DE102008037518B3 - Terrazzo floor and manufacturing process - Google Patents

Abstract

The invention relates to a method of producing a terrazzo floor and a terrazzo floor.

Description

The The invention relates to a method of producing a terrazzo floor and a terrazzo floor.

Out In the prior art are different arrangements and related manufacturing methods known to terrazzo floors manufacture.

Terrazzo floors are locally manufactured, seamless floor coverings. Traditionally, these terrazzo floors are made using limestones and cements, aggregates, such as natural stones - soft and Hard rock - all Type and surcharges executed in different colors.

The Terrazzo floors find application in residential buildings, Entrance halls public and private buildings, Canteens and hospitals, Shopping malls, pharmaceutical companies and similar. The terrazzo floors are usually load-bearing Concrete slabs or floor slabs whose concrete strength is at least one grade B 25 concrete However, the application is on dam layers, interlayers or other floors possible. The surfaces are prepared by cleaning of dirt and loose components. If necessary a primer to a uniformly absorbent surface achieve or a bonding layer to realize. Traditional cement-based terrazzo floors artificially by separating rails limited, otherwise the terrazzo floor tends to tear. applied The terrazzo soil is traditionally covered with a terrazzo tile the height the order is about 15 mm to 40 mm. After the mixture of Portland cement, colored supplements and water is applied, becomes the fresh flooring created this way rolled. The rolling serves to compact the fresh flooring.

To a corresponding curing time is the surface by grinding with grindstones of different grits and diamond occupied tools. In the surface treatment By grinding, about 3 mm to 5 mm of the surface is abraded. After cleaning are still existing pores with a closed corresponding filler and sanded after curing. This entire implementation The soil preparation is very time consuming.

From the DE 20 2004 015 209 U1 is a Terrazzo floor and a manufacturing process known to it, in which first the rock granules are applied to the surface to be covered and then a polymeric plastic is applied. A statement about the distribution of the rock granules within the plastic can not be found in the document.

For some time now, attempts have been made not only to make small fields, which are delimited by corresponding separating rails, as terrazzo floors, but also to design large areas, such as well over 100 square meters of floor space, as terrazzo floors. For this purpose, different plastics are added to the cement, so as to increase the strength in terms of susceptibility of cracks. Such an embodiment is in the prior art under the document DE 199 18 598 A1 known.

The publication DE 199 18 598 A1 discloses a method and apparatus for making a terrazzo floor and a composition for a floor made in the form of a seamless, especially colored floor covering from a mixture of aggregates and binders. For this purpose, the mixture is mixed in a mixing device with water such that it is flowable and pumpable. The flowability of the batch on the subfloor causes an approximately flat surface of the facing layer. The densification of the introduced facing layer is carried out by self-compression under the action of gravity.

Next is from the DE 195 49 104 A1 a pigmented plastic floor with natural stone effects, produced on the basis of synthetic resin and aggregates customary for synthetic resin floors, which is produced in a layered structure. After preparing the substrate, an epoxy resin layer is applied, which is mixed with fillers and additives, but not with the pigmentation mass. Before this base layer has cured, the pigmentation mass is applied. Wherein the pigmentation mass is integrated at least to a large extent superficial. However, sedimentation does not take place in this case, rather only a slight penetration into the base layer is desired. After curing of the base layer, the application of a cover layer made of a conventional synthetic resin. Particularly preferably then the created plastic bottom surface is ground. In particular, a grinding takes place up to the depth in which as a result of sinking only one enriched with the pigmentation mass surface is present. In this way, so much is abraded until coarser structures are exposed. By adding Betonit, it is possible to further reduce the sedimentation so as to prevent too deep penetration of the pigmentation mass into the base layer.

From the publication DE 196 49 616 C1 is a method for producing a floor covering be is known, is distributed in the flowable curable plastic on the floor, and in the still liquid base coat color pigments are introduced. These color pigments can be mixed with the still fresh base coat by mixing with the aid of metallic combs or a stream of air. This gives a pigmented on the surface or even different surface color effect. A subsidence of color pigments is not desired here, since a superficial discoloration of the Kunststofffußbodens should be achieved.

Next is from the DE 197 28 000 A1 a method for the production of terrazzo floors known. In this case, a mixture of different sands or glass or mosaic bricks, as well as color pigments or pastes with an epoxy resin or the like prepared in place and applied to a prepared floor. To produce such a floor structure, a primer is first applied to the prepared raw concrete with a lambskin scooter, wherein the uncured primer is sprinkled with a quartz sand of grain size 0.8 mm. Subsequently, the mixture or the mixture of the different sands or other additives together with the further addition of epoxy resin or a comparable plastic can be applied to the primer and distributed.

In the further state of the art is from the US Pat. No. 6,770,328 B1 a process for producing a continuous terrazzo floor, in which a surface is prepared with a primer on which a mixture of epoxy resin and crushed glass is applied as a homogeneous mixture on the primer, then smoothed and additionally by the application of recycled glass in the surface is improved. After curing of the resin, the surface is sealed and smoothed.

Problematic in the known arrangements and methods is that in the state not suitable for the technique and compositions used are big surfaces consistent with to achieve a terrazzo floor with the traditional look. especially are the known methods and compositions with negative Properties occupied, so that in particular pore formation a big problem represents. Likewise, the crack resistance of the produced Terrazzo soil not guaranteed since the methods and compositions known in the art for the production of a terrazzo floor As a result, they tend to crack. Another disadvantage is the large amount of labor as well as spending time on a terrazzo floor with those in the state of the art Technique known methods and compositions produce.

Of the The present invention is based on the object, a production process and to show a terrazzo soil that makes it easy to create, maintenance-free and low-wear Terrazzo floor can be made with traditional look. Such a terrazzo floor is also for high laying and processing speeds designed and withstands high forces and loads, in particular its permanent crack resistance especially on big ones surfaces guaranteed is.

Further It is an object of the invention to carry out preliminary work, such as priming, or rework, such as filling of Gefügehohlräumen or the like, so low as possible to keep, as these pre-and especially the reworking very time-consuming and also vulnerable for defects are. It is also an object of the invention, defects or holes in to prevent the Terrazzo-floor look or to prevent it from the outset and at the same time to ensure sufficient compaction.

Be solved These objects with a manufacturing method according to claim 1 and A terrazzo floor according to claim 7.

Due to the fact that the manufacturing process for a terrazzo floor the steps:
Preparing the floor for applying a Terrazzo floor, applying and distributing a flowable polymeric plastic on the prepared soil, self-leveling of the polymeric resin by deliquescence, applying a granular rock on the not yet cured polymeric plastic, sedimentation of the rock granules in the polymeric plastic, curing of the polymeric plastic with the sedimented rock granules contained, grinding the upper layers of the only partially sedimented rock granules to the polymer plastic with the sedimented rock granules contained until a flat closed surface is formed comprises, it is possible a high quality and crack-free on large surfaces durable and in particular to produce crack-resistant terrazzo soil with little time and effort. Here, in particular, a high cost saving, in contrast to the known terrazzo soil production method is particularly advantageous. The classic terrazzo-floor look is achieved on the one hand by the high packing density of the sedimentary granulate and on the other hand by the grinding of the surface, so that overall the structure of a classic terrazzo floor is created. The distribution of the polymeric plastic can be done by a toothed spatula. The rock granulate density can be both homogeneous be as well decrease from top to bottom.

The high crack resistance is also realized by the fact that the lower area in a section has a lower aggregate density due to the terrazzo soil and thus a lower packing density of the rock granules in the lower area is present. By the previous spreading and distributing the polymeric plastic is in the lower part of a continuous from the created polymeric plastic existing bottom layer. hereby becomes a more even plastic layer realized that less approaches for breakages As the underside of a terrazzo floor is often the exit side for cracking represents. Since the bottom of the terrazzo floor now not through Storage of granular rock weakened forms one high crack resistance of the entire terrazzo soil. In particular, air pockets are on prevents the underground sides of the rock granules, because the granular rock sediments in the polymeric plastic.

If before the application of the rock granules on the not yet cured polymeric plastic the granular rock with preferably the same polymeric plastic is coated, in particular no curing of the polymeric plastic Before applying, a better matrix connection can be made between the applied uncured polymeric plastic and the coated with a polymeric plastic granular rock be achieved because the introduction is done "wet on wet". It is ensured that the granular rock completely is enclosed with the polymeric plastic, allowing a consistent contact between rock granules and the polymeric plastic.

Thereby, that before applying the flowable polymeric plastic on the prepared soil a rock flour and / or Feinstgranulat in the polymeric plastic is introduced homogeneously, the binder matrix further optimized. By varying the rock flour and / or the finest granules let yourself the introduction behavior of the rock granules, which is poured up, vary. additionally let yourself an improvement in crack resistance or the crack arrest within the terrazzo soil.

Thereby, that after application of the flowable polymeric plastic on the prepared soil a rock flour and / or ultrafine granules is applied to the polymeric plastic, it is possible cheaper more Flooring heights to achieve because less plastic mass is used. Next is it makes it possible to influence the sedimentation behavior of the rock granules and so the special properties of a classic terrazzo floor to bring to bear, while the surrounding plastic mass visually resembles a classic terrazzo floor.

If individual surface sections of the total terrazzo soil with different applied Granulated rock mixtures can be so different patterns and thus different areas within the total terrazzo floor be prepared without several work passes are performed have to. The Areas can very sharp from each other by short-term laying of rails be demarcated, the rails after distribution or application of the rock granules are removed again. Especially advantageous Here is that an overall height already achieved during application, resulting in a time savings in particular in the further processing by the grinding leads. The grinding can here after the curing of the total area over the the whole area of the newly laid terrazzo floor without giving consideration to individual transitions to take.

If immediately before applying the rock granules on the still not cured polymeric plastic applying a pre-scattered rock granules on the not yet cured polymer plastic takes place, wherein the pre-litter rock granules preferably a higher specific Density as the rock granules sedimented the pre-bedding granules stronger in the polymeric plastic, whereby higher layer structures are possible, which have a corresponding high crack resistance. Such pre-scattered rock granules can For example, known additives of a heavy metal, such as barite, Ilmenite, magnetite, hematite or heavy metal slags. Furthermore, but also known additives for radiation protection concretes be used.

According to the order this is Granulated rock not homogeneously distributed in the polymeric plastic and but the density of the rock granules is at the free surface within the polymeric plastic highest. This will in particular the hollow spaces and / or the least possible held. Continue to receive a terrazzo floor designed in such a way the look of traditional terrazzo floors and also has sufficient compaction. Especially here is the resistance of the terrazzo soil in terms of crack resistance compared to the arrangements known in the art above average is high, especially considering the traditional terrazzo-floor look.

If the surfaces of the rock granules with a polymeric plastic, preferred coated with the polymer plastic of the terrazzo floor, elevated The adhesion of the plastic with the granular rock within the matrix. The improved adhesion leads to further maximization the resistance of the terrazzo soil. To increase the optical value can the granular rock with a differently colored polymer plastic wrapped so that when later sanding a contrasting border around the respective rock formed. Particularly interesting here are combinations of complementary colors and color combinations with a high contrast ratio, wherein the chosen one Granulated rock color and the chosen color of the polymeric plastic in the choice of the color of the enveloping polymer Plastic be included.

Thereby, that the polymeric plastic on the surface of the rock granules not cured is, the plastic compound is further improved because of the plastic hardens evenly as a total batch.

Especially there are no paragraphs or defects within the dressing, especially at the material transition of the plastic to the granular rock.

Around to ensure a long shelf life of the terrazzo floor, For example, the polymeric plastic is a low viscosity epoxy resin is formed transparent or pigmented, in particular is yellowing. Particularly advantageous is the color fastness of Terrazzo floor, if the plastic is formed with little yellowing is.

If the granular rock sizes between 1 mm and 30 mm, preferably 2 mm to 14 mm, is the optics and thus a certain value for the traditional terrazzo floor customized. It makes sense, as usual in traditional terrazzo, itself to adjust to certain bandwidths of rock granules. For longevity within this total terrazzo floor arrangement is a limitation to a smaller granular rock size range does not need, so that the spectrum can be exploited from 1 mm to 30 mm. Prefers However, the range of 2 mm to 14 mm, and more preferably the Range of 2 mm to 6 mm granulate size used as within these areas a very high packing density is achieved, the to a very low overall height of only a few millimeters leads. The height of the terrazzo soil is in the range of 6 mm to 20 mm and is in this range only dependent of the removed material or the desired optical effect.

Thereby, that the polymeric plastic granulated with particle sizes between 0 and 0.125 mm and / or ultrafine granules with grain sizes up to to 1 mm, there is a better distribution of the flowable plastic on the surface to be covered with the terrazzo floor. The larger the amount of rock flour and / or finest granules in the total mixture consisting of plastic and rock flour and / or ultrafine granules, the more fluid the plastic becomes. Depending on the proportion of rock meal and / or ultrafine granules on the Total mixture takes a weaker, with larger quantities of rock flour and / or finest granules, or even stronger, with lower rock meal and / or Superfine granulate content, sinking of the rock granules into the overall mixture made of plastic and rock flour and / or ultrafine granules.

If the polymeric plastic having polyethylene fibers becomes the basic strength of the plastic increases. By this increase The soil structure can be even thinner thicknesses done without causing a reduction in crack resistance comes.

Thereby, that aggregates, especially glass, metal, colored plastic pellets and / or natural stones in which rock granules are present becomes the sprinkled granulate can be individually adjusted. An application of certain mixtures of rock granules in well-defined soil sections leads to individualized patterns within the total terrazzo floor. After curing can subsequently regardless to take on the differently occupied sections the entire Terrazzo ground to be ground, resulting in a superior overall result is achieved. Such sections may, for example, lateral boundaries Runs or the like., Which later by blending color additives significantly are recognizable.

In order to realize maximum load capacity with respect to temperature variations or variation of environmental influences, reinforcing fibers and / or flour of reinforcing fibers and / or sections of reinforcing fibers, preferably glass fibers or carbon fibers, are contained in the floor composition. By varying the length of the fibers, this leads to a changed sinking behavior and at the same time to a partial enclosure of the rock granulate, which in turn leads to a stronger overall composite. Here, the fibers may be contained in the rock granules or preferably partially contained in the plastic and partially applied before applying the rock granules on the already applied plastic or be included in the plastic already. Particularly advantageous is the use of carbon fibers in the overall arrangement. The use of these carbon fibers results in an electrical conductivity of the overall floor structure, so that the floor can also be used in electrically sensitive areas, for example in operating theaters.

following is an embodiment of the inventive production process described in detail with reference to the accompanying drawings.

In this shows:

1 a section through the entire bottom structure of a terrazzo floor.

In 1 is a schematic section through the entire bottom structure of a terrazzo floor shown.

On a floor 2 is a terrazzo floor 1 applied. This terrazzo floor 1 consists of a polymer plastic 11 and a granular rock contained therein 12 ,

The density of rock granules 12 is at the surface O of the terrazzo soil 1 largest and decreases with increasing depth, viewed from the surface O.

The floor 2 can here be a floor slab of concrete or reinforced concrete, wood, or the like. Or in particular a screed. However, the floor can also be insulation, whereby in this case particular attention must be paid to a uniform sinking behavior of the insulation. Extruded polystyrene is preferably used here, the transitions being correspondingly improved with a fabric, or alternatively the entire floor consisting of insulation being provided with a fabric fleece. The screed is preferably a surface-ready anhydride screed on the insulation, the impact sound insulation or directly on a raw floor, it is unimportant whether a simple prior art to be taken screed or designed for underfloor heating and provided with a corresponding floor heating screed use place.

following will be discussed in more detail on the method for creating such Terrazzo soil.

To apply a terrazzo floor 1 on a floor 2 becomes the floor to be occupied 2 prepared. For this purpose, the removal of coarse impurities, soils, such as oils or fats, is well known in the art and is performed first. After cleaning the soil 2 of coarse impurities, this is then freed from dust and dirt. For a sufficiently smooth and leveled ground 2 are at this point the preparatory work on the ground 2 completed. In particular, can be dispensed with a primer in the rule. Should the ground 2 can not be sufficiently leveled, this can for example be improved by a leveling mass or face milling. Alternatively, the floor, which is not sufficiently leveled, can be compensated by correspondingly more plastic in the further process. In this case, the soil situation must be considered economically from case to case and calculated according to the insufficient leveling, whether it is better to prepare the soil in an additional step and to level accordingly with more plastic mass.

After preparing the soil 2 becomes the flowable polymeric plastic 11 on the prepared soil 2 applied. This can be done by simply pouring the preferably 2-component polymeric plastic on the floor. The application can be done simultaneously by several workers or sections. For this purpose, for example, with appropriate trowels, a pre-distribution of the polymer plastic can be performed. The flowable polymeric plastic 11 spreads itself on the prepared soil 2 by deliquescence. After the polymeric plastic 11 either in sections or over the entire surface has spread by deliquescence itself, the granular rock 12 on the not yet cured polymeric plastic 11 applied. This application can be carried out either in sections, in analogy to the application of the flowable polymeric plastic 11 or over the entire surface. This can be done by sprinkling by hand or with the help of a bottom slide box. After application of the rock granules 12 on the not yet cured polymeric plastic 11 the sedimentation of the rock granules takes place 12 in the polymeric plastic 11 , This is done exclusively by the self-sedimentation, caused by the weight of the rock granules 12 , During and after the rock granules 12 in the polymeric plastic 11 is sedimented or still sedimented, hardens the polymeric plastic 11 with the sedimented rock granules contained 12 out.

After a certain curing time of the polymeric plastic 11 the abrading of the upper layers of the only partially sedimented rock granules takes place 12 , The grinding is done down to the polymer plastic. As a result, parts of the rock granules are ground so that cross sections of the rock granules 12 come to light. After grinding to the polymer plastic 11 with the sedimented rock granules contained 12 This creates a flat, even surface that looks like a classic and traditional terrazzo floor 1 having. In addition, the soil has a very high crack resistance.

1

Terrazzo floor

11

polymeric plastic

12

rock granules

2

ground

O

surface

Claims (14)

Production method for a terrazzo floor ( 1 ) comprising the steps of: - preparing the soil ( 2 ) for application of a terrazzo floor ( 1 ) - applying and distributing a flowable polymeric plastic ( 11 ) on the prepared soil ( 2 ) - Self-leveling of the polymeric plastic ( 11 ) by deliquescence - application of a rock granulate ( 12 ) on the not yet cured polymeric plastic ( 11 ) - Sedimentation of rock granules ( 12 ) in the polymeric plastic ( 11 ) - curing of the polymeric plastic ( 11 ) with the sedimented rock granules ( 12 ) - Abrading of the upper layers of the only partially sedimented rock granules ( 12 ) to the polymeric plastic ( 11 ) with the sedimented rock granules ( 12 ) until a plane closed surface (O) is formed. Manufacturing method according to claim 1, characterized in that prior to the application of the rock granules ( 12 ) on the not yet cured polymeric plastic ( 11 ) the rock granules ( 12 ) with preferably the same polymeric plastic ( 11 ) is coated, in particular no curing of the polymeric plastic ( 11 ) before application. Manufacturing method according to claim 1 or 2, characterized in that prior to the application of the flowable polymeric plastic ( 11 ) on the prepared soil ( 2 ) a rock flour and / or Feinstgranulat in the polymeric plastic ( 11 ) is introduced homogeneously. Manufacturing method according to claim 1 or 2, characterized in that after the application of the flowable polymeric plastic ( 11 ) on the prepared soil ( 2 ) a rock flour and / or Feinstgranulat on the polymeric plastic ( 11 ) is applied. Production method according to claim 1, 2, 3 or 4, characterized in that individual surface sections of the total terrazzo floor ( 1 ) with different rock granulate mixtures to be applied ( 12 ) and / or be coated with differently pigmented polymeric plastics. Manufacturing method according to one of the preceding claims, characterized in that immediately before the application of the rock granules ( 12 ) on the not yet cured polymeric plastic ( 11 ) applying a pre-scattered rock granules on the not yet cured polymeric plastic ( 11 ), wherein the pre-scattered granular rock preferably has a higher specific gravity than the rock granules ( 12 ) having. Terrazzo floor ( 1 ) comprising a polymer material which is flowable during application ( 11 ) and one in plastic ( 11 ) stored rock granules ( 12 ), characterized in that the granular rock ( 12 ) is not homogeneous in the polymeric plastic ( 11 ) and is stored, but that the density of rock granules ( 12 ) on the free surface (O) within the polymeric plastic ( 11 ) is highest. Terrazzo floor ( 1 ) according to claim 7, characterized in that the surfaces of the rock granules ( 12 ) with a polymeric plastic, preferably with the polymeric plastic ( 11 ) of the terrazzo soil ( 1 ) are wrapped. Terrazzo floor ( 1 ) according to claim 7 or 8, characterized in that the polymeric plastic ( 11 ) is a low-viscosity epoxy resin, which is formed transparent or pigmented, in particular, it is low in yellowing. Terrazzo floor ( 1 ) according to claim 7, 8 or 9, characterized in that the granular rock ( 12 ) Grain sizes between 1 mm and 30 mm, preferably 2 mm to 14 mm and particularly preferably 2 mm to 6 mm. Terrazzo floor ( 1 ) according to one of claims 7 to 10, characterized in that the polymeric plastic ( 11 ) Has rock flour with grain sizes between 0 and 0.125 mm and / or ultrafine granules with grain sizes up to 1 mm. Terrazzo floor ( 1 ) according to one of claims 7 to 11, characterized in that the polymeric plastic ( 11 ) Comprises polyethylene fibers. Terrazzo floor ( 1 ) according to one of Ansprü 7 to 12, characterized in that aggregates, in particular glass, metal, colored plastic pellets and / or natural stones, in the rock granules ( 12 ) available. Terrazzo floor ( 1 ) according to any one of claims 7 to 13, characterized in that reinforcing fibers and / or flour of reinforcing fibers and / or portions of reinforcing fibers, preferably glass fibers or carbon fibers, are contained in the floor composition.