Patent EA-003038-B1 (EA)
Title: Device for producing wall elements
IPC: B28B7/24
Filed: 1999-10-13
Abstract: 1. A process for producing wall elements which contain at least two layers (11, 12) - an outer layer (11) and a loadbearing or intermediate layer (12) - and internal fittings (14, 15, 16), for external and internal walls and for floors of buildings, with the following steps: a) a pivoting table (1) having two supporting surfaces (3, 4) at an angle to each other for wall elements to be produced is moved into a construction position, in which one of the supporting surfaces (3) is aligned horizontally as a construction surface and the other supporting surface (4) is at an angle thereto, as a wall element supporting surface; b) a bottom outer layer (11) is applied to the supporting surface (3) in order to adjoin the wall-element supporting surface (4); the outer layer (11) can belong to one or more wall elements to be produced and can have one or more cutouts, into which spacers and/or protective devices (49) for elements of windows, doors or other openings are introduced, these spacers and/or protective devices reaching into the interspace that is provided for the loadbearing layer (12); c) internal fittings (14, 15, 16) and spacers (17) are laid on the inside of the outer layer (11), leaving an interspace free for concrete and the internal fittings (14, 15, 16), and a covering (13) is provided; d) the interspace between outer layer (11) and covering (13) is delimited by respective shuttering elements (20) at narrow sides which extend perpendicular to the wall-element supporting surface (4); e) the covering (13) constitutes either a second outer layer for the bottom layer (41) of wall elements to be produced - the wall elements are then of substantially three-layer construction or the covering (13) already belongs to the second layer (42) of wall elements to be produced - the bottom wall elements is/are then of two-layer construction; f) the second wall element layer (42) of outer layer and loadbearing layer is constructed on the bottom wall element layer (41) in accordance with steps c), d), and the process is continued with the construction of further wall element layers (43, 44, 45, 46, 47, 48), until a stack (10) is formed; g) the top wall element layer (48) is covered with a cover (7), which is pressed in the direction of the construction surface (3) with a pressing force and is fastened to the pivoting table (1) with lasting compression of the stack (10); h) the pivoting table (1) is rotated through 90 degree , so that the open narrow sides point upward, with access to the respective interspaces; i) the interspaces in the respective wall element layers (41-48) are filled from above with liquid concrete; j) after the concrete has set, the cover (7) is released from its pressing position and the wall elements are lifted individually and transported away from the wall-element supporting surface (4). 2. The process as claimed in claim 1, characterized in that the spacers (17) are laid using a binder between spacer and respective outer layer. 3. The process as claimed in claim 1 or 2, characterized in that the pressing force exerted on the stack is sufficient to clamp the spacers (17) in between their outer layer (11) and covering (13) in order to withstand shock forces occurring because of the concrete flowing in and also to withstand the hydrostatic pressure of the liquid concrete. 4. The process as claimed in one of claims 1 to 3, characterized in that the wall element layers (41, 42, 43, 44, 45, 46, 47, 48) are separated from one another in the stack (10) by separating films. 5. The process as claimed in one of claims 1 to 4, characterized in that at least some of the layers (41, 42, 43, 44) have a thick foam panel as outer layer (11) in order to form wall elements for external walls. 6. The process as claimed in claim 5, characterized in that a thin cladding layer is provided as an outer layer on the inside of a building in each wall element. 7. The process as claimed in one of claims 1 to 6, characterized in that each layer (41 to 48) is constructed in the manner of a sandwich with two outer layers and an intermediate layer. 8. The process as claimed in one of claims 1 to 7, characterized in that space fillers are provided in order to make up the stack (10) to a parallelepiped. 9. The process as claimed in one of claims 1 to 8, characterized in that shuttering elements, which come to lie in the vicinity of the outside of the stack (10), are protected from the passage of heat by matched rigid foam blocks. 10. An apparatus for producing wall elements, in particular in accordance with a process as claimed in claim 1, comprising: a tilting table (1) with supporting surfaces (3, 4) at an angle to each other, of which one surface constitutes a construction surface and the other surface constitutes a wall-element supporting surface and the tilting table (1) being rotatably suspended on a holding apparatus (60); a pivoting device (67) to move the tilting table (1) into a construction position, in which the construction surface is horizontal, and into a casting and unloading position, in which the construction surface is vertical. 11. The apparatus as claimed in claim 10, characterized in that the angle between the construction surface (3) and the wall-element supporting surface (4) is a right angle. 12. The apparatus as claimed in claim 10 or 11, characterized in that the pivoting table (1) has a fixed end wall (5), which is perpendicular to the construction surface (3) and the wall-element supporting surface (4). 13. The apparatus as claimed in claim 12, characterized in that a further, removable end wall (6) is provided, which can be mounted on the pivoting table (1), parallel to the fixed end wall (5). 14. The apparatus as claimed in one of the preceding claims, characterized in that the apparatus has a lifting device (68) to lift. and lower the supporting surfaces (3, 4). 15. The apparatus as claimed in one of the preceding claims, characterized in that the tilting table (1) is suspended at the center of gravity (64) on a holding device (60) such that it can be rotated. 16. The apparatus as claimed in one of the preceding claims, characterized in that the tilting table has a rotation device (68a, 69) for rotating the supporting surfaces (3, 4). 17. The apparatus as claimed in one of the preceding claims, characterized in that the apparatus has a lifting device (68) for lifting and lowering the supporting surfaces (3, 4). 18. The apparatus as claimed in one of the preceding claims, characterized in that the apparatus comprises a pit area (71), in which the tilting table (1) can be lowered. 19. The apparatus as claimed in one of the preceding claims, characterized in that the supporting surfaces (3, 4) can be used alternatingly, as a construction surface or wall-element supporting surface. 20. The apparatus as claimed in one of the preceding claims, characterized in that the supporting surfaces (3, 4) comprise a rigidly welded angular girder profile. 21. The apparatus as claimed in one of the preceding claims, characterized in that reinforced profiles can be flanged-mounted on the girder profile in order to lengthen the supporting surfaces (3, 4). 22. The apparatus as claimed in one of the preceding claims, characterized in that the apparatus comprises an impression plate (7) for the press connection of one or more wall elements applied in a stack to the construction surface. 23. The apparatus as claimed in claim 22, characterized in that the impression plate (7) for the press connection supports the wall-elements applied in a stack to the construction surface at a pressing pressure of preferably 1.5t/m<2>. 24. The apparatus as claimed in one of the preceding claims, characterized in that parts of the operation of moving the construction surface (3) into the vertical are carried out in a pit area (71). 25. The apparatus as claimed in one of the preceding claims, characterized in that parts of the operation of moving the construction surface into the vertical are carried out in a synchronized rotational and lifting movement in a pit area (71). 26. The apparatus as claimed in one of the preceding claims, characterized in that the apparatus comprises a supporting means (70) for supporting the tilting table (1). 27. The apparatus as claimed in claim 26, characterized in that the supporting means preferably comprises three double-T girders and has a deviation in the vertical of substantially less than 9 mm. 28. The apparatus as claimed in one of the preceding claims, characterized in that the supporting surfaces (3, 4) have a maximum length of 22 m and preferably a length of 12 m to 18 m. 29. A shuttering element for use in step d) of claim 1, characterized by a pipe (21) with longitudinal ribs (23) and transverse slots (22), which are disposed in a specific angular position in relation to the pipe axis, the transverse slots (22) being made at specific intervals in order to hold connecting reinforcement (27) , which reaches part-way into the interspace to be filled with concrete in a wall element layer and, outside the interspace, are shaped into a loop in order to form an eye (29). 30. The shuttering element as claimed in claim 29, characterized in that a centering bar (24) is provided, which is designed to be pushed through the center of the pipe and eyes (29) in the connecting reinforcement (27) and to be kept centered. 31. The shuttering element as claimed in claim 30, characterized in that stop lugs (26) are provided on the centering bar (24) and are disposed in order to further hold the connecting reinforcement (27). 32. A wall element, produced in accordance with one of claims 1 to 9, characterized in that connecting loops (31) with bent-over eyes (33) are disposed along a line which runs along a side surface of the wall element, and in that the bent-over eyes (33) can be raised by being bent up in order to connect a transverse wall. 33. The wall element, produced in accordance with one of claims 1 to 9, char