• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Method of manufacturing a high strength concrete plate member comprising the steps of: - first spraying an outer skin layer against a mould where said outer skin layer is a reinforced high strength conerete mix comprising fibres, said outer skin layer hav ing a thickness of between 2 mm to 10 mm; -secondly backfilling with a high strength concrete vertically or horizontally, having a layer thickness between 10 mm and 100 nim -allowing the two layers to harden and chemically react hydraulic or pozzolanic together, to finally form one monolithie layer. -removing the mould
    公开号:DK201100558A
    申请号:DKP201100558
    申请日:2011-07-19
    公开日:2013-01-20
    发明作者:Serwin Bo
    申请人:Gb Holding Hoejbjerg Aps；
    IPC主号:
    专利说明:

    Method of manufacturing a high strength concrete plate member having a superior surface, as well as. a high strength concrete panel manufactured by said method.
    The present invention discloses a method of conducting a high, strength concrete plate member having a superior surface, as well as a high, strength concrete panel manufactured by said method.
    Casting a three: or more sided concrete structure with unique and superior surfaces on all sides is a challenging and almost impossible task, which normally requires extreme flow (ie low viscosity) in the concrete material combined with high vibration to avoid air bubbles and trapped air in the surface. Normally this type of casting is followed by finishing and / or repair works on the visible surfaces in order to achieve an acceptable evenly smooth surface, free of'air voids.
    Alternatively, the concrete structure must be assembled from a number of separate panels, all east with the visible surface horizontally and downwards, in order to avoid voids and other irregularities.
    With the first procedure the repairs / finishing work will be visible and over time the repaired areas will not be as durable as the integrally cast areas, leading to damage and further repairs.
    With the second procedure the separate panels have to be assembled, leaving seams or cracks between panels, which require special constructions to leave them moisture tight etc.
    For both procedures the aesthetic result is not pleasing and will in most instances require finishing work or surface treatment, for example paint or the like.
    Accordingly, it is an object of the present invention to provide a method and a panel which alleviates these disadvantages.
    The invention addresses this by a method of manufacturing a high strength concrete · plate member comprising the steps of: first spraying an outer skin layer against a mold where said outer skin layer is a reinforced high strength concrete mix comprising fibers, said outer skin layer having a thickness of between 2 mm to 10 mm; secondly backfilling with a high strength concrete vertically and / or horizontally, having a layer thickness between 10 mm and 100 mm allowing the two layers to harden and chemically react hydraulically or poz-zolaniealiy together, to finally form one monolithic layer; removing the mold.
    The present invention in this less demonstrates a method by which, all surfaces independent, of position horizontally or vertically as well as upwards or downwards curved, both convex or concave as well as planar 'will achieve the same perfect void free surface quality in High Performance Concrete on all surfaces.
    Spraying concrete against a mold provides a very smooth, homogeneous ,, and dense surface. This is further improved when using high performance high strength concrete in that the high strength concrete from the outset is more dense and compact and when sprayed onto a surface, becomes even more compact and dense, thereby providing a very compact and smooth finish.
    By achieving the perfect surface by shøtereting. High Performance Concrete or Glass-fiber Reinforced High Performance spraying techniques against the front mold the backfilling material, between the sprayed surface and the back mold can further be chosen to be of the same high quality High. Performance Concrete as the surface or an even stronger and outstanding Ultra High Performance Concrete to achieve slim constructions with extreme strength.
    By further securing cohesion between the spray layer and the backfill, i.e. avoiding the presence of a boundary whereby a monolithic concrete structure is achieved, a strong panel is obtained.
    The strong backfilling material is furthermore perfect for anchors, profiles ete. to cast Into this material, making outstanding properties and using the full potential of these.
    In a further preferred embodiment the compressive strength of the high strength concrete is between 80 and 200 MPa. At these strengths very strong panels are achieved, and direct to the presence of fibers, at least in the outer skin layer, which is sprayed on, a high degree of ductility is also achieved, together with a perfectly finished surface.
    In a further-advantageous embodiment the high strength concrete in the backfilling is not vibrated, hut cast as self-compacting high performance concrete wet-in-wet with the skin layer.
    Since the surface quality has already been optimized, the hack filling High Performance Concrete can be cast without vibration as a self compacting High Performance Concrete both vertically and horizontally. This is a dramatic advantage to the size and strength of the mold, which normally must be extremely strong: due to the heavy vi brations imparted to the mold in order to compact the concrete. In most cases, only heavy steel molds can be used for this kind of casting, whereas simple wooden or plastic molds can be used when casting without vibration, as is the case with the present invention.
    Even when the skin layer has hardened either partially or completely, it is possible to secure conditions similar to wet-in-wet conditions due to a special hydration-lic / pozzolanic activator applied to the ions surface of the skin layer making it possible to cast the backfill concrete at a later stage, and still achieve a monolithic construction.
    In a further advantageous embodiment of the invention, the concrete for the outer skin layer comprises an additive, making it possible to spray and allowing the high strength concrete to remain in situ when spraying, vertically up and horizontally against the mold.
    Preferred products to serve as additives in this procedure can be either polymers like Axilat PAY 29 or alternatively a Si02 Nanosilica like Aerosil Fumed Silica from. Evonik Degussa GmbH to adjust the consistency and stability of the Ultra High Performance Concrete perfectly.
    The manufacture of concrete structures / panels using the method above may be industrialized as set out in a further advantageous embodiment of the manufacturing process for the manufacture of a concrete panel comprising a number of stations: - a first station where the concrete casting molds are prepared, and assembled; - a second station where the skin high strength concrete layer is sprayed onto a front side mold in a layer thickness of between 2 and IQ mm; -an optional third station where insulation, reinforcement and anchors and / or mounting / lifting devices are arranged in the mold; - a fourth station where a rear part of the mold is. positioned and fastened relative to the front side mold; - a fifth station where the backfill concrete is entered into the cavity between the outer skin layer and the rear part mold; - a sixth station where the concrete panel is cured and de-naoulded - a seventh storage station for the finished cured concrete panels.
    By arranging the production in this maimer a rational, controllable and fast manufacturing process is achieved. By further adding work stations arranged between the sixth and seventh stations further advantages are achieved, where at least: - a station impregnating or surface treating the front side of the panel with an agent, is arranged where the agent is selected from one or more of the following agents; liquid silicone impregnating agent, nano surface treatment like Contec F3. Nanosealer. Acrylic sealers like Contec F2 or chemically reacting sealers like Contec FI surface hardener, acid staining, water repellent agent, coloring agent etc ,; - a concrete panel drying station optionally comprising an autoclave; - a polishing and / or grinding station finishing edges and surfaces
    The invention is also directed to a concrete panel manufactured according to the inventive method disclosed above.
    The invention will now be explained with reference to the accompanying drawing:
    FIG. 1 illustrates the outer mold of a three sided panel onto which the sprayed skin layer is applied.
    Fig. 2 illustrates the. final three sided panel after casting ..
    FIG. 3 illustrates the mold principle with an outer and inner mold to work as a platform for the outer sprayed skin (Outer mold) and mold to be. mounted before casting the back, filling High Performance Concrete (veneer mold) A gap to cast the back filling concrete is located at the top of the mold.
    FIG. 4 illustrates a concrete panel cast in the mold depleted in fig 3.
    Detailed description
    Turning two FIG. 1 in outer mold. 1 having three planar sides 2, 3, 4 is illustrated. The mold 1 is suitable to be sprayed upon. Due to the. composition of the concrete sprayed onto the mold, the concrete panel's side feeing, the mold (typically the exterior side of the panel) will have a surface substantially similar, to the mold. Therefore if the mold surface is very smooth which is achievable with plastics or steel, the panels' surface will be very smooth.
    Jumping to Fig 3 further illustrates an embodiment. The outer mold 1 'is in this embodiment four sided 2'23', 5, 6. The inner mold 10 is arranged such that the space between the two mold parts 1 10 provides space for the concrete panel to be cast.
    Before the inner mold 10 is positioned, the outer concrete skin layer 20 is sprayed against all outer mold 1 surfaces. Typically the layer thickness is between 2 and 10 mm and preferably contains fibers, in order to provide the hard but brittle concrete with high ductility.
    After spraying the outer skin layer 20, the inner mold 1Θ is positioned as illustrated. Along an upper edge an opening 2.1 is provided, through which the back fill concrete 22 is poured. The back fill concrete is a self-compacting concrete, whereby vibrating the mold is not neccessary in order to achieve a monolithic structure. The back fill concrete will flow into the mold and occupy the space not taken up by the outer skin layer.
    In this less using high strength concretes both when spraying and when backfilling a very strong and monolilthic panel is obtained,
    Prior to pouring the bacilli concrete 22 and positioning the inner mold 10, reinforcement 23, anchors, bolts, insulation and other desired features can be arranged in the mold. When pouring the backfill concrete 22, these features will be cast in with the backfill concrete, as illustrated in fig. 4th
    FIG. 4 illustrates a-finished panel 7 according to the invention. The panel comprises an outer skin 20 containing fibers 24. where the outer skin consists of .a high performance concrete sprayed onto a mold, as described above, A backfill 22 - also high performance or ultra high performance self-compacting comcrete, also optionally containing fibers 24 'and reinforcement 23 is positioned on the outer skin layer. Typically, the backfill layer will have a thickness of between 50 and 150 mm depending on the intended apiication.
    For the sake of illustration the figures described above do not contain all. details pertaining to. the molds, casting, equipment etc, only schematically illustrates the principles of the present invention. The fi gures mainly cross-sections through the molds and. panels are illustrated.
    权利要求:
    Claims (10)
    [1]
    1. Method of manufacturing a high strength concrete plate member comprising the steps of: first spraying an outer skin layer against a mold where said outer skin layer is a reinforced high strength concrete mix comprising fibers, said outer skin layer having a thickness of between 2 mm to 10 mm; secondly backfilling with, a high strength concrete vertically or horizontally, having a layer thickness between 10 mm and 100 mm. allowing the two layers to harden and chemically react hydraulic or pozzolanic together, to finally form one monolithic layer. - removing the mold.
    [2]
    The method according to claim 1 wherein the high strength concrete used for the backfilling contains fibers wherein the fiber material is selected from: glass, steel, stainless steel, carbon, polymer, bauxite, wood (celluloses), kapok or other natural fibers .
    [3]
    3. Method according to claim 1 or 2 means for mounting the concrete plate member to a construction embedded in the backfilled high strength concrete ;.
    [4]
    4. Method according to. any preceding claim where the compressive strength of the high strength concrete is 80-200 MPa or more.
    [5]
    5. Method according to any preceding claim, where the high strength concrete in the backfilling is not vibrated, but cast as self compacting high performance concrete wet-in-wet with the skin layer,
    [6]
    6. Method according to any preceding claim, where the high strength concrete in. the backfilling is not. vibrated, but cast as self compacting high performance concrete after the skin layer has hardened, securing the wet-in-wet condition due to a special hydraulic-lic / puzzolanic. activator applied to the inner surface of the skin layer.
    [7]
    7, A method according to any preceding claim, wherein the concrete for the outer skin layer comprises an additive, making it possible to spray and allowing the high strength concrete to remain in situ when spraying vertically up and horizontally against the mold. Possible products to serve this purpose can be either polymers like Axilat PAV 29 or alternatively a SiC) 2 Nanosilica like Aerosil Fumed Silica from Evonik Degussa GmbH to adjust the consistency and stability of the Ultra High Performance Concrete perfectly.
    [8]
    8. A method according to any preceding claim wherein the manufacturing process for the manufacture of a concrete panel comprises a number of stations: - a first station where the concrete: casting molds are prepared and assembled; - a second station where the. skin high strength concrete layer is sprayed onto a front side mold in a layer thickness of between 2 and 10 mm; -an optional third station where insulation, reinforcement and anchors and / or mount-mg / lifting devices are arranged in the mold; - a fourth stati on, where a rear part of the mold is positioned and fastened relative to the front, side mold; - a fifth station where the backfill concrete is entered into the cavity between the outer skin layer and the rear part mold; -a sixth station where the concrete panel is cured and de-molded - a seventh storage station for the finished cured concrete panels.
    [9]
    A method according to claim 7 where further stations are arranged, between the sixth and seventh stations, where at least: - a station impregnating or surface treating the front side of the panel with an agent, is arranged where the agent is selected among one or more of the following agents: liquid silicone impregnating agent, nano surface treatment like Contee F3 Nano sealer, Acrylic sealers like Contee F2 or chemically reacting sealers like Contee FI surface hardener, acid staining, water repellent agent, coloring agent etc .; - a concrete panel drying station optionally comprising an autoclave; - a polishing and / or grinding station finishing edges and surfaces
    [10]
    10. High strength concrete panel manufactured according to any of claims 1 to 7.
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    同族专利:
    公开号 | 公开日
    WO2013010544A1|2013-01-24|
    EP2734349A1|2014-05-28|
    DK177523B1|2013-09-02|
    引用文献:
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    DKPA201100558A|DK177523B1|2011-07-19|2011-07-19|Method of manufacturing a high strength concrete plate member having a superior surface, as well as a high strength concrete panel manufactured by said method|
    DK201100558|2011-07-19|DKPA201100558A| DK177523B1|2011-07-19|2011-07-19|Method of manufacturing a high strength concrete plate member having a superior surface, as well as a high strength concrete panel manufactured by said method|
    EP12735772.1A| EP2734349A1|2011-07-19|2012-07-06|Method of manufacturing a high strength concrete plate member having a superior surface, as well as a high strength concrete panel manufactured by said method|
    PCT/DK2012/050257| WO2013010544A1|2011-07-19|2012-07-06|Method of manufacturing a high strength concrete plate member having a superior surface, as well as a high strength concrete panel manufactured by said method|
    PCT/DK2012/050258| WO2013010545A1|2011-07-19|2012-07-06|Method of manufacturing a complete insulated high strength concrete element having a superior surface, as well as a high strength concrete element manufactured by said method|
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