EP2792806A1 - Prefabricated slab with ruptured thermal bridge, its manufacturing process and method of building of a floor with such a slab - Google Patents

Abstract

The present invention relates to a prefabricated slab (1) with thermal break for example made of concrete for the manufacture of a floor (2) comprising a plurality of first blocks (3) distributed along two of its edges made of a material different from that of said prefabricated slab (1) and integrated in the thickness of said prefabricated slab (1). Second blocks (4) are superimposed on the first blocks (3), also made of different materials, to create a thermal bridge break or not combined with fire resistance properties of the floor (2) obtained.

Description

Technical area :

The present invention relates to a precast slab with thermal break made of a curable molding material, in particular concrete, for the manufacture of a floor obtained by the juxtaposition of several prefabricated slabs, said prefabricated slab having rectilinear lateral and longitudinal edges for the juxtaposition of several prefabricated slabs and delimiting the circumference of the prefabricated slab.

The present invention also relates to a method of manufacturing a prefabricated slab with a thermal break comprising a casting step in a mold of a curable molding material, for example concrete.

Finally, the present invention relates to a method of constructing a floor made of a curable molding material, for example concrete, cast on a formwork formed by the juxtaposition of several prefabricated slabs with a thermal break, said method comprising a step of laying at least one prefabricated slab and a step of casting a layer of molding material.

Prior art:

The invention relates to the technical field of building construction, and more specifically the construction of buildings from prefabricated elements in the factory, such as slabs intended to be conveyed to the place of construction, in particular with a view to reducing the duration of the construction. construction site.

Usually, a prefabricated slab, also called pre-slab, is formed by pre-casting in the factory a layer of a curable hydraulic mixture, for example concrete, in a mold, also called formwork table. Several prefabricated slabs are then juxtaposed and resting on bearing elements such as walls, beams, etc. They then make it possible both to form a formwork for the casting in place of a complementary compression slab, and also constitute the lower part of the floor. Thermal breakers are conventionally used, for example in the form of polystyrene blocks which are inserted and inserted between the ends of the floor and the walls in order to achieve the isolation of the floor-wall junction to avoid the formation of a thermal bridge. . For this purpose, the publication is known FR 2 873 727 A1 a method for limiting thermal bridges by adding blocks of insulating material during the construction of a wall and a slab. Publication is also known EP 1 355 013 A1 a similar method of assembling a wall and a slab comprising between the chaining of the wall and the slab a plurality of thermal insulation blocks distributed discontinuously to improve the thermal insulation. It is well known that this floor-wall junction generates significant energy losses which must be treated to comply with the standards in force. Thermal breakers having additional properties of fire resistance, such as those described in the publication, are also known. FR 2 854 417 A1 . Such thermal breakers are also reported to be inserted between the ends of the floor and the wall. This configuration nevertheless has disadvantages, because it requires on site a step of additional and tedious installation. This expensive solution is not more satisfactory from the point of view of implementation, because it is difficult to ensure the good position in position of the thermal switches in the casting phase of the floor.

It is also known from the publication FR 2 861 767 B1 owned by the plaintiff, prefabricated slabs for concrete floors that include at least one of its edges thermal breakers. The thermal breakers are attached to the prefabricated slab at the place of construction and are positioned by holding elements integrated into the slab. Then, one comes pouring a layer for example of concrete which then seals the thermal breakers in the floor. This solution makes it possible to isolate more simply the floor-wall junction while maintaining a good mechanical resistance. However, from the point of view of thermal insulation, this solution is not completely satisfactory because there is a thermal bridge. In fact, the thermal flow passes through the thickness of the prefabricated slab or pre-slabs, and reaches the wall. In this case, the thermal breakers do not cut the thickness of the prefabricated slab, but only the thickness of the compression slab cast in place. This solution therefore guarantees only a partial break of the thermal bridge.

The publication GB 2,355,024 A discloses an insulating building panel that can be used as a wall or slab and having a layer of polystyrene covered with a layer of concrete. The polystyrene layer has longitudinal slots and forms a mold for the concrete layer. Such insulating construction panels do not guarantee the rupture of the thermal bridge over the entire thickness of the slab. In addition, these require a large amount of insulating material since the insulating layer forms a single block covering the entire surface of the slab.

The publication EP 1 350 898 A1 discloses cellular building boards formed of a first concrete layer whose surface has a peak and hollow shape. The hollows are filled with polystyrene blocks and a second layer of concrete similar in shape to the first layer of concrete is deposited on this assembly. In this embodiment also the insulating blocks which are arranged on the entire surface of the slab use a large amount of material. In addition, such a slab must be cast on site and thermal bridges remain in the thickness of the concrete layers.

For all these reasons, the currently known solutions are not satisfactory.

Presentation of the invention

The present invention aims to overcome these disadvantages by providing a prefabricated slab or pre-slab to ensure the rupture of the thermal bridge at the floor-wall junction and without degrading the fire resistance characteristics of the floor obtained. The invention achieves such a goal by a design and implementation simple and inexpensive respecting current standards including in terms of mechanical properties, thermal and fire resistance if necessary.

For this purpose, the invention relates to a prefabricated slab as defined in the preamble, characterized in that it comprises a plurality of first blocks of material disposed along at least one of said rectilinear lateral or longitudinal edges of said prefabricated slab and remote from said lateral or longitudinal edges on the periphery of said prefabricated slab, in that the material of said first blocks has specific properties different from those of said molding material, and in that said first blocks are integrated at least partly in the thickness of said prefabricated slab.

In this way and as a function of the properties of the material of said first blocks, the invention advantageously makes it possible to achieve a strong reduction of the thermal bridge and, where appropriate, a fire resistance over the entire thickness of the prefabricated slab.

In a variant according to the invention, said prefabricated slab comprises at least one holding element for holding said first blocks in position.

In a preferred embodiment, said first blocks are integrally integrated in the thickness of said prefabricated slab.

Another feature is that said blocks are arranged discontinuously and are aligned substantially parallel to said edge so as to provide at least one gap for the passage of reinforcement between them.

In the preferred embodiment, the prefabricated tile comprises a plurality of second blocks of material superimposed on said first blocks of material and in that the material of said second blocks may have specific properties different from those of said molding material.

Said first and second blocks may be coupled at least in part to a holding element arranged to allow their superposition.

In this case, each holding element is superimposed on said first block and contains at least in part said second block, or said holding member embraces at least partially said first block and said second superimposed block.

Preferably, said first and second blocks are substantially parallelepipedic.

Said first and / or second blocks advantageously comprise materials having thermal insulation properties and / or fire resistance properties.

In this case, said materials of said first blocks and / or said second blocks are selected from the group consisting of polystyrene, polyurethane, vacuum panels, rock wool, sheep wool, glass wool, concrete lightweight, wood, wood concrete, cellular concrete, silico-limestone, plaster, concrete expanded glass, perlite, pumice, porous stone, cellular glass, thermoplastic foam or a combination of these materials.

The invention also relates to a method of manufacturing a prefabricated slab as defined in the preamble, characterized in that it comprises a step of fixing a plurality of first blocks on the bottom of said mold along at least one said rectilinear lateral or longitudinal edges of said mold.

According to an alternative embodiment, during said fixing step, is fixed beforehand on the bottom of said mold a plurality of holding elements arranged to maintain in position said first blocks.

Finally, the invention also relates to a method of constructing a floor as defined in the preamble, characterized in that a plurality of second blocks are superimposed on said first blocks integrated in said prefabricated slab.

According to an alternative embodiment, each second block is superimposed on a first block of said prefabricated slab by means of at least one holding element.

A particular feature is that the thickness of said second block is determined to be at most equal to the thickness of said casting material layer cast in said casting step.

Brief description of the drawings:

• la figure 1A représente une vue en coupe d'une dalle préfabriquée avec un premier bloc intégré,
• la figure 1B représente une vue en coupe d'une dalle préfabriquée avec un premier bloc intégré surmonté d'un second bloc,
• la figure 2 est une vue en coupe d'un bord d'une dalle préfabriquée équipée de blocs selon la figure 1B,
• la figure 3 est une vue en perspective de la dalle préfabriquée de la figure 2 vue de dessus sans armature,
• les figures 4A et 4B sont des vues en perspective des premier et second blocs et leur élément de maintien, respectivement en vue éclatée et en vue assemblée,
• la figure 5 est une vue en perspective d'une dalle préfabriquée de la figure 2, et
• la figure 6 est une vue en perspective d'un plancher lors du coulage de la couche de béton complémentaire sur chantier.

The present invention and its advantages will appear better in the following description of several embodiments given by way of non-limiting example, with reference to the appended drawings, in which:

• the Figure 1A represents a sectional view of a prefabricated slab with a first integrated block,
• the Figure 1B represents a sectional view of a prefabricated slab with a first integrated block surmounted by a second block,
• the figure 2 is a sectional view of an edge of a prefabricated slab equipped with blocks according to the Figure 1B ,
• the figure 3 is a perspective view of the prefabricated slab of the figure 2 top view without reinforcement,
• the Figures 4A and 4B are perspective views of the first and second blocks and their holding element, respectively exploded view and assembled view,
• the figure 5 is a perspective view of a prefabricated slab of the figure 2 , and
• the figure 6 is a perspective view of a floor during the pouring of the complementary concrete layer on site.

Illustrations of the invention:

With reference to the figures, the prefabricated slab 1 according to the invention is cast in a curable molding material such as concrete in the factory and allows the construction of a floor 2 in a building, as partially shown in FIG. figure 6 , by juxtaposition of several prefabricated slabs 1.

The Figure 1A shows a first step of construction of the prefabricated slab 1 which incorporates at least in part in its thickness a first block 3 of material near the edge 11 of the prefabricated slab 1. This first block 3 is of smaller dimensions than those of the slab prefabricated 1 and is made of a thermally insulating material and / or fire resistant as needed. As represented by Figure 1A in a particular example, the height h of the first block 3 is equal to the thickness of the prefabricated slab 1, while the thickness e of the block 3 is less than the length or the width of the prefabricated slab 1. the block 3 is disposed at a distance d from the edge 11 and at least a portion of the periphery 12 of the prefabricated slab 1. In addition, the first block 3 is integrated in the whole of the thickness of the prefabricated slab 1 so as to cross and cut. This configuration advantageously makes it possible to reinforce the thermal break, without degrading the fire resistance in the thickness of the prefabricated slab 1, so as to substantially improve the thermal insulation and / or fire resistance at the floor junction. Wall. Of course, it is also possible to integrate the first block 3 only partially in the thickness of the prefabricated slab 1.

The Figure 1B shows a second construction step in which the prefabricated slab 1 comprises a second block 4 of material superimposed on the first block 3. This second block 4 is intended to provide thermal insulation and / or fire resistance over the entire thickness of the layer 8 of the floor 2 which will be poured on the site. The combination of the first 3 and second 4 blocks thus provides these thermal insulation properties and / or fire resistance on the total thickness E of the floor-wall junction. This configuration advantageously makes it possible to greatly reduce the thermal bridge located at the floor-wall junction. Advantageously, the first and / or second blocks 3, 4 are located only on the periphery 12 of the prefabricated slab 1 and are not distributed over the entire surface of the prefabricated slab 1 as in certain embodiments of the state of the art. art, which allows to significantly limit the amount of insulating material and reduce manufacturing costs, while providing a thermal result more than optimal.

These blocks 3, 4 are arranged along at least one of the edges 11 of the prefabricated slab 1, in particular that which will rest on an outer bearing wall 9. In the configuration illustrated in figure 2 it is observed that the length L of the blocks 3, 4 is parallel to the edge 11 of the prefabricated slab 1. In addition, the blocks 3, 4 are aligned on the following ones and are spaced apart by a given interval 5, making it possible to pass These reinforcements 6 provide the mechanical strength at the floor-wall junction. They are usually made of steel or the like. As shown for example in figures 3 and 5 , the blocks 3, 4 are arranged along a lateral edge 11 and a longitudinal edge 11 and at a distance d from said edges 11. Of course, the four edges 11 may comprise blocks 3, 4. In addition, the thickness e of the blocks 3, 4 is included in the periphery 12 of the prefabricated slab 1 delimited by the edges 11. This configuration makes it possible to avoid report separate insulating blocks at the ends of the prefabricated slab complicating the implementation on site.

In a variant of the invention with reference to Figures 3, 4A and 4B specific holding elements 7 are arranged to couple the first 3 and second 4 blocks in a superimposed manner. This coupling makes it possible to ensure the correct and aligned positioning, and the good superposition of the first 3 and second 4 blocks. The holding element 7 is more particularly superimposed on the first block of material 3 and held in position by feet 10 which enclose it laterally. The holding element 7 is in the form of a box formed of a bottom and four lateral faces for receiving the second block 4. This holding element 7 can correspond to that described in the publication FR 2 861 767 B1 owned by the applicant incorporated by reference.

In another variant, not shown, the holding element 7 may be in the form of an open frame embracing the first block 3 so as to form a belt at a portion of at least its thickness and extending in the upper part to also embrace the second block 4 so as to form a belt at least in part of its thickness.

The first 3 and second 4 blocks are substantially in the form of a parallelepiped. As stated above, these first 3 and second 4 blocks have thermal insulation and / or fire resistance properties. They can be made of materials such as polystyrene, polyurethane, vacuum panels, rock wool, sheep wool, glass wool, lightweight concrete, wood, wood concrete, cellular concrete, silico-limestone, plaster, expanded glass concrete, perlite, pumice stone, porous stone, glass cell, or a combination of these materials depending on the results to be achieved. They can each be made of different materials or not, to be complementary or not, integrated into a single piece or separated into two separate rooms.

To produce a prefabricated slab 1 according to the invention, the first blocks 3 are placed in a mold (not shown) also called a formwork table along at least one edge of the mold. The first blocks 3 are fixed to the bottom of the mold for example with glue. Then, a layer of molding material is poured, for example concrete. We then obtain the prefabricated slab 1 shown Figure 1A which is completed by reinforcement 6 embedded and / or protruding like any other prefabricated slab. In this variant of the method, the holding elements 7 will be reported on site during the installation of the prefabricated slab 1.

In another variant of the method, the holding elements 7 are added which are coupled to the first blocks 3 to obtain a prefabricated slab 1 already incorporating the holding elements 7 and the first blocks of material 3. This configuration has the advantage to simplify the work on site by avoiding the establishment of the holding elements 7 later on the place of construction.

The figure 6 illustrates the method of construction of a floor 2. The prefabricated slab 1 is initially placed on the end of the load-bearing walls 9. Then, we superpose the second blocks 4 to the first blocks 3. It is possible to couple the first 3 and second 4 blocks by means of holding elements 7, as illustrated in FIGS. Figure 4A and 4B . Of course, any other definitive or temporary holding means may be used such as anchoring rods between the two blocks 3, 4. This step makes it possible to fix the second blocks 4 on the first blocks 3 in order to make possible the step casting, without displacement or shift of the second blocks 4. This consists of a layer 8 for example of concrete poured on the prefabricated slab 1 incorporating the second blocks 4. During this step, the second blocks 4 are then frozen in the floor 2. In addition, the thickness of the second block 4 must be determined so as to be equal to the thickness of the layer 8 of concrete cast on site so as to ensure insulation or rupture over the entire thickness E floor 2.

Possibilities of industrial application:

It is clear from this description that the invention achieves the goals set, namely, a strong reduction of thermal bridges with the possibility of simply adding a fire resistance at the entire floor junction. Wall.

The present invention finds an industrial application in the field of construction of buildings from prefabricated elements, and more generally in the field of public works and all types of construction.

The present invention is not limited to the embodiments described but extends to any modification and variation obvious to a person skilled in the art.

Claims (16)

Prefabricated slab (1) with a thermal break made of a curable molding material, in particular of concrete, for the manufacture of a floor (2) obtained by the juxtaposition of several prefabricated slabs (1), said prefabricated slab (1) having rectilinear lateral and longitudinal edges (11) for the juxtaposition of several prefabricated slabs and delimiting the periphery (12) of the prefabricated slab (1), characterized in that it comprises a plurality of first blocks (3) of material arranged along at least one of said rectilinear lateral or longitudinal edges of said prefabricated slab (1) and at a distance (d) from said lateral or longitudinal edges (11) over at least a portion of the periphery (12) of said slab prefabricated (1), in that the material of said first blocks (3) has specific properties different from those of said molding material, and in that said first blocks (3) are integrated in the less in part in the thickness of said prefabricated slab (1). Prefabricated tile according to claim 1, characterized in that it comprises at least one holding element (7) arranged to hold said first blocks (3) in position. Prefabricated slab of one of claims 1 or 2, characterized in that said first blocks (3) are integrally integrated in the thickness of said prefabricated slab (1). Prefabricated tile according to any one of the preceding claims, characterized in that said first blocks (3) are arranged discontinuously and are aligned substantially parallel to said edge (11) so as to provide at least one gap (5) between them the passage of reinforcement (6). Prefabricated tile according to any one of the preceding claims, characterized in that it comprises a plurality of second blocks (4) of material superimposed on said first blocks of material (3) and in that the material of said second blocks (4) has specific properties different from those of said molding material. Prefabricated tile according to claim 5, characterized in that said first (3) and second (4) blocks are coupled at least in part to a holding element (7) arranged to allow their superposition. Prefabricated tile according to claim 6, characterized in that each holding element (7) is superimposed on said first block (3) to contain at least partly said second block (4). Prefabricated tile according to claim 6, characterized in that each holding element (7) embraces at least partly said first block (3) and said second block (4) superimposed. Prefabricated slab according to any one of the preceding claims, characterized in that said first (3) and second (4) blocks are substantially parallelepipedic. Prefabricated tile according to any one of the preceding claims, characterized in that said first (3) and / or second (4) blocks comprise materials having thermal insulation properties and / or fire resistance properties. Prefabricated tile according to Claim 10, characterized in that the said materials of the said first blocks (3) and / or the said second blocks (4) are chosen from the group comprising polystyrene, polyurethane, vacuum panels, rockwool, sheep's wool, glass wool, lightweight concrete, wood, woodcrete, cellular concrete, silico-limestone, plaster, expanded glass concrete, perlite, pumice, porous stone, cellular glass, thermoplastic foam or a combination of these materials. A method of manufacturing a prefabricated slab (1) with a thermal break according to any one of the preceding claims, comprising a casting step in a mold of a curable molding material, for example concrete, characterized in that said method comprises a step of fixing a plurality of first blocks (3) on the bottom of said mold along at least one of said rectilinear lateral or longitudinal edges of said mold. A method of manufacturing a prefabricated slab (1) according to claim 12, characterized in that , during said fixing step, a plurality of holding elements (7) arranged to maintain position said first blocks (3). Method of constructing a floor (2) made of a curable molding material, for example concrete, cast on a formwork formed by the juxtaposition of several prefabricated slabs (1) with a thermal break according to any one of claims 1 to 11 comprising a step of laying at least one prefabricated slab (1) and a step of casting a layer (8) of molding material, characterized in that a plurality of second blocks (4) are superimposed on said first blocks (3) integrated in said prefabricated slab (1). A method of constructing a floor (2) according to claim 14, characterized in that each second block (4) is superimposed on a first block (3) of said prefabricated slab (1) by means of at least a holding member (7). A method of constructing a floor (2) according to any one of claims 14 and 15, characterized in that the thickness of said second block (4) is determined so that it is at most equal to the thickness said layer (8) of molding material cast in place in said casting step.

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