METHOD FOR ASSEMBLING A FORMWORK UNIT

Abstract

Method for assembling a formwork unit, in particular a wall formwork unit, comprising the steps: a. prefabricating the formwork unit in a prefabrication area by—providing a first formwork element, —providing a second formwork element,—attaching a reinforcement between the first and the second formwork element,—connecting the first to the second formwork element in order to obtain the formwork unit, b. Transporting, in particular lifting, the formwork unit together with the reinforcement from the prefabrication area to a site of operation.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a U.S. National Phase of International Application No. PCT/EP2023/084649 entitled “METHOD FOR CONSTRUCTING A FORMWORK UNIT,” and filed on Dec. 7, 2023. International Application No. PCT/EP2023/084649 claims priority to European Patent Application No. 22212472.9 filed on Dec. 9, 2022. The entire contents of each of the above-listed applications are hereby incorporated by reference for all purposes.

TECHNICAL FIELD

The invention relates to a method for assembling a formwork unit and a method for producing a concrete element. Finally, the invention relates to a prefabricated formwork device.

BACKGROUND AND SUMMARY

Wall formwork is used in the production of concrete walls. The wall formwork is composed of two formwork halves, the positioning formwork and the closing formwork, which are installed at the manufacturing location of the concrete wall and connected to each other. In the formworked state, the concrete is poured into the space between the positioning formwork and the closing formwork in order to produce the concrete wall. A certain degree of prefabrication can be achieved by forming the positioning and closing formwork from framing formwork, which is transported to the site of operation as prefabricated formwork units. An example of the assembling of such a wall formwork is shown, for example, in AT10946U1. Nevertheless, many work steps must be carried out on site of operation under changing working and environmental conditions. This hinders the construction progress. In addition, the installation of the wall formwork on site of operation entails safety risks, which must be minimized by appropriate additional measures. In any case, this requires a high level commitment of trained personnel. Another disadvantage is the construction noise caused by the assembling of the formwork.

In addition, it has been proposed in the prior art to manipulate in-situ concrete formwork with lifting traverses. An example of this is shown in FR 3 104 148 A1. With such a lifting traverse, opposing formwork halves can be transported and assembled together. The formwork halves are then either slipped over the reinforcement at the construction site or the formwork halves are opened and the reinforcement is subsequently introduced. However, it is disadvantageous that a large amount of work is still required to prepare the concreting on site. Although the wall formwork halves are brought to the site of operation together, the other components must be procured separately. A crane is often used for transport, but it is heavily used on construction sites and can prove to be a bottleneck for construction progress.

Precast concrete parts, which are produced in a prefabrication plant, are another approach. WO0238878, for example, describes concrete walls that are connected by means of reinforcement rods that can be folded together by joints. This allows the transport volume to be minimised.

Precast concrete parts are usually transported on trucks. These transports are very complex due to the heavy weight and dimensions of the precast concrete parts. Furthermore, there is a risk of damage during transport. Furthermore, precast concrete parts do not allow for flexible responses to short-term changes in requirements.

In contrast, the object of the present invention is to alleviate or eliminate at least individual disadvantages of the prior art. In particular, the invention aims to simplify and standardize the assembling of in-situ concrete formwork at the site of operation.

This object is achieved by a method for assembling a formwork unit, a method for producing a concrete element, and a prefabricated formwork device as described herein.

In the method according to the invention, at least the following steps are carried out:

• • a. prefabrication of the formwork unit in a prefabrication area by
    • providing a first formwork element,
    • providing a second formwork element,
    • installing a reinforcement between the first and second formwork elements,
    • connecting the first formwork element to the second formwork element to obtain the formwork unit,
  • b. transporting, in particular lifting, the formwork unit together with the reinforcement from the prefabrication area to a site of operation, i.e. to the manufacturing location of the concrete element.

In the method according to the invention for producing a concrete element, in particular a wall element, at least the following steps are carried out:

• • i. assembling a formwork unit as described above,
  • ii. arranging the formwork unit in a formwork position at the site of operation, and
  • iii. concreting the concrete element with the formwork unit in the formwork position.

According to the invention, the prefabricated formwork device comprises at least:

• • a formwork unit comprising a first and a second formwork element,
  • a formwork connection element connecting the first and second formwork elements so that a interstice is formed between the first and second formwork elements for filling with concrete,
  • a reinforcement, and
  • a suspension, with which the reinforcement is suspended in the interstice between the first and second formwork elements, so that the prefabricated formwork device, including the reinforcement, can be transported from a prefabrication area to a site of operation, in particular by lifting with a hoist.

Thus, the formwork unit is assembled in the prefabrication area. The prefabrication area is spatially separated from the site of operation, i.e. from the place where the concrete element is produced with the formwork unit. The prefabrication area is preferably located adjacent to the site of operation on the construction site. In the prefabrication area, the working and environmental conditions can be controlled better than on site of operation. Thus, a precise floor space can be provided in the prefabrication area, on which the formwork unit is prefabricated. In contrast, the floor space at the site of operation, for example the top of a previously concreted ceiling element, may have unevenness or dirt, which makes it difficult to assemble the formwork. Furthermore, particularly high safety standards can be set in the prefabrication area. There may also be protection against environmental conditions, which cannot be achieved at the site of operation, during the production of the concrete body. In the prefabrication area, the formwork unit can therefore be mounted precisely, safely and quickly. Any number of formwork units can also be prefabricated in order to avoid delays at the site of operation as much as possible. Finally, the prefabrication area can also be equipped with soundproofing, which significantly reduces the noise emissions from the construction site. According to the invention, during prefabrication in the prefabrication area, not only are the first and second formwork elements, i.e. the positioning formwork and the closing formwork, connected to the formwork unit, but the reinforcement is also already installed in the interstice between the first and second formwork elements. For this purpose, the reinforcement can be attached to one formwork element, i.e. to the first or second formwork element, before the other formwork element, i.e. the second or first formwork element, is provided in order to arrange the reinforcement in the interstice of the formwork unit. When arranging the reinforcement, the first or the second formwork element is preferably in an upright, in particular vertical, state. As reinforcement preference is given to using individual reinforcement rods, individual reinforcement brackets or reinforcement mesh or reinforcement cages made of reinforcement elements preferably connected to one another by means of wires or welded connections. In particular, the reinforcement is made of steel. The reinforcement reinforces the concrete element to be produced. The second or first formwork element is preferably also connected to the first or second formwork element in the upright, in particular vertical, state. After prefabrication, the formwork unit is transported to the site of operation and set up there together with the reinforcement in the interstice between the first and second formwork elements. The concrete element, in particular a wall element, can then be produced by filling concrete into the interstice. Advantageously, the preparation of the concreting process at the site of operation can be significantly simplified thanks to the prefabricated formwork unit.

To connect the first and second formwork elements, a formwork connection element, in particular a support element, for example a connecting bar, is preferably connected to the first and second formwork elements, in particular respectively to an upper end of the first and second formwork elements. In the connected state, the formwork connection element brings about such a rigid connection between the first and the second formwork element that the formwork unit, together with the reinforcement, can be transported in a predetermined position from the first to the second formwork element, in particular can be lifted to the site of operation by means of a hoist. For this purpose, the formwork connection element which preferably connects the upper ends of the first and second formwork elements to one another, is preferably provided as the support element, in particular made of metal. The support element can have at least one profile part. The support element preferably comprises two profile parts, for example two C-profiles, which are connected to one another. In the connected state, the support element may extend substantially perpendicular to the major planes of the first and second formwork elements. Depending on the embodiment, a plurality of formwork connection elements may be provided for connecting the first formwork element to the second formwork element. The formwork connection elements are preferably connected to the upper ends of the first and second formwork elements and spacingly arranged from one another in the horizontal direction. Each two formwork connection elements can be connected to one another via a guiderail element, for example a round element, in particular a round tube, as a result of which an additional function is realized.

For purposes of this disclosure, the location and direction details, such as “top,” “bottom,” “horizontal,” “vertical,” refer to a vertical condition of the formwork unit for concreting a vertical wall element. The formwork unit can also be used in a different position, in which case the location and direction details must then be transmitted accordingly.

In a preferred embodiment, the formwork connection element is mounted on the first formwork element, moved from a resting position into a connecting position, in particular pivoted, and connected to the second formwork element. In the resting position, the formwork connection element is detached from the second formwork element, i.e. the formwork connection element is connected to the first formwork element, but not to the second formwork element. In the resting position, the formwork connection element is mounted on the first formwork element, in particular by means of a bolt connection, while the first formwork element is preferably arranged in a horizontal position, in particular in a horizontal state, in the prefabrication area. During the prefabrication of the formwork unit, the first formwork element is connected to the second formwork element by means of the formwork connection element, preferably in an upright, in particular vertical, state of the first and second formwork elements. The formwork connection element is moved from the resting position into the connecting position and is reversibly detachably connected to the second formwork element, preferably by means of at least one additional bolt connection.

In order to connect the formwork connection element to the first or second formwork element, it is advantageous for the formwork connection element to be connected to the first formwork element by means of a first mounting in the resting and in the connecting position, in particular via a first retaining tab, and to be connected to the second formwork element in the connecting position by means of a second mounting, in particular by means of a second retaining tab. The first mounting is preferably attached, in particular at the upper end, to a first retaining beam, in particular a first vertical beam, which is preferably mounted on at least one frame part of the first formwork element. Accordingly, the second mounting can be attached, in particular at the upper end, to a second retaining beam, in particular a second vertical beam, which is preferably mounted on at least one frame part of the second formwork element.

In a preferred embodiment, the first mounting comprises a guide, in particular an arched guide, with which the formwork connection element is guided during the transfer from the resting position into the connecting position. The guide is preferably designed as an arched elongated hole in the first mounting, in which a guiding element, in particular a guide bolt, is guided on the formwork connection element.

In a preferred embodiment, a fixing device, in particular with at least one bolt connection, is provided for fixing the formwork connection element in the resting position, preferably also for fixing the formwork connection element in the connecting position.

For stable handling, it is advantageous if the first mounting and/or the formwork connection element comprises a first attachment point for a hoist for lifting the first formwork element and/or the second mounting comprises a second attachment point for a hoist for lifting the second formwork element. The first and second attachment point may each include an eyelet, a hook element, or a bar to enable attachment of a hook of the hoist.

In addition, a third attachment point, for example with an offset eyelet, can be provided on the formwork connection element for displacing the formwork unit together with the reinforcement from the prefabrication area to the site of operation, in particular reversibly detachably mounted. Alternatively, the formwork unit can also be grabbed with a hoist independently of the formwork connection element. For this purpose, for example, a transfer bar can be used.

To increase the degree of prefabrication, it is advantageous if at least one formwork anchor is connected to the first and second formwork elements during prefabrication. As known in the prior art, the formwork anchor can be inserted and secured through a hole in each of the first and second formwork elements. The formwork anchor preferably extends substantially perpendicular to the main planes of the formwork panels of the first and second formwork elements, respectively. The formwork anchor can be designed as a formwork connection element, which connects the first and second formwork elements to one another in such a way that the first and second formwork elements are fixed in their relative position to one another in the prefabrication area. Furthermore, the wall thickness of the concrete element to be produced at the site of operation can already be adjusted with the formwork anchor in the prefabrication area. These advantages can also be used independently of the arrangement of the reinforcement in the prefabrication area. For example, a concrete element made of fiber-reinforced concrete can be produced at the site of operation, so that in this application no reinforcement is provided in the prefabrication area. Thus, the present disclosure also relates to a method for assembling a formwork unit, in particular a wall formwork unit, comprising the steps of:

• • prefabrication of the formwork unit in a prefabrication area by
    • providing a first formwork element,
    • providing a second formwork element,
    • providing at least one formwork anchor between the first and second formwork elements,
    • connecting the first formwork element to the second formwork element, preferably by means of the at least one formwork anchor, in order to obtain the formwork unit,
  • transporting, in particular lifting, the formwork unit including the at least one formwork anchor from the prefabrication area to a site of operation.

In order to secure the reinforcement in its position in the interstice during transport from the prefabrication area to the site of operation, a suspension, in particular with a suspension bracket, is provided in a preferred embodiment during prefabrication, on which the reinforcement is suspended between the first and the second formwork element. The suspension is preferably mounted on the formwork connection element, from which the suspension preferably extends downward into the interstice. In a preferred embodiment, the suspension comprises a suspension bracket, which has at least one receptacle for receiving a portion of the reinforcement. The suspension bracket can thus engage under the section of the reinforcement, so that the reinforcement cannot slide down in the interstice during transport, in particular during crane transport. The suspension bracket preferably comprises two suspension parts, which protrude laterally from a central part that is mounted on the formwork connection element. In a preferred embodiment, a height adjustment is also provided, with which the height position of the suspension bracket in the interstice between the first and second formwork elements can be adjusted. This allows the suspension bracket to be precisely aligned with the reinforcement.

In order to further increase the degree of prefabrication in the prefabrication area away from the site of operation, in a preferred embodiment, a gap formwork, in particular for a door or window cutout, is arranged between the first and the second formwork element during prefabrication. Within the interstice between the first and second formwork elements, the gap formwork delimits a cutout that is not filled with concrete. This cutout serves in particular as a door or window cutout. In this embodiment, the formwork unit can be created together with the gap formwork in the prefabrication area and transported to the site of operation.

Depending on the embodiment, the prefabrication of the formwork unit in the prefabrication area may also comprise the installation of at least one electrical and/or sanitary component on the first and/or second wall formwork element. For example, an empty conduit or a switch box for creating a cavity for a light switch may be provided as electrical components. A water pipe or sewer pipe, for example, can be provided as a sanitary component. In this embodiment, the formwork unit can be transported together with the electrical and/or sanitary component from the prefabrication area to the site of operation.

In addition, the prefabricated formwork unit may have at least one front formwork, with which the interstice between the first and second formwork elements is laterally delimited. The front formwork is mounted on the first and/or second formwork element during prefabrication. In this embodiment, the formwork unit can be transported together with the front formwork from the prefabrication area to the site of operation.

For lifting the formwork unit together with the reinforcement, preferably also together with the gap formwork, a hoist, in particular a crane, is preferably used. Thus, the formwork unit together with the installation components, such as the gap formwork, can be lifted from the floor space of the prefabrication area with the crane, transported to the site of operation hanging freely above the floor, and lowered onto the floor space of the site of operation.

At the site of operation, the prefabricated formwork unit is preferably placed on a floor space, in particular on an already concreted ceiling element.

In this case, the formwork unit can be placed on the floor space at the site of operation in such a way that a floor connection reinforcement protruding from the floor space is arranged between lower regions of the first and second formwork elements. Thus, in this embodiment, the prefabricated formwork unit is threaded onto the floor connection reinforcement.

In a preferred embodiment the formwork unit is connected to a lifting device, preferably to at least one spindle lifting element, together with the reinforcement for height adjustment of the formwork unit, in order to be able to arrange the formwork unit at the site of operation in the desired formwork position for the production of a concrete element. The lifting device is designed to adjust the height (i.e. in the vertical direction) of the formwork unit together with the reinforcement, optionally also together with installation components such as the gap formwork. The first and second formwork elements as well as the reinforcement, optionally also the installation component, remain in the predetermined position with respect to one another, which was already defined during prefabrication in the prefabrication area.

In a first embodiment variant, the first and/or the second formwork element of the formwork unit can be connected to at least one lifting element, in particular to at least one spindle lifting element, of the lifting device during prefabrication. In this embodiment, at least one of the first and second formwork elements is therefore connected to a respective lifting element in the prefabrication area. In this embodiment, the formwork unit is transported together with at least one lifting element of the lifting device from the prefabrication area to the site of operation. Preferably, the lifting element is mounted at the lower end of the first or second formwork element.

In a second embodiment variant, the first and/or the second formwork element of the formwork unit is in each case placed on at least one further lifting element, in particular at least one further spindle lifting element, of the lifting device at the site of operation. In this embodiment, the further lifting element is mounted at the site of operation, for example on an end of an already concreted ceiling element, and the first or second formwork element is placed on the further lifting element at the site of operation.

These two embodiment variants can be used alternatively or in combination with one another.

For the production of an exterior wall, it is preferably provided that one of the first and second formwork elements is provided with the lifting element during the prefabrication of the formwork unit and the other of the first and second formwork elements is placed on the additional lifting element at the site of operation, which is preferably mounted on the end of the underlying ceiling element.

For the production of an interior wall, it is preferably provided that, during prefabrication in the prefabrication area, the lifting element is mounted on the first formwork element and the additional lifting element is mounted on the second formwork element.

Since the interior of the prefabricated formwork unit is not easily visible at the site of operation, the problem may arise that an installation component hidden in the interstice of the formwork unit, in particular the gap formwork described above, is not arranged at the desired height to the floor space of the site of operation, for example due to unevenness of the floor, contamination or other unavoidable tolerances.

In order to resolve this problem, a marking can be provided on the first and/or second formwork element during the prefabrication of the formwork unit in the prefabrication area, with which marking a reference height for at least one installation component, in particular for the gap formwork, is marked in the interstice between the first formwork element and the second formwork element relative to the floor space of the prefabrication area. In the prefabrication area, a reference height, for example 1 meter, above the floor space of the prefabrication area is therefore first determined and projected onto the formwork unit, for example by means of projection of a laser. At this reference height, the marking is applied to the first or second formwork element, which can be, for example, a sticker, a line marking, a meter mark sticker, a QR code, a magnetic strip or an electronic component. The installation component is then provided at a predetermined height distance from the reference height on the first and/or second formwork element before the formwork unit is assembled by connecting the first and second formwork elements. In the prefabrication area, a virtually perfect floor space can be provided, so that the installation height of the installation component in the interstice of the formwork unit can be determined with high accuracy before the prefabricated formwork unit is closed by connecting the first to the second formwork element.

In a preferred embodiment, the marking is provided on the rear side of the first formwork element or the second formwork element facing away from the interstice. As a result, the marking remains visible at the site of operation or accessible for electronic reading.

In a preferred embodiment, a height of the marking relative to the floor space of the site of operation is measured at the site of operation, for example with a laser measuring device, and a deviation of the height from the reference height is compensated for with the help of the lifting device. If the floor space at the site of operation is not perfect, as is often the case, the installation component could not be arranged at the correct height position when the prefabricated formwork unit is set up at the site of operation, even if the installation component has been precisely positioned relative to the formwork unit in the prefabrication area. By comparing the measured height of the marking above the floor space of the site of operation with the reference height, a deviation is determined, which can be compensated for with the help of the lifting device, so that the height distance of the marking from the floor space of the site of operation is identical to the reference height, i.e. to the height distance of the marking from the floor space of the prefabrication area.

The method described above can be carried out analogously to compensate for a deviation of the horizontal position of the installation component at the site of operation from a horizontal reference distance of the installation component in the prefabrication area from a side edge of the first and/or second formwork element.

In a preferred embodiment, the first and second formwork elements are each a frame formwork element, which in each case comprises a formwork panel with a front side facing the concrete and a rear side facing away from the concrete and a frame on the rear side facing away from the concrete. The frame may have longitudinal frame parts and transverse frame parts supporting the formwork panel.

The first and second formwork elements may each have a plurality of first and second formwork parts, respectively, which are connected to one another, in particular via formwork tension element, in such a way that the front sides of the formwork panels are arranged substantially in one plane.

As first and second formwork elements, a first and a second wall formwork element are preferably provided, which are arranged at a distance from one another, so that a wall element can be cast in the interstice between the first and the second formwork element.

The invention is explained in more detail below with reference to exemplary embodiments illustrated in the drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows an overview of a construction site, which is divided into a prefabrication area and a site of operation.

FIG. 2 to FIG. 12 show various steps in the prefabrication of a formwork unit.

FIG. 13 and FIG. 14 show the transport of the prefabricated formwork unit from the prefabrication area to the site of operation.

FIG. 15 to FIG. 19 show various steps in setting up the formwork unit at the site of operation.

FIG. 20 shows the production of a wall element with the formwork unit set up at the site of operation.

FIG. 21 and FIG. 22 show the disassembly of the formwork unit after the production of the wall element.

FIG. 23 shows the cleaning of the disassembled formwork unit in the prefabrication area.

FIG. 24 to FIG. 27 show the installation of an alternative embodiment of the formwork unit at the site of operation.

DETAILED DESCRIPTION

FIG. 1 shows an overview of a construction site, which is divided into a prefabrication area 1 and a site of operation 2. The prefabrication area 1 is preferably located adjacent to the site of operation 2, at which a concrete body, for example a building with several floors, is to be constructed. In the prefabrication area 1, a (in-situ concrete) formwork unit 3 can be prefabricated, which is then transported to the site of operation 2 in order to produce a concrete element, in particular a wall element, as part of the concrete body there.

According to FIG. 2 and FIG. 3, a first formwork element 4 is preassembled in the horizontal state on a surface of the prefabrication area 1. The first formwork element 4 is a frame formwork element with a frame 5, which preferably comprises longitudinal frame parts 6 and transverse frame parts 7 on the rear side of a formwork panel 8 facing away from the concrete (cf. FIG. 18). The first formwork element 4 is preferably reversibly detachably connected to a formwork connection element 9. For this purpose, a first retaining beam 10 is attached to the rear side of the frame 5 and carries a first mounting 11, in this case a first retaining tab, at the upper end. The first mounting 11 is preferably connected to the first retaining beam 10 via a reversibly detachable connection, in particular a bolt connection. The formwork connection element 9, which in the embodiment shown is a support element in the form of a connecting bar, here with two bolt profiles, for example C-profiles (cf. FIG. 11A), is mounted on the first mounting 11. The formwork connection element 9 is pivotably attached to the first mounting 11, in particular via an additional bolt connection 9A. The first mounting 11 comprises an arched, here circular arc-shaped, curved guide 12 for guiding a bolt 12A on the formwork connection element 9. In FIG. 2 and FIG. 3, the formwork connection element 9 is shown in a resting position. The formwork connection element 9 comprises, preferably at the longitudinal end facing away from the first mounting 11, a first attachment point 13, for example with a support bolt 13A, to which a hoist 14, in particular a crane, can be attached in order to bring the first formwork element 4, as described in more detail below, from the horizontal state of FIG. 2 and FIG. 3 into the upright state of FIG. 7.

According to FIG. 4 and FIG. 5, a second formwork element 15 is preassembled in the horizontal state on the surface of the prefabrication area 1. The second formwork element 15 is designed as a frame formwork element, corresponding to the first formwork element 4. Attached to the rear side of the frame 5 of the second formwork element 15 is a second retaining beam 16, which carries a second mounting 17, in this case a second retaining tab, at the upper end. The second mounting 17 comprises a second attachment point 18, here with an transfer bracket 19, to which the hoist 14 can be attached in order to bring the second formwork element 15, as will be described in more detail below, from the horizontal state of FIG. 4 and FIG. 5 to the upright state of FIG. 9. Furthermore, a work platform 20 can be mounted on the second retaining beam 16. Finally, a support device 21 is mounted on the second formwork element 15, with which, as will also be described in more detail below, a bracing and inclination adjustment can be carried out at the site of operation 2.

According to FIG. 6, a temporary bracing 22 is provided on a floor space 1A of the prefabrication area 1, which is only required during the prefabrication of the formwork unit 3, but not during concreting at the site of operation 2.

According to FIG. 7, the first formwork element 4 with the hoist 14 is brought into the upright, here vertical, state and mounted on the temporary bracing 22, which in the embodiment shown comprises an angle bracket 22A. By means of the temporary bracing 22, the first formwork element 4 can be held in the stationary state independently, even without the hoist 14.

According to FIG. 8, a reinforcement 23, here a reinforcement cage with longitudinal and transverse reinforcement elements, is arranged on the front side of the first formwork element 4. The reinforcement 23 is designed as a reinforcement cage, which extends substantially over the entire width, length and height of the interstice between the first formwork element 4 and the second formwork element 15. In the embodiment shown, a reference height, here for example 1 meter, above the floor space 1A of the prefabrication area 1 is measured, cf. line 25 in FIGS. 6, 7 and 8. In addition, a gap formwork 24 is installed at a defined height distance from the reference height. Further installation components can also be mounted at defined height distances from the reference height.

According to FIG. 9, the second formwork element 15 is brought into the upright state with the hoist 14, set up at a horizontal distance from the first formwork element 4, and supported with the support device 21. The interstice 26, in which the reinforcement 23 and the gap formwork 24 are arranged, is formed between the first formwork element 4 and the second formwork element 15.

According to FIG. 10, connecting the first 4 to the second formwork element 15 is prepared. Furthermore, a worker 27 makes a marking on the rear side of the second formwork element 15 at the reference height, in this case 1 meter. This reference height defines a reference plane. In addition, a further marking for the reference plane can be attached to the rear side of the first formwork element 4 and/or to the bracing 22.

FIG. 11A shows in detail the upper end region of the formwork unit 3, wherein the formwork connection element 9 is in the unfolded resting position. This illustration shows that several formwork connection elements 9 are provided in the embodiment shown, whereby two adjacent formwork connection elements 9 can be connected to each other via at least one guiderail element 9B, in this case two guiderail elements 9B.

According to FIG. 11B and FIG. 12, the formwork connection element 9 is folded over from the resting position shown in FIG. 11A into the connecting position and connected, for example via an additional bolt connection 9A, to the second mounting 17 on the second formwork element 15. In addition, a suspension 28 is mounted on the formwork connection element 9, on which the reinforcement 23 is suspended in the interstice 26 between the first formwork element 4 and the second formwork element 15. The suspension 28 comprises a suspension bracket 29, which is reversibly detachably connected to the formwork connection element 9 via a connecting element 30, in this case a threaded rod. In the embodiment shown, the suspension 28 comprises a height adjustment 31, with which the height position of the suspension bracket 29 in the interstice 26 can be adjusted. In this case, the height adjustment 31 comprises a nut 32, which can be screwed onto the threaded rod to different extents in order to adjust the height of the suspension bracket 29 in the interstice 26 accordingly.

According to FIG. 13, the hoist 14 is connected to the formwork unit 3, in particular via an offset eyelet 33 attached to the formwork connection element 9. After the release of the formwork unit 3 from the bracing 22, the formwork unit 3, together with the reinforcement 23 and the gap formwork 24, is lifted from the surface of the prefabrication area 1 and, as shown symbolically in FIG. 14, is lifted to the site of operation 2, i.e. is transported freely suspended above the surface.

According to FIG. 15, the formwork unit 3 is brought up above the floor space 2A of the site of operation 2 with the hoist 14.

According to FIG. 16, the formwork unit 3 is lowered onto a floor connection reinforcement 34 that is raised from the floor in such a way that the floor connection reinforcement 34 is arranged in the interstice 26 between the lower regions of the first formwork element 4 and the second formwork element 15.

As can be seen from FIG. 16 and FIG. 17, the formwork unit 3 is connected at the site of operation 2 to a lifting device 35 for height adjustment of the formwork unit 3, together with the reinforcement 23 and the gap formwork 24. In the embodiment shown, a lifting element 36 of the lifting device 35 is mounted on the lower end of the second formwork element 15. The lower end of the first formwork element 4 is lowered onto an additional lifting element 37 of the lifting device, which is mounted at the site of operation 2, in this case on the end of the floor.

FIG. 17 shows that the lower edge of the second formwork element 15 is sealed off from the floor space 2A via a seal 38, for example a sealing sheet. By actuating the lifting device 35, the formwork unit 3, together with the reinforcement 23 and the gap formwork 24, can be adjusted in height, i.e. in the vertical direction, in order to set a desired height of the installation component, in particular of the gap formwork 24, relative to the floor space 2A of the site of operation 2. For this purpose, the height of the marking above the floor space 2A of the site of operation 2 can be measured. If this height deviates from the reference height, here 1 meter, the lifting device 35 is actuated to compensate for the deviation.

FIG. 18 and FIG. 19 diagrammatically show the formwork unit 3 in the constructed state on the floor space 2A of the site of operation 2. In this case, the floor space 2A is formed as the top of a ceiling element of the floor below.

According to FIG. 20, concrete 39 is filled into the interstice 26 of the formwork unit 3 from above in order to produce the concrete element, here a vertical wall element. As indicated in FIG. 20, an inclination of the formwork unit 3 can be adjusted by adjusting the support device 21. Prior to concreting, the suspension 28 of the reinforcement 23 may be removed and the formwork connection element 9 may be opened. In the open position (resting position) of the formwork connection element 9, the formwork connection element 9 forms a counter-rail with the guiderail element 9B, which protects the worker against falling. So that the counter-rail does not tilt back, the formwork connection element 9 can be blocked against pivoting in the open position with a bolt.

According to FIG. 21, after the concrete 39 has hardened or after the anchor rods have been removed, the first formwork element 4 is lifted away from the site of operation 2 by means of the hoist 14.

According to FIG. 22, after the concrete 39 has hardened, the second formwork element 15 is lifted away from the site of operation 2 by means of the hoist 14. At the position of the gap formwork 24, the concrete element comprises a cutout 40, here a window cutout.

According to FIG. 23, the first formwork element 4 and the second formwork element 15 are cleaned in the prefabrication area 1 before an additional formwork unit 3 is reassembled for the production of the next concrete element.

FIGS. 24 to 27 illustrate an alternative method in which both the lifting element 36 for the second wall formwork element 15 and the additional lifting element 37 for the first wall formwork element 4 are mounted on the formwork unit 3 during prefabrication. Thus, the lifting element 36 and the additional lifting element 37 are lowered together with the first 4 and the second wall formwork element 15 onto the floor space 2A of the site of operation 2.

According to FIG. 24 and FIG. 25, the additional lifting element 37 may be arranged at the lower end of the first formwork element 4 and the lifting element 36 may be arranged at the lower end of the second formwork element 15 during transport from the prefabrication area 1 to the site of operation 2. This embodiment can be used in the production of interior walls, because in this case both lifting elements 36 and 37 can be supported on the floor space 2A. In FIG. 25, the lifting elements 36, 37 are shown in different positions to illustrate adjustability.

According to FIG. 26 and FIG. 27, the lifting element 37 on the first formwork element 4 and the lifting element 36 on the second formwork element 15 can be actuated in order to adjust the height of the prefabricated formwork unit 3.

LIST OF REFERENCE NUMBERS

• • 1 prefabrication area
  • 1A floor space of the prefabrication area
  • 2 site of operation
  • 2A floor space of the site of operation
  • 3 formwork unit
  • 4 first formwork element
  • 5 frame
  • 6 longitudinal frame parts
  • 7 transverse frame parts
  • 8 formwork panel
  • 9 formwork connection element
  • 9A additional bolt connection
  • 9B guiderail element
  • 10 first retaining beam
  • 11 first mounting
  • 12 guide
  • 12A bolt
  • 13 first attachment point
  • 13A support bolt
  • 14 hoist
  • 15 second formwork element
  • 16 second retaining beam
  • 17 second mounting
  • 18 second attachment point
  • 19 transfer bracket
  • 20 work platform
  • 21 support device
  • 22 temporary bracing
  • 22A angle bracket
  • 23 reinforcement
  • 24 gap formwork
  • 25 line
  • 26 interstice
  • 27 worker
  • 28 suspension
  • 29 suspension bracket
  • 30 connecting element
  • 31 height adjustment
  • 32 nut
  • 33 offset eyelet
  • 34 floor connection reinforcement
  • 35 lifting device
  • 36 lifting element
  • 37 additional lifting element
  • 38 seal
  • 39 concrete
  • 40 cutout

Claims

1. A method for assembling a formwork unit, comprising the steps of:

a. prefabricating the formwork unit in a prefabrication area by providing a first formwork element, providing a second formwork element, attaching a reinforcement between the first and the second formwork element, and connecting the first formwork element to the second formwork element in order to obtain the formwork unit, and

b. transporting the formwork unit together with the reinforcement from the prefabrication area to a site of operation.

2. The method according to claim 1, wherein, in order to connect the first formwork element to the second formwork element, a formwork connection element is connected in each case to the first formwork element and the second formwork element.

3. The method according to claim 2, wherein the formwork connection element is mounted on the first formwork element, moved from a resting position into a connecting position, and connected to the second formwork element.

4. The method according to claim 3, wherein a fixing device is provided for fixing the formwork connection element in the resting position.

5. The method according to claim 3, wherein a first mounting and/or the formwork connection element comprises a first attachment point for a hoist for lifting the first formwork element, and/or a second mounting comprises a second attachment point for a hoist for lifting the second formwork element.

6. The method according to claim 1, wherein during the prefabrication, at least one formwork anchor is connected to the first formwork element and the second formwork element, respectively.

7. The method according to claim 1, wherein during prefabrication, a suspension is provided, on which the reinforcement is suspended between the first formwork element and the second formwork element.

8. The method according to claim 1, wherein during prefabrication, a gap formwork is arranged between the first formwork element and the second formwork element.

9. The method according to claim 1, wherein the first formwork element is connected to a lifting device for height adjustment of the formwork unit, together with the reinforcement at the site of operation.

10. The method according to claim 9, wherein the first and/or the second formwork element is connected to at least one lifting element of the lifting device during the prefabrication of the formwork unit.

11. The method according to claim 1, wherein during the prefabrication of the formwork unit, a marking is provided on the first formwork element or the second formwork element, with which a reference height for at least one installation component is marked in the interstice between the first formwork element and the second formwork element relative to a floor space of the prefabrication area.

12. The method according to claim 11, wherein the marking is provided on a rear side of the first formwork element or the second formwork element.

13. The method according to claim 11, wherein a height of the marking relative to the floor space of the site of operation is measured at the site of operation, and a deviation of the height from the reference height is compensated for by means of a lifting device.

14. A method for producing a concrete element, comprising:

i. assembling a formwork unit with the method according to claim 1,

ii. arranging the formwork unit in a formwork position at the site of operation, and

iii. concreting the concrete element with the formwork unit in the formwork position.

15. A prefabricated formwork device, comprising:

a formwork unit with a first formwork element and a second formwork element,

a formwork connection element, which connects the first formwork element to the second formwork element, so that an interstice for filling with concrete is formed between the first formwork element and the second formwork element,

a reinforcement, and

a suspension for the reinforcement in the interstice between the first formwork element and the second formwork element, so that the prefabricated formwork device, including the reinforcement, can be transported from a prefabrication area to a site of operation.

16. The method according to claim 1, wherein the formwork unit is a wall formwork unit.

17. The method according to claim 1, wherein transporting the formwork unit together with the reinforcement from the prefabrication area to the site of operation comprises lifting the formwork unit together with the reinforcement from the prefabrication area to the site of operation.

18. The method according to claim 2, wherein the formwork connection element is a connecting bar.

19. The method according to claim 2, wherein the formwork connection element is connected in each case to an upper end of the first formwork element and the second formwork element.

20. The method according to claim 3, wherein moving the formwork connection element from the resting position into the connecting position comprises pivoting the formwork connection element.