EP3006639B1

EP3006639B1 - Module for slabs and metho to make said module

Info

Publication number: EP3006639B1
Application number: EP15189022.5A
Authority: EP
Inventors: Franco Daniele
Original assignee: Tecnostrutture Srl
Current assignee: Tecnostrutture Srl
Priority date: 2014-10-08
Filing date: 2015-10-08
Publication date: 2018-08-29
Anticipated expiration: 2035-10-08
Also published as: EP3006639A1

Description

FIELD OF THE INVENTION

The present invention concerns a module for slabs.
The term "slab" is intended here as the traditional horizontal or sub-horizontal structure that contributes to making the floors and/or ceilings of a building.
In particular, the module according to the present invention comprises at least one panel made of insulating material in which one or more reinforcement elements, such as metal lattices, are incorporated.
Moreover, the module according to the present invention is the disposable type, that is, it remains in situ once installed in the positioning place and constitutes a base for the casts and/or the subsequent coverings.
The present invention also concerns a method to make said module for slabs.

BACKGROUND OF THE INVENTION

In the building trade, to replace the traditional formworks for containing a concrete cast, construction modules are known, consisting of a panel made of polymer material such as polystyrene or polyurethane in which reinforcement or stiffening elements are drowned.
Such known construction modules are installed in situ one adjacent to the other, on support elements such as beams, walls or suchlike, in order to make slabs.
The panels of the construction modules, once installed in situ, define a substantially continuous surface with the function of containing the concrete cast that is distributed upon it, and also for application of the materials that make up the ceiling.
The reinforcement or stiffening elements, on the contrary, confer on the construction module a predefined mechanical resistance to stresses, so as to render it stable in situ and before further operations.
In some known solutions, the reinforcement elements are completely drowned in the polymer material when the panel is made.
This solution does not however allow to reciprocally connect the reinforcement elements of several construction modules to each other in a stable and concurrent manner with the concrete. This considerably limits the bearing capacity of the slab that will be made, and poses additional problems of reinforcement and installation.
One solution of a construction module is also known in which the panel of polymer material is provided with one or more longitudinal cavities made in correspondence with the reinforcement elements, said reinforcement elements being contained in the upper plane of the panel.
In this known solution, the reinforcement elements are generally conformed as an open triangular lattice. However, this solution also poses problems of reinforcement and installation.
In the known solution, the cross section of each reinforcement element has two sides disposed converging toward a respective edge in which they are connected, for example by welding.
The sides of the cross section together define an open cavity.
During use, the free edges of the cross section of the reinforcement elements and the cavities defined by the latter are drowned in the polymer material, while the end edges, connected to each other, of each reinforcement element protrude into the longitudinal cavities of the panel, remaining inside the plane of the panel.
A concrete cast is distributed to fill the longitudinal cavities and to incorporate the portions of the reinforcement elements that protrude into the latter and the reinforcement rods. If it needs additional reinforcement, this operation must provide said reinforcement in the concrete cast.
Therefore, this solution is not optimal either, from the point of view of the bearing capacity and structural capacity of the artefact obtained: it also has technical and operating limits in installation and in making up the slab.
Furthermore, this known solution leads to the production of slabs that require support structures, foundations, and oversized reinforcements to support them.
Other known solutions of traditional formworks are disclosed in DE-A-24.05.949 , DE-A-2.060.128 , WO-A-2011/073731 , US-A-4.157.640 and DE-A-10.2004.039576 . FR 2 449 175 A2 discloses a module for slabs according to the preamble of claim 1. One purpose of the present invention is to obtain a module for slabs having a bearing capacity and resistance to stresses higher than solutions currently known.
Another purpose of the present invention is to obtain a module for slabs that is simple and economical to produce.
Another purpose of the present invention is to obtain a module for slabs that allows industrialization, simplifying the installation operations and the concrete cast.
Another purpose of the present invention is to obtain a module for slabs that, immediately after installation, can be walked on by the operators.
Another purpose of the present invention is to obtain a module for slabs that allows to reduce the overall weight of the slab defined thereby.
Another purpose of the present invention is to perfect a method to make a module for slabs that is simple and economical.
Another purpose of the present invention is to perfect a method to install a module for slabs that simplifies the operations of the operators on the installation site.
The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

SUMMARY OF THE INVENTION

The present invention is set forth and characterized in the independent claims, while the dependent claims describe other characteristics of the invention or variants to the main inventive idea.
In accordance with the above purposes, a module for slabs according to the present invention as defined in independent claim 1 comprises at least one panel made of polymer material and at least one reinforcement element. The reinforcement element has an oblong development and a cross section of an open polygonal shape, defined by at least two free sides provided with free end edges, that is, not connected to other sides. The free sides of the at least one reinforcement element are partly incorporated in the thickness of the panel, disposing their free end edges protruding from the panel.
The module according to the present invention, when installed, has the reinforcement elements with the cavities defined by the free sides facing upward. This allows to industrialize the module simplifying the installation operations. The module comprises connection elements connected to the free end edges of the reinforcement element.
This solution allows to close the cross section of the reinforcement elements, conferring a greater mechanical resistance thereon, at the same time obtaining a panel that when installed admits the presence of workmen that pass on it and at the same time is ready for the concrete cast.
In this way it is possible to produce slabs with the same bearing capacity but weighing less than those made with known modules for slabs, merely by way of example with a weight of about 50% less than traditional slabs.
The connection elements, moreover, can be such as to make the connection (continuous iron) not only between reinforcement elements of one module but also between reinforcement elements of modules located adjacent to each other. The reinforcement elements also allow to pre-assemble several modules with each other before installation, for example in the site where the module is made or in the building site.
According to a possible variant, the reinforcement elements have a triangular, rectangular, square or trapezoid cross section.
According to another variant, at least the free sides that define the reinforcement element comprise at least two reinforcement rods, or rebars, connected to each other and kept reciprocally distanced by connection elements, also called cores.
The present invention also concerns a slab comprising a plurality of modules as described above and reciprocally connected by connection elements provided between the reinforcement elements. The invention also concern a method to make a module for as defined in independent claim 7 comprising making at least one panel made of a polymer material and making at least one reinforcement element with an oblong development and a cross section of an open polygonal shape defined by at least two free sides provided with free end edges.
According to the present invention, the free sides of the at least one reinforcement element are partly incorporated in the thickness of the panel, disposing the free end edges protruding from the panel. The present invention also concerns a method to make a slab that provides to install a plurality of modules as described above on a vertical support structure, disposing the free end edges of the reinforcement elements facing upward, and a step of distributing a concrete cast on the panels to incorporate the protruding part of the reinforcement elements.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other characteristics of the present invention will become apparent from the following description of some forms of embodiment, given as a non-restrictive example with reference to the attached drawings wherein:

fig. 1 is a schematic perspective view of a module for slabs not forming part of the present invention;
fig. 2 is a section view of a module for slabs not forming part of the present invention;
fig. 3 is a schematic perspective view of a module for slabs not forming part of the present invention;
fig. 4 is a schematic perspective view of a module for slabs not forming part of the present invention;
fig. 5 is a schematic view of the module for slabs in fig. 2 in its installed condition;
fig. 6 is a schematic sectioned view of a module for slabs according to a first variant of fig. 5 according to the present invention;
fig. 7 is a schematic sectioned view of a module for slabs according to a second variant of fig. 5 not forming part of the present invention;
fig. 8 is a schematic sectioned view of a module for slabs according to a third variant of fig. 5 not forming part of the present invention;
fig. 9 is a schematic perspective view of a module for slabs according to a first variant of fig. 5;
fig. 10 is a sectioned view of a module for slabs according to a possible variant of fig. 2 not forming part of the present invention.

To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one form of embodiment can conveniently be incorporated into other forms of embodiment without further clarifications.

DETAILED DESCRIPTION OF SOME FORMS OF EMBODIMENT

With reference to fig. 1, a module for slabs not according to the present invention is indicated in its entirety by the reference number 10.
The module 10 comprises at least one panel 11 made of polymer material.
The panel 11 can be made either of polystyrene, polyurethane, expanding resins or possibly a combination of said materials.
In a preferential form the panel 11 can be made of expanded polystyrene. This makes the panel 11 extremely light and simple to make.
In a preferential form the panel 11 has a substantially flat shape, although possible applications having a curved shape, with segments located on offset planes are not excluded, or possible combinations of the two.
The panel 11 has a first surface 12, facing upward during use and on which, when installed, a concrete cast 14 is distributed, and a second surface 13 opposite the first surface 12.
The panel 11 is also provided with step-shaped lateral edges 15, that is, provided with a protruding portion and a recessed portion.
It is advantageous to provide that a first of the lateral edges 15 has the protruding portion in correspondence with the first surface 12, whereas a second of the lateral edges 15, opposite the first, has the protruding portion in correspondence with the second surface 13. This allows to position the panels 11 adjacent to each other so that the respective protruding and recessed portions of the panels 11 are reciprocally coupled.
Once the panels 11 of several modules 10 are positioned adjacent to each other, the presence of the step-shaped lateral edges 15 allows to define a substantially continuous and watertight surface, suitable to contain the concrete cast, preventing it from overflowing toward the lower part of the panel 11.
In a possible variant, the lateral edges 15 can be flat, or suitably shaped to allow coupling of the parts.
Merely by way of example, the panels 11 can have a thickness varying between 0.2 and 0.5 meters, preferably about 0.3 meters.
According to the present invention, the module 10 comprises a plurality of reinforcement elements 16, disposed reciprocally distanced from each other by a predefined pitch.
Merely by way of example, the reinforcement elements 16 can be distanced from each other by a pitch comprised between 0.1 and 0.5 meters.
In this way, once a plurality of modules 10 have been installed, a uniform slab surface is defined, in which the parts of the reinforcement elements 16 define a surface that can be trodden or walked upon immediately and is self-supporting.
The reinforcement elements 16 have an oblong development and a cross section with an open polygonal shape.
By the term open polygonal shape, here and hereafter in the description and the claims, we mean that the sides that define the cross section of the reinforcement elements 16 are reciprocally connected and have an open side.
According to the forms of embodiment shown by way of example in fig. 2, the reinforcement elements 16 have a triangular, rectangular or trapezoid open cross section.
In particular, the reinforcement elements 16 comprise a plurality of sides 17a, 17b, reciprocally connected to define an open cavity 18.
The reinforcement elements 16 comprise at least two free sides 17a, each having a connection edge 19 connected to another side and a free end edge 20, that is, not connected to other sides.
If the reinforcement elements 16 have a triangular open shape, there are only two free sides 17a, which are disposed converging with each other and connected in proximity to the connection edges 19.
If the reinforcement elements 16 have a rectangular, trapezoid or polygonal shape, there are two free sides 17a which are connected with the connection edges 19 at one or more intermediate sides 17b.
According to possible solutions, for example shown in figs. 1-9, the reinforcement elements 16 are conformed as a lattice, allowing to reduce the overall weight of the module 10. The reinforcement elements 16 are defined by reinforcement rods 21, also called rebars, with an oblong development, located substantially parallel to each other and reciprocally connected by connection rods 23, also called cores.
The connection rods 23 are connected transversely to the longitudinal development of the reinforcement rods 21 and keep them distanced from each other.
The connection rods 23 can be defined by a plurality of rectilinear segments connected to the reinforcement rods 21, or by tracts of segments shaped with a triangular shape repeated along the longitudinal extension of the reinforcement rods 21.
One of the reinforcement rods 21 defines the connection edge 19 while another reinforcement rod 21 defines the free end edge 20 of the free sides 17a. The connection rods 23 instead define the width of the free sides 17a.
According to the present invention, the reinforcement elements 16 are partly incorporated in the thickness of the panel 11, and are disposed so as to position part of the free sides 17a protruding, with their free end edges 20, from the first surface 12.
In this way, when the modules 10 according to the present invention are installed on a structure, they are positioned so that the open cavities 18 of the reinforcement elements 16 are facing upward during use.
This condition allows to reciprocally connect the free sides 17a of the same reinforcement element 16 and also of adjacent reinforcement elements 16 or those present in the module 10, conferring a greater bearing capacity on the latter.
The free sides 17a of the reinforcement elements 16 are connected reciprocally, in correspondence with the free end edges 20, with connection elements 22 comprising round pieces 24 (fig. 3) and/or metal nets 25 (fig. 4).
The connection of the free sides 17a with the round pieces 24 and with the metal nets 25 can be obtained by welding.
According to a possible form of embodiment (fig. 3), if the connection elements 22 comprise round pieces 24, these are connected with the reinforcement elements 16 transversely to their longitudinal development, that is, transversely to the longitudinal development of the reinforcement rods 21. In this way, the reinforcement rods 21 of the reinforcement elements 16 and the round pieces 24 together define a highly resistant reticular structure.
According to a preferential solution, the round pieces 24 are distanced from each other by a pitch P which, merely by way of example, is comprised between 50mm and 1000mm. This allows to define on the module 10 a reticular surface on which the operators can walk even before the concrete cast is distributed on it.
According to the form of embodiment in which the connection elements 22 comprise a metal net 25, this latter has sizes of the mesh comprised between 50mm and 200mm.
According to the invention, the connection elements 22 are provided to reciprocally connect all or at least some of the reinforcement elements 16 belonging to a single module 10.
According to a variant form of embodiment, the connection elements 22 not only allow to connect reinforcement elements 16 of one module 10, but also allow to connect reinforcement elements 16 of modules 10 adjacent to the one considered, in order to obtain a pre-assembled construction unit.
According to a possible solution, the construction unit can be made directly on the installation site of the modules 10 or, alternatively, in a production site and then subsequently transferred to the installation site.
According to possible formulations (fig. 5), the reinforcement elements 16 are disposed protruding with their free sides 17a from the first surface 12 by a distance K comprised between 0.1 and 0.4 times the height H of the reinforcement element 16. In the form of embodiment shown in fig. 5, the distance K is about 0.125 times the height H.
This condition allows to dispose the reinforcement elements 16 protruding from the panel 11 for a distance K sufficient to allow the operations to connect the connection elements 22 to the reinforcement rods 21.
Furthermore, the distance K is such that the portions of the reinforcement elements 16 protruding from the panel 11 can be incorporated together with the connection elements 22 in the concrete cast 14 to constitute a compact structure.
According to the solutions shown in figs. 1, 3 and 4, the reinforcement elements 16 have terminal ends protruding from the length of the panel 11. This allows to reciprocally connect several reinforcement elements 16 with each other if several modules 10 are located aligned with each other, or it allows to connect the reinforcement elements 16 to the vertical support structures.
Furthermore, the protruding ends of the reinforcement elements 16 are located during use resting on the vertical support structures and each of them defines a respective resting point of the module 10 on the support structure. The presence of a plurality of reinforcement elements reciprocally distanced and resting on the support structures allows to define a surface which, as soon as the modules 10 are first positioned on the support structure, is stable and safe even if the operators walk upon it.
According to a possible form of embodiment of the present invention (fig. 5), the reinforcement elements 16 are partly incorporated in the thickness of the panel 11 already when the latter is being made. The panel 11 therefore has a uniform conformation and a homogeneous composition.
According to the invention (fig. 6), a plurality of housing seatings 26 are made in the panel 11, open toward the first surface 12 and having shapes and sizes suitable to house a reinforcement element 16 each.
The housing seatings 26 can have a depth, in the thickness of the panel 11, substantially equal to the part of the height of the reinforcement element 16 that is to be incorporated in the thickness of the panel 11.
During the production steps of the module 10, the reinforcement elements 16 are disposed in the housing seatings 26 and kept protruding with respect to the first surface 12.
A filling material 28 is distributed in the housing seatings 26, to fill the cavities defined by the housing seatings 26 and to incorporate inside them the reinforcement elements 16. This allows to obtain a single, compact structure with the panel 11, the filling material 28 and the reinforcement elements 16, suitable to support the weight of the concrete cast 14 that is distributed on the modules 10 during the installation step.
The housing seatings 26 can be provided with at least one hollow 27, in this specific case several hollows, suitable to define undercuts.
The hollows 27 made in the housing seatings 26 allow to increase the connection action between the filling material 28 and the material that the panel 11 is made of; they also prevent the reinforcement elements 16 from coming out of the housing seatings 26, for example during the transport and handling steps of the module 10.
According to a possible solution, the filling material 28 can be an expanding polyurethane resin.
According to the invention, before they are filled with the filling material 28, the housing seatings 26 can be closed using plugging layers 29, disposed to close the top of the housing seatings 26.
The plugging layers 29 can be made with panels made of polymer material, for example expanded polystyrene.
According to another solution, shown in fig. 9, plugging elements 30 can be inserted into the housing seatings 26, provided to at least partly fill the open cavity 18 defined by the reinforcement element 16.
According to a first solution, the plugging elements 30 are disposed in the open cavity 18 in correspondence with one of the terminal ends of the reinforcement elements 16. In this way the plugging elements 30 define a front and rear closure of the open cavities 18, allowing to contain, together with the plugging layers 29, the filling material 28.
As shown in the form of embodiment in fig. 9, the plugging elements 30 can also be provided in intermediate positions along the longitudinal extension of the reinforcement elements 16.
This allows to reduce the quantity of filling material 28 used to fill the open cavities 18.
The filling material 28 also has the function of making the plugging elements 30 integral with the panel 11, and allows to simplify the operations and reduce the time for making the module 10 according to the present invention.
According to variant forms shown in figs. 7 or 8, the panel 11 can be defined by a plurality of blocks 32 made of polymer material, disposed adjacent to each other to define between them an interspace 31 in which to position a reinforcement element 16.
The interspace 31 is filled with the filling material 28 to incorporate the reinforcement elements 16 inside it and to make the connection between the blocks 32.
In this form of example
too, in the upper part of the interspace 31 a plugging layer 29 can be disposed, to define a containment of the filling material 28.
In some variants, not shown in the drawings, in the same way as described above with reference to fig. 9, for this form of embodiment too plugging elements 30 can be provided, positioned in the interspace 31 and, in particular, in the open cavity 18 of the reinforcement elements 16.
According to possible solutions (fig. 7), the blocks 32 can have their lateral edges, which define the interspace 31, shaped mating with the external shape of the reinforcement elements 16.
According to a variant form of example (fig. 8), the blocks 32 have a substantially parallelepiped shape with substantially flat lateral edges which define the interspace 31.
According to the form of example in fig. 7, the blocks 32 have a thickness less than the overall height of the reinforcement elements 16.
During the production of the panel 11, the blocks 32 are positioned on a support plane, adjacent to each other to define the interspace 31. Subsequently, the reinforcement elements 16 are positioned in the interspace 31.
According to fig. 7, the reinforcement elements 16 are disposed resting also on the support plane, whereas in the case shown in fig. 8 the reinforcement elements 16 are disposed in suspension with respect to the support plane.
In both cases, the reinforcement elements 16 are disposed so that their free sides 17a protrude with the free end edges 20 from the first surface 12 of the panel 11.
Subsequently, the filling material 28 is inserted into the interspace 31 to partly incorporate the reinforcement elements 16 and define the reciprocal connection between the blocks 32, so as to make the panel 11.
The module 10 according to the present invention can be installed on vertical support structures by disposing the longitudinal cavities 18 of the reinforcement elements 16 facing upward.
In particular, a plurality of modules can be installed, one adjacent to the other, to define the plane of the slab to be made. Operations of reciprocal connection can also be provided between the modules 10 and the connection elements 22, both before and after installation.
Subsequently, a concrete cast 14 is distributed on the first surface 12 of the modules 10, to incorporate inside it the protruding portions of the reinforcement elements 16 and connection elements 22.
It is clear that modifications and/or additions of parts may be made to the module 10 and corresponding method as described heretofore, without departing from the field and scope of the present invention defined by the appended claims. For example, one possible form of embodiment of the present invention, possibly combinable with the forms of embodiment described here and shown in fig. 10, provides that, when the panel 11 is being made, the reinforcement elements 16 are completely drowned in the polymer material. Subsequently, it is provided to remove the polymer material in correspondence with the free sides 17a of the reinforcement elements 16 to define, in the thickness of the panel 11, a cavity 33 from which the free end edges 20 protrude. The cavity 33 is positioned recessed with respect to the first surface 12.
According to another variant, it can be provided that already when the panel 11 is being made, for example by using suitable molds, the cavities 33 are defined, configured so as to put the free end edges 20 of the free sides 17a of the reinforcement elements 16 protruding from the thickness of the panel 11.
It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art shall certainly be able to achieve many other equivalent forms of module 10 and method to make the module 10, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.

Claims

Module for slabs comprising at least:
- one panel (11) made of a polymer material having a substantially flat shape and provided with a first surface (12), facing upward during use and on which, when installed, a concrete cast (14) is distributed, and

- a plurality of reinforcement elements (16) disposed reciprocally distanced from each other by a predefined pitch, each reinforcement element (16) having an oblong development, defined by reinforcement rods (21) with an oblong development, located substantially parallel to each other and reciprocally connected by connection rods (23), said reinforcement elements (16) having a cross section of an open polygonal shape defined by at least two free sides (17a) provided with free end edges (20) each of which is defined by one of said reinforcement rods (21), wherein the free sides (17a) of said reinforcement elements (16) are partly incorporated in the thickness of the panel (11), disposing said free end edges (20) protruding from said panel (11) and from said first surface (12),

- connection elements (22) connected at least to the free end edges (20) of said free sides (17a), to close the cross section of the reinforcement elements (16), said connection elements (22) being provided to reciprocally connect at least some of the reinforcement elements (16),
characterized in that at least one housing seating (26) is made in said panel (11), open toward the outside and with a shape and size suitable to house at least one of said reinforcement elements (16), and wherein a filling material (28) is disposed in said at least one housing seating (26), to incorporate said reinforcement element (16) inside it, said filling material (28) defining a single, compact structure between the panel (11) and said reinforcement elements (16) and in that said housing seating (26) is closed at the upper part by a plugging layer (29).
Module as in claim 1, characterized in that said connection elements (22) are chosen from a group comprising round pieces (24), metal nets (25) or a combination thereof.
Module as in any claim hereinbefore, characterized in that said free sides (17a) are protruding from the first surface (12) by a distance (K) comprised between 0.1 and 0.4 times the height (H) of the reinforcement element (16).
Module as in any claim hereinbefore, characterized in that said filling material (28) is an expanding polyurethane resin.
Module as in any claim herein before, characterized in that plugging elements (30) are inserted in said housing seating (26), provided to at least partly fill the open cavity (18) defined by the reinforcement element (16).
Slab comprising a plurality of modules (10) as in any claim hereinbefore, reciprocally connected by connection elements (22) provided between the free end edges (20) of said reinforcement elements (16).
Method to make a module (10) for slabs comprising making at least one panel (11) made of a polymer material having a substantially flat shape and provided with a first surface (12), facing upward during use and on which, when installed, a concrete cast (14) is distributed, and making a plurality of reinforcement elements (16), each having an oblong development, which provide to dispose reinforcement rods (21) with an oblong development substantially parallel to each other and to reciprocally connect them by connection rods (23), in order to define a cross section of said reinforcement element (16) of an open polygonal shape defined by at least two free sides (17a) provided with free end edges (20), each defined by one of said reinforcement rods (21), wherein said free sides (17a) of the at least one reinforcement element (16) are partly incorporated in the thickness of the panel (11), disposing said free end edges (20) protruding from said panel (11) and from said first surface (12), said reinforcement elements (16) being disposed reciprocally distanced from each other by a predefined pitch, wherein said method comprises the connection of connection elements (22) at least to the free end edges (20) of said free sides (17a) to close the cross section of the reinforcement elements (16), said connection elements (22) reciprocally connecting at least some of the reinforcement elements (16), characterized in that at least one housing seating (26) is made in said panel (11), open toward the first surface (12) and in which at least one of said reinforcement elements (16) is inserted, and wherein a filling material (28) is disposed in said at least one housing seating (26), to incorporate said reinforcement element (16) inside it, and in that said housing seating (26) is closed at the upper part by a plugging layer (29).
Method as in claim 7, characterized in that said filling material (28) is an expanding polyurethane resin.
Method as in claim 7 or 8, characterized in that plugging elements (30) are inserted in said housing seating (26) in order to at least partly fill the open cavity (18) defined by the reinforcement element (16).
Method to make a slab that provides to install a plurality of modules as in any of the claims from 1 to 5 on a vertical support structure, disposing said free end edges (20) of said reinforcement elements (16) facing upward, and a step of distributing a concrete cast (14) on said panels (11) to incorporate the protruding part of said reinforcement elements (16).