Method for manufacturing a building component with a concrete layer and mesh formwork, and a building component with a concrete layer and mesh formwork
The proposed invention can be applied in construction for the creation of building components with a concrete layer. Unlike traditional concrete building component manufacturing, the proposed method eliminates the need for removable formwork, reduces labor costs, and enables the production of complex geometries efficiently. A method for creating a building component with a concrete layer comprises applying at least one layer of waterproofing material to the base; installing permanent formwork on the base; threading at least one reinforcement bar through the formwork; pouring concrete mixture into the internal space enclosed by the formwork; curing concrete mixture until it reaches the required strength. The invention also discloses a building component produced by the proposed methods.
1 . A method for manufacturing a building component, comprising:
applying at least one layer of waterproofing material to a base comprising a wooden, metal, plastic, or composite panel, wherein the base constitutes a permanent structural layer of the building component;
installing a permanent formwork on the base,
wherein the formwork is made of wave-shaped segments arranged to form a closed contour with overlapping edges defining an internal space;
wherein each formwork segment comprises a composite wall structure formed of at least three superimposed mesh layers, including two outer mesh layers and an inner mesh layer positioned between and in contact with the outer mesh layers, wherein mesh openings in the outer mesh layers are sized to be at least twice the size of the mesh openings of the inner mesh layer;
placing a reinforcement into the formwork;
threading at least one reinforcement bar through the formwork,
wherein the reinforcement bar passes through an opening in at least one outer layer of the formwork with openings larger than a diameter of the threaded reinforcement bar and pierces the inner mesh layer to form a friction fit aperture;
pouring a concrete mixture into the internal space enclosed by the formwork;
and curing the concrete mixture until the building component could be moved.
2 . The method of claim 1 , wherein at least a portion of the reinforcement is placed on a support element and the support element is mechanically fastened to the base.
3 . The method of claim 1 , wherein the reinforcement is placed above the base in at least two layers.
4 . The method of claim 1 , wherein the formwork segments are attached to the base using brackets having pre-formed fixing holes by means of at least one fastener through at least one hole in the brackets.
5 . The method of claim 1 , wherein the wave-shaped formwork has an amplitude in the range of 5-200 mm and a wavelength in the range of 30-300 mm.
6 . The method of claim 1 , wherein the mesh openings in the outer layers of the formwork through which the reinforcement bar is threaded are larger than a diameter of the reinforcement bar to allow passage without cutting the outer mesh.
7 . The method of claim 1 , wherein the formwork and reinforcement are positioned by robotic equipment.
8 . A method for manufacturing a building component, comprising:
applying at least one layer of waterproofing material to a base comprising a wooden, metal, plastic, or composite panel, wherein the base constitutes a permanent structural layer of the building component;
installing a permanent formwork on the base,
wherein the formwork is made of wave-shaped segments arranged to form a closed contour with overlapping edges defining an internal space, and each formwork segment comprises at least three mesh layers, including two outer mesh layers and an inner mesh layer positioned between the outer mesh layers, wherein mesh openings in the outer mesh layers ae sized to be at least twice the size of the mesh openings of the inner mesh layer;
placing a reinforcement into the formwork,
wherein the reinforcement is placed on at least one support element and attached to the base by fixing at least one clamping bracket over the reinforcement, wherein the clamping bracket is secured to the base using at least one mechanical fastener passing through a hole in the clamping bracket;
wherein the clamping bracket is a separate part from the support element and from the reinforcement, and is secured to the base by a screw, anchor, or bolt;
wherein at least a portion of an outer mesh layer is left exposed along an external side surface of the building component, the exposed outer mesh layer providing a mechanical interlock for a cementitious joint material when the building component is positioned adjacent to another building component;
threading at least one reinforcement bar through the formwork,
wherein the reinforcement bar passes through an opening in at least one outer layer of the formwork with openings larger than a diameter of the threaded reinforcement bar, pierces the inner mesh layer and is attached to the reinforcement inside the space enclosed by the formwork;
pouring a concrete mixture into the internal space enclosed by the formwork;
and curing the concrete mixture until the building component could be moved.
9 . The method of claim 8 , wherein the support element is mechanically fastened to the base.
10 . The method of claim 8 , wherein the reinforcement is placed above the base in at least two layers.
11 . The method of claim 8 , wherein the wave-shaped formwork has an amplitude in the range of 5-200 mm and a wavelength in the range of 30-300 mm.
12 . The method of claim 8 , wherein the formwork and reinforcement are positioned by robotic equipment.
13 . The method of claim 8 , wherein the mechanical fastener also passes through a hole of the support element to secure the support element to the base.