Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
  • E04G9/00—Forming or shuttering elements for general use
  • E04G9/10—Forming or shuttering elements for general use with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
  • B28B7/368—Absorbent linings

Definitions

• the invention relates to a novel concrete formwork, which is suitable for the production of one-sided or two-sided concrete formwork, concrete forms containing such concrete formwork and methods for producing the concrete formwork panels.
• the concrete In the manufacture of concrete, it is usually cast using a concrete mold, the concrete taking the form of the concrete form. For this, the wet, unconsolidated concrete is poured into or onto the concrete mold, after hardening and removal of the concrete panel, the newly exposed concrete surface is a negative impression of the inner surface of the concrete form. For example, if wooden board panels are used as formwork, the concrete takes on the appearance of the wooden board grain.
• the concrete mixture often contains large amounts of air, and usually more water than is necessary for the setting.
• the air contained in the concrete mixture and the water present make the concrete mix more fluid and thus facilitate handling and casting.
• Concrete formwork has long been known from the prior art. So that describes US Patent 4730805 a mold for forming concrete using a support and at least two layers of fabric on the support.
• the carrier may have tabs for spacing the sheet from the carrier, wherein the sheet layers and tabs aid in draining the water from the hardening concrete.
• the carrier may have drainage holes for removing excess water and air.
• the sheet is bound to the carrier and immovable to it.
• EP-A-0429752 is a pattern for patterned concrete or concrete surfaces with a support means, a grid with interconnected spacers forming in the grid holes with a single surface of at least 0.25 cm 2 , at least a part of which rests on the support means, and a porous, textile Sheet, which is arranged next to the grid and spaced by the grid from the carrier, known.
• the sheet generally has a pore size of 10 to 250 ⁇ m on each side, so that a number of small concrete particles (typically 30 to 90 ⁇ m) can penetrate and fill the open spaces of the sheet. Furthermore, excess water and air can pass through, so that drainage is given.
• Fine concrete particles typically fill the larger pores of the sheet, especially when excessive concrete compaction occurs. If enough fine concrete particles have penetrated into the structure of the sheet and sufficient concrete hardening has taken place, usually the release of the sheet from the hardened concrete becomes very difficult or even impossible without damaging the concrete surface. Furthermore, the concrete facing side of the concrete formwork is unusable.
• the special glass fleece finish or surface finish of the formwork enables it to be reused much more often than concrete formwork.
• the special glass fleece finish or surface finish of the formwork is cost-effective and available in commercial quantities. Also the material recycling after intended use is possible.
• the special glass fleece finish or surface finish of the formwork according to the invention makes it possible to produce very smooth concrete surfaces as well as patterned concrete surfaces, such as are required, in particular, in exposed concrete or as structural concrete.
• the support used according to the invention is preferably wood-based materials, such as panels, which may have additional wood-material constructions, such as frames, grids or three-dimensional reinforcing structures, so-called honeycombs, which further reinforce the wood-based materials.
• the wood-based materials are plate-shaped or strand-shaped wooden materials which are produced by mixing the various forms of wood particles with natural and / or synthetic binders in the course of hot-pressing.
• the wood-based materials used according to the invention preferably include barrier or plywood, chipboard, in particular chipboard and OSB (Oriented Strand Boards), wood fiber material, in particular porous wood fiber boards, diffusion-open wood fiber boards, hard (high density) wood fiber boards (HDF) and medium-density wood fiber boards (MDF), and Arboform , Arboform is a thermoplastically processable material made of lignin and other wood components.
• the wood-based materials used according to the invention may be formed as one or more layers and preferably comprise several layers of barrier or plywood and / or wood-chip materials. To increase the stability of these layers can be glued together.
• the choice of the carrier is essentially not limited but rather determined by the type of formwork, i. whether it is a wall formwork, column formwork, beam formwork, staircase formwork, slip formwork, frame formwork, carrier formwork or lost formwork.
• the textile fabrics used according to the invention are all structures which are produced from fibers and from which a textile surface has been produced by means of a surface-forming technique.
• the fiber-forming materials are preferably fibers of synthesized polymers, ceramic fibers, mineral fibers or glass fibers, which may also be used in the form of mixtures. In the presence of fiber mixtures, these may also contain cellulose or natural fibers. Textile surfaces are understood as meaning fabrics, scrims, knits, knitted fabrics and nonwovens, preferably nonwovens.
• the textile fabrics used according to the invention preferably have a sufficient water or moisture barrier effect towards the wearer.
• the textile fabric may additionally have a reinforcement of fibers, threads, or filaments. This is particularly useful when the textile fabric is exposed to high mechanical requirements.
• Preferred reinforcing threads are multifilaments or rovings based on glass, polyester, carbon or metal.
• the reinforcing threads can be used as such or in the form of a textile fabric, for example as a woven fabric, scrim, knitted fabric, knitted fabric or fleece.
• the reinforcements consist of a parallel bundle of threads or a scrim.
• the textile surfaces of mineral and ceramic fibers are aluminosilicate, ceramic, dolomite wollastonite fibers or, preferably, fibers of volcanics, preferably basalt, diabase and / or melaphyre fibers, in particular basalt fibers.
• Diabase and melaphyre are collectively referred to as paleo-basalts and Diabas is often referred to as greenstone.
• the mineral fiber fleece can be formed from filaments, ie infinitely long fibers or from staple fibers.
• the average length of the staple fibers in the nonwoven fabric of mineral fibers used according to the invention is between 5 and 120 mm, preferably 10 to 90 mm.
• the mineral fiber fleece contains a mixture of continuous fibers and staple fibers.
• the average fiber diameter of the mineral fibers is between 5 and 30 microns, preferably between 8 and 24 microns, more preferably between 8 and 15 ⁇ .
• the basis weight of the textile fabric of mineral fibers is between 15 and 500 g / m 2 , preferably 40 and 250 g / m 2 , which refers to a sheet without binders.
• nonwovens are preferred. These are made of filaments, i. infinitely long fibers or staple fibers.
• the average length of the staple fibers is between 5 and 120 mm, preferably 10 to 90 mm.
• the glass fiber fleece contains a mixture of continuous fibers and staple fibers.
• the average diameter of the glass fibers is between 5 and 30 .mu.m, preferably between 8 and 24 .mu.m, more preferably between 10 and 21 .mu.m.
• microfibers In addition to the above-mentioned diameters, it is also possible to use so-called glass microfibers.
• the preferred average diameter of the glass microfibers here is between 0.1 and 5 microns.
• the microfibers forming the textile surface can also be present in mixtures with other fibers, preferably glass fibers.
• a layered structure of microfibers and glass fibers is possible or the setting of a gradient in which the content of microfibers, to the side facing away from the carrier of the textile fabric, increases. As a result, a drainage effect can be adjusted.
• the weight per unit area of the textile fabric of glass fibers is between 15 and 500 g / m 2 , preferably 40 and 250 g / m 2 , these details referring to a sheet without a binder.
• Suitable glass fibers include those made from A-glass, E-glass, S-glass, C-glass, T-glass or R-glass.
• the textile surface can be produced by any known method.
• this is preferably the dry or wet laid process.
• nonwovens in particular so-called spunbonds, i. Spun nonwovens produced by a disposition of melt-spun filaments are preferred. They consist of continuous synthetic fibers made of melt-spinnable polymer materials.
• Suitable polymeric materials include, for example, polyamides, e.g. Polyhexamethylenediadipamide, polycaprolactam, aromatic or partially aromatic polyamides ("aramids”), aliphatic polyamides, e.g. Nylon, partially aromatic or wholly aromatic polyesters, polyphenylene sulfide (PPS), polymers having ether and keto groups, e.g.
• Polyether ketones PEK
• polyetheretherketone PEEK
• polyolefins e.g. Polyethylene or polypropylene
• cellulose or polybenzimidazoles e.g. Polyethylene or polypropylene
• polybenzimidazoles e.g. Polyethylene or polypropylene
• those polymers which are spun from solution are also suitable.
• the spunbonded nonwovens preferably consist of melt-spinnable polyesters.
• Suitable polyester materials are in principle all known types suitable for fiber production. Particular preference is given to polyesters which contain at least 95 mol% of polyethylene terephthalate (PET), in particular those of unmodified PET.
• PET polyethylene terephthalate
• the individual titres of the polyester filaments in the spunbonded web are between 1 and 16 dtex, preferably between 2 and 10 dtex.
• the spunbonded nonwoven fabric can also be a meltbond-bonded nonwoven fabric which contains carrier and hot-melt adhesive fibers.
• the carrier and hot melt adhesive fibers can be derived from any thermoplastic fiber-forming polymers.
• Such meltbond-solidified spunbonded nonwovens are, for example, in EP-A-0,446,822 and EP-A-0,590,629 described.
• the textile surfaces can also be composed of staple fibers or mixtures of staple fibers and continuous filaments.
• the individual titres of the staple fibers in the nonwoven amount to between 1 and 16 dtex, preferably 2 to 10 dtex.
• the staple length is 1 to 100 mm, preferably 2 to 50 mm, more preferably 2 to 30 mm.
• the textile fabric can also be constructed of fibers of different materials in order to achieve special properties.
• the filaments and / or staple fibers constituting the nonwovens may have a practically round cross-section or also have other shapes, such as dumbbell, kidney-shaped, triangular or tri- or multilobal cross-sections. It is also possible to use hollow fibers and bicomponent or multicomponent fibers. Furthermore, the hotmelt adhesive fiber can also be used in the form of bi- or multicomponent fibers.
• the fibers forming the textile fabric may be modified by conventional additives, for example by antistatic agents such as carbon black.
• the basis weight of the textile fabric of synthetic polymer fibers is between 10 and 500 g / m 2 , preferably 20 and 250 g / m 2
• the textile fabrics can be produced without chemical binders.
• thermoplastic binder polymers and / or use known needling methods.
• needling methods Besides the possibility of mechanical solidification, e.g. by calendering or needling, mention should be made here in particular of hydrodynamic needling.
• the fabrics are preconsolidated with a chemical binder.
• the binders used preferably come from the group of B-stage binder compatible binder systems.
• the binder content is at most 25 wt .-%.
• the textile fabric used according to b) was finished or solidified by means of a so-called B-stage binder.
• B-stage binders are binders or binder systems which are used stepwise, i. only partially solidified or hardened and still a final consolidation, for example, by thermal treatment can learn.
• Suitable B-stage binders or binder systems are in US-A-5,837,620 . US-A-6,303,207 and US-A-6,331,339 described in detail.
• the B-stage binders disclosed there can also be used in the context of the present invention.
• the amount of final solidified B-stage binder and chemical binder together is min. 30 wt .-%, in particular min. 35 wt .-%, more preferably min. 40 wt .-%, wherein the weight indication also optionally present in the binder system aids such. Filler and / or stabilizers, and refers to the total weight of the fabric.
• B-stage binders or B-stage-capable binders are preferably binders based on furfuryl alcohol-formaldehyde, phenol-formaldehyde, melamine-formaldehyde, urea-formaldehyde and mixtures thereof. Preferably, they are aqueous systems. Other preferred binder systems are formaldehyde-free binders. B-stage binders are characterized by the fact that they can be subjected to two- or more-stage curing, i. after the first curing or the first hardenings still have a sufficient binder effect to use this for further processing.
• Such binders are finally solidified after addition of a catalyst at temperatures of about 175 ° C (about 350F).
• binders are cured, if appropriate after addition of a catalyst.
• the curing catalyst content is up to 10 wt .-%, but preferably 0.05 to 7 wt .-% (based on the total binder content).
• the curing catalyst for example, ammonium nitrate, as well as organic, aromatic acids, e.g. Maleic acid and p-toluenesulfonic acid, since this can reach the B-stage state faster.
• maleic acid and p-toluenesulfonic acid are all materials suitable as a curing catalyst, which have a comparable acidic function.
• the addition of a catalyst can also be dispensed with altogether.
• the textile fabric impregnated with the binder can be dried under the influence of temperature without effecting complete curing of the binder.
• the required process parameters depend on the selected binder system.
• the B-stage-capable binders used according to the invention allow variable process control.
• the first stage of solidification of the B-stage capable binder serves to stabilize the fabric in its manufacture, if not otherwise preconsolidated, e.g. through other chemical binders.
• the textile fabric preconsolidated with the B-stage binder is fixed on the support, e.g. obtained by pressing / lamination, and the composite of carrier and textile fabric.
• the B-stage binder is finally solidified, whereby any structuring desired, e.g. by structured press plates or rollers, is generated and fixed.
• the textile fabric is already pre-consolidated elsewhere in the production of the formwork or formwork panels according to the invention, e.g. through other chemical binders.
• the first stage of solidification of the B-stage capable binder for attachment or fixation of the fabric on the support is followed by a desired structuring, e.g. by structured press plates or rolls, or else a particularly smooth surface, e.g. be produced by particularly smooth press plates or rollers.
• a desired structuring e.g. by structured press plates or rolls, or else a particularly smooth surface, e.g. be produced by particularly smooth press plates or rollers.
• the stability of the concrete formwork in particular when using wood-based material carriers, can be further increased, as a result of which more compact and also lighter formwork panels are accessible, which considerably facilitates their handling.
• the lower as well as the upper temperature limit can be influenced by choice of the duration or by addition or avoidance of larger or more acidic curing catalyst or optionally by using stabilizers.
• the second stage of solidification of the binder in the B-stage state thus serves to fix the textile fabric to the support or , insofar as the fabric is preconsolidated by other methods and the fixation of the fabric textile fabric was carried out on the carrier by means of the first stage of solidification of the binder, for generating and fixing three-dimensional structures which were produced on the surface of the composite of carrier and textile fabrics, or special smoothing, which on the surface of the composite from carrier and textile sheet on the concrete facing side of the concrete formwork were to fix.
• the surface can be processed by means of heated molds or heated press / rolling tools, eg structured press plates or structured press rolls, so that the structures present in the molds and tools are transferred to the textile fabric and after cooling or final solidification of the Binders are permanently present
• the carrier is formed from a wood material
• the semi-finished product of carrier and textile fabric can also be processed together as described above.
• the fabric is pressed into and additionally bonded to the upper layer of the carrier, so that excellent strength can be achieved while maintaining low weight.
• the lamination or second stage of the solidification takes place under the action of pressure and heat in such a way that the existing B-stage binder is largely finally solidified.
• the lamination can be carried out by means of batch or continuous pressing or by rolling, e.g. Calender, done.
• the parameters pressure, temperature and dwell time are selected individually.
• the second stage of solidification can also be used for further smoothing and fixing the surface of the formwork.
• the application of the B-stage capable binder on the fabric can be done using all known methods.
• the binder can also be applied by means of coating or foam application.
• foam application a foaming foam is produced with the aid of a foaming agent in a foam mixer, which is applied to the nonwoven by suitable coating units.
• the B-stage capable binder may include other adjuvants, such as fillers and / or stabilizers.
• the fillers play in particular materials for Increase of abrasion and scratch resistance is a role.
• particles of SiC and / or SiO 2, corundum (AL 2 O 3) or similar materials are preferably used, grain sizes of less than 1 mm are used, whereby a very hard surface can be produced.
• the proportion of these fillers can be up to 40% by weight.
• the concrete formwork has a three-dimensional structure on the surface of the textile fabric or the composite of support and textile fabric.
• the structures may be regular or irregular. Particular preference is given to regular structures, in particular regular and symmetrical, in particular repetitive, structures such as grooves, rhombuses and knob-shaped structures or even self-cleaning structures.
• the three-dimensional structures preferably have a connection to one another, so that drainage is possible as a result. It is particularly preferred if the three-dimensional structures have a preferred direction, which favor a drainage of the water from the concrete. It has been found that groove-shaped structures which have a substantially vertical or vertical preferred direction, are particularly well suited. These groove-shaped structures have a depression or increase of up to 3 mm, in particular of up to 1 mm. The width of the structures is up to 3mm, especially up to 1mm.
• Pimple-shaped structures are needed in particular for improving the skid resistance of concrete surfaces.
• the concrete formwork according to the invention may have a further, additional textile fabric, preferably a nonwoven or spunbonded fabric, with a special surface quality and porosity, which allows use as formwork for the production of Luncker-free concrete surfaces.
• a special load eg surfaces of dams, as well as overflow and discharge channels of hydroelectric power plants, or water treatment or sewage treatment plants, concrete pipes for Passage of liquids, must have sufficient durability.
• a corresponding surface quality of the concrete this is particularly well suited for the above purpose.
• the additional textile fabric has a pore size (cross-section) of 10 to 80 .mu.m, preferably 10 to 60 .mu.m, determined by means of a Coulter Porometer in porofil.
• the additional textile fabric has an air permeability of up to 2501 / m 2 s at 200 Pa (determined according to DIN 53887) and a water-tightness of 40 to 300 mm water column (determined according to DIN 53886)
• the additional textile fabric is not firmly or flatly connected to the composite of carrier and textile fabric, it can also be stretched over a composite of carrier and textile fabric.
• the additional textile fabric measures a maximum tensile force of at least 400 N, preferably 400 to 600 N (in the longitudinal direction) and at least 300 N, preferably 300 to 500 N (in the transverse direction), measured on a 5 cm wide strip according to DIN EN 290733.
• the additional textile fabric may also have reinforcements of fibers, filaments or filaments.
• reinforcing threads multifilaments or rovings based on glass, polyester, carbon or metal are preferably used.
• the reinforcements consist of a parallel bundle of threads or a scrim.
• a spacer can additionally be installed between additional textile fabrics and the composite of carrier and textile fabric.
• Suitable spacers are grids, nets, perforated sheets, etc, which allow drainage of the water from the concrete.
• the spacers should advantageously have openings or free areas of at least 0.25 cm 2 (single area).
• an additional barrier layer can be formed between the backing and the textile fabric.
• the barrier layer may also be applied to the carrier in the form of additional equipment, in particular on the side of the carrier facing the textile fabric.
• the barrier layer prevents swelling of the support insofar as the support, taken alone, does not possess sufficient resistance to water and / or moisture.
• the durability of the wearer is i.a. depending on which binder was used in the production of the carrier.
• the barrier layer has the effect that the side or surface of the formwork according to the invention facing the concrete, comprising the textile fabric and the barrier layer, has a sufficient water or moisture barrier effect towards the support.
• the barrier layer can be obtained or applied, for example, by incorporating a corresponding polymer film, flocking with thermoplastic polymer materials or applying hydrophobic materials to the side of the backing facing the textile fabric.
• films are preferably used.
• films of B-stage capable materials are used.
• B-stage-capable materials are preferably furfuryl alcohol-formaldehyde, phenol-formaldehyde, melamine-formaldehyde, urea-formaldehyde and mixtures thereof. Films based on formaldehyde-free materials are also preferred.
• the functional material used according to c) are preferably materials which facilitate the shuttering and are customary in concrete technology or formwork technology.
• functional materials or auxiliaries its here called release agent, water repellents, scarf oils, this list is not exhaustive.
• the structuring or smoothing of the surface can take place during step c).
• step e this is done by means of known coating, printing, spraying or painting technologies.
• the drying takes place depending on the selected system.
• the application of the functional material can also be done on site, i. during or after the construction of the concrete form, done before filling the concrete.
• the support is first formed in step a) or the textile fabric is already applied flat during the production of the support.
• the pressing of the carrier formed takes place together with the finished textile fabric, wherein the textile fabric is introduced into the pressing or drying device for the carrier accordingly.
• the preparation of the composite of carrier and textile fabric can be continuous or discontinuous.
• the textile fabric supplied in accordance with step b) is already used in some other pre-consolidated manner, e.g. through other chemical binders.
• the fabric is provided with an additional B-stage capable binder and bonded to the backing, with the first stage of consolidation of the B-stage capable binder resulting in attachment or fixation of the fabric to the backing.
• a desired structuring e.g. by structured press plates or rolls, or else a particularly smooth surface, e.g. is produced and fixed by means of particularly smooth press plates or rolls.
• the B-stage binder is finally solidified.
• barrier layer between the support and the textile fabric
• it may already be present as equipment on the support supplied in accordance with step a), or it may be incorporated in an additional step between step a) and b).
• the barrier layer can be present both in the form of an independent layer or as a coating on the support.
• Another object of the present invention is a formwork form for concrete, which is produced from the formwork according to the invention or at least partially.
• the formwork according to the invention can also be offered in the form of formwork panels, which are also the subject of the present invention.
• the present invention also includes the use of the formwork, formwork panels and molds according to the invention for the production of concrete moldings and for the production of concrete surfaces.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Chemical & Material Sciences (AREA)
• Ceramic Engineering (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Laminated Bodies (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

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Citations (7)

• 2009
  • 2009-01-14 DE DE102009004573A patent/DE102009004573A1/de not_active Withdrawn
• 2010
  • 2010-01-07 EP EP10000059.5A patent/EP2208836B1/fr active Active
  • 2010-01-07 PL PL10000059T patent/PL2208836T3/pl unknown
  • 2010-01-07 EP EP15151632.5A patent/EP2886743A1/fr not_active Withdrawn

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