Patent Application
20240352751
The present application claims the priority of German patent application 10 2021 120 438.0, the content of which is incorporated herein by reference in full.
The invention relates to a formwork system for a wall element, comprising at least one formwork panel, at least one connection component, and at least one frame section, wherein the connection component comprises at least one frame interface, which is designed to be releasably connected to a frame section, and at least one formwork interface, which is designed to be releasably connected to the formwork panel. The at least one connection component is connected here with its frame interface to the frame portion, and the connection component is connected with its formwork interface to the at least one formwork panel. The connection between the connection component and the formwork panel and/or the connection between the connection component and the frame section is designed to be releasable when the system is constructed, and the frame section can be separated from the formwork panel, wherein the frame section can be used as a free-standing frame section after being separated from the formwork panel. The invention additionally relates to a method for producing a wall element using such a system.
The invention relates to the field of construction. When erecting or remodeling buildings, building parts are often molded by casting concrete. The shape of these cast building parts is predetermined by formwork, wherein the formwork is erected on the construction site before casting. In particular, ceilings or walls of a building are erected with the aid of circuits. In the production of high walls or wall elements, a frame is required in order to be able to prepare the formwork for the production of the wall element. A frame is required on the one hand to connect individual formwork panels to one another to form the overall formwork, for example by attaching formwork locks. Furthermore, two mutually opposite formwork panels have to be connected to one another by anchors before the production of a wall element in order to absorb the outward pressure of the cast concrete material. For this purpose, the formwork panels must be reachable over their entire height to workers, which is usually accomplished by a frame or by a working platform. Furthermore, in most cases, prior to the production of the wall element, a reinforcement is attached to an already positioned adjustable formwork or between such an adjustable formwork and a closing formwork which is opposite the adjustable formwork. According to the prior art, frames or working platforms which are provided for attaching formwork locks are arranged on the formwork so that no reinforcement can be attached from these frames or working platforms. The locations at which the reinforcement must be positioned are simply not reachable from these frames or working platforms which serve to prepare the formwork panels, since they are located on the opposite side of the formwork panel. In practice, this means that a first type of frame is required for operating the formwork, and a second type of frame is required for positioning and introducing the reinforcement into the formwork. In addition, a plurality of different types of frames and formwork panels usually exist on the construction site, whereby it is often not possible to connect the frames to the formwork panels, especially for the applications described above. Differences in the grid which exist between the frame systems and the formwork systems usually prove to be problematic. Lastly, in many applications after the casting of a wall element with the aid of the formwork, work is still carried out on the wall element after removal of the formwork, for example the filling of anchor holes or also plastering or painting work. In order to be able to reach the wall element over its entire height, a frame or a working platform is thus again required after the actual casting in order to be able to perform final work. For the production of a wall element with the aid of a formwork, a plurality of different frames or working platforms are thus required, which leads to complicated work processes and a need for a plurality of different frame elements.
The object of the invention is thus to propose solutions with which the production of a wall element can be simplified.
This object of the invention is achieved by a formwork system for a wall element, comprising at least one formwork panel, at least one connection component, and at least one frame section,
The system according to the invention comprises at least one formwork panel, at least one frame section, and at least one connection component which connects the formwork panel to the frame section. A connection, in particular a structurally stable connection, between the formwork panel and the frame section is possible by means of the connection component. By means of the connection component, the formwork panel and the frame section can be connected to one another in a simple manner, wherein the connection and also the separation of this connection can be carried out easily and quickly. A system according to the invention usually comprises a plurality of formwork panels and can also comprise more than one frame section. For connection, a plurality of connection components are usually provided, which are arranged at different positions between the formwork panel or the formwork panels and the frame section.
The frame section of the system according to the invention is formed by a frame section according to the prior art and comprises a plurality of vertical posts which are substantially vertically oriented in the constructed state and a plurality of horizontal bars oriented substantially horizontally in the constructed state. These elements of the frame section are connected to one another and in the constructed state form a frame section extending in three spatial directions. The frame section can comprise further elements, such as tread surfaces, ladders, railings, and the like. The frame section is preferably constructed in a modular manner, which means that the frame section can be constructed from standard elements in different sizes and shapes. The frame section can, for example, be a so-called system frame.
The system according to the invention further comprises at least one formwork panel, with a supporting framework and a formwork skin, which is releasably connected to the framework. The framework is preferably constructed in the form of a grid, wherein a plurality of longitudinal struts which are oriented substantially vertically in the constructed state and a plurality of cross struts which are substantially horizontally oriented in the assembled state form this framework. The longitudinal struts and the cross struts are oriented at right angles to one another. The formwork skin is fastened to the framework and rests at least on a part of the longitudinal struts and cross struts. As a result of this contact, during the production of a wall element, forces which act on the formwork skin from the concrete material are diverted into the supporting framework of the formwork panel. At least a part of the longitudinal struts and/or of the cross struts has an undercut. An undercut is to be understood here as a region which is set back relative to adjacent regions. If a counter element is connected to the framework of the formwork panel in such a way that it engages in the undercut in regions, a form fit is created by which the counter element is connected to the framework. The undercut is provided to enter into a form-fitting and frictionally engaged connection with a formwork interface of a connection component, which will be described later. The undercut extends in the longitudinal direction of the longitudinal struts and/or cross struts. For example, the undercut can be formed by a groove which is set back relative to the remaining surface of the longitudinal struts and/or cross struts and which extends along these struts. This extension of the undercut in the longitudinal direction ensures that a connection component can be continuously fastened to different positions on the framework of the formwork skin. This variability with respect to the position at which a connection component can be connected to the framework has the effect that formwork panels and frame sections with different grids can very easily be connected to one another. Due to the undercut extending in the longitudinal direction, a connection can take place at virtually any position, as a result of which the grid applied between a plurality of formwork panels in the formwork panel or in the formwork system does not play a role for the connection to the connection component. Preferred embodiments of the undercut are described later.
The system according to the invention further comprises at least one connection component having a frame interface and a formwork interface. The formwork interface is provided for connection to the formwork panel, in particular with the framework of the formwork panel. For this purpose, the formwork interface comprises at least one clamping element which in turn comprises at least two gripping arms. These gripping arms are designed to be movable relative to one another. The distance of one gripping arm to the other gripping arm is designed to be variable or adjustable. The gripping arms of the clamping element are provided to engage at least in regions in the undercut in the framework of the formwork panel and thus establish a form-fitting connection between the connection component and the formwork panel. In addition to the gripping arms, the clamping element can have further elements, for example a mechanism for actuating and locking the gripping arms. The connection between the connection component and the framework of the formwork panel is produced by the two gripping arms initially being set such that they can partially grip around a cross strut or a longitudinal strut of the framework. In this state, the gripping arms are pushed partially over the longitudinal strut or the cross struts until a region of the gripping arms is positioned adjacent to one or more undercuts on the cross strut or the longitudinal strut. Subsequently, the distance between the two gripping arms is reduced, wherein these engage at least in regions in the undercut on the framework. This results in the previously described form fit between the connection component and the framework of the formwork panel. Preferably, with this connection, a frictionally engaged connection, in particular a clamping between the gripping arms and the framework, is simultaneously established. Such a frictionally engaged connection has the effect that there is no play between the connection component and the formwork panel and thus a stable, statically and dynamically resilient connection is produced. It is particularly advantageous at this connection that it can be produced at different positions in the longitudinal direction of the cross strut or of the longitudinal strut. The connection component can thus be positioned variably relative to the framework of the formwork panel. The undercut favorably extends over the entire free length of the cross struts and the longitudinal struts. A connection to the connection component can thereby take place at almost all locations of the framework of the formwork panel. Such a connection is not possible, or only possible by using an additional component, merely at the points of intersection of the longitudinal struts with the cross struts. The connection between the connection component and the formwork panel via the clamping element is designed such that it can be separated in a simple manner, even in a state in which the formwork panel and the frame section are constructed and used to produce a wall element. In the system according to the invention, the connection component is thus designed to be detachable from the formwork panel and/or the connection component from the frame section in the constructed state. This has the advantage that the frame section can be separated from the formwork panel in the constructed state, during the production of a wall element. Advantages in the production of the wall element result from such separability. For example, one and the same frame section can be used for different tasks during the production of the wall element. The frame section of a system according to the invention is designed such that it can be used as a free-standing frame section after being separated from the formwork panel, in which separation the connection component is preferably also removed. This means that the frame section itself stands on the underlying surface in a load-bearing and stable manner and can be used by operating personnel as a frame section. By means of the connection component, the frame section can be connected to the formwork panel, for example in order to transport or position both components together in the connected state. After a separation of the frame section and formwork panel, the frame section can however be used like a known frame section. Furthermore, in a system according to the invention, it is possible for a new connection to be made between the two components after a previous separation of the formwork panel and frame section. For this purpose, at least one connection component is simply brought into connection with both the formwork panel and the frame section.
The system according to the invention enables a connection of different types or systems of formwork panel and frame section. In particular the connection, which is continuously adjustable in its position, between the formwork interface of the connection component and the framework of the formwork skin allows a simple and flexible connection. Preferably, a plurality of connection components attached at different positions are provided for connecting a formwork panel to a frame section. The frame interface of the connection component is preferably designed such that it is compatible with a connection interface used within the frame section. The connection component can thus be combined in a simple manner with different types of frame sections via a variation or adaptation of the frame interface. The connection component is simple to construct, whereby a system according to the invention can be provided in a simple and cost-effective manner, which system uses an existing frame section. Thus, existing equipment can advantageously be retrofitted to form a system according to the invention. The simple separability of the formwork panel and frame section, which is brought about by the connection component with its formwork interface and its frame interface, offers a number of advantages in the production of a wall element. The frame section can be used for a plurality of tasks, for example for attaching a reinforcement to or in the formwork, for securely filling the concrete material into the formwork, and, after removal of the formwork panel, for further work on the already-cast wall element. Thus, a system according to the invention saves effort and working time during the production of a wall element, which is effected by the multiple use of a single frame section. The system according to the invention is thus particularly suitable for producing a wall element. In addition, the system according to the invention can of course also be used to produce other building elements, such as pillars or columns.
In one embodiment of the system, it is provided that the clamping element is designed to be dimensionally complementary to one element of the formwork panel at least in regions. The term “dimensionally complementary” is to be understood here to mean that a region of the clamping element, in particular the tip region of the gripping arms, has a negative shape relative to the undercut on the framework of the formwork panel. A secure form-fitting connection between the formwork interface and the formwork panel is thereby effected.
Furthermore, it is provided that the frame interface is designed to be dimensionally complementary to an interface at the frame section, at least in regions. Here, the term “dimensionally complementary” is to be understood to mean that at least a partial region of the frame interface has a negative shape relative to a partial region at an interface at the frame section. The frame section has interfaces for connecting its components, for example vertical posts and horizontal bars. A partial region of the frame interface of the connection component is preferably designed to be similar or identical in shape and size to an interface which is also used in the frame section. For example, connecting disks can be arranged on a vertical post of the frame section with recesses into which interface elements of a horizontal bar can be introduced in a form-fitting manner. In this case, the frame interface of the connection component can be designed to correspond to the interface on the horizontal bar. In this way, the frame interface can be connected to a vertical post in the same way as a horizontal bar of the frame section. As a result of this embodiment, the connection component can be fastened in a simple manner at different positions on the frame section.
In an advantageous embodiment, it is provided that a support element is provided which is connected to the formwork interface and the frame interface, In particular wherein the support element is rod-shaped, wherein the formwork interface and the frame interface are arranged at a distance from one another on the support element. In this embodiment, a support element is provided which connects the formwork interface and the frame interface to one another. The support element can have different shapes. The support element is preferably rod-shaped and can be formed, for example, by a tube or a tube portion. Due to the distance at which the formwork interface and the frame interface are arranged relative to one another on the support element, the distance between the formwork panel and the frame section can be adapted when the system is in the constructed state. In order to be able to individually adjust the distance between the formwork panel and the frame section, the length of the support element can also be adjustable, for example telescopic. The frame interface and the formwork interface can be rigidly connected to the support element, or can be adjustably connected thereto in terms of their position and alignment.
It is preferably provided that the support element has a longitudinal axis and the formwork interface and the frame interface are arranged at a distance from one another along the longitudinal axis, and wherein the longitudinal axis is oriented substantially parallel to the surface of the formwork skin or substantially perpendicular to the surface of the formwork skin. In this embodiment, the support element has a longitudinal axis which runs between the formwork interface and the frame interface. Preferably, the connection component is oriented relative to the formwork panel such that the longitudinal axis runs substantially parallel to the surface of the formwork skin or substantially perpendicular to the surface of the formwork skin. However, the longitudinal axis can also be oriented relative to the surface of the formwork skin at a different angle.
Advantageously, it is provided that a compensating element is provided which is arranged between the support element and the frame interface, wherein the compensating element has a linear bearing by means of which the frame interface and the support element can be displaced relative to the support element at least in regions in a direction parallel to the longitudinal axis of the support element. In this embodiment, a compensating element is provided which enables a displacement between the frame interface and the support element and thus also a displacement between the frame interface and the formwork interface. For this purpose, the compensating element has a linear bearing which guides a linear movement in a direction parallel to the longitudinal axis of the support element. This displaceability between the frame interface at the formwork interface further increases the flexibility in the connection between the formwork skin and the frame section. Due to the displaceability, the distance between the two interfaces can be continuously adjusted, whereby tolerance differences or also grid differences between the frame section and the formwork panel can be compensated. In addition, the compensating element also enables the compensation of height differences in the underlying surface of the system. If, for example, the underlying surface below the formwork panel is higher than the underlying surface below the frame section, this height difference can be continuously compensated by the compensating element, without adaptation work being required on the system.
Furthermore, it is provided that the distance between the frame interface and the formwork interface, in particular in a direction perpendicular to the longitudinal axis of the support element, is greater than or equal to the thickness of the formwork panel. The distance between the frame interface and the formwork interface defines the distance between the formwork panel and the frame section. The distance between the two interfaces is preferably greater than the thickness of the formwork panel in a direction perpendicular to the surface of the formwork skin. However, this distance can also be smaller. Furthermore, the distance can also be selected to be significantly greater, for example the distance between the frame interface and the formwork interface, in particular in a direction perpendicular to the longitudinal axis of the support element, can also be greater than three times the thickness of the formwork panel, or greater than five times the thickness of the formwork panel.
In a further embodiment, it is provided that two frame interfaces and two formwork interfaces are provided, which are each arranged at a distance from one another on a common support element. In this embodiment, two frame interfaces and two formwork interfaces are each arranged on a support element. In this embodiment, the length along the longitudinal direction of the support element is greater than in the embodiments described above. In this embodiment, the longitudinal direction of the support element is arranged parallel to a vertical post of the frame section in the system. The length of the support element is at least 1 m. Two frame interfaces, which will be or are connected to interfaces on the frame section, are arranged on the support element pointing in a first direction. Two formwork interfaces, which will be or are connected to the framework of the formwork panel, are likewise arranged on an opposite second side. Such a connection component enables a connection via two points to the formwork panel and to the frame section. The connection component is thus more stable and better able to support a load. Furthermore, the number of components required to construct a system is reduced by such a connection component, whereby the logistics on the construction site can be simplified and the construction time of the system can be reduced.
It is provided in a skillful manner that the clamping element of the two formwork interfaces, which are arranged on a common support element, has an unlocking mechanism which can be actuated by a simple linear or rotational movement, wherein the form fit between the formwork interface and the formwork panel can be canceled by actuating the unlocking mechanism. In this embodiment, the clamping element has an unlocking mechanism which is quickly and easily actuated by hand. The formwork interface of the connection component can thereby be separated quickly and easily from the formwork panel. This is advantageous if the formwork panel is to be separated from the frame section during the production of a wall element in the disassembled state of the system. Due to the unlocking mechanism, such a separation is quickly and easily carried out. The unlocking mechanism can be actuated by a simple movement, which can be linear, rotational or a simple combination of both types of movement. For example, the unlocking mechanism can have a rod-shaped lever which is actuated in a linear movement or a rotational movement and in so doing releases the form-fitting connection between the formwork interface and the formwork panel. In order to prevent accidental actuation of the unlocking mechanism, a securing mechanism can be provided which initially has to be deactivated before the unlocking mechanism is actuated. Such an unlocking mechanism is preferably used in a connection component which has two or more formwork interfaces. Such a connection component is described in the preceding embodiment. It can be provided here that a common unlocking mechanism is provided for a plurality of formwork interfaces or each formwork interface has its own unlocking mechanism, wherein the unlocking mechanisms are coupled to one another. In this way, a plurality of formwork interfaces can be simultaneously separated from the formwork panel by a single actuating process. The required time for separating the formwork panel and frame section is thereby further reduced. It is, of course, also possible to provide an unlocking mechanism in embodiments of a connection component which only has a formwork interface.
In a further embodiment, it is provided that the direction of movement of at least one of the gripping arms of the clamping element is oriented substantially parallel to the connection direction of the frame interface and/or substantially parallel to the surface of the formwork skin. The distance between the two gripping arms of the clamping element is adjustable, wherein at least one of the gripping arms is designed to be movable. In one embodiment, at least one of these gripping arms is movable in one direction, which in the disassembled state of the system runs substantially parallel to the surface of the formwork skin. In this way, by the movement of the gripping arm, an at least partial gripping of a longitudinal strut or a cross strut of the framework of the formwork panel can be performed. The direction of movement of the gripping arm is to be understood here as meaning the direction along which the distance between the two gripping arms is designed to be adjustable. The clamping element can also be designed such that both gripping arms are designed to be movable. The direction of movement of the gripping arm preferably runs parallel to a connection direction of the frame interface. This connection direction is the direction in which the frame interface is moved for establishing or releasing a connection to the frame section. In this case, the connection direction can be oriented parallel to a vertical post of the frame section, i.e., when the system is constructed, substantially vertically. In this case, the direction of movement of the gripping arm is also substantially vertical, whereby a gripping of the clamping element around a cross strut of the formwork panel is made possible.
In an alternative embodiment, it is provided that the direction of movement of at least one of the gripping arms of the clamping element is oriented substantially perpendicular to the connection direction of the frame interface and/or perpendicular to the surface of the formwork skin. In this embodiment, the direction of movement of a gripping arm is oriented perpendicular to the direction of movement in the embodiment described above. The direction of movement of at least one of the gripping arms runs here perpendicular to the surface of the formwork skin. This makes it possible for the clamping element to grip around an edge region of the framework of the formwork panel. This makes it possible for the connection component to be arranged at the edge of the formwork panel, whereby, for example, the arrangement of a second formwork panel between the formwork panel and the frame section is made possible. When the system is constructed, the direction of movement preferably runs in the horizontal direction. The direction of movement is thus oriented substantially perpendicular to a connection direction of the frame interface, which preferably runs in the vertical direction.
It is provided in a skillful manner that the length of the support element is designed to be adjustable. In this embodiment, the distance between the frame section and the formwork panel can be varied by an adjustability of the support element. This is advantageous in particular if objects having different thicknesses, for example wall elements to be produced, are to be arranged between the frame section and the formwork panel. For this purpose, the support element can be designed to be telescopic. The support element can furthermore have at least one locking device with which a set length of the support element can be fixed in a stable manner.
In an advantageous embodiment, it is provided that the undercut on the framework of the formwork panel is designed as a groove which is oriented in the longitudinal direction of the longitudinal struts and/or cross struts, wherein the groove has a U-shaped, rectangular or curved cross-section. The undercut can be designed as a groove which is introduced into the longitudinal struts and/or cross struts and which extends, at least in regions, along these struts. Preferably, the longitudinal struts and the cross struts have a rectangular cross-section, wherein the formwork skin rests on a side surface of this rectangular cross-section. The undercut is preferably arranged on a side surface which is adjacent to the side surface on which the formwork skin rests. Two undercuts can also be arranged on a cross strut or longitudinal strut and are preferably arranged on two opposite side surfaces of the struts. In cross-section, such an undercut designed as a groove can have a U-shaped, rectangular, polygonal or semicircular shape. In general, a wide variety of shapes are suitable for the cross-section of the groove, as long as these cross-sections generate an undercut relative to the adjacent regions on the cross strut or the longitudinal strut.
In a further embodiment, it is provided that at least two connection components are provided and each connection component has at least two formwork interfaces, and the formwork panel has a plurality of cross struts with an undercut arranged thereon at least in regions, wherein the distance between the at least two formwork interfaces on the connection component corresponds to an integer multiple of the distance between two adjacent cross struts of the formwork panel. In this embodiment, the grids of the formwork panel and of the connection component are coordinated with one another, so that a flexible usability of the components of the system is made possible. Each connection component has two formwork interfaces which are arranged at a distance from one another on a support element. The distance between the two formwork interfaces on the support element corresponds here to an integer multiple of the distance between two cross struts of the formwork panel. The distance between two adjacent cross struts of the formwork panel is smaller than the distance between the two formwork interfaces on the connection component. Due to this choice of dimensions, the connection component can be connected to different cross struts of the formwork panel at different positions. When the system is constructed, the connection component can thus be arranged in a vertical direction at different heights relative to the formwork panel. Such a variability of the connection position between the connection component and the formwork panel is then particularly useful if a plurality of formwork panels are used in combination as formwork for a wall element. In the regions of the combined formwork in which two formwork panels meet, an attachment of the formwork interface may not be possible. In this case, the connection to the connection component can be offset from the locations at which two formwork panels meet. A connection of a frame section to a formwork panel by the connection component is thus also possible if the overall size or overall shape of the formwork and/or of the frame section is varied.
Advantageously, it is provided that the formwork panel and the frame section are oriented parallel to one another, wherein the distance between the formwork panel and the frame section is determined by the connection component. Such a parallel arrangement of formwork panel and frame section is particularly advantageous in the production of a wall element, since the formwork or the wall element is always at a constant distance from the frame. Of course, it is also possible, however, to arrange formwork panel and frame section at a different angle to one another, for example if the wall element to be produced has an irregular or angular shape.
Furthermore, it is advantageously provided that the clamping element comprises a pin element and a tensioning element, wherein the pin element is introduced form-fittingly into a recess, in particular into a bore, in one of the longitudinal struts or the cross struts of the formwork panel, and the tensioning element is designed to be movable relative to the pin element, and the tensioning element rests against one of the longitudinal struts or the cross struts at least in regions, wherein a tensioning mechanism is provided which generates the relative movement between the pin element and the tensioning element, and wherein the tensioning mechanism generates a form fit and a frictional engagement between the connection component and the framework of the formwork panel. In this embodiment, the undercut is formed on the framework of the formwork panel by a recess or a groove in a cross strut or a longitudinal strut. A pin element is provided on the clamping element and is introduced form-fittingly into the recess on the framework during the connection. In some regions, the pin element has a negative shape relative to the recess and forms a movable gripping arm of the clamping element. In this embodiment, the second gripping arm is formed by a tensioning element which, when connected to the framework, rests against a longitudinal strut or a cross strut and partially encloses it. A tensioning mechanism, which generates a relative movement between the two elements or gripping arms, is arranged between the pin element and the tensioning element. By actuating the tensioning mechanism, the distance between the pin element and the tensioning element is reduced, whereby a force flow and a form fit are produced between the frame interface and the framework of the formwork panel.
In a skillful manner, it is provided that the frame interface, which is arranged at a distance from the formwork interface on a support element, is designed as a connection clip, wherein the connection clip is fastened by way of frictional engagement to a vertical post of the frame section. In this embodiment, the frame interface is designed as a connection clip which is connected by way of frictional and form-fitting engagement to a vertical post of the frame section. This connection point can be positioned almost arbitrarily on the vertical post. In this embodiment, the frame interface is thus not identical to an interface which is used to connect components within the frame section. The connection clip encloses a vertical post in the circumferential direction and is clamped to the desired connection position, for example with the aid of a screw connection. A frame interface designed as a connection clamp has the advantage that it can be used particularly flexibly with respect to the relative position between the connection component and the frame section. Thus, in this embodiment, compensation of tolerances or of different heights of the underlying surface under the formwork panel and the frame section between the connection component and the frame section is also possible.
In an alternative embodiment, it is provided that the formwork interface is formed by a compensating rail and the frame interface by means of a clamping clip, wherein the compensating rail is introduced into the undercut in the framework of the formwork panel with a first partial region which forms a gripping arm, wherein the second gripping arm is formed by a securing pin which can be inserted into the first partial region, and the compensating rail has a second partial region which is designed as a rail with a constant cross-section and the clamping clip has a connection region which is designed to be dimensionally complementary to the compensating rail at least in part, and the clamping clip furthermore has a bar element which can be inserted into the connection region and in the connected state the connection region and the bar element together completely enclose the compensating rail, wherein the clamping clip is designed to be displaceable in a manner parallel to the longitudinal direction of the compensating rail and the clamping clip furthermore has a connection clip which is arranged adjacently to the connection region, wherein the connection clip is fastened by way of frictional engagement to a vertical post of the frame section. In this embodiment, the formwork interface is designed as a compensating rail. A formwork interface designed in this way comprises a first partial region which is introduced in a form-fitting manner into an undercut in the framework and which forms a first gripping arm. In this embodiment, the undercut penetrates a longitudinal strut or a cross strut in the framework and the first partial region is introduced into the undercut in such a way that it penetrates the entire longitudinal strut or cross strut. In this embodiment, a securing pin which can be introduced into the first partial region is provided as the second gripping arm. During the connection, the first partial region is guided through the undercut in the framework and then the securing pin is introduced into the part which protrudes beyond the longitudinal strut or the cross strut. In this way, the formwork interface is connected to the framework of the formwork panel in a form-fitting manner. Adjacent to the first partial region, the compensating rail has a second partial region which is designed as a rail with a constant cross-section. This rail then serves for connection to the frame interface, which is designed as a clamping clip. Providing the second partial region as a rail with a constant cross-section allows improved flexibility with respect to the relative position between the formwork panel and the frame section. With the aid of this rail with a constant cross-section, the relative position between the formwork interface and the frame interface in the connection component can be varied along the length of this rail. Thus, in this embodiment, not only is variability provided with regard to the attachment of the connection component to the formwork panel and to the frame section, but there is an additional variability or adjustability within the connection component. This embodiment is particularly favorable if the formwork panel has undercuts on its framework only at discrete points. Such formwork panels often exist in the stock of construction companies and should continue to be used in the future. Such formwork panels from older stock can be used very flexibly in a system by a connection component according to this embodiment. The adjustability of the frame interface relative to the formwork interface is furthermore possible by the connection region of the clamping clip which, in this embodiment, forms the frame interface. This connection region is designed to be at least partially dimensionally complementary to the second partial region of the compensating rail. This means that the connection region grips around a partial region of the compensating rail. For the fixed connection of the frame interface to the formwork interface, the clamping point additionally has a bar element which can be introduced into the connection region and, together with the connection region, completely grips around the rail with a constant cross-section in the connected state. The bar element is designed such that a frictionally engaged connection can additionally be established between the clamping point and the compensating rail. During the connection, the connection region is first pushed over the second partial region of the compensating rail. In this state, the connection region is displaceable relative to the compensating rail along the length of the rail with a constant cross-section, whereby the position between the formwork interface and the frame interface can be set. The bar element is then introduced into the connection region, whereby a form fit and a frictional engagement between the components is produced. In this state, the connection component is then fixed. As in the embodiment described above, the frame interface is connected to the frame section via a connection clip which, in the connected state, encloses a vertical post of the frame section and is fastened to it in a frictionally engaged manner. As described above, this connection clip is advantageous here, since it can be positioned virtually continuously relative to a vertical post of the frame section. The described embodiment thus has a very high adaptability with respect to the shape and the positioning of the connection component between the formwork panel and the frame section.
The object of the invention is further achieved by a method for producing a wall element, comprising the steps of
The method according to the invention can be carried out for producing a wall element of a building. However, this method is also suitable for producing other building elements, such as columns or pillars. The method is preferably carried out in the indicated sequence of method steps A) to I). However, it is also possible to modify the sequence of the method steps.
In a first method step, an adjustable formwork is constructed which comprises at least one formwork panel. An adjustable formwork is to be understood here as a formwork which is set up as a first part of the formwork before a wall element is erected. The adjustable formwork is usually placed on the underlying surface on which the wall element is to be created. In order to secure the adjustable formwork against falling over, it preferably has a support which during setting up is arranged on the side of the adjustable formwork facing away from the wall element to be erected. The adjustable formwork preferably comprises a plurality of interconnected formwork panels. Method step A) is complete as soon as the entire adjustable formwork is set up and thus positioned.
In a second method step B), a reinforcement is arranged and fastened on or in front of the adjustable formwork. The reinforcement serves to reinforce the wall element to be erected and can be made, for example, of iron mesh. In the case of high wall elements, a frame or a working platform is required for fastening the reinforcement to the adjustable formwork. The reinforcement is preferably positioned and fastened to the adjustable formwork using fastening elements such as wire.
After the reinforcement is put in place, as a third method step C) a closing formwork is set up opposite the adjustable formwork. According to the invention, this closing formwork is formed by a system according to one of the embodiments described above. The system forming the closing formwork is set up such that the formwork skin of the formwork panel of the system faces toward the reinforcement and toward the adjustable formwork. In the removed state, the adjustable formwork and the formwork panel of the closing formwork then delimit the spatial region in which the wall element is to be created. The reinforcement is also arranged between the adjustable formwork and the closing formwork. The system, comprising at least one formwork panel, at least one connection component and at least one frame section, is assembled, with the frame section being arranged on the side of the formwork panel of the system facing away from the adjustable formwork. In this way, a formwork is created which is formed on one side by the adjustable formwork and on the other side by the closing formwork formed by the system. The frame section is here arranged outside the spatial region in which the wall element is to be formed. At the end of method step C), all components are fixed. The frame section, which is connected to the formwork panel of the system, can then be accessed by workers and used to carry out work.
In a fourth method step D), the formwork made up of the adjustable formwork and the formwork panel of the closing formwork is prepared for the filling of a liquid concrete material. Usually, the closing formwork also comprises a plurality of formwork panels which must be tightly connected to each other before the wall element is created. In order to connect a plurality of formwork panels, formwork locks are attached which connect adjacent formwork panels to one another. This attachment of the formwork locks takes place from the frame section of the closing formwork. On the frame section, workers can reach the entire back side of the formwork panels. Furthermore, in the preparation of the formwork, anchors are attached between the formwork panels of the adjustable formwork and the closing formwork which ensure the static stability of the formwork during the filling of the concrete material. A plurality of anchors must be arranged at different positions between the adjustable formwork and the closing formwork. This attachment or introduction of the anchors is also done by persons on the frame section. The frame section is thus used for different tasks and work in the preparation of the formwork.
In a fifth method step E), liquid material, preferably a concrete material, is filled into the formwork. The material can also be filled in from the frame section. Here, the frame section offers a secure support surface from which feed elements for the concrete material, such as hoses, can be positioned in relation to the spatial region enclosed by the formwork. Alternatively, the frame section can also be used only for observing and evaluating the filling of the formwork.
In a sixth method step F), the filled material is given time to cure and form a load-bearing wall element. In this method step, the frame section can be used to observe and under certain circumstances influence the curing process, such as by supplying water.
In a seventh method step G), in the closing formwork formed by the system the formwork panel is separated from the frame section in the disassembled state. For this purpose, either the frame interface of the connection component can be separated from the frame section, wherein the connection component remains on the formwork panel, or alternatively the formwork interface of the connection component can be released from the formwork panel, wherein the connection component remains on the formwork panel. Due to the corresponding design of the connection component, this solution of the connection can take place quickly and easily from the frame section. In particular, no special tool is required for the separation of formwork panel and frame section, and all or at least most of the steps required for this can be carried out manually. The advantage of the method is that even during and after the separation from the formwork panel the frame section is load-bearing, by itself and stably, and can be continuously accessed and used for work by workers.
In an eighth method step H), the formwork panel of the closing formwork is removed, the frame section remaining in an unchanged position. The formwork panel of the closing formwork is preferably removed upwardly by a crane, in the vertical direction. It is possible that before the formwork panel is removed, it must be separated from the produced and cured wall element in further working steps. After the formwork panel is removed, the frame section is at a distance from the newly produced wall element. The distance between the frame section and the wall element is approximately as large as the thickness of the formwork panel previously removed. Due to this small distance, it is now possible to reach from the wall element from the frame section. In addition, in this method step the adjustable formwork can also be removed, since the wall element is cured and is load-bearing on its own.
In a last, ninth method step I), the cast wall element is now further processed from the frame section, which has remained in its position. In this further processing, for example holes in the wall element caused by the previously attached anchors can be filled. In addition, uneven parts on the wall element can be remedied. Finally, it is also possible to carry out plastering or painting work on the wall element from the frame section. Work can be carried out very efficiently here, since directly after stripping the formwork and removing the formwork skin the next work steps can be carried out from the same already-erected frame section.
The method according to the invention has the advantage that the frame section, which is part of the closing formwork, is used multiple times during the production of the wall element. First, the frame section is set up in method step C) together with the formwork panel, which forms the closing formwork. In particular if the system is constructed or assembled before the closing formwork is set up, the frame section can be set up or positioned very quickly. The assembled system is preferably easily positioned using a crane. Thus, within a very short time the closing formwork is set up and brought into position with the frame section already arranged thereon. The formwork can then be prepared from the frame section. The concrete material can then be poured into the formwork from the frame section without any further changes to the frame section and the formwork. Finally, after stripping the formwork, the formwork panel of the system can be removed, and the same frame section remains in the same position and can be used for the subsequent processing of the produced the wall element. Compared to the conventional procedure, only a single frame section is required for activities for which at least two different frame sections would otherwise be required. This saves effort and time when creating the wall element. In addition, the logistics on the construction site are simplified, since only a single frame section has to be produced, assembled, dismantled, and removed again, where otherwise at least two different frame sections must be kept available and processed. Efficiency on the construction site can thus be significantly increased by the method according to the invention, and the production of a wall element is significantly simplified. In the method according to the invention, at least one system according to one of the embodiments described above for producing a wall element is used. The use of an embodiment of a system for producing a wall element brings about the same advantages described above for the method.
In one embodiment of the method, it is provided that the formwork panel, the frame section, and the at least one connection component of the system are assembled before method step C) is carried out. In this embodiment, the complete system or at least part of the system is assembled as a closing formwork before the system is set up. This assembly can be carried out for example lying on the ground or underlying surface. The advantage of this is that there is no risk of falling during the assembly, which there would otherwise be in setting up a frame section. Constructing the system on the ground thus significantly improves the working safety of the workers. In addition, in this way the system can be set up in preparatory fashion away from the location where the wall element is to be installed. The fully assembled system can then be transported very quickly, for example using a crane, to the location where the wall element is to be produced. This procedure thus also improves the logistics at the location of the erection of the wall element, and fewer persons are in the danger area close to the installation location of the wall element.
In a further embodiment, it is provided that the connection component is connected to the side of the formwork panel facing away from the formwork skin, and thus the frame section is connected to the framework on the side of the formwork panel facing away from the formwork skin, by the connection component. In this embodiment, the connection component is connected to the formwork panel, in particular to the framework thereof, on the side facing away from the formwork skin. Preferably, a plurality of connection components are arranged between a formwork panel and a frame section. The framework of the formwork panel can thereby be used to connect one or more connection components. The framework has a plurality of cross struts and longitudinal struts, so that one or more connection components can be fastened at different points of the formwork panel. It is thereby also possible to establish a stable and load-bearing connection via connection components at a plurality of points between the formwork panel and the frame section.
The object of the invention is further achieved by an alternative method for producing a wall element, comprising the steps of
This second method according to the invention is linked by the common inventive idea of first connecting a frame section to a formwork panel and then later separating these two components from each other, the frame section being used multiple times. The two methods according to the invention represent alternative solutions for the same object and are complementary to one another.
The second method according to the invention also serves to produce a wall element using a system according to one of the embodiments described above. Preferably, the second method is also carried out in the indicated order of the method steps. If required, however, the method steps can also be partially interchanged.
In a first method step I) such a system is constructed, wherein the connection component is arranged between a formwork panel, which serves as an adjustable formwork, and a frame section at a distance from the formwork panel. In contrast to the method according to the invention described above, the distance between the formwork panel and the frame section of the system is significantly greater in the second method. The distance between the formwork panel, which here forms an adjustable formwork, and the frame section is selected such that the wall element and a closing formwork still to be introduced fit into this distance. After the system has been set up, it is stable and load-bearing on the underlying surface, wherein the frame section holds the formwork panel in position via the connection to the connection component, so that no further support mechanisms are required for the adjustable formwork. This eliminates the need for such additional support mechanisms, which reduces costs.
In a second method step II), a reinforcement is fastened to the formwork skin or formwork panel of the system, which reinforcement serves as an adjustable formwork. The reinforcement is attached to the formwork panel by workers who are located on the frame section of the system and can easily reach the entire height of the formwork panel from there. This eliminates the need for an additional frame or additional working platforms, which are required according to the prior art for attaching the reinforcement to the formwork panel.
In a third method step III) a closing formwork is set up, where the closing formwork is formed in particular by a further formwork panel which is inserted into the already set-up system between the formwork panel, which serves as an adjustable formwork, and the frame section. After the closing formwork has been set up, the adjustable formwork and the closing formwork delimit the spatial region in which the wall element is to be produced and in which the reinforcement was attached in the preceding step. The formwork panel which forms the closing formwork is preferably introduced vertically from top to bottom between the frame section and the adjustable formwork. For this purpose, for example a crane can be used which lowers the closing formwork at this point.
In a fourth method step IV), the formwork is prepared for filling a liquid concrete material between the adjustable formwork and the closing formwork. During this preparation, in particular locks are arranged between adjacent formwork panels and anchors are inserted that hold the adjustable formwork and closing formwork together and absorb forces exerted on the formwork by the subsequently introduced concrete material. This preparation of the formwork can take place from the frame section, which is now located on the side of the closing formwork facing away from the adjustable formwork. The closing formwork can thus be reached very conveniently from the frame section. It is advantageous here that the frame section is already positioned and the preparation of the formwork can be carried out from there directly after the closing formwork has been set up.
In a fifth method step V), the formwork is filled with a liquid concrete material which encloses the reinforcement arranged therein. This forms the wall element. Here the liquid material can be filled into the formwork of the frame section, which remains in the same position.
In a sixth method step VI), the concrete material is cured, resulting in a load-bearing wall element. A test of the curing can be performed from the frame section.
In a seventh process step VII), the system made up of the formwork panel, which forms the adjustable formwork, frame section, and connection component is dismantled. For this purpose, the connection component is separated at least from the formwork panel or from the frame section. Alternatively, the connection component can also be separated from both the formwork panel and the frame section. In the disassembled state, the formwork panel, which forms the adjustable formwork, is then removed. This removal can be carried out using a crane, for example. The separation of the connection component from the formwork panel or from the frame section can also be carried out from the frame section.
In an eighth method step VIII), the formwork panel, which is located between the produced wall element and the frame section and has formed the closing formwork there, is then removed. This removal is again preferably carried out in a vertical direction, for example by a crane. During and after the removal of the closing formwork, the frame section remains in its original position.
In a ninth method step IX), the produced wall element is further processed. During this processing, for example the anchor holes in the wall element can be filled and smoothed. In addition, other further processing can be carried out, for example plastering or painting the wall element. This further work is again carried out from the frame section, which remains in the same position through the entire method. As a result, after the removal of the formwork the subsequent work can be started directly, and a complicated setting up of a working frame after the wall element has been produced is dispensed with. Furthermore, it is possible to attach further formworks from the frame section, for example to produce a cover section which is to be arranged adjacent to the created wall element.
The second method according to the invention also has the advantage that a frame section which is already set up in the first method step I) is used multiple times and for different tasks during the production of the wall element. This saves time and effort for assembling and dismantling different frame systems for different tasks. Furthermore, the frame section is advantageously used via its connection to the connection component as a support of the adjustable formwork, to prevent falling over. This eliminates the need for other support mechanisms, such as pivoting supports which are arranged on the formwork. As a result, the method for producing the wall element is further simplified and accelerated compared to the prior art.
In one embodiment of the second method, it is provided that in method step I) the formwork panel and the frame section are constructed at a distance from one another and the length of the at least one connection component is equal to or greater than the thickness of the wall element to be produced. In this embodiment, the length of the connection component determines the distance between the formwork panel, which serves as an adjustable formwork, and the frame section. The length of the connection component between its formwork interface and frame interface is equal to or greater than the thickness of the wall element to be produced. The length of the connection component is preferably greater than the total thickness of the wall element and the thickness of the closing formwork to be used in this way.
Furthermore, it is provided that in method step I), the at least one connection component is fastened to the upwardly facing edge of the formwork panel by the formwork interface. In this embodiment, the fastening of the connection component to the formwork panel takes place in that the formwork interface is fastened to the edge of the formwork panel facing upward in the vertical direction. The connection component is thus arranged outside the region in which the reinforcement is fastened and the wall element is later produced. As a result of this arrangement, there is thus no risk of collision between the connection component and the wall element to be produced. The arrangement of the connection component at the upper edge of the formwork panel is also particularly effective for securing the formwork panel, which here forms the adjustable formwork, against falling over. The connection component is preferably connected to the frame section in an upper region via the frame interface. This arrangement also makes it possible to introduce the formwork panel, which forms the closing formwork, between the frame section and the reinforcement after the reinforcement has been attached, without colliding with the connection component. Alternatively, it is also possible to connect the connection component or one or more further connection components to the formwork panel at one or more lateral edges via the formwork interface. For this purpose, the formwork interface can be designed, for example, in such a way that it encloses the edge region of the formwork panel and clamps it in the closed state.
It is also possible for method steps VII) and VIII) to be carried out in reverse order. In this embodiment of the second method, after the wall element has been produced, first the closing formwork, which is arranged between the frame section and the wall element, is removed. During this removal of the closing formwork, the connection component can still remain in the assembled position and can connect the frame section with the formwork panel which forms the adjustable formwork. The connection component is then dismantled only after the closing formwork has been removed and the formwork panel which forms the adjustable formwork is removed. Even in this alternative sequence of the method steps, the frame section always remains in its original position in order to then enable later processing of the wall element.
It is expediently provided that the frame section is anchored in the ground when method step I) is carried out. Such an anchoring further improves the stability of the system during and after the production of the wall element. The frame section, which simultaneously serves as a support for the adjustable formwork, can thus divert forces into the underlying surface or ground via the anchoring. Additionally or alternatively, the formwork panel which forms the adjustable formwork and is part of the system can also be anchored in the ground.
It is expediently provided that in method step I) the frame section is constructed on the underlying surface as in the application, or the frame section is placed on the underlying surface for construction. Several possibilities result for the construction of the system and method step I). On the one hand, the system can be constructed from bottom to top starting from the ground or underlying surface, which corresponds to the construction sequence which is usually used for a frame section. Alternatively, the frame section can also be constructed on the underlying surface at a different location away from the position at which the wall element is to be produced. This has the advantage that, during the construction of the frame section, there is no risk of falling for working persons and thus fewer safety precautions have to be taken. Furthermore, the frame can be constructed at a location on the construction site which is less frequented than the location at which the structure is created. This relieves the logistics and facilitates the work on the construction site. The frame section assembled in a lying position can then be positioned, for example by a crane, at the location at which the wall element is to be produced. The connection of the formwork panel which forms the adjustable formwork to the frame section by the connection component is preferably carried out at the location at which the wall element is to be produced. Alternatively, it is also possible to assemble the system consisting of formwork panel, connection component and frame section at a different location and to position it completely in the assembled state at the location where the wall element is to be created.
Features, effects, and advantages disclosed in conjunction with the system also apply as disclosed in conjunction with the methods. The same applies in the reverse direction: features, effects, and advantages which are disclosed in conjunction with the methods also apply in conjunction with the system as disclosed.
Embodiments of the invention are shown schematically in the figures. In the figures:
In the figures, like elements are provided with like reference signs. In general, the described properties of an element which are described in relation to one figure also apply to the other figures. Directional specifications as above or below relate to the described figure and are to be transferred analogously to other figures.
Each formwork panel 2 comprises a framework 21, on which a formwork skin 22 is arranged on the side pointing to the rear left in the representation. The framework 21 is constructed here from steel pipes with a rectangular cross-section. The framework is surrounded by a rectangular edge that runs around the framework 21. A plurality of cross struts 212, which are oriented horizontally in the representation, are provided within this rectangular edge. Perpendicular thereto, in the embodiment depicted a total of two vertically oriented longitudinal struts 211 are arranged in the framework 21. The cross struts 212 and the longitudinal struts 211 cross each other and are connected to one another at each crossing point. This results in a stable, grid-shaped framework 21 on which the formwork skin 22 rests at least in regions. The connection between the formwork skin 22 and the framework 21 is preferably designed such that it can be easily separated, which enables a simple replacement of the formwork skin 22. The cross struts 212 and the longitudinal struts 211 are oriented substantially perpendicular to one another. Of course, different struts can also be arranged at a different angle to one another. In the embodiment depicted, all cross struts 212 have at least one undercut 213. In the embodiment depicted, each cross strut 212 has two undercuts 213, which are arranged on opposite sides of the cross struts 212, namely on the sides which point upward and downward in the representation. Details of a cross strut 212 and the undercuts 213 are depicted in
The frame section 3 extends in three spatial directions, is three-dimensional in its construction, and, in the embodiment depicted, has three tread planes which are arranged parallel and one above the other. Due to these three tread planes, the entire rear side of the formwork panel 2 can be conveniently reached by persons located on the frame section 3. The frame section 3 comprises a plurality of vertical posts 51 oriented vertically in the representation and a plurality of horizontal bars 52 oriented horizontally in the representation. The vertical posts 51 and the horizontal bars 52 are connected to one another via interfaces. These interfaces are designed here as connecting disks or rosettes which are fixedly arranged on the vertical posts 51. The horizontal bars 52 have connection regions which can be introduced in a form-fitting manner into the connecting disks or rosettes. In this way, the frame section 3 is of modular design and can thus have different shapes and sizes, wherein these different shapes and sizes can be formed by standardized vertical posts 51 and horizontal bars 52. In addition, in each of the three tread planes the frame section 3 depicted has tread coverings, which are here each connected to a plurality of horizontal bars 52. The frame section 3 can additionally comprise further frame elements, such as railings or ladders.
In the system 100 depicted, the formwork panel 2 and the frame section 3 are connected to each other via a total of four connection components 1. Each of these connection components 1 comprises a support element 13, which is rod-shaped here. The support element 13 has a longitudinal axis which extends in a direction in which the support element 13 has its longest dimension. In the embodiment depicted, the longitudinal axis of the support elements 13 is oriented vertically and runs parallel to the vertical posts 51 of the frame section 3. In the embodiment depicted, the support element 13 is formed by a metal tube having a square cross-section. Of course, it is also possible to design the support element 13 differently, for example as a tube with a round cross-section or also as an aluminum profile or plastics material profile. In the embodiment depicted, each connection component 1 has two formwork interfaces 12 and two frame interfaces 11. Each formwork interface 12 is provided for connecting the connection component 1 to the formwork panel 2 and each frame interface 11 is provided for connecting the connection component 1 to the frame section 3 and is connected to these components in the depicted state. Details relating to the formwork interface 12 and the frame interface 11 are depicted enlarged in
The cross struts 212 of the framework 21 are for the most part arranged at a constant distance from one another. The distance between two formwork interfaces 12 is significantly greater than the distance between two adjacent cross struts 212. The distance between the two formwork interfaces 12, which are arranged on a common support element 13, corresponds to an integer multiple of the distance between two adjacent cross struts 212. As a result, the grids of the framework 21 and of the connection component 1 are compatible with one another. This means that the positions of two cross struts 212 and the two formwork interfaces 12 match one another, enabling a form-fitting connection to one another. It is possible here for the connection component 1 to be attached at different positions relative to the framework 21. The connection component 1 can thus be displaced relative to the formwork panel 2 in the grid of the spacings of the cross struts 212. This means that it is always possible to connect a connection component 1 to one or more formwork panels 2. In the embodiment depicted, two formwork panels 2 are arranged vertically one above the other and connected to one another. At this connection point, which is located approximately in the center of the system 100 in the vertical direction in the representation, attaching a formwork interface 12 is often not possible. Due to the fact that the distance between two formwork interfaces 12 on a connection element 1 is designed to be an integer multiple of the distance between two cross struts 212, the connection component 1 can also be arranged such that one of the two formwork interfaces 12 is fastened to a formwork panel 2 and the second of the two formwork interfaces 12 is fastened to an adjacent formwork panel 2, wherein the connection component 1 easily overlaps the boundary region between the two formwork panels 2. As a result, the system 100 can be flexibly assembled with different positions of the components relative to one another and can thereby always be adapted to individual cases of application. In the embodiment depicted, each connection component 1 is connected to only one formwork panel 2. However, it would also be possible, for example, to arrange a further, fifth connection component 1 in such a way that it is connected, between the already-positioned connection components 1, to the upper formwork panel 2 with a first formwork interface 12 and to the lower formwork panel 2 with its second formwork interface 12. The position of the connection component 1 relative to the formwork panel 2 can also be flexibly selected in a direction parallel to the cross struts 212. Details of this are depicted and described in
In the detail view in
The embodiments of a connection component 1 depicted in
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 120 438.0 | Aug 2021 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/071944 | 8/4/2022 | WO |
