EP2886733A1

EP2886733A1 - A method for assembling and the construction of a plane or inclined floor for residential and industrial use, with unidirectional or bidirectional reinforcement, and means for its implementation

Info

Publication number: EP2886733A1
Application number: EP14198820.4A
Authority: EP
Inventors: Roberto Dissegna; Antonio PAGANELLI
Original assignee: Ediltravet Srl
Current assignee: Ediltravet Srl
Priority date: 2013-12-18
Filing date: 2014-12-18
Publication date: 2015-06-24
Also published as: ITRM20130697A1

Abstract

A method for the construction of horizontal or inclined floors for residential and industrial use, with unidirectional reinforcement or bidirectional reinforcement (criss-cross structure), characterized in that it envisages construction, via assembly, of at least one hybrid structural element by mechanically inserting reinforcement elements (2, 3, 4) into purposely provided longitudinal seats (SL, SL'), appropriately made within at least one purposely provided element of expanded material (1), without the need to have any type of dies/block-making machines on the assembly site.

Description

The present invention relates to the building sector and in particular to the construction of reinforced floors.
There are currently well known hollow-core floors with metal reinforcements.
Also known are floors made of expanded material with metal reinforcement, which are characterized in that an expanded mass is envisaged semi-embedded in which are the lattices of the reinforcement having top portions without expanded material.
The above floors present a series of problems, amongst which the following may be listed:

for laying these floors it is necessary to have dies or block-making machines, in which the metal reinforcements are to be positioned before the pre-expanded material at high temperature is expanded therein;
the expanded material, such as for example expanded polystyrene, is a material that protects the metal reinforcement from corrosion only partially; and
the possible corrosion-resistant protective layer of the reinforcement, for example paint, is jeopardized by the high temperature of the material during expansion.

The main purpose of the present invention is to overcome the above drawbacks by providing an innovative method for assembly and construction of floors at ambient temperature.
The above has been obtained, according to the invention, by providing a method of assembly in which there is envisaged laying a hybrid structural element by mechanically inserting reinforcement elements into purposely provided seats, appropriately made within at least one element of expanded material, which has been obtained previously without the need for any type of dies/block-making machines on the assembly site.
Advantageously, the method that is described enables use of metal reinforcements that are also appropriately treated against corrosion.
A better understanding of the invention will be obtained with reference to the ensuing detailed description with reference to the attached figures, which illustrate, purely by way of non-limiting example, a preferred embodiment, along with a number of variants.
In the drawings:

Figure 1 is a 3D view illustrating schematically the main constructional elements of the invention and showing some types of reinforcements that can be used;
Figure 2 is a schematic illustration of an example of use of the invention, with two different types of reinforcements, where the concrete cast in situ forms joists arranged in a formwork of expanded material that form a single body with the concrete slab;
Figure 3 is a schematic illustration of another example of use of the invention, where the lattice reinforcements are pre-cast in the factory within the formwork, leaving just the top projecting part of said reinforcements free for subsequent casting in situ of the concrete slab;
Figure 4 is a schematic illustration of a variant of the invention, in which the floor is particularly lightened in so far as it does not envisage any part made of concrete: it is suitable for limited loads in addition to its own weight.

According to the invention, there is envisaged assembly of a hybrid structural element for the construction of a horizontal or inclined floor for residential and industrial use, with unidirectional reinforcement or bidirectional reinforcement (criss-cross structure), said floor being made up of expanded insulating material, inserted in which are metal reinforcements, such as for example lattices of the baustrada type 2 or other type, metal girders 3 with IPN, IPE, HEA, HEB profiles or the like, and re-rods 4.
In the preferred embodiment that is described, the structural element is constituted by insulating material 1, such as for example, but not exclusively, expanded polystyrene (referred to also as "polystyrene foam") having a shape with plane development, in which longitudinal grooves SL are provided, where the metal reinforcements 2, 3, 4 are inserted in order to constitute a kind of formwork, in which said metal reinforcements are present during preparation and construction of the floor in situ (Figure 2).
Advantageously, the aforesaid reinforcements, provided during assembly in the factory, can be integrated with further reinforcements prepared in situ prior to casting of concrete.
According to the present invention, it should be noted that it is advantageously possible, according to the structural requirements of the design, to lay floors with a higher or lower flexural strength by modifying the amount of reinforced concrete present in the floor itself. In fact, if casting of concrete is carried out to obtain a concrete slab 7, adding the usual electrowelded mesh, the lattices 2, or in any case the metal reinforcements 3, 4, will have to be completely embedded in the concrete to obtain a plurality of reinforced joists that constitute a single body with the concrete slab 7, which is also reinforced.
If, instead, it is necessary to lay a lighter or more insulating floor, there is envisaged mechanical insertion - within the reinforcements 2 provided in the longitudinal grooves - of further inserts 2a of expanded material that function as "cores" for preventing the concrete cast in situ from filling completely said grooves SL, in which the reinforcements are housed (Figure 1). In this way, the concrete slab 7 cast in situ will be provided with simple bottom ribbings 6 and not with concrete load-bearing joists proper.
In the examples so far illustrated, the longitudinal grooves SL preferably have a cross section with a substantially symmetrical trapezial shape.
If instead, on the basis of the design requirements, there is the need for a type of structural element that is designed to support only limited loads in addition to its own weight and has characteristics of extreme lightness and high thermal insulation, it is advantageously possible to use the method according to the invention without laying any concrete slab or other parts made of concrete.
In this case, with particular reference to Figure 4, the grooves provided in the insulating material 1 for insertion of the metal lattices 2 have an inverted-V cross section and are designed to be filled, after insertion of the reinforcement 2, with further insulating material I, such as for example foam or other suitable material.
In this case, the top part of the reinforcement 2 is completely covered by the additional insulating material I in so far as construction of the slab 7 made of concrete is not envisaged.
From what has been set forth so far, it is clear that, thanks to the possibility of inserting the reinforcements either during assembly in the factory or directly in situ, according to the final arrangement of the reinforcements at the moment of casting of concrete, it is advantageously possible to lay unidirectional or bidirectional floors.
A peculiar characteristic of the invention lies in the fact that provision of said lightening inserts or cores 2a of the floor in the reinforcements 2 enables use of painted or in any case anti-corrosion-treated reinforcements, without said treatment or painting being damaged during assembly, thus obtaining that said reinforcements 2 are protected from corrosion even though they are not completely embedded in the concrete.
From what has been said, it is clear that the connection between the metal reinforcements 2 and the concrete slab 7, which has a load-distribution reinforcement, such as for example the electrowelded mesh and/or the intermediate supporting transverse re-rods 8, is obtained by means of the concrete casting for the longitudinal ribbings 6 and transverse ribbings provided in the shaped element made of (insulating) expanded material 1.
In the case where the reinforcements 2 are embedded in the concrete in situ (Figure 2), the hybrid structural element according to the present invention functions to all effects as formwork and requires the same type of propping necessary for construction of a traditional floor to be laid in situ with the possibility of use for bidirectional floors.
If, instead, the floor to be laid envisages that the reinforcements are not completely embedded in the concrete (Figure 1), and hence the lightening cores 2a are provided within the lattice reinforcements 2, it is sufficient to use props in the middle in order to be able to carry out the operations of casting.
A further possible application (illustrated in Figure 3) envisages pre-casting, in the factory, a part of the concrete just to cover a part of the metal lattices 2, leaving exposed the top area of the lattices themselves, which is located within the groove 6 for creating the longitudinal ribbings between the bottom part of the slab 7 and the top part of the insulating material 1. In this way, the reinforcements are completely embedded in the concrete, and the floor can be mounted in situ by casting just the concrete slab 7, which binds to the rest precisely thanks to the reinforcements.
In order to contain costs for transport of the product made of expanded material, inserted in which are the metal reinforcements, the typical width of the standard element is preferably 120 cm (like the majority of prefabricated floors). It is, however, possible to envisage any size between 15 and 240 cm.
Furthermore, the shaped slots or grooves SL provided in the standard plates of expanded material are set at regular intervals in a number preferably ranging from one to seven.
The height of the standard element is 16 cm, 20 cm, 25 cm, 30 cm, 35 cm, to be added to which is the thickness of the completing concrete slab 7.
The standard structural element obtained according to the present invention may be used, for example, for:

"aerated" floors on the ground (i.e., ground floor), by virtue of its characteristics of thermal insulation;
intermediate floors, by virtue of its characteristics of lightness and speed of laying in situ; and
horizontal and inclined top floors (i.e., roof floor), by virtue of the characteristics of thermal insulation, lightness, and speed of laying.

For each type of floor there is normally envisaged finishing of the surface in view by simple levelling carried out using commercially available products for cladding systems.
It should also be noted that other finishings of the intrados surface can be carried out with application of plaster plates or plaster board, or other known materials, also having characteristics of fire resistance, which can be fixed to the floor using mechanical elements anchored to a suitable shaped metal sheet 5 that has been appropriately provided on the bottom of the grooves SL for metal reinforcement.
With the fixing system described above, it is also possible to install either adherent or suspended false ceilings.
From what has been set forth so far, it is clear that the present invention affords the following advantages:

possibility of protecting each metal structural element from corrosion when the reinforcements are not coated by concrete;
possibility of removing or shortening, directly in situ, the insert or core of (expanded) insulating material inserted within the metal reinforcements to be able to insert within the compartment thus made further reinforcement elements necessary, for example, to obtain cantilever elements;

possibility of obtaining, with the same product, cantilever elements that have the peculiarity of preventing thermal bridges;
possibility of adapting the product to any shape required in the design stage according to the configuration in plan view of the building (from various angled shapes to curved shapes);
considerable reduction of the structural loads on the structure of the building thanks to the reduced weight of the floors built according to the invention; and
high value of thermal insulation, such as to find efficient use especially in structures where a high degree of containment of energy consumption is required.

LEGEND:

1: insulating material (e.g., polystyrene foam/expanded polystyrene)
2: lattice reinforcement
2a: insert of insulating material to be inserted in the lattice reinforcement
3: girder reinforcement
4: reinforcement with re-rods
5: rolled profile for engagement of supports for finishing elements or for fire-resistant elements, etc.
6: groove for longitudinal ribbing made in the top part of the insulating material
7: completing concrete slab
8: transverse reinforcement
SL: longitudinal groove
SL': longitudinal groove with inverted-V cross section
ST: transverse groove
CLS: concrete

Claims

A method for the construction of horizontal or inclined floors for residential and industrial use, with unidirectional reinforcement or bidirectional reinforcement (criss-cross structure), characterized in that it envisages construction, by assembly at ambient temperature, of at least one hybrid structural element by mechanically inserting reinforcement elements (2, 3, 4) into purposely provided longitudinal seats (SL, SL'), appropriately made within at least one purposely provided element made of expanded material (1), without the need to have any type of dies/block-making machine on the assembly site; wherein said longitudinal grooves (SL) preferably have a cross section with a substantially symmetrical trapezial shape or any other shape suitable for the reinforcement.
The method according to Claim 1, characterized in that the structural element is constituted by insulating material (1) such as for example, but not exclusively, expanded polystyrene (or polystyrene foam) having a shape with plane development, wherein longitudinal grooves (SL) are provided where the metal reinforcements (2, 3, 4) are inserted in order to constitute a kind of formwork in which said metal reinforcements are present during preparation and laying of the floor in situ.
The method according to the preceding claim, characterized in that it is possible for said reinforcements, provided during assembly in the factory, to be integrated with further reinforcements prepared in situ prior to casting of concrete.
The method according to the preceding claim, characterized in that, according to the structural requirements of the design, it envisages construction of floors by carrying out a casting of concrete to create a completing concrete slab (7), adding the usual electrowelded mesh, so that lattices (2) or the metal reinforcements (3, 4) are completely embedded in the concrete, thus obtaining a plurality of reinforced joists that constitute a single body with the concrete slab (7), which is also reinforced.
The method according to the preceding claim, characterized in that, for the construction of a light or insulating floor, it envisages mechanically inserting - within the reinforcements (2) provided in the longitudinal grooves (SL) - further inserts (2a) made of expanded material that function as "cores" to prevent the concrete from filling completely said grooves (SL) so that the slab (7) made of concrete cast in situ is provided, in its part facing the insulating material (1), with simple bottom ribbings (6) and not with load-bearing joists proper made of concrete.
The method according to Claim 2, characterized in that to provide a structural element for floors that are designed to support a limited load in addition to its own weight and have characteristics of extreme lightness and high thermal insulation, it envisages construction of the floor without any concrete slab (7) or other concrete parts.
The method according to the preceding claim, characterized in that the longitudinal grooves (SL') provided in the insulating material (1) for insertion of the metal lattices (2) have an inverted-V cross section and are designed to be filled, after insertion of the reinforcement (2), with further insulating material (I), such as for example foam or other suitable material.
The method according to the preceding claim, characterized in that it envisages covering completely the top part of the reinforcement (2) with said additional insulator (I) in so far as provision of the concrete slab (7) is not envisaged.
The method according to any one of Claims 1 to 6, characterized in that construction of unidirectional or bidirectional floors envisages inserting the reinforcements either during assembly in the factory or directly in situ, at the moment of casting of the concrete.
The method according to Claim 5, characterized in that it envisages using painted reinforcements or in any case ones treated against corrosion in such a way that said treatment or painting will not be damaged during assembly; thus obtaining that the reinforcements (2) themselves are protected from corrosion, even though they are not completely embedded in the concrete.
The method according to any one of Claims 1 to 6 or 9 onwards, characterized in that it envisages that the connection between the metal reinforcements (2) and the concrete slab (7), which is provided with a load-distribution reinforcement, is obtained by casting of the concrete of the longitudinal ribbings (6) and transverse ribbings (8) made in the shaped insulating element of expanded material (1).
The method according to any of the preceding claims, characterized in that, in order to contain the cost of transport of the product made of expanded material, inserted in which are the metal reinforcements, the typical width of the standard element is 120 cm; it being, however, possible to envisage any size between 15 cm and 240 cm.
The method according to the preceding claim, characterized in that the shaped slots or grooves (SL) provided in the standard plates of expanded material are made at regular intervals in a number preferably ranging from one to seven.
The method according to Claim 12 or Claim 13, wherein it envisages that the height of the standard element is 16-20-25-30-35 cm to be added to which is the thickness of the completing concrete slab (7).
The method according to any one of Claims 1 to 6, characterized in that it envisages providing a suitable shaped metal sheet (5) on the bottom of the grooves (SL) to enable execution of other finishings of the intrados surface by application of plates of plaster or plaster board or other known materials, also having characteristics of fire resistance, that can be fixed to the floor by means of mechanical elements anchored to said shaped metal sheet (5).