EP1905915B1 - Method for the production of a concrete slab, and concrete slab produced by this method - Google Patents

Description

The invention relates to the field of building technology and in particular to a method for producing a concrete ceiling and to a ceiling produced by this method.

STATE OF THE ART

In modern architecture, surfaces are desired which are flat and as smooth as possible. Furthermore, it is often desired that parts of the building structure, e.g. Concrete ceilings, integrated with their mass in the energy concept of the house, e.g. as a heat storage or as a cooling ceiling (thermoactive component). This often leads to complications with the room acoustics, because with such constructions no sound absorber can be installed, since such are usually also heat-insulating. This sound-absorbing material on the surface inevitably leads to increased thermal resistance and hinders the flow of heat from or into the ceiling.

DE 38 37 430 A1 describes the production of moldings from a mixture of plastic, preferably acrylic resin and hardener, with pebbles. The goal is the production of molded parts, in which the natural shape and color of natural stones to full advantage. It is the production of plates for Describe facade cladding, wherein the stones are compacted with the uncured plastic in a mold by shaking.

WO 02/096824 A1 discloses the production of wall elements which consist of a granulate whose grains are glued to a synthetic binder. The amount of binder is preferably such that the wall elements remain vapor permeable. The elements may be formed as smaller tiles or as larger plates, and are preferably attached to a support plate for stabilization.

DE 1 609 519 shows a lower layer of lightweight concrete with expanded clay or expanded slate as a supplement. In the lightweight concrete, a main reinforcement is embedded as Zugarmierung.

DE 1 658 804 shows a ceiling with a lightweight concrete layer, in which the entire reinforcement is inserted into the lightweight concrete layer. As a lightweight concrete aerated concrete is not mentioned as advantageous, and it is also described foam concrete with enclosed foam pieces.

NL 1 018 156 shows a concrete pavement with a "light core (8)", which has a mortar with light aggregates such as expanded clay, plastic grains, foam or lumps.

The acoustic properties of these ceiling structures with respect to the acoustics of the enclosed space do not differ significantly from conventional solid concrete ceilings.

NEITHALATH N. ET AL: Acoustically Efficient Concretes Through Engineered Pore Structure, 2005-01-03, AUTOCLAVED AERATED CONCRETE: PROPERTIES AND STRUCTURAL DESIGN, FARMINGTON HILLS, ME. : AMERICAN CONCRETE INST., 2005, US, pp. 135-152 , inter alia, describes an "enhanced porosity concrete" with open pores and its properties for sound absorption.

PRESENTATION OF THE INVENTION

It is therefore an object of the invention to provide a method for producing a concrete floor of the type mentioned, so that the blanket produced thereby can be adjusted to predetermined thermal engineering, acoustic and aesthetic requirements.

This object is achieved by the method for producing a concrete floor having the features of claim 1, as well as the concrete floor produced by this method having the features of claim 11.

Thus, the following steps of the method of claim 1 are carried out for the production of a concrete ceiling in a building.

This makes it possible to produce a ceiling that meets high requirements regarding the conflicting criteria heat conduction, acoustics and aesthetics. The grains of the granules are wetted on all sides by the binder, so that the contact surfaces of the individual grains stick to each other and thus secure the compound of the mass, but retain spaces between the grains, channels form through the granular layer, and thus ensure the required sound absorption.

By applying the filler to the formwork, the granule layer is produced in a freely selectable form as part of the ceiling so there are no prefabricated panels on the - possibly irregular - shape of the ceiling are cut and there are no dividing lines between plates.

• Eine Vergrösserung des Anteils der Fläche der Granulatschicht verbessert die Schallabsorption (auf Kosten der Wärmeleitfähigkeit).
• Die Wahl von gut wärmeleitenden Materialien für das Granulat verbessert die Wärmeleitfähigkeit der Granulatschicht als Ganzes.

The parameters relating to heat conduction and acoustics can be controlled and optimized by selecting on the one hand the proportion of the area of the granulate layer on the entire ceiling surface and on the other hand the choice of material for the granules:

• An increase in the proportion of the surface of the granule layer improves the sound absorption (at the expense of thermal conductivity).
• The choice of highly thermally conductive materials for the granules improves the thermal conductivity of the granular layer as a whole.

Good heat-conducting materials are preferably chippings or pebbles made of stone, or metal chips or grains of metal. Of course, a mixture of such different types of grains can be used to meet predetermined criteria with respect to heat conduction and sound absorption and possibly color design. If the thermal conductivity plays a minor role, too Grains or grit from clay or expanded clay can be used. If the granule layer remains unpainted, other materials (glass breakage, fine metal shot, colored gravel) and material combinations can be used for decorative design.

In a preferred embodiment of the invention, the proportion of the surface of the granular layer is limited to the entire ceiling surface, so there are only one or more sub-areas provided with a granular layer. This limitation is preferably done by placing spacers, forming one or more frames, on the formwork. Then the filler is poured and distributed within the frame or frames on the formwork. The Distanzierungslatte also form a reference for subtracting the filler ensprechend the height of Distanzierungslatten. After the granules have hardened, the spacer slats can be removed again. It is also possible, if the entire ceiling surface is to be provided with the granular layer, to use the Distanzierungslatten only for distancing, to remove them after peeling off the filler and to fill the gaps thus formed with the filler.

The ratio between granules and binder depends i.A. From the Komgröße and porosity of the granules and can be determined in a simple manner by experiments.

In order to improve the heat conduction through the granule layer, in another embodiment of the invention, heat-conducting sheet can be arranged in the granulate layer, which leads into the concrete layer of the ceiling. In another embodiment of the invention, reinforcing iron passed through the region of the granule layer. For this, the reinforcements are placed before pouring the granule layer. This is especially advantageous for thicker granule layers for mechanical anchoring as well as for heat dissipation.

In a preferred embodiment of the subject invention, the concrete ceiling on thermo-active elements such as heating pipes or cooling pipes, which accomplish a heat transfer from or to the ceiling. Due to the granulate layer and / or areas without granulate layer, the ceiling is coupled to the room in terms of heat conduction, so that an efficient heat exchange with the room is possible.

In a further preferred embodiment of the invention, after removal of the formwork, an air-permeable plaster, in particular a microporous white plaster, is applied to the underside of the ceiling. This air permeability, ie the presence of continuous channels in the plaster layer, means that sound energy also passes through the plaster, and can be absorbed in the granular layer.

In another preferred embodiment of the invention, the ceiling soffit is coated or covered with a fabric, fleece or other open-pored cover material to provide an acoustically effective separation between the space and the granule layer. If desired, after the stripping of the element, however, the surface of the granule layer can also be left so or only be painted.

• eine bestimmte Porositiät aufweist und somit Schallenergie aufnehmen und absorbieren kann;
• eine minimale Dicke aufweist, so dass auch tieferfrequente Schallanteile des menschlichen Hörbereiches absorbiert werden können;
• eine Verbindung zwischen dem Raum und der Decke herstellt, die über eine ausreichende Wärmeleitfähigkeit verfügt; und
• in einem Stück ohne sichtbare Fugen gefertigt und gegebenenfalls offenporig verputzt werden kann.

Overall, therefore, the construction of a ceiling or an area of a ceiling is possible, the

• has a certain porosity and thus absorbs and absorbs sound energy;
• has a minimum thickness, so that lower-frequency sound components of the human hearing range can be absorbed;
• creates a connection between the room and the ceiling, which has sufficient thermal conductivity; and
• can be made in one piece without visible joints and optionally plastered open-pore.

Further preferred embodiments emerge from the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Figur 1

eine Schalung mit aufgelegten Distanzierungslatten;

Figur 2

nach Einbringen von Füllmaterial;

Figur 3

nach Betonieren der Decke; und

Figur 4

nach Anbringen eines Verputzes.

In the following, the subject invention will be explained in more detail with reference to preferred embodiments, which are illustrated in the accompanying drawings. Each show schematically, in cross section through a ceiling during their production:

FIG. 1

a formwork with applied Distanzierungslatten;

FIG. 2

after introduction of filling material;

FIG. 3

after concreting the ceiling; and

FIG. 4

after applying a plaster.

The reference numerals used in the drawings and their meaning are listed in the list of reference numerals. Basically, the same parts are provided with the same reference numerals in the figures.

WAYS FOR CARRYING OUT THE INVENTION

FIG. 1 shows a formwork 3 with applied Distanzierungslatten 5. On the formwork 3 is optionally a release film 4, for example, made of polyethylene or other plastic inserted to facilitate the removal of the formwork 3 later. The height of the formwork 3 corresponds to the height of the bottom view of the future ceiling.

On the one hand the granulate layer 2 can be limited to a partial area of the ceiling with the distancing battens 5 and on the other hand the height of the granular layer 2 can be defined by removing the filling material by hand up to the height of the distancing battens 5. A thickness of the granule layer 2 is preferably 2 cm to 20 cm and in particular 4 cm to 8 cm. After curing or setting of the binder of the granular layer 2, the spacer slats 5 can be removed.

The grain size of the granules with fine grain size is preferably 0.5 mm to 10 mm and in particular 1 mm to 5 mm or 7 mm. The granules preferably have grains of grit, gravel, or a mixture of such grains. The use of chippings usually results in a better connection of the grains with each other because of the flat fracture surfaces of the individual grains - in comparison to round grains of pebbles.

The binder for bonding or bonding the granules of the granules is preferably a mineral binder based on cement, gypsum or ceramic materials, or a plastic binder based on acrylic compounds (acrylic resins), polyurethane or the like. Preference is given to using heat-resistant substances with low smoke formation. In principle, the various types of granules described are freely combinable with the different types of cattle.

For example, a plastic binder has two components, such as resin and hardener, which are combined before or during mixing with the granules. The binder is preferably mixed with the granules by means of a compulsory mixture, ie by stirring - in contrast to a drum mixer. As a result, in the comparatively small amount of binder which is required to ensure the porosity of the granule layer 2, a sufficient distribution of the binder to the granules can be achieved.

FIG. 2 shows the situation after introduction of filler material to form a granular layer 2. Because the granule layer is produced on the construction itself, no support plates for mechanical stabilization are required, as is the case with prefabricated plates. By way of example, optional heat-conducting sheets 10 are shown on the left-hand side of the granulate layer 2 (in the case of actual use of heat-conducting sheets 10, these would preferably be distributed over the entire granulate layer 2). The heat-conducting sheets 10 protrude into the region of the future bedding roof and improve the heat transfer between the granulate layer 2 and concrete. The heat conducting plates 10 have, for example, profiles in the form of an "S", or a horizontal "U" or "H". Alternatively or additionally, anchoring brackets can also be inserted into the granulate layer 2.

FIG. 3 shows the situation after concreting the ceiling and forming a reinforced concrete layer 8. Before pouring the concrete layer 8, the reinforcement 6 and preferably other elements such as heating or cooling pipes are placed as thermo-active elements 7. In a preferred embodiment of the invention, a sealing layer is used up on the granule layer 2 prior to casting of the concrete. This consists for example of a cement slurry or a plastic and prevent the penetration of cement slurry from the concrete into the pores of the granular layer 2. Basically, the concrete layer adheres to the Granule layer 2 sufficiently strong, so that - with a thickness of the granular layer 2, for example, to ten or more centimeters - no special anchoring of the granular layer 2 is required.

FIG. 4 shows the ceiling after removing the formwork 3 and optionally the release film 4 and after attaching an optional plaster 9. The plaster or top coat 9 is made of an open-pore or microporous material, so it is permeable to air. Thus, sound energy can pass through the top coat 9 in the Granulate layer 2 are passed, where it is absorbed. The top coat 9 can be attached, for example, in a known manner by mounting. The top coat 9 may be constructed in a single-layer or multi-layered. A suitable plastering material is sold, for example, by BASWAacoustic AG, Marmorweg 10, CH-6283 Baldegg, under the brand name "BASWAphon", or by Sto AG, Ehrenbächstr. 1, D-79780 Stühlingen under the brand name "StoSilent".

LIST OF REFERENCE NUMBERS

1

blanket

2

Granülatschicht

3

formwork

4

release film

5

distancing laths

6

reinforcement

7

Thermoactive elements

8th

concrete

9

deck cleaning

10

heat conducting

Claims (11)

1. A method for manufacturing a concrete ceiling (1) in a building, having the following steps

   • creating a horizontal formwork (3);

   • distributing a filler on the formwork (3), wherein the filler consists of a mixture of a granulate and a binder;

   • curing the binder and forming a first layer (2);

   • placing of reinforcement elements (6) and optionally further elements (7) to be embedded;

   • pouring and setting a concrete layer (8) above the first layer;

   characterised in that the first layer (2) is a granulate layer and the mixing ratio of granulate and binder is selected in a manner such that on the one hand the grains of the granulate are connected to one another by way of contact surfaces of the individual grains bonding to one another and on the other hand continuous intermediate spaces remain between the grains, said intermediate spaces forming channels through the granulate layer and effecting a sound absorption in the granulate layer, and that a sealing layer is deposited on the granulate layer (2) before pouring the concrete layer (8).
2. A method according to one of the preceding claims, wherein the step of creating the formwork includes the laying of a separating sheet (4) onto the formwork (3).
3. A method according to one of the preceding claims, wherein spacer laths (5) are applied onto the horizontal formwork (3) before the distribution of the mixture of granulate and binder, and are subsequently removed again.
4. A method according to one of the preceding claims, wherein the grain size of the granulate is 0.5 mm to 10 mm and preferably 1 mm to 5 mm.
5. A method according to one of the preceding claims, wherein the granulate comprises grains of grit, gravel, or of a mixture of such grains, and in particular the binder is a plastic binder, a cement-based binder, a plaster-based binder or a ceramic binder.
6. A method according to one of the previous claims, wherein the granulate comprises grains of metal and/or metal fragments and/or the granulate comprises grains of clay or expanded clay.
7. A method according to one of the preceding claims, wherein the thickness of the granulate layer is 2 cm to 20 cm and preferably 4 cm to 8 cm.
8. A method according to one of the preceding claims, wherein at the latest, before the pouring of the concrete layer (8), and preferably before the distribution of the mixture of granulate and binder, heat-conduction plates (10) are incorporated and these are co-embedded into the granulate layer (2) and preferably project out of the granulate layer (2) in the vertical direction and are thus subsequently enclosed by the concrete (8).
9. A method according to one of the preceding claims, wherein the further elements (7) to be embedded are thermo-active elements such as heating or cooling conduits.
10. A method according to one of the preceding claims, wherein the formwork (3) is removed after the pouring and setting of the concrete (8), and an air-permeable plaster (9) is deposited onto the lower side of the granulate layer (2).
11. A concrete ceiling, manufactured according to one of the preceding claims, comprising a granulate layer of a mixture of a granulate and a binder, and a concrete layer lying thereabove, into which reinforcement elements and optionally further elements are embedded, wherein the mixing ratio of the granulate and binder of the granulate layer is selected in a manner such that on the one hand the grains of the granulate are connected to one another by way of the contact surfaces of the individual grains bonding to one another, and one the other hand continuous intermediate spaces exist between the grains, said intermediate spaces forming channels through the granulate layer and effecting a sound absorption in the granulate layer, and wherein a sealing layer is placed on the granulate layer, between the granulate layer and the concrete layer.

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