EP1529893B1 - Method of manufacturing a building panel - Google Patents

Description

The invention relates to a method for producing a board for building technology using a prefabricated semi-finished product.

Reinforced concrete ceilings are subject to considerable requirements due to building regulations, standards and technical rules. The most important here are a high load-bearing capacity according to the structural requirements, a high fire resistance, soundproofing measures for the suppression of airborne and impact sound as well as a high level of thermal insulation. Further requirements, which concern more production-technical, assembly-technical and economical aspects, are the production of the reinforced concrete ceiling in an economical production procedure and a low material use. Furthermore, in the event that prefabricated ceiling elements are used as prefabricated components, the transport weight of the ceiling elements should be low in order to be able to economically transport these ceiling elements from the factory to the construction site. The ceiling elements were intended to enable technically simple and cost-effective installation on the site of a reinforced concrete floor. Furthermore, the ceiling elements should be flexible for different types of buildings.

Thermal insulation has become one of the most important criteria for ceiling systems due to the 1995 Heat Protection Ordinance and the forthcoming Energy Saving Ordinance, as well as the general wish of building owners for energy saving. The aim is generally to exceed the heat protection values specified in the Heat Insulation Ordinance. To achieve this, a high technical effort is operated in previous ceiling systems. This effort is mainly incurred at the construction site and thus contradicts the technical trend for factory prefabrication. Thermal protection measures on site also represent a significant economic disadvantage.

From the EP-A-1 106 745 the same applicant is known a prefabricated part in the form of a plate in which the space between two reinforced concrete slices is filled with foamed polyurethane. The prefabricated component is transported in this form to the construction site and used there as a ceiling element. These ceiling elements can be made as prefabricated large-sized and are mounted on a construction site. For mounting a plurality of ceiling elements with each other, a circumferential annular belt reinforcement is required, which is provided along the circumference of a plurality of ceiling elements. At joints between two ceiling elements connecting elements are arranged so that adjacent ceiling elements are well connected with each other. Concreting work is no longer required on the construction site. A disadvantage is the relatively high weight of the prefabricated component and the required assembly and connection measures for connecting several prefabricated components on the construction site.

In the EP 02 026 013.9 (not prepublished) the same applicant, a method for producing a prefabricated component as well as a prefabricated component itself is described, in which the upper concrete slab contains in concrete embedded heating cables of a floor heating. By integrating the heating in the upper concrete slab, the degree of prefabrication in producing a concrete slab is further increased, and thus the cost-effectiveness. The manufacture of such prefabricated component reduces the total number of steps and in the assembly site eliminates the concreting and the application of screed.

In the EP 0 511 193 A2 a reinforcing body for a ceiling slab is described which comprises an upper and a lower concrete slab. Between the concrete slabs displacement bodies, for example made of polyurethane, are arranged at predetermined distances from one another. These displacement bodies are used exclusively to save concrete in the finished ceiling slab and thus to reduce their weight. Due to the spacing of the displacement body from each other arise rib cavities that are filled in the production of the ceiling slab with concrete and thus form stiffening ribs for the ceiling plate according to the static requirements. These with concrete filled rib cavities form strong heat-conducting bridges between the upper concrete disc and the lower concrete disc, so that thermal insulation does not take place.

It is an object of the invention to provide a method for producing a board for construction, which meets high technical requirements, simplifies the overall process in the production and has a high efficiency. This object is achieved for a method for producing a board for construction by an edge formwork is erected on the smooth surface of a steel plate and lattice girders are arranged within the edge formwork. By pouring concrete into the edge formwork and hardening, a lower sheet of reinforced concrete is made, with only a lower portion of the lattice girders wrapped in concrete and a longer upper portion of the lattice girders protruding from the concrete. In a next step, insulating material is placed above the concrete layer. The semi-finished product thus produced is transported in this state to a construction site. At the construction site, in-situ concrete is applied to the semifinished product to a level above the lattice girder, whereby an upper disc made of reinforced concrete is produced. Subsequently, the in-situ concrete is cured.

In the method according to the invention, the manufacturing steps are cleverly divided. In the factory for the manufacture of prefabricated components, a lower concrete disc is manufactured with an insulating layer, so that all economic and technical advantages of a manufacturing plant can be used. For example, standard dimensions can be used and made in stock. The semifinished product thus produced has a relatively low weight and can be easily transported. On the construction site, the semi-finished product is then assembled and the final concreting process takes place, with the upper concrete pane being produced. In this final concreting step on the construction site specific requirements for the house to be built can be taken into account for the upper concrete pane, for example special recesses, connecting elements, shafts, connections and lines. These specific embodiments would be relatively problematic in a production of the upper concrete slab prefabricated factory and only small quantities could be produced for certain variants. According to the invention, on the one hand, it is thus achieved that the prefabrication can take place with semifinished products with a relatively high degree of automation. On the other hand, specific designs of the plate can be taken into account in the formation of the upper concrete disc without great effort on site. The above-mentioned technical requirements for the plate, for example in the form of a floor covering or basement ceiling, are met.

According to a preferred embodiment of the invention, the upstanding lattice girders are provided on the construction site with an additional reinforcement made of steel. This additional reinforcement can be dimensioned so that it also covers adjacent semi-finished products. When concreting the upper concrete disc thus adjacent semi-finished products are firmly connected together, so that special fasteners between adjacent plates are not required. For example, in the case of several plates or semi-finished products, a ring belt reinforcement on the circumference of the various plates can be dispensed with.

Figur 1

einen Querschnitt durch ein Deckenelement herkömmlicher Art mit zwei ausgehärteten Betonscheiben,

Figur 2

ein Fertigbauteil mit nur einer unteren Betonscheibe,

Figur 3

ein nach der Erfindung hergestelltes Deckenelement mit in der oberen Betonscheibe integrierten Heizelementen, und

Figur 4

das Herstellverfahren zum Herstellen des Fertigbauteils als Halbfabrikat und zum Herstellen einer Decke.

Embodiments of the invention are explained below with reference to the drawing. It shows:

FIG. 1

a cross section through a ceiling element of conventional type with two hardened concrete slices,

FIG. 2

a prefabricated component with only one lower concrete disc,

FIG. 3

a ceiling element produced according to the invention with integrated in the upper concrete disc heating elements, and

FIG. 4

the manufacturing method for producing the prefabricated component as a semi-finished product and for producing a blanket.

FIG. 1 schematically shows the structure of a prefabricated ceiling element as a prefabricated component. This example is the EP-A-1 106 745 taken from the same applicant. The content of this document is hereby incorporated by reference into the disclosure of the present application. The conventional ceiling element comprises a reinforced concrete sheet 10 and a reinforced concrete upper sheet 12. In each disc 10, 12 end portions of lattice girders 14 are embedded in concrete, ie the longitudinal bars 15a and cross bars 15b and associated welded strut nodes 15c are completely embedded in concrete. Both the lower disc 10 and the upper disc 12 are reinforced by crosswise arranged round steels, some of which are exemplified by 15a, 15b. In the cavity 16 between the two panes 10, 12 is filled during production polyurethane-local foam, which hardens. Thus, the cavity 16 is completely filled with polyurethane. Although the lattice girders 14 form thermal bridges between the two panes 10, 12, due to the small cross-sections of the lattice girders 14, the heat flow between the two panes 10, 12 is relatively low, so that the polyurethane layer as a heat-insulating layer is fully effective. In this way, a high thermal insulation is achieved. Both the lower disc 10 and the upper disc 12 are reinforced by round steel 15a, 15b, which help fulfill the structural requirements for a ceiling as longitudinal reinforcement and as transverse reinforcement.

FIG. 2 shows an example of a ceiling element according to the invention. Same parts as in FIG. 1 are the same. The lower concrete slab 10 contains concrete that envelops the lower portions of the lattice girders 14 and gives strength to the semi-finished product after the concrete has set. The lattice girders 14 project out of the concrete 10 with a longer upper section. In the manufacture of semi-finished insulating material 16 is disposed above the concrete layer 10, for example by polyurethane foam filled and cured. From the semifinished product so produced still protrude the upper end portions of the lattice girders 14. These lattice girders 14 may be provided in the upper portion with a reinforcement 15a, 15b. It is more advantageous, however, to attach this reinforcement in the upper portion of the lattice girders 14 only on the construction site, wherein several ceiling elements can be interconnected by this reinforcement. This in FIG. 2 shown semi-finished product has a significantly reduced weight compared to in FIG. 1 shown prefabricated component and can thus be easily transported. In addition, the upper concrete disc, which is not formed during manufacture in prefabricated factory, on the site still be varied according to local requirements, for example, then shafts, cutouts, lines, recesses for pipes, additional reinforcements, etc. are taken into account.

The lattice girders 14 each include a top chord 14a, two bottom chords 14b and two lateral diagonals 14c connecting top chord 14a and bottom chord 14b on each side. At least one diagonal 14c, preferably both diagonals 14c, is made of corrosion-resistant stainless steel, e.g. VA steel. As a result, the corrosion resistance is ensured because there is no corrosion protection in the polyurethane insulating layer 16.

FIG. 3 shows another ceiling element, as it has been completed on site by filling with in-situ concrete and forming the upper concrete slab. A special feature here is that in the finished components factory on the end portions of the lattice girder 14 and on a reinforcement, indicated by a transverse bar 20, heating cables 22 a floor heating are arranged. The semi-finished product thus produced is transported to the construction site in this state. The upper concrete slab 12 is produced on site by applying in situ concrete, wherein self-compacting concrete is preferably used as in-situ concrete. Such a self-compacting concrete is very fluid and forms a very smooth surface, so that on the surface of the upper concrete pane directly a floor covering, such as tiles, carpeting, parquet or plastic floor, can be applied. A special screed may be omitted if necessary. The cured polyurethane 16 has sufficient stability to support the weight of the applied in-situ concrete. Further details in connection with the heating cables 22 are the patent application EP 02 026 013.9 the same applicant, which is hereby incorporated by reference in the disclosure of the present patent application. It is also possible to install the heating cables 22 only on the site, with local structural conditions can be considered.

FIG. 4 shows the process for making a ceiling or plate in the form of a flow chart. In step S1, a steel pallet of a pallet circulation system is provided in a prefabricated factory. In the following step S2, an edge formwork is erected on the smooth surface of the steel pallet. In the following step S3 lattice girders and possibly the lower reinforcement are arranged and connected to each other within the edge formwork.

In step S4 concrete is poured into the edge formwork, so that the lower end portions of the lattice girders and the lower reinforcement are embedded in concrete. In the next step S5, the pallet is conveyed to a drying oven and the concrete is cured. Thus, the lower disc made of reinforced concrete for the semi-finished product is completed.

In the next step S6 insulating material is applied to the cured concrete. This can be done in the form of polyurethane foam, which is then cured. Alternatively, insulating material can be applied in a plate form, which has sufficient stability for receiving the in-situ concrete.

In step S7, the semi-finished product thus produced is transported in this state to a construction site. The transport of the semifinished product is facilitated because it has a relatively low weight. This means that possibly also a larger format can be used for the semi-finished product.

In step S8, the semi-finished product is mounted on the construction site as part of a ceiling, wherein an additional reinforcement is applied to the free upper sections of the lattice girders for increasing the stability. This additional reinforcement can be dimensioned so that it covers adjacent semi-finished products as parts of the entire ceiling, so that in the subsequent concreting these semi-finished products are rigidly interconnected. Furthermore, in this assembly local Given the circumstances of the architecture of the building, for example, recesses can be provided, or it can be formed duct shafts.

In the following step S9, in situ concrete is applied to the insulating material and the upper concrete disc is formed. Preferably, self-compacting concrete is used which forms a smooth surface. This is followed by a drying process in which the upper concrete disc dries.

Before step S6, optional heating cables for underfloor heating can be attached to the lattice girders in the factory. In addition, an upper reinforcement can be inserted. Preferably, such an upper reinforcement serves as a carrier plane for the fixation of the heating cables.

The described method can be used to produce a floor covering or a basement ceiling.

Claims (12)

1. A method of manufacturing a plate for the construction technology,
   in which on the smooth surface of a steel plate a peripheral formwork is erected,
   within the peripheral formwork, lattice girders (14) are arranged,
   by pouring concrete into the peripheral formwork and by curing, a lower disk (10) of reinforced concrete is manufactured, wherein only a lower portion of the lattice girders (14) is covered with concrete and a longer upper portion of the lattice girders (14) projects from the concrete,
   above the concrete layer, an insulating material (16) is arranged,
   the semi-finished product manufactured in this way, is transported in this state to a building site,
   at the building site, in-situ concrete is applied to the semi-finished product up to a level above the lattice girders (14),
   and in which the in-situ concrete is cured, the space between the lower disk (10) and an upper disk (12) made of in-situ concrete is completely filled with insulating material (16).
2. The method according to claim 1, characterized in that as an insulating material (16) polyurethane is used.
3. The method according to claim 1 or 2, characterized in that after concreting and curing of the lower concrete disk (10), polyurethane foam is applied thereto and is cured.
4. The method according to one of the preceding claims, in which the lattice girders (14) are provided in the lower region with a reinforcement (15a, 15b) of steel for manufacturing the semi-finished product.
5. The method according to one of the preceding claims, characterized in that the lattice girders (14) are provided in the upper region with a reinforcement (15a, 15b) of steel at the building site.
6. The method according to one of the preceding claims, characterized in that self-compacting concrete is used as in-situ concrete.
7. The method according to one of the preceding claims, characterized in that when the semi-finished product is manufactured, heating lines (22) for an underfloor heating are mounted above the lattice girders (14).
8. The method according to one of the preceding claims, characterized in that to the surface of the upper concrete layer (12) a floor covering is directly applied.
9. The method according to claim 8, characterized in that tiles, carpeting, parquet floor or plastic floor is used as a floor covering.
10. The method according to one of the preceding claims, characterized in that the semi-finished product is manufactured in a pallet circulation system.
11. The method according to one of the preceding claims, characterized in that it is used for manufacturing an intermediate floor or for manufacturing a basement ceiling.
12. The method according to one of the preceding claims, characterized in that at least one diagonal strut (14c) of the lattice girders (14) is made of stainless steel.

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