DE102004006165B4 - Water-permeable floor covering and method for producing a floor covering - Google Patents

Abstract

Multilayer, water-permeable floor covering (1) with a top and bottom construction (6 or 2) for application to a building ground, the substructure (2) comprising at least one water-permeable structural layer of sand or gravel (4) and the superstructure (6) of Floor covering (1) is a combination of compacted, mineral aggregates and organic adhesives, characterized in that the substructure (2) has a superstructure - side layer of ballast (5) whose average size k is _{gravel of} the undersize ≥ 5 mm and the layers of Upper and the substructure (6 and 2) are connected by gluing together.

Description

The The invention relates to a multi-layered, water-permeable floor covering with a top and substructure for application to a subsoil. Of the Substructure is at least one water-permeable composite layer made of sand or gravel and the superstructure of the flooring a connection made of compacted, mineral aggregates and organic Adhesives. The invention further relates to a process for the preparation a floor covering.

Such a floor covering is in the DE 196 05 990 C2 disclosed.

The Attachment of surfaces through floor coverings for the production of roads, squares, building covers and other accessible or passable surfaces is a well-known technique. Common are Concrete, asphalt, stone and wood coverings. A disadvantage for a discharge of surface water is the low or even lack of water permeability; from a seal the surfaces is therefore common the speech that one tries to counter by usually elaborate drainage.

An ecological undesirable Concomitant of surface sealing is the increased burden of rivers, which are strong or continuous downpours or transform it into roaring torrents through meltwater. The consequences are catastrophic: more and more often floods occur on, municipal sewage treatment plants are overloaded and fall off, groundwater levels drop.

Further Requirements are made with regard to structural properties. These concern moisture behavior, resistance to pests, acoustic properties, behavior against chemical influences and against fire. The durability of a floor plays as the most important requirement a big Role, where properties such as compressive strength, flexural strength, wear resistance against sanding, rolling, bumping and Impact, resistance to crimping essential structural parameters represent.

For special applications, such as riding and sports field construction, grid plates made of plastic have proven. Such grid plates are from the DE 197 20 006 C2 known. By a sophisticated structure of elevations and openings allow grid plates on the one hand a walkable or passable surface mounting and on the other hand they avoid by their Wasserregulierungsfähigkeit a seal.

The flat laid grid plates are directly on the ground like Laying gravel, grass, clay or humus. It can, however, also on the ground a sand or gravel layer can be applied to this then Laying layer of grid plates. Through the sand or gravel layer can Uneven floors are compensated. Depending on the use of the sports field If necessary, the application of a footing in a thickness of several centimeters. The footing, along with the Grid plates forms the superstructure of the sports field blanket, insists riding arenas usually from a sand fill, from a sand filling provided with aggregates (wood or plastic chips) or exclusively from wood chips. Depending on the stress and composition of the Footing has these a thickness between 8 to 15 centimeters, measured from the top plate of the grid plates, on.

adversely However, these are the comparatively high costs of grid plates when applying on large surfaces as well as their uneven structure.

Coverings with a uniform and visually appealing surface structure are made of DE 197 33 588 A1 known. The water-permeable surface is made of mineral aggregates and organic adhesives. The mixture is installed in the not yet cured and deformable state. As an adhesive usually organic adhesives in question, which is mixed together with mineral aggregates into a batch and processed before curing. Another example of a water-permeable coating is mentioned in the introduction DE 196 05 990 C2 disclosed. Here, too, the teachings disclosed serve to improve the water permeability or the water absorption values.

adversely with these coverings bound mineral aggregates is the missing link to the subsoil, which is the mechanical one for outdoor floors Stress affected during frost-thaw changes. From this, a chemical, physical and biological building material corrosion, Weathering, destruction of the underlying subfloor.

Straight public developers to wish Therefore, floor coverings the the surfaces do not seal and allow cost-effective large areas to occupy easily can cope with high mechanical loads, for example due to vehicles.

Against this background, it is an object of the invention to provide a generic water-permeable flooring, which is also in the case of a complete xen forms compared to known floor coverings and grid systems is inexpensive. With regard to the mechanical load-bearing capacity, the flooring should not result in any restrictions on the use of the occupied areas. In addition, a method for producing a floor covering is to be specified, which allows a simple and inexpensive installation.

According to the invention the object is achieved with respect to the floor covering by the features of claim 1. Accordingly, the substructure has a superstructure-side layer of ballast. The average size k _{gravel of} the undersize in the gravel is 5 mm or above. The layers of the upper and the substructure are bonded together by gluing.

In The practice has been recognized that the durability and resilience one composed solely of lattice systems or bonded mineral aggregates Belages is limited. By the construction according to the invention The top and bottom covering can have the positive characteristics in terms of the water permeability a superstructure made of bonded, mineral impact substances universal be adapted to the ground. The bulk of the substructure allows a even load distribution into the underlying ground, so that punctiform pressure loads, which act on the superstructure over a large area on the constructional sand layer distributed in the ground and thus the static and dynamic compressive strength of the superstructure decisive compared to known solutions improved.

A further improvement causes the substructure in its water-permeable transition to Superstructure in terms of water regulation capability. Especially with critical Subsoil with high clay content, the water storage capacity to complete the superstructure. So the surface water is over the Superstructure received by the substructure and distributed horizontally. So can Enormous amounts of water were temporarily absorbed and temporarily stored until the soil or other drainage facilities the water dissipate. This drainage ability is due to the high void content, making it a hassle-free Installation is possible even in water protection areas. This void fraction as well as different rock sizes and Material types lead to an excellent sound absorption

Tests have shown that the floor covering according to the invention has excellent water absorption values. Based on DIN 18 035-6, sections 5.1.6.3 and 5.1.6.2, the water absorption values of the floor covering were determined in a field study and compared with the values of a conventional permeable sports field construction. The requirements of DIN 18 035-6 were exceeded many times over. Thus, a sample with a layer thickness d _{0 of} the superstructure of 47 mm yielded a water swallowing value k ^* = 0.51 cm / s. The requirement according to DIN 18 035-6, Table 3 is> 0.01 cm / s.

A further favorable influence on the Wasserschluesswert and Wasserregulierungsfähigkeit of the soil has the grain size of the ballast in the substructure. This promises excellent values with an average grain size for the undersize of 5 mm or more. Proven average grain sizes k _{Ballast of} the ballast is in a range of 5 to 16 mm, 16 to 22 mm or 16 to 32 mm. That is, the ballast layer is composed of ballast with different grain sizes, the grain of a ballast layer is located in one of these areas. The average layer thickness d _{S of} the compacted ballast layer is preferably between 400 and 500 mm.

Also has the grain size of the aggregates a significant influence on the infiltration performance of the floor covering. Particularly preferred are aggregates whose average size of the grain between 1 and 7 mm. As mentioned above, the layer structure according to the invention has of the flooring a favorable Influence on the mechanical strength values, allowing for the average size of the grain even values of over 5 mm possible are without a significantly increased risk of breakage occurs. With This grain diameter, the infiltration performance can be further increased. About that In addition, these values will decrease the leaching rate by entry of mineral and organic fines with the time is low.

The open-pore structure of the superstructure leads to high friction coefficients on the surface, so that the flooring as non-slip ceiling for carriageways, walkways, stairs and presentation rooms is and thus reduces the risk of accidents.

Cheap layer thicknesses for the Superstructure in terms of pressure resistance and good water permeability are between 30 and 60 mm. Of course, lower values also possible, which then made compromises in terms of compressive strength Need to become. Larger layer thicknesses for the Superstructure brings for the compressibility only minor improvements and increases the cost for one Flooring. This is the optimum for most applications in the above mentioned area.

As a general rule becomes the particle size distribution defined according to DIN 66145. The parameter n is at least 9 and is under neglect of 1% oversize each and undersize determined.

At the The adhesive is preferably a two-component polyurethane adhesive. As well usable is a two-component epoxy resin or a one-component polyurethane adhesive. Two-component epoxy adhesives are for example from the company Koch Marmorit under the brand name Kryorit offered.

One significant advantage in the use of two-component epoxy resin adhesive is in its environmental seen. The flooring according to the invention for example, has no toxic effect on molds and is considered to be hard to break down microbially. Nevertheless, you can out the floor covering elutable substances are well degraded, such as material trials have shown. As washing tests prove, there is no chemical Interaction between surface water and the lining materials, so that surface water, which by the Flooring seeps untreated into the sewage system can or can safely drain into the groundwater. Finally, can the floor covering according to the invention its use phase in a soil or gravel washing plant without negative environmental impacts are disposed of. Alternatively is after comminution also reuse as granules possible.

at the processing of the adhesive, two methods are distinguished. Should the components of the surface, present as chips or sand, or substructure are stabilized, so these are advantageous mixed on site with the previously homogenized binder and applied. In the stabilization of ballast or other coarser granules Epoxy resin or polyurethane and hardener are also mixed on site and in liquid Shape on the gravel surface sprayed. The binder flows into the depth and glued the individual gravel grains or the granules with each other.

The allow mentioned adhesives through the high adhesive strength compounds of any bulk material through very good adhesion in the adhesive and capillary action area. This contributes in addition to the mentioned static and dynamic compressive strength of the flooring. Especially effective for one high resilience is adhering adjacent layers of the Top and substructure so that the flooring also used by vehicles can be.

Very often is for a visually appealing design of places desired a coloring of the floors. By the use of colored quartz sand or natural stones as aggregate can be under over 200 color variations are chosen so that the color design of a floor covering virtually no Limits are set. Just architects know these colorful ones Effectively use effects.

Next the for the suitability as a road surface important static and dynamic Strength values absorbs the floor covering according to the invention by the high Cavity also significantly better the sound of vehicles than for example asphalt. Particularly favorable values result in a void content of at least 45% in the superstructure.

Further advantageous embodiments of the invention of the floor covering result from the features of claims 11 to 14th

According to the invention Asked object with respect to the method for producing the Floor covering solved by the features of claim 15.

A intensive bonding of the layers with each other results when immediately after compacting the first layer, the next following layer is applied before the underlying layer cures. This requires a speedy Apply and compact layer by layer.

Further advantageous embodiments of the invention of the floor covering result from the features of claims 16 to 19th

advantageous embodiments The invention will be described below with reference to the accompanying drawings explained. It shows:

1 a schematic cross section through an applied to a ground floor covering with two-layer substructure and

2 a schematic cross section through an applied to a ground floor covering with three-layer substructure.

1 clearly shows in a cross section the multilayer structure of the flooring according to the invention 1 , This has in the present embodiment, three layers, the bottom layer, the substructure 2 on a building ground 3 is applied. Before the substructure 2 can be applied, is the ground 3 to prepare first. This one is down to a frost-proof Depth of 40 to 60 cm excavated. This excavation depth is recommended so that the connection between substructure 2 and subsoil 3 is spared from the erosive effects of the frost-thaw cycle.

The substructure 2 itself is made up of a structural layer of sand, the so-called sand layer 4 and the gravel layer lying thereon 5 together. For this purpose, a batch of adhesive and sand is first set, which are mixed together. The adhesive is a two-component polyurethane adhesive. Also useful is a two component epoxy resin or one component polyurethane adhesive. After the preparation of the batch, the mixture is then processed quickly, as long as it is still deformable and not cured. This is done by a uniform, even application of the sand layer 4 on the ground 3 , The layer thickness d _{sand of} the compacted sand layer 4 is at least 20 mm.

After compaction and the already beginning hardening of the sand layer 4 becomes the gravel layer 5 applied. The average grain size k _{ballast of} the ballast in the present embodiment is in a range between 5 to 16 mm, with the average size of the undersize being 5 mm. Uniform uniform properties are obtained with this narrow particle size range. Again, the gravel is mixed with adhesive to the mixture as evenly as possible on the sand layer 4 apply. After that, the gravel layer 5 compacted with a mechanical vibrator. The gravel layer 5 then has an average layer thickness d _S of about 500 mm.

Finally follows the structure of the visible in the finished state, open-pore superstructure 6 , First, the superstructure 6 bearing gravel layer 5 sprayed with adhesive in an amount of 150g / cm ² , a tighter connection between rule top and base 6 respectively. 2 to achieve. The penetration depth of the adhesive is about 150 mm. Even before the adhesive hardens, a layer of mineral aggregates is applied.

Also this is a mixed with adhesive mixture of mineral aggregates, which are still deformable state is applied. The aggregates are a selection of quartzite, Granite, basalt and quartz in question, in the described embodiment comes colored Granite for use. The average size of the granite grain is in the Range between 2 and 5 mm. The particle size distribution is defined according to DIN 66145, with a parameter of at least 9 and neglected of 1% over and under grain.

After application of the mixture, this is compacted with a roller and smoothed with a trowel. The compression is preferably carried out with a contact pressure of 10 to 50 N / cm ² . The superstructure has, after compression to a layer thickness d _O of 50 mm. After compaction, the curing of the superstructure takes place. Thereafter, the flooring is resilient.

Basically it before applying a layer to an underlying layer not necessary that the underlying layer hardens. Much more does that Applying on a not yet cured layer to a better Connection of the layers with each other.

In the 2 is an alternative embodiment of the flooring according to the invention 1 shown by an additional layer of sand 4 ' is more resilient. The additional sand layer 4 ' is on the gravel layer 5 Applied and also like the built-in sand layer 4 stabilized with adhesive. For better adhesion we use the gravel layer 5 before applying the sand layer 4 ' sprayed with glue. After compaction, the superstructure is set up 6 as for the embodiment after the 1 is described.

1

Flooring

2

substructure

3

Building

4, 4 '

sand layer

5

gravel layer

6

superstructure

Claims (19)

Multilayer, water-permeable floor covering ( 1 ) with a superstructure and substructure ( 6 respectively. 2 ) for application to a ground, the substructure ( 2 ) at least one water-permeable composite layer of sand or gravel ( 4 ) and the superstructure ( 6 ) of the flooring ( 1 ) is a compound of compacted mineral aggregates and organic adhesives, characterized in that the substructure ( 2 ) a superstructure layer of gravel ( 5 ) whose average size k is _{undersize gravel} ≥ 5 mm and the layers of the upper and lower substructures ( 6 respectively. 2 ) are bonded together by gluing. Floor covering according to claim 1, characterized in that layers of the upper or of the substructure ( 6 respectively. 2 ) are bonded together by gluing. Flooring according to one of the preceding Claims, characterized in that the grain size of the aggregates k _{Z is} 1 to 7 mm. Floor covering according to one of the preceding claims, characterized in that the average layer thickness d _{O of} the superstructure ( 6 ) Is 30 to 60 mm. Floor covering according to one of the preceding claims, characterized in that the void portion of the superstructure ( 6 ) up to 45%. Floor covering according to one of the preceding claims, characterized characterized in that the mineral aggregates a selection of quartzite, granite, basalt and quartz. Floor covering according to one of the preceding claims, characterized in that the mineral aggregates have a narrow particle size distribution, wherein the average size d _{K of} the grain in a range between 1 to 3 mm, 2 to 3 mm, 2 to 4 mm, 2 to 5 mm or 3 to 7 mm. Floor covering according to one of the preceding claims, characterized characterized in that the mineral aggregates are a mixture from round grain and at least a share of 20% edged grain having. Floor covering according to one of the preceding claims, characterized characterized in that the adhesive is a two-component epoxy resin or a one-component polyurethane or a two-component polyurethane adhesive is. Floor covering according to one of the preceding claims, characterized in that a proportion of the aggregates of the superstructure ( 6 ) are colored and the proportion is preferably made of quartz sand. Floor covering according to one of the preceding claims, characterized in that the average layer thickness d _{sand of} the compacted sand layer ( 4 ) is at least 20 mm. Floor covering according to one of the preceding claims, characterized in that the layer of ballast ( 5 ) has an _undersize whose average size k _{USchotter is} ≥ 5 mm. Floor covering according to one of the preceding claims, characterized in that the average grain _size k _{ballast of} the ballast ( 5 ) is in a range between 5 to 16 mm, 16 to 22 mm or 16 to 32 mm. Floor covering according to one of the preceding claims, characterized in that the average layer thickness d _{S of} the ballast layer ( 5 ) Is 400 to 500 mm. Process for producing a floor covering according to one of the preceding claims, characterized by the following process steps: application of a still deformable mixture of adhesive and sand to the ground ( 3 ), • compacting the adhesive-sand mixture, • even before the complete hardening of the sand layer ( 4 ) Applying a still deformable mixture of adhesive and gravel ( 5 ) on the sand layer ( 4 ), • applying the upper layer of a still deformable mixture of aggregates and adhesive on the last applied layer, • compressing the still deformable mixture and • hardening of the layers. A method according to claim 15, characterized in that after the application of the ballast layer ( 5 ) a sand layer ( 4 ) is applied. Method according to one of claims 15 to 16, characterized in that before the application of the ballast layer ( 5 ) on the sand layer ( 4 ), on the sand layer a layer ( 4 ) is applied from adhesive, for example by spraying. Method according to one of claims 15 to 17, characterized in that before the application of the superstructure ( 6 ) on the ballast layer ( 5 ), on the ballast layer ( 5 ) is applied a layer of adhesive, for example by spraying. Method according to claim 17 or 18, characterized that the penetration depth t of the layer of adhesive at least 150 mm.