EP1491697A1

EP1491697A1 - Concrete floor part

Info

Publication number: EP1491697A1
Application number: EP20040076771
Authority: EP
Inventors: Johannes De Wit
Original assignee: Dycore BV
Current assignee: Dycore BV
Priority date: 2003-06-27
Filing date: 2004-06-16
Publication date: 2004-12-29
Anticipated expiration: 2024-06-16
Also published as: DE602004014680D1; ATE399908T1; NL1023761C2; EP1491697B1

Abstract

The floor part has intermediate parts (3) that connect a bottom plate and a top plate (2a). The intermediate parts are continuous in two directions that are transverse to each other, for defining girders with the plates for bearing span in both directions. The intermediate parts define passages for connecting the cavities defined by girders, with each other in one direction. Independent claims are also included for the following: (a) a building having a floor built up from concrete floor parts (b) a method for manufacturing a concrete floor part.

Description

The invention relates to a concrete floor part or floor member for accommodation in a floor of a building, particularly such a floor part provided with cavities for passing lines through them. The invention furthermore relates to an assembly of such concrete floor parts, to a building provided with such a floor and to a method for manufacturing such a floor part.
It is known to use prefab concrete floor parts in the form of hollow core slabs. Such hollow core slabs, however, are not very suitable for passing lines through them. The channels run in the same direction and are not accessible from aside. The hollow core slabs may serve as spanning girder in one direction.
Assembled floors are also known, which assembled floors have concrete floor parts internally provided with hollow or lightweight bodies placed on a prefab (concrete) shuttering slab placed earlier on, in between which hollow or lightweight bodies half-lattice girders extend. After final casting this results in a bending stiff plate of relatively low weight. in one embodiment (French patent specification 1.525.178) in which the said bodies do not support on a shuttering slab but on a basis, the cavities are connected to each other for passing lines through them.
It is an object of the invention to provide a concrete floor part, provided with cavities for passing lines through and yet strong enough for transferring transverse forces and bending moments in two directions that are transverse to each other.
It is a further object of the invention to provide a concrete floor part, that is easy to manufacture, with as little loss of material as possible.
It is a further object of the invention to provide a prefab self-supporting concrete floor part having internal cavities.
From one aspect the invention provides a concrete floor part comprising a bottom plate and a top plate, as well as intermediate parts for connecting the bottom plate and the top plate, wherein the intermediate parts are substantially continuous in two directions that are transverse, preferably perpendicular, to each other for defining girders with the top plate and the bottom plate for bearing span in both directions, wherein the girders formed define cavities with each other, wherein the intermediate parts define passages for connecting the cavities with each other in at least one of either directions.
The concrete floor part according to the invention is able to span self-supporting in two horizontal directions, offering passage possibilities for lines in at least one of those directions.
Preferably the intermediate parts also define passages for connecting the cavities to each other in both directions, preferably in to directions that are perpendicular to each other, as a result of which the application possibilities for lines and the like are increased.
The intermediate parts can be formed by ribs extending between both plates, which ribs preferably extend in two directions that are perpendicular to each other.
Preferably the cavities are bounded by the concrete itself.
In the arrangement according to said French patent specification 1.525.178 the cavities are only accessible from the connection to the adjacent cavities after the floor has been placed.
It is a further object of the invention to provide a concrete floor part provided with internal cavities that are also easily accessible after the floor is finished.
From a further aspect the invention to that end provides a concrete floor part as described above, wherein the top plate and/or the top plate is provided with openings for access to the cavities and with removable closing parts for closing off the openings, wherein the bottom plate preferably is provided with such openings and the closing parts cover the openings and project sidewards therefrom for extending over the lower surface of the bottom plate. Thus after the building in question has been finished access can be gained to the cavities for work on the lines or for placing facilities therein, such as a lighting fitting, a ventilating grid and the like.
Preferably the bottom plate is provided with such openings. The cavities are then accessible form the side usually related to the lines therein. At that side moreover, there will always be enough room, adjacent to the ceiling.
The openings being known beforehand also determines the location of the closing parts. In a preferred embodiment, which facilitates fitting, the bottom plate is provided with means for attaching the closing parts, such as for instance fixing holes in the lower surface.
Preferably the closing parts close off the openings and project sidewards therefrom for extending over the lower surface of the bottom plate. The closing parts close off the openings in the floor with a certain overlap or projection and preferably are connected to the floor part with a quick-coupling system, as a result of which the intermediate space between the top and bottom plate remains easily accessible. The closing parts may for instance be single-plate-shaped.
Preferably the closing parts laterally at least almost butt each other, resulting in a virtually contiguous cover, as a result of which they may serve as ceiling sheathing.
Preferably the closing parts are composed from a material and provided with a surface texture that positively contributes to the acoustic properties of the floor as partitioning structure as well as to the acoustic and architectural properties of the space underneath the floor. Thus the closing parts may form a sound-damping surface, preferably covered with a sound-damping material.
In a further development the concrete floor part is composed of a separately manufactured bottom plate and top plate, wherein both plates are provided with reinforcement and the reinforcement extends from the one plate into the other plate. As will be explained below such a floor part can easily be manufactured.
Preferably the top plate is manufactured as one unity with the intermediate parts. The intermediate parts may be formed by ribs extending in between both plates, which ribs preferably extend in two directions that are perpendicular to each other. The passages also preferably extend in to directions that are perpendicular to each other.
During pouring and hardening the top plate can be provided with cast-in attachment facilities, such as fixing holes. After the top plate has hardened the fixing holes offer a possibility to secure the lines and the like to the top plate, so that they already extend in the wanted passages and cavities. This may take place before top plate and bottom plate are joined. The floor parts can be transported to the building site already provided with lines. In situ the lines only need to be connected to each other at the location of the edges of the floor parts.
From another aspect the invention provides an assembly of two concrete floor parts according to the invention, wherein both concrete floor parts at the location of a joint are placed adjacent to each other, wherein the bottom plate and the top plate at the location of the formed girders are each provided with reinforcement elements extending perpendicular to the joint, wherein the ends of the reinforcement elements of the top plate extend substantially horizontal and the ends of the reinforcement elements of the bottom plate have been turned upwards, wherein a further reinforcement element is placed in the joint for force transferring connection of both ends of the reinforcement elements of the top plate and of both turned ends of the reinforcement elements of the bottom plate. Thus a moment rigid connection can be realised between adjacent floor parts, if so desired in two direction, as a result of which the girders in the floor parts can be considered continuous girders, resulting in a considerable increase of the achievable span-length.
In a simple and effective embodiment the further reinforcement element is substantially loop-shaped having horizontally turned upper ends, wherein the loop preferably has a greatest length in vertical direction and/or the upper ends extend in the top plate to a distance from the joint. The further reinforcement element preferably is continuous from the one upper end to the other upper end.
From another aspect the invention provides a building having at least one floor built up from concrete floor parts according to the invention.
From a further aspect the invention provides a method for manufacturing a concrete floor part according to the invention, wherein the top plate is cast upside down in a top plate mould, having mid-span reinforcement and connection reinforcement extending upwards therefrom, the bottom plate is formed in a separate bottom plate mould, having mid-span reinforcement therein, the top plate after hardening is turned and placed on the bottom plate that is not fully hardened yet, and the whole after hardening of both plates is removed from the bottom plate mould. In this way a prefab floor with enclosed cavities can easily be made.
If the intermediate parts are cast along with the top plate, the cavities are bounded for the larger part by hardened concrete when placing on the bottom plate takes place.
It is possible that the cavity boundaries in the top plate are formed with moulds that are left in the top mould. Permanent shuttering therefore is not needed.
In an embodiment the connection reinforcement is left protruding slightly from the concrete of the top plate and the protruding parts of the connection reinforcement are pressed into the concrete of the bottom plate that is not yet hardened, so that the plates will form one tight unity with each other.
In order to be able to form a contiguous floor in the work using adjacent floor parts, it may be provided that at the location of the edges of the bottom plate concrete is left out and the mid-span reinforcement at that location is continued for forming joint reinforcement.
Likewise at the location of the edges of the top plate concrete can be left out and the mid-span reinforcement and/or connection reinforcement at that location can be continued for forming joint reinforcement.
From a further aspect the invention provides a method for manufacturing a concrete floor part comprising a bottom plate and a top plate, as well as intermediate parts for connecting the bottom plate and the top plate, wherein the bottom plate, the top plate and the intermediate parts define cavities and the intermediate parts define passages for connecting the cavities with each other, wherein the top plate is cast upside down in a top plate mould, having mid-span reinforcement and connection reinforcement extending upwards therefrom, the bottom plate is formed in a separate bottom plate mould, having mid-span reinforcement therein, the top plate after hardening is turned and placed on the bottom plate that is not fully hardened yet, and the whole after hardening of both plates is removed from the bottom plate mould.
In this case as well the intermediate parts are preferably cast along with the top plate.
Preferably the cavity boundaries in the top plate are formed with moulds that are left in the top mould.
Preferably attachment facilities are cast along in the top plate, and after removal of the top plate from the top plate mould lines are attached to the top plate using said facilities.
From a further aspect the invention provides a prefab concrete floor part comprising a bottom plate and a top plate, as well as intermediate parts for connecting the bottom plate and the top plate, wherein the bottom plate, the top plate and the intermediate parts define cavities and the intermediate parts define passages for connecting the cavities to each other, wherein the cavities are free from permanent shuttering.
Preferably the bottom plate is provided with openings for access to the cavities and with removable closing parts for closing off the openings.
The floor part may be provided with lines attached in the cavities and passages, which lines end at the edges of the floor part.
The invention will be elucidated on the basis of an exemplary embodiment shown in the attached drawings, in which:

Figure 1 shows a schematic top view at mid height of a portion of a floor built up from a preferred embodiment of floor elements according to the invention;
Figure 2 shows a vertical cross-section according to arrow II in figure 1;
Figure 3 shows a vertical cross-section according to arrow III in figure 1;
Figure 4 shows a vertical cross-section according to arrow IV in figure 1;
Figure 5 shows a vertical cross-section according to arrow V in figure 1;
Figures 6A-6C shows a schematic view of the production and assembling of a floor element according to the invention; and
Figure 7 shows a vertical cross-section of an alternative embodiment of a floor element according to the invention.

Floor element or floor part 1 accommodated in floor 100 of figure 1 forms a cavity plate and is made of concrete and in general has been built up from a top plate 2a, a bottom plate 2b and connection parts or connection ribs 3 extending in between them, all made of concrete. Between the top plate 2a and the bottom plate 2b cavities 4 have been formed, which in this example, have a substantially horizontal cross-section and are connected to each other by means of passages 5a, 5b left out in intermediate parts 3. As can be seen in figure 2 the passages 5a, 5b have a smaller cross-section than the cross-section of the cavities 4. The passages 5a, 5b are bounded by walls 6, in which raised wall portions 6c, inclined wall portions 6a, and wall portions 6b situated on top, can be distinguished.
The cavities 4 are situated above -in this example square- passages 15 that have been left out in the bottom plate 2b. As can be seen in figure 2 the width of the passages 15 is smaller than the width of the cavities 4, so that the bottom plate 2b forms supporting edges 16 there.
As can be seen in figure 1 longitudinal ribs 3a and transverse ribs 3b can be distinguished between the cavities 4. The longitudinal ribs and transverse ribs 3a, 3b have substantially the same build-up. As can be seen in figure 3 a connection reinforcement 9, comparable to the usual half-lattice girders, is accommodated in the ribs 3a, 3b, the rods of which reinforcement in this example extend approximately 45° upwards and downwards, also made possible by the bevelled-off shape of the walls 6 of the passages 5a, 5b.
The connection reinforcement 9 extends between mid-span reinforcement 7 present in the top plate 2a and mid-span reinforcement present in bottom plate 2b.
In figure 2 it can furthermore be seen that the passages 1 5 can be closed off by means of ceiling board tiles 10, which in cross-section may be stepped with a relatively narrow upper part 11, fitting in the passage 15, and a relatively broad bottom part 12, having such dimensions that in the placed condition, as shown, the tiles 10 are contiguous to each other. The lower surface of the part 12 may advantageously be provided with a sound-damping surface 13. The tiles may optionally be snapped into the passages 15. The bottom plate 2b may optionally be provided with fixing holes for quick-fastening of the tiles 10, for instance in the lower surface. The tiles 10 may also be plate-shaped and need not necessarily extend into the passage 15.
Figures 4 and 5 show a vertical cross-section perpendicular to the cross-sections of figures 2 and 3, at the location of the joint or transition between two floor elements 1 that are part of the floor.
In figure 4 the joint cross-section is shown at a location between the transverse ribs 3b, that means through the cavities 4 and passages 5, wherein a poured joint 22 is realised in the top plate 2a.
At the location of the joint in the meeting of the transverse ribs 3b (figure 5) the top plate 2a is provided with recesses 21, and the transverse ribs 3b also end at some distance from the joint. Thus a cavity 18 has been formed, in which continued and turned ends 7a and 8a and optionally 9a of the reinforcement rods 7 and 8, and optionally 9 extend. In the cavity 18 a number of brackets 19 of reinforcement rods have been placed. The brackets 19 extend into the recesses 21 with horizontal rod portions, over a length L1. With the rod portions they form overlaps L2 on both sides of the space 18 in which overlaps normal forces can be transferred.
The loop portions of the brackets 19 extend downwards in the cavity 18, and form an overlap L3 with the upward turned rod portions 8a, in which overlap the normal forces in the rods are transferred.
As can be seen in figure 1 a number of such rod transitions are placed adjacently, for instance four each time.
By pouring or final casting the cavity 18 and recesses 21 with concrete up to plane 20, a constructive connection can be realised in the work, which makes it possible to calculate the floor in two directions as a continuous floor. It will be understood a same joint connection in the direction according to the longitudinal ribs 3a can be realised.
In the manufacturing of the floor element 1 on the one hand a top part is made by casting, the top part comprising the top plate 2a and intermediate parts 3 upside down in a mould, having set reinforcements 7 and 9 with projecting ends 7a and 9a therein. The result is shown in figure 6A. It can be seen that the reinforcement 9 extends above the concrete body with corner areas 9b.
Parallel thereto, optionally after that, the bottom plate 2b is cast in another mould, wherein at the edges, the joint areas, reinforcements 8a are left to project upwards and turned.
Before the bottom plate 2b is hardened the hardened top plate 2a is turned and placed on top of it, wherein the projecting corner areas 9b are accommodated in the concrete of the bottom plate 2b, resulting in the top plate 2a and the bottom plate 2b forming one unity with each other after hardening.
The tile plates 10 render a floor 100, used as a ceiling, built up from floor parts 1, easily accessible from below, without cupboards or other furniture having to be moved.
By removing the tiles 10 the wanted cavity 4 situated above it can be reached for work on the lines 30 led through that cavity 4 and passages 5a, 5b (figure 2).
The drawings further show cast in lines 50, for heating or cooling the concrete, or for utilising the accumulating power of the concrete (core activation).
The passages 15 may alternatively or in addition to the tiles 10 be used for placing lighting fittings, air diffusors or exhaust grills and the like.
In figure 7 a part of another floor element according to the invention is shown, in which the half-lattice girders 9 have been left out from the top plate 2a. For the transverse forces, reinforcement fibres 45, for instance steel reinforcement fibres, have been accommodated in the concrete.
For replacing the projecting corner portions 9a the top plate 2a is manufactured having brackets 40 made of reinforcement steel cast along therein, wherein the brackets 40 form vertical legs 41 a,b, turned ends 41d,e and a horizontal portion 41 c connecting the legs 41a,b to each other, which portion 41 c is situated at a little distance from the lower surface of the top plate 2a, for, as was the case with the projecting corner areas 9a in the example discussed above, being inserted into the not yet hardened concrete of the bottom plate.

Claims

Concrete floor part comprising a bottom plate and a top plate, as well as intermediate parts for connecting the bottom plate and the top plate, wherein the intermediate parts are substantially continuous in two directions that are transverse to each other for defining girders with the top plate and the bottom plate for bearing span in both directions, wherein the girders formed define cavities with each other, wherein the intermediate parts define passages for connecting the cavities with each other in at least one of either directions.
Concrete floor part according to claim 1, wherein the intermediate parts also define passages for connecting the cavities to each other in both directions, preferably in to directions that are perpendicular to each other.
Concrete floor part according to claim 1 or 2, wherein the intermediate parts are formed by ribs extending between both plates, which ribs preferably extend in two directions that are perpendicular to each other.
Concrete floor part according to any one of the preceding claims, wherein the cavities are bounded by the concrete itself.
Concrete floor part according to any one of the preceding claims, wherein the top plate and/or the top plate is provided with openings for access to the cavities and with removable closing parts for closing off the openings, wherein the bottom plate preferably is provided with such openings and the closing parts cover the openings and project sidewards therefrom for extending over the lower surface of the bottom plate.
Concrete floor part according to claim 5, wherein the bottom plate is provided with such openings and with means for attaching the closing parts, such as for instance fixing holes.
Concrete floor part according to claim 5 or 6, wherein the closing parts laterally at least almost butt each other.
Concrete floor part according to claim 5, 6 or 7, wherein the closing parts form a sound-damping surface, preferably covered with a sound-damping material.
Concrete floor part according to any one of the preceding claims, composed of a separately manufactured bottom plate and top plate, wherein both plates are provided with reinforcement and connection reinforcement extends from the one plate into the other plate, wherein the top plate preferably is manufactured as one unity with the intermediate parts.
Assembly of two concrete floor parts according to any one of the preceding claims, wherein both concrete floor parts at the location of a joint are placed adjacent to each other, wherein the bottom plate and the top plate at the location of the formed girders are each provided with reinforcement elements extending perpendicular to the joint, wherein the ends of the reinforcement elements of the top plate extend substantially horizontal and the ends of the reinforcement elements of the bottom plate have been turned upwards, wherein a further reinforcement element is placed in the joint for force transferring connection of both ends of the reinforcement elements of the top plate and of both turned ends of the reinforcement elements of the bottom plate.
Assembly according to claim 10, wherein the further reinforcement element is substantially loop-shaped having horizontally turned upper ends, wherein the loop preferably has a greatest length in vertical direction and/or the upper ends extend in the top plate to a distance from the joint.
Assembly according to claim 11, wherein the further reinforcement element is continuous from the one upper end to the other upper end.
Building having at least one floor built up from concrete floor parts according to any one of the preceding claims.
Method for manufacturing a concrete floor part according to any one of the claims 1-9, wherein the top plate is cast upside down in a top plate mould, having mid-span reinforcement and connection reinforcement extending upwards therefrom, the bottom plate is formed in a separate bottom plate mould, having mid-span reinforcement therein, the top plate after hardening is turned and placed on the bottom plate that is not fully hardened yet, and the whole after hardening of both plates is removed from the bottom mould.
Method according to claim 14, wherein the intermediate parts are cast along with the top plate.
Method according to claim 14 or 15, wherein the cavity boundaries in the top plate are formed with moulds that are left in the top mould.
Method according to claim 14, 15 or 16, wherein the connection reinforcement is left protruding slightly from the concrete of the top plate and the protruding parts of the connection reinforcement is pressed into the concrete of the bottom plate that is not yet hardened.
Method according to any one of the claims 14-17, wherein at the location of the edges of the bottom plate concrete is left out and the mid-span reinforcement at that location is continued for forming joint reinforcement.
Method according to any one of the claims 14-18, wherein at the location of the edges of the top plate, particularly at the location of the formed girders, concrete is left out and the mid-span reinforcement and/or connection reinforcement at that location is continued for forming joint reinforcement.
Method for manufacturing a concrete floor part comprising a bottom plate and a top plate, as well as intermediate parts for connecting the bottom plate and the top plate, wherein the bottom plate, the top plate and the intermediate parts define cavities and the intermediate parts define passages for connecting the cavities with each other, wherein the top plate is cast upside down in a top plate mould, having mid-span reinforcement and connection reinforcement extending upwards therefrom, the bottom plate is formed in a separate bottom plate mould, having mid-span reinforcement therein, the top plate after hardening is turned and placed on the bottom plate that is not fully hardened yet, and the whole after hardening of both plates is removed from the bottom mould.
Method according to claim 26, wherein the intermediate parts are cast along with the top plate.
Method according to claim 20 or 21, wherein the cavity boundaries in the top plate are formed with moulds that are left in the top mould.
Method according to claim 20, 21 or 22, wherein attachment facilities are cast along in the top plate, and after removal of the top plate from the top plate mould lines are attached to the top plate using said facilities.
Prefab concrete floor part comprising a bottom plate and a top plate, as well as intermediate parts for connecting the bottom plate and the top plate, wherein the bottom plate, the top plate and the intermediate parts define cavities and the intermediate parts define passages for connecting the cavities to each other, wherein the cavities are free from permanent shuttering.
Floor part according to claim 24, wherein the bottom plate is provided with openings for access to the cavities and with removable closing parts for closing off the openings.
Floor part according to claim 24 or 25, provided with lines attached in the cavities and passages, which lines end at the edges of the floor part.