DE102008030954A1 - Water permeable, drivable multilayered flooring for applying on buildings, comprises covering layer based on mineral-bound aggregates, reinforcement mesh fabric, and base layer - Google Patents

Abstract

Water permeable, drivable multilayered flooring comprises a covering layer (2) having a thickness of 2-6 inches based on mineral-bound aggregates, and a reinforcement mesh fabric (3) made of organic or inorganic fibers. A base layer (4) made of rounded or angular-sharp-edged mineral material is also included. All layers are stuck together with 6-12 wt.% of organic materials including one-component adhesive or two-component adhesive. An independent claim is included for a method for preparing flooring, which involves preparing building usually, where malleable mixture of components is compacted on the prepared building for forming base layer.

Description

• – eine Deckschicht, basierend auf gebundenen mineralischen Zuschlagsstoffen sowie
• – mindestens eine Tragschicht aus gerundeten und/oder eckigkantigen Mineralstoffen.

zum Aufbringen auf einem Baugrund, wobei alle Gesteinsschichten sowohl in sich als auch untereinander mit organischen Stoffen verklebt sind. Die Erfindung betrifft ebenfalls ein Verfahren zu seiner Herstellung.The invention relates to a water-permeable, drivable, multi-layer flooring with the following structure from top to bottom:

• - a top layer based on bonded mineral aggregates as well as
• - At least one support layer of rounded and / or square-edged minerals.

for application on a building ground, wherein all rock layers are bonded both in themselves and with each other with organic substances. The invention also relates to a process for its preparation.

Such a floor covering is known, for. B. from the patent DE 10 2004 006 165 B4 , Therein, a multi-layer, water-permeable flooring with a superstructure and substructure for application to a subsoil is described, wherein the substructure is at least one water-permeable composite layer of sand or gravel and the superstructure of the flooring is a combination of compacted, mineral aggregates and organic adhesives and the substructure has a superstructure-side layer of ballast whose average size of the undersize is> 5 mm and the layers of the upper and the substructure are adhesively bonded together. This patent is expressly incorporated in all parts. Your teaching will be integrated and improved in the present application.

One a major disadvantage is the formation of up to 20 mm wide Cracks not only in the top layer, but also in the substructure. she occur mainly on the front and on the edges a z. B. 3.20 m wide and 150 m long track, and indeed across several lanes.

Of these, Based on the object of the invention, a corresponding floor covering to provide a significantly lower cracking or even avoid them altogether, and at the lowest possible Cost increase and easier production.

• a) eine Deckschicht (2), basierend auf gebundenen mineralischen Zuschlagsstoffen,
• b) mindestens ein armierendes Gittergewebe (3) aus anorganischen oder organischen Fasern sowie
• c) mindestens eine Tragschicht (4) aus gerundeten und/oder eckigkantigen Mineralstoffen, wobei alle Schichten sowohl in sich als auch untereinander mit organischen Stoffen verklebt sind.

The solution according to the invention can be found in the patent claims. It consists essentially in the installation of a reinforcing mesh fabric below the cover layer in the manufacture of the floor covering. According to the main claim, the invention is a water-permeable, drivable, multi-layer flooring ( 1 ) with the following structure from top to bottom:

• a) a cover layer ( 2 ), based on bound mineral aggregates,
• b) at least one reinforcing mesh fabric ( 3 ) of inorganic or organic fibers as well
• c) at least one support layer ( 4 ) of rounded and / or square-edged minerals, wherein all layers are bonded both in themselves and with each other with organic substances.

The substances mentioned are widely known in the construction industry and described in patents on the problem of "water-permeable floor coverings", not only in the already mentioned DE 10 2004 006 165 B4 and in the numerous publications cited therein, but also in other documents, for. In DE 20 2005 004 625 U1 and in DE 10 2004 014 473 B4 , Only the reinforcing mesh fabric and the special polyurethane are not described therein. Both will be described later in detail.

The preferred embodiments are the subclaims refer to.

The Cover layer is preferably on average 2 to 6, in particular 3 to 4 cm thick. It is based on with 6 to 12, preferably 7 to 9 wt .-% of an organic adhesive bound mineral aggregates, especially from chippings especially of hard rocks such as granite, Basalt and quartzite. Particularly preferred are aggregates whose average size of the grain is between 1 and 7, in particular between 1 and 4 mm.

The Support layer is preferably on average about 10 to 30, in particular 15 to 25 cm thick. It is based on 1 to 4, preferably 2 to 3 wt .-% of an organic adhesive bound rounded or angular-edged minerals from mainly middle gravel or coarse gravel or grit or gravel from hard rocks. their Grain should suitably be in the range from 8 to 28, in particular from 11 to 16 mm.

• a) 10 bis 98 Gew.-% mindestens eines oleochemischen Polyols,
• b) 1 bis 7,5 Gew.-% mindestens eines Diols mit einer Hydroxylzahl von 400 bis 2000 und
• c) 1 bis 7,5 Gew.-% mindestens eines drei-, vier- oder fünffunktionellen Polyols mit einer Hydroxylzahl von 200 bis 2000, wobei die Gew.-% jeweils auf das Polyol-Gemisch insgesamt bezogen sind. Dieser 2-K-Klebstoff lässt sich besonders gleichmäßig und in relativ dünner Schicht über die Gesteine aller Schichten, und zwar über deren ganze Fläche und Dicke verteilen, sodass die Oberflächen des Gesteins und der Fasern nur benetzt sind.

All rock layers of the floor covering are glued together with organic substances (adhesives) both internally and internally - through the mesh fabric. These are in principle also 1-K adhesives, z. As the hot melt EVA. However, preference is given to 2-component adhesives such as two-component epoxy resin adhesives and polyurethane adhesives. With these crosslinking adhesives, the cover layer, the reinforcing mesh fabric and the support layer are bonded, whereby different adhesives can be used. Above all, a highly crosslinking PU adhesive based on the following polyol mixture is suitable for this purpose

• a) from 10 to 98% by weight of at least one oleochemical polyol,
• b) 1 to 7.5 wt .-% of at least one diol having a hydroxyl number of 400 to 2000 and
• c) 1 to 7.5% by weight of at least one of three, four or five-functional polyol having a hydroxyl number of 200 to 2000, wherein the wt .-% respectively based on the polyol mixture in total. This 2-component adhesive can be spread evenly and in a relatively thin layer over the rocks of all layers, over their entire surface and thickness, so that the surfaces of the rock and the fibers are only wetted.

from that not only results in a high strength, but also an open-pored System with a large pore volume.

Contrary Expect a good and fast mixing all liquid and solid components of a rock layer if you can not reach the resin and the hardener of the 2K adhesives previously separately mixed with each other to the adhesive, but if you she adds unmixed to the remaining ingredients and then mix everything together.

It has long been known, mesh fabric made of glass fibers for reinforcement Both organic materials such as plastics and inorganic Fabrics such as screed and plaster in the construction sector to prevent cracks use. However, it is not known, as a precaution such mesh fabric at to use navigable floor coverings. It would be too fear that a Faserarmierung such large Demands is not equal.

It is in selecting the appropriate reinforcing mesh fabric thereon to pay attention that the tensile strength and the elasticity of the meshing mesh are larger than the the rock strata, but the elongation at break is smaller. That will happen all by inorganic reinforcing fibers such as glass, Basalt and ceramic fibers and organic reinforcing fiber as aramid and carbon fibers allows, if the Textile construction is appropriate. This should be be so open that on the one hand the water flow and the direct Bonding of the top layer with the gravel layer is possible and On the other hand, the strength properties are sufficiently high. Thanks to the invention, it is possible with floor coverings with one or more webs wider than 1 m, in particular from 2 to 4 m, and with a length of more than 50 m, in particular from 100 to 200 m, the number and depth of Significantly reduce or completely prevent cracks. Preferably the mesh fabric should have the following geometric properties: Fiber thickness: about 1 mm, grid size: from 3 × 3 to 14 × 14 mm and web width: 20 to 120 cm, preferably 40 to 100 cm.

• – Der Baugrund wird wie normgerecht vorbereitet.
• – Das noch verformbare Gemisch der Komponenten für die Tragschicht wird auf den vorbereiteten Baugrund vollflächig aufgebracht, geebnet, verdichtet und ausgehärtet.
• – Das Gittergewebe wird auf die Riss-gefährdeten Stellen der ausgehärteten Tragschicht gelegt, und zwar mittig unter die Metallschienen, die als Einbauhilfen für die Deckschicht dienen, stramm gezogen und mittels der seitlich angebrachten Laschen mit Nägel an der Tragschicht befestigt,
• – Schließlich wird das noch verformbare Gemisch für die Deckschicht vollflächig auf das armierende Gittergewebe bzw. direkt auf die Kiesschicht zwischen den Metallschienen aufgebracht, geebnet, verdichtet und ausgehärtet.

The floor covering according to the invention can be produced simply, since most of the method steps are known in principle:

• - The ground is prepared as standard.
• - The still deformable mixture of the components for the support layer is applied over the entire surface of the prepared ground, leveled, compacted and cured.
• - The mesh fabric is placed on the crack-vulnerable points of the cured support layer, namely centrally under the metal rails that serve as installation aids for the cover layer, pulled tight and attached by means of the side-mounted tabs with nails on the support layer,
• - Finally, the still deformable mixture for the cover layer is applied over the entire surface of the reinforcing mesh fabric or directly on the gravel layer between the metal rails, leveled, compacted and cured.

It is advantageous if one considers all the components of a rock layer together and then mixes with the adhesive component preferably as a resin and hardener is added. It is also advantageous the mineral aggregates of the top layer and the minerals of the Gravel layer when mixing with the adhesive or the adhesive components as dry and dust-free as possible, so their water content less than 0.5 wt .-% and their dust content with a grain size is also less than 0.5 wt .-% under 0.5 mm.

After all It is advantageous if the adhesive of the rock layer is completely is cured when the still deformable mixture of next layer is applied.

The Grain size is determined by weighing one Particle quantity with a sieve set with mesh sizes of 11, 8, 5, 4, 3, 2 and 1 mm sieves and the resulting fractions weigh. The weight These sieve passes will each affect the total amount and thus gives the proportion of the respective sieve passage in% by weight. If you carry the sieve passes in wt .-% depending on the mesh size in mm, receives one the grain in the form of the grading curve. If one uses z. B. a sieve with mesh sizes of 5, 2, and 1 mm, so receives individual fractions> 5, 5-2, 2-1 and <1 mm. If you sieve 1000g of particles and weigh 10, 500, 430 and 60g Fractions, the sieve passage is 1.0, 50.0, 43.0 and 6.0 wt .-%, respectively in the order of said fractions. at The investigations used particles whose particle size through sieve passes between the indicated mesh sizes were obtained.

Now the invention will be explained with reference to a drawing.

1 shows a schematic cross section through a multilayer floor covering according to the invention ( 1 ). He has a cover layer ( 2 ), a reinforcing mesh fabric ( 3 ) and a base layer ( 4 ) on. It differs in structure from that of DE 10 2004 006 165 B4 only by the reinforcing mesh fabric ( 3 ). Of course, the flooring of the invention could contain more rock layers. The subsoil ( 5 ) was prepared in accordance with the regulations for the installation of a frost-resistant substructure, wherein preferably no layer of a sand / adhesive mixture is used for the installation of the flooring according to the invention of a support layer, a mesh fabric and a support layer. For the production of the approx. 20 cm thick base course ( 4 ) was hard stone with a particle size of 11 to 22 mm with 1.7 wt .-% of a homogeneous mixture of a resin and a hardener of a 2-component epoxy adhesive in a mixer intensively mixed together for 4-6 min. The still easily deformable grit / adhesive mixture quickly moved to the frost-proof ground ( 5 ), leveled and compacted with a shaker. After 3 days, the base course ( 4 ) cured so that it was fully loadable.

Then a 1 m wide and 150 m long glass fabric with 4 mm × 4 mm grids and a tensile strength of 1.6 kN / 5 cm was applied to the cured base course ( 4 ) in the middle where metal rails should subsequently be laid to produce a 320 cm wide top coat web. The ends of the grid cloth webs were overlapped by transverse grid fabrics 50 cm. The mesh fabric ( 3 ) was pulled tight and with nails through the tabs on the support layer ( 4 ) attached.

For the production of the approx. 4 cm thick cover layer ( 2 ) granite chips with a particle size of 1.4 to 3 mm with 8 wt .-% of a 2-component polyurethane adhesive from Henkel in a mixer for 14 to 16 minutes long mixed thoroughly. The still slightly deformable grit / adhesive mixture was rapidly between the metal rails on the support layer ( 4 ) or the mesh fabric ( 3 ), leveled and compacted with a roller. In order to prevent sticking of granite chips on the roll surface, it was sprayed with a mixture of 40 to 80 wt .-% technical linseed oil in residual benzine. At 15 to 25 ° C after 4 to 6 hours, the top layer was passable and cured after 2 to 3 days and fully loaded. Now the nails were pulled out and the metal rail was removed.

A floor covering produced in this way - in contrast to the floor covering without a mesh fabric - showed no cracks on the longitudinal edges and no transverse cracks on an area of 10,000 m ² .

As in the known flooring the rain seeped immediately: The water permeability was so not affected. The areas were for released the heavy goods traffic. It could drive trucks and park without the formation of ruts or cracks.

1

Flooring

2

topcoat

3

mesh

4

base course

5

Building

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 102004006165 B4 [0002, 0006, 0020]
• - DE 202005004625 U1 [0006]
• DE 102004014473 B4 [0006]

Claims (12)

Water-permeable, drivable multi-layer flooring ( 1 ), with the following structure from top to bottom: a) a cover layer ( 2 ), based on bonded mineral aggregates, b) at least one reinforcing mesh fabric ( 3 ) of inorganic or organic fibers and c) at least one base layer ( 4 ) of rounded and / or square-edged minerals and for application to a subsoil ( 5 ), wherein all layers are bonded both in themselves and with each other with organic substances. Floor covering according to claim 1, characterized in that - the cover layer ( 2 ) is on average about 2 to 6 cm thick and - are the mineral aggregates of chippings of hard rocks such as granite, basalt and quartzite, in particular with a grain size in the range of 1 to 7 mm, and - they are 6 to 12 wt .-% of a 2-component adhesive are glued together. Floor covering according to claim 1, characterized in that the base layer ( 4 ) - is on average about 10 to 30, preferably 15-25 cm thick and - contains predominantly middle gravel or or chippings or gravel of hard rocks, preferably with a grain size of 8 to 28, in particular 11 to 16 mm and - with 1 to 4 , is preferably bonded with 2 to 3 wt .-% adhesive, wherein in addition to the 2-K adhesives and 1-K adhesives in question, z. Eg EVA. Floor covering according to claim 1, characterized in that it is in the adhesives for the top layer ( 2 ), the reinforcing mesh ( 3 ) and the base layer ( 4 ) are 2-component polyurethane adhesives, in particular if they are based on a polyol component, containing the following substances: a) 10 to 98 wt .-% of at least one oleochemical polyol, b) 1 to 7.5 wt. % of at least one diol having a hydroxyl number of 400 to 2000 and c) 1 to 7.5 wt .-% of at least one tri-, tetra- or five-functional polyol having a hydroxyl number of 200 to 2,000, wherein the wt .-% each on the total polyol mixture are obtained. Floor covering according to claim 1, characterized that the adhesive evenly over the Whole thickness and area of the layers is distributed, so the surfaces of the minerals and fibers are only wetted and an open-pore system with a large pore volume. Floor covering according to claim 1, characterized in that the tensile strength and the elasticity of the reinforcing mesh fabric ( 3 ) are larger than those of the rock strata, but the elongation at break is smaller, which is made possible in particular by inorganic reinforcing fibers such as glass, basalt and ceramic fibers and by organic reinforcing fibers such as aramid and carbon fibers. Floor covering according to claim 1, characterized in that the textile construction of the reinforcing mesh fabric ( 3 ) is so open that, on the one hand, the water flow and the direct bonding of the cover layer to the base layer ( 4 ) is possible and on the other hand its strength properties are sufficiently high. Floor covering according to claim 1, characterized in that the reinforcing mesh fabric ( 3 ) only at cracks-endangered places, there but possibly also in several layers. Floor covering according to one of the preceding claims, characterized by one or more webs having a width of more than 1 m, in particular from 2 to 4 m, and with a length of more than 50 m, in particular from 100 to 200 m. Process for producing the floor covering according to at least one of claims 1 to 9, characterized in that - the ground ( 5 ) usually prepared, - the still deformable mixture of the components for the base layer ( 4 ) on the prepared subsoil ( 5 ) applying, leveling, compacting and curing all over the surface, - the reinforcing mesh fabric ( 3 ) on the crack-endangered areas of the cured base course ( 4 ), pulls tight and fastened, z. As with nails, and - the still deformable mixture for the top layer ( 2 ) over the entire surface of the reinforcing mesh fabric ( 3 ) or directly on the base layer ( 4 ), levels, densifies and sets. Method according to claim 10, characterized in that that when compacting with a roller a mixture of linseed oil and benzine is applied to the surface thereof. A method according to claim 11, characterized in that the minerals of the top layer ( 2 ) and the base layer ( 4 ) are as dry and dust-free as possible when mixing with the adhesive or the adhesive components, ie their water content is less than 0.5% by weight and their dust content with grains below 0.5 mm is less than 0.5% by weight.