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(11) | EP 0 730 063 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | A box molding process for realizing projecting elements in reinforced concrete and a molding system therefor |
| (57) The invention relates to a molding system for realizing projecting elements in reinforced
concrete, and comprises a bracket (6) to which a support bracket (8) is rotatably
constrained, which bears a squaring beam (9). The system further comprises a molding
slab (10), extremities of which rest respectively on the squaring beam (9) and the
bearing structure (2). Also described is a box molding process comprising the phases
of positioning of a support (3) provided with a pivot (4) on a bearing structure (2)
and insertion of a tie-rod (5) on the bearing structure (2), and a constraining and
positional adjustment of the bracket (6). The process also includes a phase in which
a support bracket (8) is positioned and constrained to the bracket (6) by means of
insertion of at least a plug (12), and a phase of placing a squaring beam (9) between
the bracket (6) and the support bracket (8); and insertion of a molding slab (10)
between the support bracket (8) and the bearing structure (2). Also comprised are
phases of dismounting, with the disengaging of the support bracket (8), and an externalwise
rotation of the support bracket (8) with recuperation for further utilization of both
the bracket (6) and the support bracket (8). |
[0001] The invention relates to a box molding process for realizing projecting elements in reinforced concrete, and a molding system therefor, in particular for building elements for bridges, viaducts and roofs.
[0002] The prior art teaches various systems for realizing projecting elements: the projecting beams, however, are always of limited dimensions due to the considerable difficulties involved in making them.
[0003] A first building method proposes the use of special reinforced supports equipped with trestles, which are fixed to an underlying bearing structure, such as a beam, a box-shaped element or the like.
[0004] The drawback of the above system is that the trestles are expensive. Further, it is considerably difficult to set and place the trestles due to the presence of reinforcement rods projecting from the underlying structure.
[0005] A further drawback inherent in the above system is the difficulty of positioning the reinforcement rods due to their having to pass through the inside of the stirrups of the trestles, a time-consuming task. A still further inconvenient is the occurrence of uneven settling during the concrete casting operation. This unevenness leads to incorrect alignments of the trestle caissons, which are impossible to put right: consequently, a second operation is needed for setting the lateral wings.
[0006] A second constructional system for realizing projecting elements involves the use of a projecting bridge system supported by a strut and tie-rod assembly. In more detail, this system requires the presence of a strut element extending vertically from the bearing structure, which strut opposite end is constrained on one side by a tie rod fixed to the underlying structure and on the other side by a free end of a projecting slab.
[0007] This system also exhibits a series of problems, a first of which is the elevated deformability of the system, rendering the system utilizable only with limited-size projections. Further, the slab must be provided with attachments for anchoring the tie-rod; then, once the concrete has been cast and the slab rendered solid, the tie rods and cut and the attachments, being situated inside the setting concrete, are lost.
[0008] A third constructional system for realizing projecting elements involves the creation of an external mold, supported by a scaffold.
[0009] This system also incurs several drawbacks, among which are the lengthy construction of the scaffold, and the considerable costs connected with the sheer amount of specialized work needed for erection of a long scaffold at considerable height.
[0010] A still further system proposes the use of a slab supported by a bracket anchored to the side wall of the bearing structure.
[0011] This system too is beset by drawbacks, among which are the considerable stress the bearing structure is subjected to. Further, significant difficulties have been encountered during the mounting and dismounting phases, not least of which is a considerable danger to life and limb especially during dismounting. Further to this is the impossibility of making small adjustments to the molding slab height before casting.
[0012] The main aim of the present invention is to resolve the above-described problems inherent in the prior art by providing projecting elements of considerable size by means of a boxing system and process therefor which permits of varying the size of the projections of the concrete simply, without incurring increased manufacturing costs, and without any time-wasting. The invention is also easy to construct and use.
[0013] A further aim of the invention is to provide a box mold system and realization process therefor which do not necessitate the use of massy and complex structures disturbing the insertion of the reinforcement rods of the slab, as happened in the prior art systems.
[0014] A still further aim of the present invention is to obtain projecting elements having various geometrical and static properties, without having recourse to making alterations in the conformation of the box molds used. Further, with the process, correct positioning of the mold slab is ensured since the projections can be aligned and any height errors made during casting can be corrected, unlike in the prior art realizations.
[0015] A further aim of the present invention is to realize a support structure for the mold box which can be saved after used and reutilized.
[0016] A still further aim of the invention is to realize the projections at contained cost with regard to the plant and the tools used, to better use of work time, considerable adaptability of use, and with regard to increased, indeed optimum safety for operators during both mounting and dismounting phases of the elements which constitute the projection mold box.
[0017] These aims and others besides, which will better emerge during the following description, are attained by the process for box molding for realizing projecting elements in reinforced concrete, and a molding system therefor, in particular for building elements for bridges, viaducts and roofs, which is herein described in the form of a non-limiting preferred embodiment, made with reference to the accompanying figures of the drawings, in which:
figure 1 is a frontal schematic view of the elements for realizing the molding system of the invention;
figure 2 is a schematic view of a first operative phase of the process for obtaining a projection in reinforced concrete;
figure 3 is a schematic view of a further operative phase of the process of the invention;
figure 4 is a schematic view of a further operative phase of the mounting of the molding system;
figure 5 is a schematic view of a subsequent operative phase of the process;
figure 6 is a still further schematic view of a subsequent operative phase of the process;
figure 7 is a schematic view of an operative phase of the process relating to the dismounting of the molding system according to the present invention;
figure 8 is a schematic view of a further operative phase of the process;
figure 9 is a schematic view of a phase relating to a finishing operation of the finalized reinforced concrete projection.
[0018] With reference to the figures, and in particular to figure 1, 1 denotes in its entirety a manufacture comprising a projecting element and relative box mold system according to the present invention.
[0019] In particular, 2 denotes a bearing structure which can be a beam or a box-like structure for making bridges and\or roofing elements.
[0020] The box mold system used in the process of the present invention comprises a bracket 6 predisposed to contact with a pivot 4 located on a support 3 made in reinforced concrete and having a parallelepiped conformation. The support 3 rests on and\or is anchored to the bearing structure 2.
[0021] In greater detail, an attachment element 5a is situated on an end 6a of the bracket 6, which attachment element 5a will engage with a tie-rod 5 anchored to the bearing structure 2 such as to constrain the bracket 6 to the bearing structure 2.
[0022] At another end 6b of the bracket 6 is a plurality of holes 7 arranged in two parallel lines and specially distanced one from another. The holes 7 will be engaged by a pair of plugs 12 constraining a support bracket 8 to the bracket 6 at a predetermined distance corresponding to the dimensions of the projecting element to be constructed. A first plug 12a serves to rotatably engage the support bracket 8, while a second plug 12b serves to block rotation thereof.
[0023] In more detail, the support bracket 8 is substantially L-shaped, one arm of the L being constrained to the bracket 6 by means of the plugs 12 which insert in the holes 7 in the bracket 6 while the other arm of the L constitutes a rest base of a small support square 9.
[0024] The squaring beam 9 is placed on the support bracket 8, and has the task of supporting a molding slab 10 the ends whereof are rested on the bearing structure 2 and the squaring beam 9.
[0025] The process of the present invention comprises a plurality of operative phases for realizing the molding, with the aim of constructing a projecting element of considerable dimensions on the bearing structure 2, and of dismounting the mold itself once the concrete cast and the concrete slab have hardened.
[0026] The process, as can clearly be seen in figure 2, comprises a first phase in which a support 3 in concrete or like material exhibiting a pivot 4 on its summit is rested or anchored on the bearing structure 2. A tie rod 5 is constrained to the bearing structure 2 at a prefixed distance.
[0027] Figure 3 illustrates a subsequent phase involving the positioning of a bracket 6 restingly on the pivot 4 and constrained to the tie-rod 5 by an attachment element 5a.
[0028] By acting on the tie-rod 5 through the attachment element 5a the bracket 6 is adjusted, bringing it to the exact height required: this adjustment operation can be repeated during subsequent operative phases.
[0029] Next, a support bracket 8 is positioned at a predetermined distance from the pivot 4, said predetermined distance depending on the length of the projection to be realized. The support bracket 8 is connected to the bracket 6 by means of a first plug 12a which is inserted in a hole 7 and blocked by a second plug 12b which is inserted in another hole 7 arranged vertically with respect to the preceding hole 7.
[0030] The following phase of the process involves the placing of a squaring beam 9 between the bracket 6 and the support bracket 8, as shown in figure 4.
[0031] Then the molding slab 10 is positioned, the ends whereof rest respectively on the squaring beam 9 and the bearing structure 2.
[0032] At this point, the mold box for the projecting element is ready and the reinforcements can be arranged ready for the slab and projection.
[0033] When the rods of the reinforcements have been positioned, the height of the future projection can once more be adjusted if necessary.
[0034] At this point, the concrete can be cast into the mold constituted by the squaring beam 9, the molding slab 10 and the bearing structure 2, as shown in figure 6.
[0035] When the concrete has hardened the support bracket 8 is loosened, removing one of the two plugs 12 by means of which it was constrained to the bracket 6. Once the plug 12b has been released, as shown in figure 7, the support bracket 8 is rotated such as to be distanced from the squaring beam 9.
[0036] Figure 8 shows how the bracket 6 is removed: after having been detached from the tie-rod 5 and the support bracket 8, it is lifted while the tie-rod 5 and the pivot 4 are immersed in the cast.
[0037] Finally, a lateral curb 11 can be made, already squared in the external side of the squaring beam 9, meaning that it is sufficient to add a containing element in the internal side to complete the squaring of the lateral curb 11.
[0038] The invention thus achieves its set aims. Indeed, a multiplicity of realizations can be achieved using the invention, all having different projection reaches thanks to the flexibility and practicality of use of the elements composing the molding system of the invention.
[0039] The process according to the invention obviates all the drawbacks in the prior art and does away with the need for awkward trestles while allowing for great simplicity in the arranging of the reinforcing rods in the mold slab.
[0040] Further, the process of the invention enables repeated aligning of the projections and therefore correction of small height errors, considerably reducing the possibility of deformations in the completed system.
[0041] The box-molding system of the invention comprises simple elements which can be utilized for obtaining projections having different dimensions and which can be reutilized many times.
[0042] The elements which make up the box mold of the present process enable the incorporating of the lateral beam 9 and the recuperation of the support bracket 8, which can be reutilized.
1. A box molding process for realizing projecting elements in reinforced concrete, comprising
the following phases:
positioning of a support (3) provided with a pivot (4) on a bearing structure (2) and insertion of a tie-rod (5) on said bearing structure (2);
positioning of a bracket (6) by resting thereof on said pivot (4) and constraining of said bracket (6) to said tie-rod (5);
positional adjustment of said bracket (6) through exact height regulation of the bracket (6) by acting on said tie-rod (5);
positioning of a support bracket (8) and constraint thereof to said bracket (6) by means of inserting therein of a first plug (12a);
positioning of a squaring beam (9) between the bracket (6) and the support bracket (8);
positioning of a molding slab (10) between the support bracket (8) and the bearing structure (2);
freeing of said support bracket (8) by removal of the first plug (12a) from a hole (7) afforded in said bracket (6);
externalwise rotation of said support bracket (8);
recuperation of said bracket (6) and said support bracket (8).
2. A process as in claim 1, characterized in that a second plug (12b) is inserted in
a hole (7) arranged vertically and alignedly to said first plug (12a).
3. A process as in claim 1, comprising a phase wherein reinforcements of a mold slab
for a projection are set in a correct position.
4. A process as in claim 1, comprising a casting phase of liquid concrete which flows
entirely into a mold box constituted by said squaring beam (9), said mold slab (10)
and said bearing structure (2).
5. A process as in claim 1, comprising a drying and setting phase of the liquid concrete.
6. A process as in claim 1, comprising a control and adjustment phase of projection length
and height before the concrete is cast.
7. A process as in claim 1, characterized in that it comprises a phase of partial box-molding
followed by a casting of concrete for realizing a lateral curb (11), already squared
on an external side thereof.
8. A molding system for realizing projecting elements in reinforced concrete, characterized
in that it comprises:
a bracket (6) to which a support bracket (8) is rotatably constrained;
a squaring beam (9) supported by the support bracket (8);
a molding slab (10) extremities of which rest respectively on the squaring beam (9) and the bearing structure (2).
9. A molding system as in claim 8, characterized in that said bracket (6) exhibits at
one end (8b) thereof a plurality of holes (7) arranged in two parallel and specially
distanced lines.
10. A molding system as in claim 8, characterized in that said support bracket (8) is
L-shaped, wherein a first arm of said L-shape is constrained to the support bracket
(8) by means of plugs (12) which insert into the holes (7) in the bracket (6) while
another arm of said L-shape constitutes a rest base for the squaring beam (9).
11. A molding system as in claim 8, characterized in that it comprises a support (3) located
on said bearing structure (2).
12. A molding system as in claim 11, characterized in that said support (3) exhibits a
pivot (4) which is predisposed to contact said bracket (6).
13. A molding system as in claim 8, characterized in that said bracket (6) exhibits an
attachment element (5a) predisposed to be constrained to a tie-rod (5) provided on
the bearing structure (2).