened on at least one of its sides for the reception of at least one pre-assembled rail and a mixture of fluid concrete, the mold being provided with at least two opposite faces through which to have prestressing cables leaving grip portions of said cables out of the mold;
    • prestressing masts, arranged outside the mold facing said at least two opposite faces, provided with openings through which to dispose said gripping portions, the cables remaining from prestressing masts to opposite prestressing masts crossing said mold;
    • a bed formed by an elongated rigid structure comprising said mold, said prestressing masts and tensioning devices of said cables, and
    • cable retention bushes;
    Thus, the necessary tooling for the prefabrication of concrete elements comprises a bench equipped with prestressing masts and a mold located between said prestressing masts.
    It will be understood that the ferralla refers to the set of passive reinforcements that have been cut, folded and joined according to a predefined pattern obtaining a corrugated steel bar frame whose arrangement is coincident with that of the passive reinforcement provided to reinforce the concrete element manufacture.
    Similarly, it will be understood that the prestressing cables will preferably be steel cables of the type commonly used in construction.
    The steps of the method known in the state of the art include:
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    a) preparing the mold with the ferrule and the cables therethrough, said gripping portion protruding from the mold passing through said openings of the prestressing masts;
    b) place the retaining bushes in the grip portions, and subject the cables to a regulated tension;
    c) pour concrete into the mold and keep the cables in tension until an at least partial setting of the concrete is completed.
    Therefore, it is required to subject the prestressing cables that pass through the mold at a predetermined tension typically before concrete pouring, although it is also contemplated that said tensioning could be performed during or immediately after said pouring, and in any case before that the setting of the same begins, and maintaining said tension until the concrete has hardened enough to resist the compression introduced by said prestressing, and so that the concrete surrounding said cables manages to retain them opposing resistance against said prestressing.
    Typically the concrete will include accelerating additives to reduce the setting time, allowing the mold to be released first.
    For tensioning said cables are retained in the prestressing masts by means of the aforementioned retaining bushes, which are preferably split conical elements with a serrated interior in which the cable is arranged, the conical element being within a conical space. When the cable is tensioned, the retaining bushing is held against one face of the prestressing mast, so that the conical element tends to enter more into said conical space causing a greater closure of the serrated interior around the cable, producing its greatest grip.
    To produce such tension in the cable, hydraulic jacks are typically used.
    It is also understood that the cables cross two opposite faces of the mold but that the gaps through which said cables pass are sealed in the usual way in the sector to prevent the filtration of the liquid concrete out of the mold. Usually, partial covers are used which are placed between series of superimposed cables closing the space between said series of superimposed cables, said partial covers constituting at least a part of said opposite faces of the mold.
    In contrast to the aforementioned state of the art, the present invention proposes in a novel way, to include in stage a) in which the mold with the ferrule and cables is prepared, the following steps:
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    a.1) pre-assemble, outside the mold, the ferrule and the prestressing cables in the flaccid state arranged longitudinally in a position close to or coinciding with its final position with respect to the ferralla, the grip portions of said cables protruding from the ends of ferralla;
    a.2) disposing said pre-assembled ferrule with said cables inside the mold, the grip portions of the cables protruding through said at least two opposite faces of said mold;
    a.3) arrange the grip portions through the openings of the prestressing masts.
    The inclusion of the cables inside the ferralla, being the ferralla outside the mold, facilitates the tasks of placing said cables, since the ferralla is more accessible since it is not contained in the mold, and therefore results in a faster operation.
    Said cables are placed in their final position, or near their final position with respect to the ferralla, and held in said position by means of fixing pieces anchored to the adjacent bars and provided with a seat in which to place said cable. Said fixing piece holds the cable in its relative position with respect to the adjacent bars, but allows its longitudinal displacement when the cables are subjected to tension.
    The cables will be longer than the ferralla on which they are mounted, and will be placed so that said cables protrude from opposite ends of said ferralla. The cable portions that protrude from the ferralla are the so-called grip portions, since their purpose is to be used as cable grip points to produce their prestressing from outside the mold during concrete setting.
    Subsequent to the preassembly of stage a.1), said ferralla that includes the cables is moved and introduced into the mold that has the counterform of the concrete element to be manufactured. Typically the ferralla will distance itself from the inner faces of the mold by means of separators, thus ensuring that said ferralla is correctly covered with concrete that protects it from oxidation.
    The cable grip portions are then removed from the mold through two opposite faces of the mold, and disposed through the aforementioned openings of the prestressing masts. Said opposite faces of the mold crossed by the cables preferably have a recess through which to introduce said cables, and which will subsequently be sealed by means of partial covers. The portions of wires that remain outside the mold are the grip portions.
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    Said gripping portions are then introduced into said openings of the prestressing masts, and then the previously described steps b) and c) are executed.
    According to an additional feature of the proposed method, the arrangement of the grip portions of the cables in the openings of the prestressing masts, carried out in step a.3), is carried out by a region of the grip portion away from the end of the cable, by means of the lateral insertion of said gripping portion into said openings which are grooves defined by separation spaces existing between spaced walls formed in the prestressing masts.
    Thus the openings are not a closed conduit with two accesses at opposite ends, but it is a space delimited by at least two facing walls and a bottom wall that communicates them, said space being open to the outside through a single elongated access accessible from outside the prestressing mast.
    This configuration allows the grip portion of the cable does not have to be threaded into the opening at its end, but can be introduced laterally by a portion thereof away from the end of the cable. This operation is much simpler and faster to perform, especially if the weight and relative stiffness of the cables and their number are taken into account. Therefore, this feature allows an additional saving of time that allows reducing the time during which the mold is occupied, and therefore increasing the productivity of the precast concrete elements prefabrication plant.
    In addition, it is also proposed that in step a.3) a plurality of gripping portions be introduced into the same opening of the prestressing masts. This is possible because said openings are grooves, which allows a plurality of overlapping grip portions to be placed within the same opening. This feature also simplifies and accelerates mold preparation operations.
    The proposed invention also concerns a tooling for the fabrication by molding of prestressed concrete elements, said tooling comprising:
    • at least one mold, opened on at least one of its sides for the reception of at least one pre-assembled rail and a mixture of fluid concrete, the mold being provided with at least two opposite faces through which to have prestressing cables leaving grip portions of said cables out of the mold;
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    • prestressing masts, arranged outside the mold facing said at least two opposite faces, provided with openings through which to dispose said gripping portions, the cables remaining from prestressing masts to opposite prestressing masts crossing said mold;
    • a bed formed by an elongated rigid structure comprising said mold, said prestressing masts and tensioning devices of said cables, and
    • cable retention bushes.
    These elements are the same as those initially described in the description of the method and include the same characteristics.
    However, the proposed tooling contemplates that, in a novel way, the openings of the prestressing masts are grooves defined by existing separation spaces between spaced apart facing walls formed in the prestressing masts, in which to insert the gripping portions of the cables with the cables pre-assembled in a position close to or coinciding with their final position with respect to the ferralla.
    Thus, it is proposed that said prestressing masts have a pint configuration, being provided with a plurality of walls spaced apart by grooved spaces of a certain depth into which said cable grip portions can be introduced. The corrugated spaces are defined by the separation between the facing faces of the distanced walls, and by a bottom wall that joins the facing faces and that is part of the prestressed mast where the walls are firmly anchored.
    Said groove forms an opening of the prestressing mast, said opening being communicated with the outside by a single elongated access that runs through different faces of the prestressing mast.
    Preferably said walls will be parallel, and / or have parallel facing faces. Furthermore, it is also contemplated that said prestressing mast walls have a flat face perpendicular to the prestressing direction of the cable on its most distant side of the mold. Said flat face serves as a support on which to seat the retention bushes.
    Preferably, the minimum separation between the facing walls will be greater than the thickness of the grip portions of the cables, and less than the retention bushes.
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    According to another additional embodiment of the tooling, this includes a plurality of fixing pieces anchored to adjacent bars of the ferralla and each provided with a seat in which to hold a cable in a certain position with respect to said adjacent bars during transport of the ferralla , the prestressing of the cables and the pouring and setting of the concrete.
    It will be understood that references to geometric position, such as parallel, perpendicular, tangent, etc. they admit deviations of up to ± 5 ° with respect to the theoretical position defined by said nomenclature.
    Other features of the invention will appear in the following detailed description of an exemplary embodiment.
    Brief description of the figures
    The foregoing and other advantages and features will be more fully understood from the following detailed description of an exemplary embodiment with reference to the accompanying drawings, which should be taken by way of illustration and not limitation, in which:
    Fig. 1 shows a perspective view of an empty elongated mold disposed on a bench provided with two prestressing masts arranged opposite two opposite faces of said mold, and in which a ferrule with prestressing cables integrated in superposition is shown. with said mold, showing the end of step a.1) of the proposed method;
    Fig. 2 shows the same view as Fig. 1, but at the end of step b) of the proposed method, the ferrule being inside the mold and the prestressed cables.
    Detailed description of an embodiment example
    Figs. 1 and 2 show two different stages of the method for the manufacturing by molding of prestressed concrete elements, as well as the necessary tooling, according to an exemplary embodiment not illustrative.
    According to the proposed method, a mold 10 is disposed on a bench 12 provided with at least two prestressing masts 40 facing opposite ends of said mold 10, and in a first stage a rail 20 is prepared outside said mold 10 to the that a plurality of prestressing cables 30 are integrated in predefined positions coinciding or close to the final position, in relation to the rest of the rail 20, which said cables 30 must adopt.
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    It will be understood that the rail 20 will form the passive reinforcement of the precast prestressed concrete element, typically corrugated steel bars of different diameters joined forming a framework, and that the cables 30 constitute, after their prestressing, an active reinforcement.
    The cables 30 will be fixed in said position with respect to the rail 20 by means of a plurality of fixing pieces (not shown) that will each be anchored to the bars of the rail 20 adjacent to the desired position of the cable 30, said fixing pieces being arranged of at least one seat in which to retain a point of the cable 30 in a precise position with respect to said adjacent bars. By arranging a plurality of said fixing pieces arranged along the rail 20 it is possible to keep the cables in position, or close to their position (preferably less than 10 cm from their position) until the concrete hardens . Said fixing parts are intended to be embedded within the concrete, so they will be of a material suitable for this use. Said fixing pieces are also provided to allow a certain movement and a certain longitudinal displacement of the cable 30, since when it is subjected to tension, its position with respect to the rail 20 will be altered, within permissible limits by said fixing elements.
    Said cables 30 will have a length greater than that of the ferralla 20, and also greater than that of the mold 10. Said cables 10 will be placed in the ferralla 20 so that some grip portions 31 of said cables 30 protrude at two opposite ends. of the ferralla 20, the cables being extended in a straight line through the ferralla.
    It should be borne in mind that the prestressing cables 30 can only draw a rectilinear path, so that their position within the rail 20 must also be rectilinear, whereby the grip portions 31 necessarily protrude at opposite ends of said rail 20 .
    The integration of the prestressing cables 30 into the rail 20, said rail 20 being outside the mold 10, allows this task that requires a long run time to be carried out without occupying the mold 10, thus reducing the occupancy time of each mold 10 and therefore increasing the production of each mold 10, which allows to reduce manufacturing prices. Furthermore, placing the prestressing cables 30 on the rail 20 during its assembly, or after its assembly, but being outside the mold 10 is much easier, since the rail 20 can be more accessible by not being confined within the mold 10, which facilitates and therefore accelerates this task.
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    Once the assembly of the rail 20 with the prestressing cables 30 is completed, said rail 20 and said cables 30 are placed inside the mold 10 which will be open on its upper face, typically with the help of bridge cranes.
    The gripping portions 31 of the cables 30, which protrude through the two opposite ends of the rail 20, are extended and removed from the mold 10 through the two opposite faces 21 of the mold 10, which will have holes provided for this purpose. , preferably large gaps through which to extract multiple cables 30 from the mold 10, or the opposite faces 21 of the mold 10 being decoupled from the rest of the mold 10 during this operation, as shown in Fig. 1.
    At this stage of the method, said grip portions 31 of the prestressing cables 30 are introduced into the openings 41 of the prestressing masts 40 which, as indicated above, are arranged facing opposite faces 21 of the mold 10, through which the grip portions 31 leave the mold 10.
    Said insertion of the grip portions 31 into the openings 41 is produced by a portion of the cable 30 away from its end, so that said insertion is not produced by inserting the end of the cable 30 into the opening 41, but occurs by a lateral movement, for example by a middle section of the Grip Proportion 31.
    This is possible thanks to the configuration of said prestressing masts 40 and their respective openings 41. In the present exemplary embodiment, said openings 41 are defined by the separation spaces existing between a plurality of walls 42 with facing faces spaced apart and parallel. , the walls 42 being joined by its base to the rest of the prestressing mast 40, and making the defined space between said faces facing the functions of the opening 41.
    By means of this configuration of the prestressing mast 40 and the openings 41, it is achieved that said openings 41 are in contact with the outside through a single elongated access that crosses three different faces of the prestressed mast 40, where it can be inserted laterally the grip portion 31 by inserting it into the opening 41 without ever introducing the end of the cable 30 into said opening 41.
    After said insertion, each cable 30 will be anchored by means of a retaining bushing 50, like those commonly used in this type of methods, which retain the cable 30 making a clamp effect on it that applies greater clamping force to greater tension of the cable 30.
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    Preferably a plurality of grip portions 31 of different cables 30 can be inserted into the same opening 41, in adjacent positions.
    This method of joining the cables 30 and their corresponding gripping portions 31 to the prestressing masts 40 also allows a significant saving of time with respect to the traditionally used method, according to which the openings 41 of the prestressing mast 40 are simple through holes which must be individually threaded each end of each of the prestressing cables 30. Therefore this additional feature of the method also allows a significant saving of time that allows to increase the productivity of the installation.
    The cables 30 are subjected to controlled tension, either individually or in groups of cables 30. This tension is usually applied to the cables 30 by means of hydraulic jacks that pull the cables 30 from the gripping portions. 31 until the desired tension is reached, said cables 30 being retained, maintaining the tension, by means of the retaining bushes 50 located at the two opposite ends of each cable 30, said retaining bushes 50 being supported against a face of the masts of prestressed 40 which is preferably flat and perpendicular to the tension direction of the cable 30.
    Then or before the tensioning of the cables 30, the gaps are sealed, by which the grip portions 31 of the mold 10 have been removed, in the usual way in the sector, for example by partial covers that close the space existing between groups of parallel cables 30, or by placing the opposite faces 11 of the mold 11 that had been removed to facilitate said insertion of the rail 20 and the cables 30 inside the mold 10, appropriately provided with notches 22 or hollow spaces provided for the passage through the prestressing cables 30 from the inside of the mold 10 to the outside, while preventing a substantial filtration of liquid concrete towards the outside of the mold 10 at the time of pouring, as It is shown in the attached Figs. 1 and 2.
    Finally, the concrete is poured into the mold 10, maintaining the tension of the prestressing cables 30 until the hardening of the concrete is sufficient to be able to resist the tension of the cables 30 by itself, at which time it is cut said gripping portions 31 already extract the prestressed precast concrete element from the mold 10, then being released for the production of a new prestressed precast concrete element.
    In order to accelerate the concrete curing process, it is also common to use additives in concrete to accelerate its hardening.
    According to another aspect of the invention, the tools necessary for the application of this method, already described above, are protected. In that sense, the use 5 of a prestressing mast 40 provided with deep grooves that serve as openings 41 is considered novel. Said grooves are defined, in the present preferred embodiment, by the separation spaces between a plurality of walls. 42 with faces facing and parallel, said walls 42 being vertical and said faces being facing parallel to the direction of the cables 30 subjected to tension. The said 10 walls 42 are joined by their base to the rest of the prestressing mast 40 forming a pint configuration.
    Thus, said grooves the grooved openings 41 communicate with the outside through an elongated access that runs, in this example, three faces of the prestressing mast 40, a first flat face being perpendicular to the prestressing direction 15 of the cable 30, being placed on its most distant side of the mold 10. Said flat face serves as support for the retaining bushings 50, which transmit the force exerted by the tension of the prestressed cable 30 to the prestressing mast 40, and this in turn transmits that tension to the bench 12.
    For this reason it is preferable that the thickness of the groove that forms the opening 41 20 is greater than that of the prestressing cable 30, to facilitate its insertion, but less than that of the retaining bushings 50, to ensure that said retaining bushings 50 do not can be introduced inside.
    权利要求:
    Claims (8)
    [1]
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    1.- Method for the manufacturing by molding of prestressed concrete elements, which is carried out by using the following tools:
    • at least one mold (10), opened on at least one of its sides for the reception of at least one pre-assembled rail (20) and a mixture of fluid concrete, the mold (10) being provided with at least two opposite faces ( 11) through which to provide prestressing cables (30) leaving grip portions (31) of said cables (30) outside the mold (10) and another portion within the mold (10);
    • prestressing masts (40), arranged outside the mold (10) facing said at least two opposite faces (11), provided with openings (41) through which to dispose said gripping portions (31) leaving the cables (30) extended from at least one prestressing mast (40) to at least one other opposite prestressing mast (40), said cable (30) passing through said mold (10);
    • a bed (12) formed by an elongated rigid structure comprising said mold (10), said prestressing masts (40) rigidly attached to the bed (11) and tensioning devices of said cables (30), and
    • retention bushes (50) of the cables (30); comprising the following stages:
    a) preparing the mold (10) with the ferrule (20) and the cables (30) therethrough, said gripping portion (31) of the cables (30) running through said openings (41) protruding from the mold (10). of the prestressing masts (40);
    b) place the retaining bushes (50) in the grip portions (31), and subject the cables (30) to a regulated tension;
    c) pour concrete into the mold (10) and keep the cables (30) in tension until an at least partial setting of the concrete is completed;
    characterized in that stage a) includes the following stages:
    a.1) pre-assemble, outside the mold (10), the ferrule (20) and the prestressing cables (30) in flaccid state arranged longitudinally in a position close to or coinciding with its final position with respect to the ferralla (20), protruding the grip portions (31) of said cables (30) by the ends of the ferralla (20);
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    a.2) arranging said ferrule (20) preassembled with said cables (30) inside the mold (10), the grip portions (31) of the cables (30) protruding through said at least two opposite faces (11) of said mold (10);
    a.3) arrange the gripping portions (31) through the openings (41) of the prestressing masts (40).
    [2]
    2. - Method according to claim 1 characterized in that the arrangement of the gripping portions (31) of the cables (30) in the openings (41) of the prestressing masts (40), carried out in step a.3), it is made by a region of the grip portion (31) away from the end of the cable (30), by the lateral insertion of said grip portion (31) into said openings (41) which are grooves defined by separation spaces existing between spaced walls (42) formed in the prestressing masts (40).
    [3]
    3. - Method according to claim 2 characterized in that step a.3) a plurality of grip portions (31) are introduced into the same opening (41) of the prestressing masts (40).
    [4]
    4.- Tooling for the manufacturing by molding of prestressed concrete elements, comprising:
    • at least one mold (10), opened on at least one of its sides for the reception of at least one pre-assembled rail (20) and a mixture of fluid concrete, the mold (10) being provided with at least two opposite faces ( 11) through which to provide prestressing cables (30) leaving grip portions (31) of said cables (30) out of the mold (10);
    • prestressing masts (40), arranged outside the mold (10) facing said at least two opposite faces (11), provided with openings (41) through which to dispose said gripping portions (31) leaving the cables (30) from at least one prestressing mast (40) facing one end of the mold (10) to at least one prestressing mast (40) facing the opposite end of the mold (10) crossing said mold (10);
    • a bed (12) formed by an elongated rigid structure comprising said mold (10), said prestressing masts (40) rigidly attached to the bed (12) and tensioning devices of said cables (30), and
    • retention bushes (50) of the cables (30);
    5 characterized because
    the openings (41) of the prestressing masts (40) are grooves defined by spacing spaces between spaced apart walls (42) formed in the prestressing masts (40), said openings (41) being provided to receive the grip portions (31) of the cables (30) pre-assembled in a position close to or coinciding with their final position with respect to the ferrule (20) are inserted.
    [5]
    5. - Tooling according to claim 4 characterized in that said walls (42) of the prestressing mast (40) are parallel.
    [6]
    6. - Tooling according to claim 4 characterized in that said walls (42) of the prestressing mast (40) have parallel facing faces.
    7. Tooling according to claim 4, 5 or 6 characterized in that said mast walls (42)
    Prestressing (40) have a flat face perpendicular to the prestressing direction of the cable (30) on its most distant side of the mold (10).
    [8]
    8. - Tooling according to any one of the preceding claims 4 to 7, characterized in that the minimum separation between the facing walls (42) will be greater than the
    20 thickness of the grip portions (31) of the cables (30), and smaller than the retaining bushes (50).
    [9]
    9. - Tooling according to any one of the preceding claims 4 to 8, characterized in that it includes a plurality of fixing pieces anchored to adjacent bars of the ferralla (20) and each provided with a seat in which to hold a cable (30 ) in a position
    25 determined with respect to said adjacent bars during the transport of the ferralla (20), the prestressing of the cables (30) and the pouring and setting of the concrete.
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    同族专利:
    公开号 | 公开日
    MX2015008504A|2016-12-08|
    WO2016198720A1|2016-12-15|
    ES2593933B1|2017-09-07|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US4051216A|1971-10-27|1977-09-27|Concrete Industries Limited|In-line moulding of prestressed concrete articles|
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