Apparatus and Method for Casting Concrete Wall Elements

Abstract

An apparatus for casting concrete wall elements, which together form a wall, running along a curvature at least in sections, of a container, in particular of a fermenter for biogas plants, comprising a horizontal foundation, to which several horizontally extending bounding elements are attached, which between them form fields to be cast with concrete, several formwork elements, which are detachably secured to at least a few bounding elements, which form formwork surfaces, which are opposite each other in a field and which are aligned at an angle with respect to the vertical, which in the erected state form the face side surfaces of adjacent wall elements, that face each other, wherein the formwork elements each have at the formwork surfaces at least one receiving device, and wherein at least one end of at least one reinforcing element to be cast in the concrete is secured in each receiving device of formwork surfaces, which are opposite each other in a field.

1 . An apparatus for casting concrete wall elements ( 20 ), which together form a wall, at least in sections running along a curvature, of a container, in particular a fermenter for a biogas plant, comprising:
 a horizontal foundation ( 10 ), on which several horizontally extending bounding elements ( 12 ) are fastened, which between them form fields ( 18 ) to be cast in concrete for the wall elements ( 20 ),—several formwork elements ( 28 ) that are connected to at least several bounding elements ( 12 ), which form formwork surfaces ( 36 ) that are located across from each other in a field ( 18 ) and are aligned at an angle (α) to the vertical, which represent the face side surfaces of adjacent wall elements ( 20 ) facing each other in the erected state,   wherein the formwork elements ( 28 ) at the formwork surfaces ( 36 ) each have at least one receiving device ( 42 ,  46 ,  60 ), and wherein one end of at least one reinforcing element ( 44 ,  48 ,  72 ) to be cast in concrete is fastened in each the receiving devices ( 42 ,  46 ,  60 ) in opposing formwork surfaces ( 36 ) in a field ( 18 ).   
     
     
         2 . The apparatus according to  claim 1 , characterized in that the at least one reinforcing element is a reinforcing rod ( 48 ) or a reinforcing cable, or that at least one reinforcing element is a reinforcing tube ( 44 ) for receiving a reinforcing rod or a reinforcing cable. 
     
     
         3 . The apparatus according to  claim 1 , characterized in that the foundation ( 10 ) is the base ( 10 ) of the container. 
     
     
         4 . The apparatus according to  claim 1 , characterized in that at least one reinforcing element ( 44 ,  48 ,  72 ) runs curved between the receiving devices ( 42 ,  46 ,  60 ) of opposing formwork surfaces ( 36 ). 
     
     
         5 . The apparatus according to  claim 1 , characterized in that at least one of the receiving devices ( 42 ,  46 ,  60 ) has a cylindrical or conical element ( 42 ) fastened in the formwork surface ( 36 ), wherein the at least one reinforcing tube ( 44 ) is slid onto the at least one cylindrical element ( 42 ). 
     
     
         6 . The apparatus according to  claim 1 , characterized in that at least one of the receiving devices ( 42 ,  46 ,  60 ) has a bore hole ( 60 ) provided in the formwork surface ( 36 ), wherein the at least one reinforcing rod or the at least one reinforcing tube is placed into the at least one bore hole ( 60 ). 
     
     
         7 . The apparatus according to  claim 1 , characterized in that at least one of the receiving devices ( 42 ,  46 ,  60 ) has a sleeve ( 46 ) fastened in the formwork surface ( 36 ), wherein the at least one reinforcing rod or the at least one reinforcing tube is slid into the at least one sleeve ( 46 ). 
     
     
         8 . The apparatus according to  claim 1 , characterized in that the at least one reinforcing rod ( 48 ) has at least on one end a head ( 50 ) with a cross section expanded with respect to the reinforcing rod ( 48 ). 
     
     
         9 . The apparatus according to  claim 1 , characterized in that at least one reinforcing rod ( 48 ) on at least one end has a head ( 50 ) with an cross section expanded with respect to the reinforcing rod, and at least one other reinforcing rod ( 48 ) on at least one end has a shaped piece ( 64 ) with an undercut ( 66 ), wherein for connecting the reinforcing rods ( 48 ) of wall elements ( 20 ) adjacent in the erected state, the head ( 50 ) of the one reinforcing rod ( 48 ) can be hooked in the undercut ( 66 ) of the opposing other reinforcing rod ( 48 ). 
     
     
         10 . The apparatus according to  claim 9 , characterized in that the at least one shaped piece ( 64 ) has a keyhole opening ( 68 ), through which the head ( 50 ) of another reinforcing rod ( 48 ) can be hooked in the respective undercut ( 66 ). 
     
     
         11 . The apparatus according to  claim 1 , characterized in that at least one end region of the at least one reinforcing element ( 44 ,  48 ,  72 ) is surrounded at least partially by a shaped element ( 54 ), that represents a recess at the end region in the cast concrete wall element ( 20 ). 
     
     
         12 . The apparatus according to  claim 1 , characterized in that shaped elements ( 76 ) are disposed at least at a few of the formwork surfaces ( 36 ), and represent the joints in the cast wall elements ( 20 ). 
     
     
         13 . The apparatus according to  claim 1 , characterized in that at least one projection ( 78 ) is provided at least one formwork surface ( 36 ), and on at least one other formwork surface ( 36 ), at least one recess ( 80 ) is provided that corresponds to the at least one projection ( 78 ). 
     
     
         14 . The apparatus according to  claim 1 , characterized in that a film ( 90 ) is provided at least in the area of contact between the formwork elements ( 28 ) and the foundation ( 10 ) that prevents cast concrete from penetrating underneath the formwork elements ( 28 ). 
     
     
         15 . The apparatus according to  claim 1 , characterized in that at least one film is disposed on the foundation of at least one field ( 18 ). 
     
     
         16 . The apparatus according to  claim 15 , characterized in that the film extends further, at least over the formwork surfaces ( 36 ) of the at least one field ( 18 ). 
     
     
         17 . The apparatus according to  claim 1 , characterized in that it has at least one retainer ( 82 ) which holds a fastening element ( 86 ,  92 ) for fastening further devices to at least one wall element ( 20 ) at least partially in a field ( 18 ) to be cast with concrete. 
     
     
         18 . The apparatus according to  claim 17 , characterized in that the fastening element ( 86 ) is an anchor element ( 86 ) for fastening a railing to the container wall. 
     
     
         19 . The apparatus according to  claim 17 , characterized in that the fastening element ( 92 ) is a rail ( 92 ) for fastening a film of a cover of the container. 
     
     
         20 . The apparatus according to  claim 1 , characterized in that at least one of the formwork surfaces ( 36 ) has a preferably conical shaped element ( 100 ), which reproduces a preferably conical recess in the associated wall element ( 20 ), and that on at least one other formwork surface ( 36 ), a threaded connector ( 106 ) to be cast in the concrete is provided, into which in the cast wall element ( 20 ) a preferably conical shaped element ( 102 ) corresponding to the recess can be screwed. 
     
     
         21 . A method for casting concrete wall elements ( 20 ), which together form a wall, running at least in sections, along a curve, of a container, in particular of a fermenter for a biogas plant, comprising the steps:
 casting a horizontal base ( 10 ) from concrete for the container at the installation site of the container,   fastening several horizontally extending bounding elements ( 12 ) onto the base ( 10 ) which between them define fields ( 18 ) for the wall elements ( 20 ) to be cast with concrete,   casting the wall elements ( 20 ) of concrete in the fields ( 18 ), defined by the bounding elements ( 12 ),   forming the walls of the container by erecting the wall elements ( 20 ) cast in the fields ( 18 ).   
     
     
         22 . The method according to  claim 21 , characterized in that in a first work step the first half of the wall elements ( 20 ) of the container are cast in the fields ( 18 ), and subsequently erected, and that in a second work step the second half of the wall elements ( 20 ) of the container are cast in the fields ( 18 ) and subsequently erected. 
     
     
         23 . The method according to  claim 21 , characterized in that several formwork elements ( 28 ) are detachably fastened at least to a few bounding elements ( 12 ), which form formwork surfaces ( 36 ) that are located across from each other in a field ( 18 ) and that are aligned at an angle (α) to the vertical, which in the erected state form face side surfaces of adjacent wall elements ( 20 ) facing each other, and that the formwork elements ( 28 ) at the formwork surfaces ( 36 ) each have at least one receiving device ( 42 ,  46 ,  60 ), and wherein one end of at least one reinforcing element ( 44 ,  48 ,  72 ) to be cast into the concrete is fastened in each receiving device ( 42 ,  46 ,  60 ) of formwork surfaces ( 36 ) lying opposite each other in a field ( 18 ). 
     
     
         24 . The method according to  claim 23 , characterized in that the at least one reinforcing element is a reinforcing rod ( 48 ) or a reinforcing cable, or that the at least one reinforcing element is a reinforcing tube ( 44 ) for receiving a reinforcing rod or reinforcing cable. 
     
     
         25 . The method according to  claim 23 , characterized in that the at least one reinforcing element ( 44 ,  48 ,  72 ) runs curved between the receiving devices ( 42 ,  46 ,  60 ) of formwork surfaces ( 36 ) opposite each other. 
     
     
         26 . The method according to  claim 23 , characterized in that with at least one of the receiving devices ( 42 ,  46 ,  60 ) a cylindrical or conical element ( 42 ) is fastened in the formwork surface ( 36 ), wherein the at least one reinforcing tube ( 44 ) is slid onto the at least one cylindrical element ( 42 ). 
     
     
         27 . The method according to  claim 23 , characterized in that at least one of the receiving devices ( 42 ,  46 ,  60 ) has a bore hole ( 60 ) provided in the formwork surface ( 36 ), wherein the at least one reinforcing rod or the at least one reinforcing tube is slid into the at least one bore hole ( 60 ). 
     
     
         28 . The method according to  claim 23 , characterized in that at least one of the receiving devices ( 42 ,  46 ,  60 ) has a sleeve ( 46 ) fastened in the formwork surface ( 36 ), wherein the at least one reinforcing rod or the at least one reinforcing tube is slid into the at least one sleeve ( 46 ). 
     
     
         29 . The method according to  claim 23 , characterized in that the at least one reinforcing rod ( 48 ) on at least one end has a head ( 50 ) with a cross-section expanded with respect to the reinforcing rod ( 48 ). 
     
     
         30 . The method according to  claim 23 , characterized in that at least one reinforcing rod ( 48 ) at least one end has a head ( 50 ) having a cross-section expanded with respect to the reinforcing rod, and at least one other reinforcing rod ( 48 ) on least at one end has a shaped piece ( 64 ) with an undercut ( 66 ), wherein for connecting the reinforcing rods ( 48 ) of wall elements ( 20 ) that in the erected state are adjacent, the head ( 50 ) of the one reinforcing rod ( 48 ) is hooked in the undercut ( 66 ) of the other reinforcing rod ( 48 ) lying across from it. 
     
     
         31 . The method according to  claim 30 , characterized in that at least one shaped piece ( 64 ) has a keyhole opening ( 68 ), through which the head ( 50 ) of another reinforcing rod ( 48 ) is hooked in the respective undercut ( 66 ). 
     
     
         32 . The method according to  claim 23 , characterized in that at least one end area of the at least one reinforcing element ( 44 ,  48 ,  72 ) is surrounded at least partially by a shaped element ( 54 ), that forms a recess at the end region in the cast concrete wall element ( 20 ). 
     
     
         33 . The method according to  claim 23 , characterized in that shaped elements ( 76 ) are disposed at least a few of the formwork surfaces ( 36 ) that form joints in the cast wall elements ( 20 ). 
     
     
         34 . The method according to  claim 23 , characterized in that at least one projection ( 78 ) is provided on at least one formwork surface ( 36 ), and at least one recess ( 80 ) corresponding to the at least one projection ( 78 ) is provided on at least one other formwork surface ( 36 ). 
     
     
         35 . The method according to  claim 23 , characterized in that a film ( 90 ) is provided at least in the area of contact between the formwork elements ( 28 ) and the foundation ( 10 ) that prevents cast concrete from penetrating underneath the formwork elements ( 28 ). 
     
     
         36 . The method according to  claim 21 , characterized in that a film is disposed at least on the foundation of at least one field ( 18 ) before casting the concrete wall elements. 
     
     
         37 . The method according to  claim 36 , characterized in that the film extends further at least over the formwork surfaces ( 36 ) of the at least one field ( 18 ). 
     
     
         38 . The method according to  claim 21 , characterized in that at least one retainer ( 82 ) is provided that holds a fastening element ( 86 ,  92 ) for fastening further devices to at least one wall element ( 20 ) at least partially in a field ( 18 ) to be cast in concrete. 
     
     
         39 . The method according to  claim 38 , characterized in that the fastening element ( 86 ) is an anchor element ( 86 ) for fastening a railing to the container wall. 
     
     
         40 . The method according to  claim 38 , characterized in that the fastening element ( 92 ) is a rail ( 92 ) for fastening a film of a cover of the container. 
     
     
         41 . The method according to  claim 23 , characterized in that at least one of the formwork surfaces ( 36 ) has a preferably conical shaped element ( 100 ), which forms a preferably conical recess in the associated wall element ( 20 ), and that a threaded connector ( 106 ) to be cast in concrete is provided on at least one other formwork surface ( 36 ), into which, in the cast wall element ( 20 ), preferably conical shaped element ( 102 ) corresponding to the recess can be screwed.