CZ37629U1 - Prefabricated ceiling elements and ceiling made of prefabricated ceiling elements - Google Patents

Description

Prefabricated ceiling panel and ceiling made from prefabricated ceiling panels

Field of technology

The technical solution relates to the field of construction, specifically prefabricated ceiling structures of wooden buildings.

Current state of the art

Wooden buildings made of perimeter frames forming the walls are very often built as single-story buildings, and this is because the dimensioning of the wall panels is carried out only for the load-bearing capacity of the roof structure and covering. The ceiling is made of a wooden frame, light plasterboard and light insulating materials. This saves a considerable amount of material and simplifies and speeds up assembly.

The situation is more complicated for multi-storey buildings. Due to the requirements for the acoustic, static, fireproof and thermal insulation function of the ceiling structure, only wood or lightweight insulating materials such as plasterboard cannot be used, but heavier materials showing the required properties must be used. One of the variants is the creation of a reinforced concrete ceiling, which is poured directly on the construction site into pre-prepared formwork and connecting elements. Thanks to concreting, the entire ceiling structure will be solidified. Such a ceiling construction brings with it complications in the form of the aforementioned formwork of the parts, supporting the ceilings, tying the fittings on the construction site and complex pouring of the ceilings with a wet concrete mixture. Therefore, hundreds of liters of water are introduced into the dry wooden construction, which must subsequently evaporate, and the ceiling structure must dry out so that construction can continue. Consequently, the entire building is dependent on the climatic conditions, the construction of a concrete ceiling is very time-consuming also due to the technological hardening of concrete, the construction of a wooden building is prolonged and therefore more expensive, moreover, it is a very robust and heavy ceiling structure.

In view of the above, demands are placed on the lightening of ceiling structures by creating so-called prefabricated composite wood-concrete ceilings. The joining of wood and concrete is done in different ways, the most well-known way being notches in the wood and cross-inserted wooden pins or connections with the help of joining screws. This coupling is also carried out on the construction site, where concrete is poured into the already finished structure. This will lighten the ceiling structure, but will not eliminate the disadvantages arising from pouring wet concrete mixture directly on the construction site into the ceiling structure of a wooden building, the handling of which is impractical, lengthy and complex due to the need for formwork.

That is why prefabricated concrete panels have recently been produced, which are the latest known available variant of bonded ceiling panels. The ceiling panel has plastic-steel stirrups encased in concrete, through which the final coupling of the ceiling is carried out on the construction site by screwing together the concrete panel and the wooden beam with the help of special static screws. This option omits the wet concreting process on site, but is lengthy and complicated. And it cannot fully rehabilitate construction inaccuracies. Another disadvantage of these jointed wood-concrete parts is the robustness of the concrete slab, which ensures suitable insulation and acoustic properties, as well as the connection of the ceiling panel to the load-bearing structures of the wooden building, as these parts create openings between the load-bearing wall and the ceiling panel. These openings must be sealed, however there is a risk of thermal bridges forming, which also increases the cost and slows down construction.

A similar solution is presented, for example, in CZ 2021-552, which describes a visible wood-concrete ceiling panel for the assembly of a monolithic stacked wood-concrete ceiling static structure for passive wood buildings, which consists of two or three parallel longitudinal wooden beams to which transverse wooden beams are attached perpendicularly. The longitudinal beams rest on the reinforced concrete slab and are equipped with partially drilled screws, which are then embedded in the concrete

- 1 CZ 37629 U1 board. During the production of the visible ceiling panel, the longitudinal and transverse beams are first assembled, screws are drilled into the longitudinal beams for connection with the concrete slab, and then a steel curry net is laid on them as a reinforcement of the concrete slab. This entire structure is placed in a pouring mold, into which the concrete mixture is subsequently poured, after which the panel is removed from the mold. A monolithic stacked wood-concrete ceiling static structure for passive wood buildings is subsequently created from these visible wood-concrete ceiling panels. The disadvantages of this solution mainly consist in the fact that the connection between the wood and the concrete slab is ensured only with the help of screws, which can be relatively easily broken, so the connection is not sufficiently strong and high-quality. From the visible side, the ceiling is made of a straight board, which can be a shortcoming in some cases if the owner of the wooden building wants to have recognized load-bearing beams in the room.

The task of the technical solution is therefore to create such a prefabricated ceiling part and a ceiling made of these prefabricated ceiling parts, which would eliminate the above-mentioned shortcomings, the use of which would speed up the construction of hybrid wood-concrete buildings, which would eliminate wet processes in the dry construction of hybrid and wooden buildings, which would improved the fire and acoustic properties of the ceiling structure and which would make it possible to create a continuous wood-concrete slab that would fit precisely on the supporting structures of a wooden building without the formation of thermal bridges, and would be strong enough and suitable for the rapid construction of concrete ceilings, on the visible underside of which wooden beams are visible beams.

The essence of the technical solution

The set task is solved using a prefabricated ceiling part according to this technical solution. The ceiling member includes at least one longitudinal wooden beam and at least one concrete slab connected to the longitudinal wooden beam and provided with an inserted steel armature.

The essence of this technical solution lies in the fact that the concrete slab rests with its lower side on the upper side of the longitudinal wooden beam and is connected to it by a coupling bar, which is fixed to the longitudinal wooden beam and at the same time protrudes into the concrete slab. The coupling strip, attached to the longitudinal wooden beam and embedded in the concrete slab, represents a solid and high-quality connection of the longitudinal wooden beam with the concrete slab, which, after pouring and hardening of the concrete mixture around the coupling strip, ensures a perfect coupling of the longitudinal wooden beam with the concrete slab.

In an advantageous embodiment, the longitudinal wooden beam is provided with at least one longitudinal groove on its upper side, at least in part, into which the longitudinal lower part of the coupling bar is fixed with a glued joint. Gluing the coupling bar into the longitudinal wooden beam using a suitable chemical adhesive for metal and wood, the so-called chemical anchor, represents a high-strength connection without any possibility of damage or tearing of the longitudinal wooden beam from the concrete slab.

In another advantageous embodiment, the longitudinal wooden beam is at least partly provided with two parallel longitudinal grooves on its upper side, while the lower part of the coupling bar is fixed in one groove with a glued joint, and the other groove is filled with an adhesive material for connection with the second concrete slab. This design speeds up the installation of the ceiling panels itself, thanks to the possibility of quick connection by gluing the groove and connecting the adjacent ceiling panel. For a larger span of the ceiling part, only one support in the middle of the longitudinal wooden beam, on which the connection is made, is sufficient during assembly. The support can be removed in 20 minutes after making the connection.

In an advantageous arrangement, the coupling bar is provided in its upper part with recesses for the placement of the steel armature at the required height, the so-called cover in concrete. Each recess is preferably equipped with a shape lock to prevent the movement of the steel armature and keep it in place during the pouring of concrete to create a reinforced concrete slab, thus preventing the movement of the steel armature during concreting, which enables the exact placement of the steel armature inside the concrete slab to be observed.

- 2 CZ 37629 U1

The steel reinforcement is preferably a curry net, which is used to reinforce the entire concrete slab, or the entire ceiling part. It is a common and affordable steel fitting that perfectly fulfills its function.

In an advantageous embodiment, the coupling bar in its lower part is provided with height holes for placing height pins for the height of the coupling bar relative to the longitudinal wooden beam. After setting the chosen height of the coupling bar in relation to the longitudinal wooden beam, the adhesive material will be introduced, thus the coupling bar will be glued into the groove of the longitudinal wooden beam.

In another advantageous embodiment, the coupling bar in its upper part is provided with shear holes for the placement of shear pins protruding into the concrete slab, if the static calculation requires it.

In another advantageous embodiment, the coupling bar in its upper part is provided with additional holes for placing additional supporting elements for connecting external and internal structures and breaking the thermal bridge. An additional load-bearing element means, for example, the so-called "isokorb" or "tronsole". Isokorb and other similar elements enable the connection of outdoor concrete structures, such as balconies, pavilions and staircases, and internal concrete staircases while maintaining thermal physics and breaking the thermal bridge. Outdoor concrete structures can also be connected during the production of ceilings, or screwed directly on the construction site. Tronsole and other similar elements are used to connect concrete structures such as balconies, pavilions and stairs. Thanks to the built-in additional load-bearing elements directly into the ceiling structure, it is possible to achieve the correct acoustic properties and thus prevent the transmission of noise and footfall noise into the ceiling structure.

The coupling bar is preferably made of steel.

In an advantageous arrangement, the concrete slab is equipped with plastic grommets to ensure the passage of technological penetrations, it can contain built-in fire protection grommets, penetrations for water, waste, air conditioning and electrical installations located in absolutely precise positions. In addition, this fact will make it possible to speed up construction work and improve the fire resistance of ceiling structures.

In an advantageous embodiment, the prefabricated ceiling part can include two longitudinal wooden beams, where one longitudinal wooden beam is connected to the concrete slab by means of a connecting strip and the other longitudinal wooden beam is connected to the concrete slab with a glued joint.

The concrete slab preferably has, on at least one of its sides, alternating protrusions creating the shape of teeth, these are unique shape locks that fit into each other.

A concrete slab formed from a clearly defined concrete mixture and coupled with longitudinal wooden beams is significantly lighter and thinner compared to standard concrete ceilings, even while maintaining its load-bearing capacity, so there is a saving in weight while maintaining the load-bearing capacity. Thanks to the longitudinal wooden beams arranged on the underside of the concrete slab, the connection of the ceiling part to the surrounding wooden structure can be done with standard connecting elements for wood, such as static and other screws.

The subject of the technical solution is also a ceiling made from the above-described prefabricated ceiling components according to this technical solution. The essence of the technical solution lies in the fact that the ceiling consists of at least two ceiling parts arranged next to each other, the concrete slabs of which are provided on their adjacent sides with alternating protrusions that fit into each other. Between two side-by-side concrete slabs, the gap is filled with grout to create a monolithic ceiling. All adjacent ceiling elements thus create a uniform reinforced concrete slab, which can be considered in the static calculation of a wooden structure.

The advantages of the prefabricated ceiling panel and the ceiling made from these prefabricated ceiling panels according to this technical solution consist mainly in the fact that their use speeds up the construction of hybrid wood-concrete buildings, eliminates wet processes in dry construction

- 3 CZ 37629 U1 of hybrid and wooden buildings, improves the fire and acoustic properties of the ceiling structure and makes it possible to create a continuous wood-concrete slab that fits precisely on the supporting structures of the wooden building without the formation of thermal bridges, and is strong enough and suitable for the rapid construction of concrete ceilings on which wooden beams are visible on the visible underside.

Clarification of drawings

The mentioned technical solution will be explained in more detail in the following illustrations, where:

Fig. 1 shows a view of the coupling bar, Fig. 2 shows a view of the coupling bar glued into a longitudinal wooden beam, Fig. 3 shows a view of the steel reinforcement inserted into the coupling bar, Fig. 4 shows a side view of the ceiling part, Fig. 5 shows top view of a ceiling panel, Fig. 6 shows a top view of two ceiling panels arranged next to each other.

An example of the implementation of a technical solution

The prefabricated ceiling part 1 according to this technical solution includes a longitudinal wooden beam 2, a connecting bar 5 and a concrete slab 3. In Fig. 1, a connecting steel element is shown, that is, a connecting bar 5, which has a length of 7860 mm and a thickness of 3 mm. In another embodiment, the coupling bar 5 may have different dimensions. In its upper part, specifically on its upper edge, the coupling bar 5 has recesses 6 created, which are 100 mm apart in this case (depends on the selected armature). Each recess 6 has a shaped lock 8 formed in it, into which the steel armature 7 fits and its movement along the coupling bar 5 no longer occurs. In its upper part, the coupling bar 5 also has shear holes 10, into which the required number of shears are subsequently placed pins with a diameter of 8 mm, in this case fifty. In its lower part, the coupling bar 5 has created height holes 9, in which height pins are subsequently placed, enabling its exact height adjustment in relation to the longitudinal wooden beam 2. In addition, additional holes 13 are created in the coupling bar 5 for inserting fittings for tying off additional supporting elements, such as isocorba and tronsole,

Fig. 2 shows the coupling bar 5, which is fitted into the longitudinal wooden beam 2. On the upper side of the longitudinal wooden beam 2, a longitudinal groove 4 with a thickness of 10 mm is milled along its entire length. HILTI HIT-RE 500 V4/500 glue is inserted into groove 4. After that, the lower part of the coupling bar 5 is inserted into the groove 4 with glue, with height and shear pins placed perpendicular to the longitudinally running groove 4. The height pins are abutted against the longitudinal wooden beam 2, and thus the height of the coupling bar 5 is set. After the glue has hardened, and therefore, after creating a solid glued connection between the coupling bar 5 and the longitudinal wooden beam 2, it is necessary to create the formwork for the concrete slab 2, including the insertion of the separation film. A steel reinforcement 7, namely a 6x100x100 curry net, is placed in the prepared formwork lined with a separation film in the upper part of the coupling bar 5, specifically in the recess 6 with a shape lock 8. In another embodiment, a different curry net of corresponding dimensions is used. When connecting the curry net, it is necessary to ensure that it overlaps by 30 to 50 cm. The lower part of the curry net is inserted so that the lower wires are perpendicular to the coupling bar 5, as shown in Fig. 3. After placing the curry net, it is necessary to check the position of the formwork to ensure the formation of alternating protrusions 11 forming a tooth shape on one side concrete slabs 2. It is also necessary to insert plastic grommets to ensure the passage of technological penetrations.

After ensuring the preparatory steps described above, the prepared high-strength concrete mixture, the so-called UHPC concrete, is poured into the formed formwork. The concrete mixture must be vibrated through a curry net. After the concrete mixture hardens, a concrete slab 3 with a jointed longitudinal wooden one is created

- 4 CZ 37629 U1 by beam 2. Concrete slabs 3 can have different dimensions according to the requirements for the size of the ceiling, in this example, concrete slab 3 has a length of 5000 mm, a width of 1590 mm and a thickness of 80 mm.

Fig. 4 shows two ceiling panels 1 arranged next to each other, of which one ceiling panel 1 has two longitudinal wooden beams 2 arranged on the lower side of the concrete slab 3. One longitudinal wooden beam 2 has one groove 4 formed on its upper side for gluing coupler bars 5 and the second longitudinal wooden beam 2 has two parallel longitudinal grooves 4 formed on its upper side. In one groove 4 the lower part of the coupler bar 5 is fixed with a glued joint, and the other groove 4 is filled with adhesive for connection with the second concrete slab 3. The second ceiling part 1 is thus connected to the first ceiling part 1 by means of a glued joint.

Fig. 5 shows a ceiling panel 1 whose side of the concrete slab 3 has a toothing which is formed by alternating protrusions 11 that fit into the alternating protrusions 11 of the concrete slab 3 of the second ceiling panel 1, as shown in Fig. 6. SikaGrout 212 grout 12 is injected into the gap between the adjacent concrete slabs 3 after the installation of the ceiling panels 1, which connects or monolithically the entire ceiling made of the ceiling panels 1 described above. he installs wooden beams 2 on the load-bearing walls of wooden buildings and screws them with standard screws.

The example described above represents only an illustrative example of specific values, in other examples of execution, individual components of the ceiling with other dimensions may be used.

Industrial applicability

A prefabricated ceiling panel and a ceiling made from prefabricated ceiling panels according to this technical solution can be used as a ceiling structure in the construction of wooden buildings.

Claims (14)

PROTECTION CLAIMS 1. A prefabricated ceiling part (1) comprising at least one longitudinal wooden beam (2) and at least one concrete slab (3) connected to the longitudinal wooden beam (2) and provided with an inserted steel armature (7), characterized in that the concrete slab ( 3) its lower side rests on the upper side of the longitudinal wooden beam (2) and is connected to it by a coupling bar (5), which is fixed to the longitudinal wooden beam (2) and at the same time protrudes into the concrete slab (3). 2. Prefabricated ceiling part (1) according to claim 1, characterized in that the longitudinal wooden beam (2) is provided with at least one longitudinal groove (4) on the upper side, at least in part, into which the lower part of the coupling bar is fixed with a glued joint ( 5). 3. Prefabricated ceiling part (1) according to claim 1, characterized in that the longitudinal wooden beam (2) is at least partially provided with two longitudinal grooves (4) on the upper side, while the lower one is fixed to one groove (4) with a glued joint part of the coupling bar (5) and the second groove (4) is filled with adhesive. 4. Prefabricated ceiling part (1) according to one of claims 1 to 3, characterized in that the coupling bar (5) is provided with recesses (6) in the upper part for placing the steel armature (7). 5. Prefabricated ceiling part (1) according to claim 4, characterized in that each recess (6) is provided with a shape lock (8) to prevent the movement of the steel armature (7). 6. Prefabricated ceiling part (1) according to one of claims 1 to 5, characterized in that the steel reinforcement (7) is a curry net. 7. Prefabricated ceiling part (1) according to one of claims 1 to 6, characterized in that the connecting strip (5) is provided in the lower part with height holes (9) for placing height pins for the height setting of the connecting strip (5) in relation to the longitudinal to the wooden beam (2). 8. Prefabricated ceiling part (1) according to one of claims 1 to 7, characterized in that the connecting strip (5) is provided in the upper part with shear holes (10) for placing shear pins protruding into the concrete slab (3). 9. Prefabricated ceiling part (1) according to one of claims 1 to 8, characterized in that the coupling bar (5) is provided in the upper part with additional holes (13) for placing additional supporting elements for connecting external and internal structures and interrupting the thermal bridge. 10. Prefabricated ceiling part (1) according to one of claims 1 to 9, characterized in that the coupling bar (5) is made of steel. 11. Prefabricated ceiling part (1) according to one of claims 1 to 10, characterized in that the concrete slab (3) is provided with plastic grommets to ensure the passage of technological penetrations. 12. A prefabricated ceiling part (1) according to one of claims 1 to 11, characterized in that it includes two longitudinal wooden beams (2). 13. Prefabricated ceiling part (1) according to one of claims 1 to 12, characterized in that the concrete slab (3) has alternating protrusions (11) on at least one side. 14. A ceiling, characterized in that it consists of at least two side-by-side ceiling parts (1) according to one of claims 1 to 13, whose concrete slabs (3) are provided with alternating protrusions (11) on their adjacent sides, which fit into each other, with a gap between - 6 CZ 37629 U1 adjacent concrete slabs (3) is filled with grout (12) to create a monolithic ceiling.