Technical field
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The present invention relates to a method for making a flooring, a flooring, in particular a flooring for outdoor areas, and a kit for making a flooring.
Technological background
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The invention is used, particularly though not exclusively, in the technical field relating to construction, in particular to floorings for outdoor areas.
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Nowadays, there is increasingly perceived the need to produce floorings by using self-locking elements which are characterized by a particular aesthetic value and which are capable of withstanding over time external forces and stresses without undergoing relevant modifications.
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However, the Applicant has found that the current technical solutions which are directed towards producing floorings for outdoor areas are particularly subjected to instability over time with a resultant loss of the desired self-locking. Therefore, the Applicant has understood the opportunity and need for producing floorings which are capable of conserving over time a specific regularity of the surface thereof, therefore withstanding external forces and stresses.
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Furthermore, the Applicant has observed that the current floorings may be subject to a respective aesthetic degradation as a result of the quantity of water which runs off and/or pools on the surface thereof.
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The technical problem addressed by the present invention is therefore to provide a method for making a flooring, a flooring and a kit for making a flooring which are configured to at least partially overcome one or more of the disadvantages set out with reference to the cited prior art.
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In the context of this problem, an object of the present invention is to provide a method for making a flooring, in particular an outdoor flooring, which is relatively stable over time.
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In the context of this problem, an object of the present invention is to provide a flooring, in particular an outdoor flooring, and a kit for making a flooring which are relatively stable over time.
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Another object of the present invention is to provide a method for making a flooring which requires relatively little maintenance.
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Another object of the present invention is to provide a flooring and a kit for making a flooring which requires relatively little maintenance.
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Another object of the present invention is to provide a method for making a flooring which keeps its own individual aesthetic characteristics substantially unchanged over time.
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Another object of the present invention is to provide a flooring which keeps its own individual aesthetic characteristics substantially unchanged over time.
Statement of invention
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In a first aspect thereof, the present invention is directed towards a method for making a flooring, in particular an outdoor flooring, comprising:
- providing and breaking up at least one stone so as to obtain stone granules;
- screening the granules so as to obtain grit having a grain size (in particular a mean grain size) between 1 and 5 mm, extreme values preferably being included;
- providing a substructure on a surface of a piece of ground;
- providing a plurality of manufactured products each having an upper face;
- positioning on the substructure the plurality of manufactured products one near another so as to define a plurality of cavities which are open at a side opposite the substructure, each cavity being delimited by relevant first manufactured product and second manufactured product which are adjacent to each other of the plurality of manufactured products and wherein the manufactured products of the plurality of manufactured products have the respective upper face directed at the opposite side to the substructure;
- introducing into the cavities respective fillers comprising the grit.
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As a result of these features, the method allows the production of a flooring which is particularly stable over time. In fact, the grain size between 1 and 5 mm of the stone grit allows it to be introduced into each cavity of the flooring (also called gaps or joints) so that the filler stabilizes and connects the mutually adjacent manufactured products, absorbing the structural tolerances of the thicknesses of the manufactured products themselves and contributing to the distribution of the stresses generated on the flooring over the substructure.
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In a second aspect thereof, the present invention is directed towards a flooring, in particular an outdoor flooring, comprising:
- a substructure which extends on a surface of a piece of ground,
- a plurality of manufactured products, wherein the manufactured products are arranged one near the other on the substructure so as to define a plurality of cavities which are open at a side opposite the substructure, each cavity being delimited by relevant first manufactured product and second manufactured product which are adjacent to each other of the plurality of manufactured products,
wherein the cavities (preferably each cavity) receive respective fillers, each filler comprising grit having a grain size (in particular mean grain size) between 1 and 5 mm, preferably between 1 and 3 mm, extreme values preferably being included.
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As a result of these features, the flooring is found to be particularly stable over time. In fact, the filler inside each cavity of the flooring (also called joints) allows the mutually adjacent manufactured products to be stabilized and connected, absorbing the structural tolerances of the thicknesses of the manufactured products themselves and contributing to the distribution of the stresses generated on the flooring over the substructure.
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Furthermore, the grit, in particular the stone grit, as a result of the particular dimension of the granules thereof and therefore the weight thereof, is found to be very insensitive to the stresses of the atmospheric agents on the flooring, tending to become stabilized in the cavity.
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Finally, the particular density and/or porosity of the filler allows water (in particular rainwater) to percolate through the cavities of the flooring, advantageously decreasing the surface discharge coefficient of the flooring itself.
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The possibility of forming weeds on the surface of the manufactured products is thereby reduced, with a resultant advantage in terms of duration of the aesthetic characteristics of the flooring.
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Conversely, fine sand (that is to say with a grain size less than 1 mm) which is commonly used as a filler for the cavities in place of the above-mentioned grit, tends to leave the cavities under the effect of rainwater, generating voids between the manufactured products and consequently loss of self-locking of the flooring. Additionally, fine sand in the joints does not allow the water to percolate, thereby generating impermeability between the manufactured products and therefore promoting the outflow of water onto the surface of the flooring.
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In a third aspect thereof, the present invention is directed towards a kit for making a flooring, in particular an outdoor flooring, comprising:
- a plurality of manufactured products intended to be arranged one near another on a substructure so as to define a plurality of cavities which are open at a side opposite the substructure, between the manufactured products,
- grit having a grain size between 1 and 5 mm, preferably between 1 and 3 mm, and intended to fill the cavities.
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In at least one of the above-mentioned aspects, the present invention may further have at least one of the preferred features set out below.
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Preferably, the granules are screened so as to obtain grit having a grain size (in particular a mean grain size) between 1 and 3 mm, extreme values preferably being included.
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In the context of the present invention, the grit has a grain size between 1 and 5 mm, preferably between 1 and 3 mm, according to the standard UNI EN 12620.
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Preferably, the grit has a density (volumetric mass) less than or equal to 3 Mg/m3, more preferably between 2.5 and 2.8 Mg/m3 (extreme values preferably being included) according to the standard UNI EN 12620.
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Preferably, the fillers are introduced into the cavities in such a manner that the fillers have a density less than or equal to 3 Mg/m3, more preferably less than or equal to 2.5 Mg/m3, inside the respective cavities.
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Preferably, this density is determined according to the standard UNI EN 12620.
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Preferably, each filler corresponds to a quantity of the grit.
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Preferably, the cavities contain exclusively respective fillers.
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According to an embodiment of the invention, each filler comprises at least 70% by weight of grit, the grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm. In other words, at least 70% by weight of the filler is grit, the grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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According to an embodiment of the invention, each filler comprises at least 80% by weight of grit, the grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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According to an embodiment of the invention, each filler comprises at least 90% by weight of grit, the grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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According to an embodiment of the invention, each filler comprises at least 95% by weight of grit, the grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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According to an embodiment of the invention, each filler comprises exclusively grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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According to an embodiment of the invention, at least 70% by weight of the content of each cavity is grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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According to an embodiment of the invention, at least 80% by weight of the content of each cavity is grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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According to an embodiment of the invention, at least 90% by weight of the content of each cavity is grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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According to an embodiment of the invention, at least 95% by weight of the content of each cavity is grit having a grain size between 1 and 5 mm, more preferably between 1 and 3 mm.
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Preferably, the filler is a porous aggregate which is provided with at least one channel which fluid-dynamically connects the substructure to an upper surface of the filler which is directed at the side opposite to the substructure. This allows a fluid, in particular water, to flow from an environment which is external to the flooring to the substructure, percolating through the filler.
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Preferably, the manufactured products are self-locking manufactured products, that is to say that they are such that they become locked per se on the substructure as a result of the weight thereof, without using adhesives or mortars.
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Preferably, the manufactured products are positioned in a dry state on the substructure, that is to say without using mortars or adhesives.
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Preferably, each manufactured product is one of: slab, tile, paving block, plate, block and grit.
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Preferably, the filler has a density less than or equal to 3 Mg/m3, preferably less than or equal to 2.5 Mg/m3, inside the respective cavities.
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Preferably, the grit comprises, in particular corresponds to, stone grit.
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Preferably, the grit comprises grit of marble and/or porphyry.
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Preferably, the filler received in the cavity extends substantially up to an upper face of the manufactured products which delimit the cavity, the upper face being directed at the side opposite the substructure.
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Preferably, at least one of the manufactured products is a monobloc comprising stone granules or comprises a layer comprising stone granules, wherein the stone granules have a grain size between 0.5 and 12 mm and define an upper face of the at least one manufactured product, the upper face being directed at the side opposite the substructure.
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Preferably, the stone granules of the at least one manufactured product correspond in chromatic terms and/or in terms of material and/or grain size to those of the grit.
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Preferably, the manufactured products are at least one of slabs, paving blocks and grit.
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Preferably, the flooring has a permeability coefficient which is greater than or equal to 1x10-3 m/s, according to UNI CEN ISO/TS 17892-11 with variable load, at the filler which is received in the relevant cavity.
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Preferably, at least one of the manufactured products has a permeability coefficient which is greater than 2x10-3 m/s, preferably greater than 4x10-3 m/s, according to UNI CEN ISO/TS 17892-11 with variable load.
Brief description of the drawings
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The features and advantages of the present invention will be better appreciated from the detailed description of preferred embodiments thereof which are illustrated by way of non-limiting example with reference to the appended drawings, in which:
- Figure 1 is a flow chart illustrating a method for making a flooring according to an embodiment of the invention,
- Figure 2 is a schematic view of a flooring obtained according to a method for making a flooring according to an embodiment of the invention,
- Figure 3 is a schematic plan view of a flooring obtained according to a method for making a flooring according to an embodiment of the invention, and
- Figure 4 is a schematic view of an embodiment of a two-layer manufactured product.
Description of embodiments of the invention
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With reference to the appended Figures, there is generally designated 100 a method for making a flooring, preferably an outdoor flooring.
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With particular reference to Figure 1, the method 100 comprises a step 101 of providing and breaking up at least one stone so as to obtain granules of the at least one stone.
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Preferably, the at least one stone is initially introduced into a hopper, from which it is subsequently discharged into a crusher for breaking it up. The method 100 further comprises a step 102 of screening, preferably via vibrating screens, the granules of the at least one stone so as to obtain grit 1 having a grain size between 1 and 5 mm according to the standard UNI EN 12620.
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More preferably, the grit 1 has a grain size between 1 and 3 mm according to the standard UNI EN 12620.
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The method 100 for making a flooring comprises a step 103 of providing, in particular laying, a substructure 2 on a surface 3 of a piece of ground.
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Preferably, the substructure comprises one or more layers of materials positioned one above the other.
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By way of example, the substructure 2 may comprise one of:
- a layer of scree (draining base) and a layer of bedding gravel,
- a ballast, a layer of woven geotextile and a layer of bedding sand (Figure 2) and
- a ballast and a layer of bedding sand.
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Preferably, once the above-mentioned surface 3 has been defined and prepared for producing a flooring, the method may provide for putting into operation a layer of geotextiles and, subsequently, the laying and tamping down of a layer of bedding sand of the substructure 2.
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The method 100 according to the invention comprises a step 104 of providing a plurality of manufactured products 4a, 4b,... each having an upper face 5. The manufactured products 4a, 4b,... further comprise a lower face 6 opposite the upper face 5 and lateral faces 7 which extend between the upper face 5 and the lower face 6.
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Preferably, the manufactured product corresponds to one of slab, tile, paving block, plate, block and grit.
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Preferably, the manufactured products 4a, 4b,... are at least one of slabs, paving blocks and grit.
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Preferably, the upper face 5 has a rectangular profile, the sides of which are preferably greater than 30 mm. By way of example, the extent (in mm) of the upper face 5 in a first direction and a second direction perpendicular to the first direction can correspond to one of: 1000 and 200, 100 and 100, 375 and 250, 74 and 222, 148 and 222, 222 and 222, 296 and 222, 250 and 500, 500 and 500, 1000 and 500, 1000 and 1000.
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Preferably, the thickness of the manufactured products 4a, 4b, that is to say the extent of the lateral faces 7 in a third direction perpendicular to the first and second directions, is greater than or equal to 50 mm, more preferably it is between 30 and 170 mm. By way of example, the thickness (in mm) of the manufactured products 4a, 4b corresponds to one of: 60, 75, 80, 85, 90, 110, 150.
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The method 100 according to the invention comprises a step 105 of positioning on the substructure 2 the plurality of manufactured products 4a, 4b,... one near another so as to define a plurality of cavities 8 which are open at a side opposite the substructure 2, each cavity being delimited by relevant first manufactured product 4a and second manufactured product 4b which are adjacent to each other of the plurality of manufactured products. The manufactured products of the plurality of manufactured products 4a, 4b,... have the respective upper face 5 directed at the opposite side to the substructure 2.
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In other words, each pair of adjacent manufactured products 4a, 4b delimits a cavity 8 (also called a joint). The cavity 8 therefore extends between two adjacent manufactured products 4a, 4b and the extent of the cavity 8 between the first manufactured product 4a and the second manufactured product 4b adjacent to the first manufactured product 4a is preferably less than or equal to 80 mm, more preferably it is between 1.5 mm and 4 mm. Preferably, the plurality of manufactured products 4a, 4b are positioned on the substructure 2 inside an area which is delimited by peripheral elements (such as, for example, kerbs or walls) fixed to the ground.
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The method 100 according to the invention further comprises a step 106 of introducing into the cavities 8 respective fillers 11 comprising grit 1 in such a manner that the fillers 11 have densities which are preferably less than or equal to 3 Mg/m3, more preferably less than or equal to 2.5 Mg/m3, inside the respective cavities 8, thereby obtaining a flooring 200.
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The flooring 200 is schematically illustrated in Figures 2 and 3.
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In an alternative embodiment of the flooring, the fillers 11 may comprise grit made of a material different from stone, this grit in any case having a grain size between 1 and 5 mm, preferably between 1 and 3 mm.
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Preferably, the filler 11 is introduced into each cavity 8 under the action of gravitational force.
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After the introduction of the fillers 11 in the respective cavities 8, there may be provided vibrating compaction of the flooring 200 in order to ensure a first arrangement of the grit in the joints (cavity 8). At the end of the vibrating compaction, the final tamping of the cavities 8 is carried out. It must be noted that the particular density of the filler 11 confers on the flooring 200 a permeability coefficient greater than or equal to 1x10-3 m/s according to UNI CEN ISO/TS 17892-11 with variable load and at the cavities 8.
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The flooring 200 obtained in this manner therefore comprises the substructure 2, the manufactured products 4a, 4b,... which are arranged near each other on the substructure 2 so as to define a plurality of cavities 8 which are each delimited by two manufactured products 4a, 4b which are adjacent to each other, and the filler 11 which is received inside each cavity 8, the grit 1 of the filler 11 having a grain size between 1 and 5 mm.
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Preferably, the grit comprises, more preferably corresponds to, grit of marble and/or porphyry.
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The grit of marble and/or porphyry is found to be particularly suitable for enhancing the appearance of the flooring 200.
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Preferably, at least one manufactured product (more preferably each manufactured product) of the plurality of manufactured products 4a, 4b,... is a monobloc comprising granules of stone or the at least one manufactured product (more preferably each manufactured product) comprises a layer comprising stone granules.
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These stone granules have a grain size between 0.5 and 12 mm and define the upper face 5 of the relevant manufactured product.
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This feature is found to be particularly advantageous for generating a substantial uniformity of the flooring 200, in particular in chromatic terms or in terms of the surface finish, such as, for example, roughness and morphology.
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Preferably, the stone granules of the at least one manufactured product correspond in chromatic terms and/or in terms of material and/or grain size to those of the grit 1.
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Preferably, the step of introducing the fillers 11 into the respective cavities 8 comprises flush filling the cavity 8 with the fillers 11, that is to say substantially up to the upper face 5 of the manufactured products 4a, 4b which delimit these cavities 8.
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In particular, the vertical distance between the fillers 11 inside the respective cavities 8 and the level of the external surface of the flooring 200 defined by the upper faces 5 of the manufactured products 4a, 4b, ... is less than 3 mm.
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This allows a particularly uniform flooring to be obtained, without any substantial indentations in the region of the joints.
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Preferably, the method 200 comprising a step 107 of producing the manufactured products 4a, 4b,... which includes:
- mixing first inert materials and cement in water so as to obtain a first admixture;
- mixing second inert materials and cement in water so as to obtain a second admixture;
- introducing the first admixture into a mould and vibro-compressing the first admixture in the mould so as to form a first layer 9;
- introducing the second admixture into the mould on the first layer 9 and vibro-compressing the second admixture in the mould so as to form a second layer 10 which is positioned above the first layer;
- drying the first and second layers 9, 10 so as to obtain a manufactured product 4a, the second layer 10 defining the upper face 5 of the manufactured product 4a,
wherein the above-mentioned second inert materials comprise granules of at least one stone having a grain size between 0.5 and 12 mm.
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Therefore, the step 107 allows a manufactured product 4a of the two-layer type to be obtained, in a state provided with a finishing layer (that is to say the second layer) serving to confer on the flooring 200 specific mechanical, chemical, physical, ergonomic, aesthetic and durability characteristics and performance levels provided by the granules contained in the second inert materials used.
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The manufactured product 4a of the two-layer type is schematically illustrated in Figure 4 .
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Preferably, the granules of the second inert materials correspond in chromatic terms and/or in terms of material and/or grain size to those of the grit 1.
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Preferably, the granules of the second inert materials correspond to granules of marble and/or porphyry.
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Preferably, the first inert materials comprise sand of natural origin constituted by clasts which are mainly broken up of a carbonate type (limestone and dolomite) and clasts which are broken up of a mainly carbonate type (carbonate rocks of the micritic and dolomite limestone types) and secondarily of a silicate type (intrusive and effusive granite rocks such as granite and porphyry) .
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Preferably, the vibro-compression step of the first admixture and/or second admixture provides for transmitting horizontal and/or vertical vibrations and/or vibrations in accordance with an elliptical or circular trajectory to the mould by means of a vibrating device. Preferably, the vibro-compression step is characterized by vibrations with a duration less than or equal to 2 seconds, preferably between 1 and 2 seconds.
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Additionally or alternatively, the vibro-compression step of the first admixture and/or second admixture provides for compressing the first admixture and/or the second admixture by means of a pressing device, applying a pressure less than or equal to 50 bar to the first admixture and/or the second admixture, preferably in a vertical direction.
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These features allow a manufactured product to be obtained having a permeability coefficient greater than 2x10-3 m/s, more preferably greater than 4x10-3 m/s, according to UNI CEN ISO/TS 17892-11 with variable load.
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Preferably, the step of producing the manufactured products 4a, 4b,... comprises washing an external surface of the second layer 10 by means of a pressurized fluid after the step of vibro-compression and preferably before the drying step.
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The external surface of the second layer 10 corresponds to the upper face 5 of the manufactured product.
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The pressurized fluid is preferably water or an aqueous solution.
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Preferably, the pressure applied by the fluid to the external surface of the second layer 10 is less than or equal to 3 bar, more preferably between 2.5 and 3 bar.
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This provision allows the upper face 5 of the manufactured products to be cleaned in respect of any saturating sands, the natural colours of these granules being highlighted and highlighting the porous portion of the manufactured products 4a, 4b which promotes the permeability thereof.
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Alternatively, the step 107 of producing the manufactured products 4a, 4b,... may include:
- mixing inert materials and cement in water so as to obtain an admixture;
- introducing the admixture into a mould and vibro-compressing the admixture in the mould;
- drying the admixture so as to obtain a manufactured product 4a, the admixture defining the upper face 5 of the manufactured product 4a,
wherein the inert materials comprise granules of at least one stone having a grain size between 0.5 and 12 mm.
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The step 107 therefore allows a manufactured product 4a of the single-layer type to be obtained, serving to confer on the flooring 200 specific mechanical, chemical, physical, ergonomic, aesthetic and durability characteristics and performance levels provided by the granules contained in the inert materials used.
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Preferably, the granules of the above-mentioned inert materials correspond in chromatic terms and/or in terms of material and/or grain size to those of the grit 1.
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Preferably, the granules of the inert materials correspond to granules of marble and/or porphyry.
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Preferably, the inert materials comprise sand of natural origin which is constituted by mainly broken-up clasts of a carbonate type (limestone and dolomite) and clasts which are broken up of a mainly carbonate type (carbonate rocks of the micritic and dolomite limestone types) and secondarily of a silicate type (intrusive and effusive granite rocks such as granite and porphyry).
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Preferably, the vibro-compression step provides for transmitting horizontal and/or vertical vibrations and/or vibrations in accordance with an elliptical or circular trajectory to the mould by means of a vibrating device.
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Preferably, the vibro-compression step is characterized by vibrations with a duration less than or equal to 2 seconds, preferably between 1 and 2 seconds.
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Preferably, the vibro-compression step provides for compressing the admixture by means of a pressing device, applying a pressure less than or equal to 50 bar to the admixture, preferably in a vertical direction.
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These features allow a manufactured product to be obtained having a permeability coefficient greater than 2x10-3 m/s, more preferably greater than 4x10-3 m/s, according to UNI CEN ISO/TS 17892-11 with variable load.
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Preferably, the step of producing the manufactured products 4a, 4b,... comprises washing an external surface of the admixture by means of a pressurized fluid after the step of vibro-compression and preferably before the drying step.
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The external surface of the admixture corresponds to the upper face 5 of the manufactured product.
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The pressurized fluid is preferably water or an aqueous solution.
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Preferably, the pressure applied by the fluid to the external surface of the admixture is less than or equal to 3 bar, more preferably between 2.5 and 3 bar.
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This provision allows the upper face 5 of the manufactured products to be cleaned in respect of any saturating sands, the natural colours of these granules being highlighted and highlighting the porous portion of the manufactured products 4a, 4b which promotes the permeability thereof.
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In any case, there may further be provision for producing manufactured products having a permeability coefficient less than the values set out above since the outflow of the water from the flooring 200 can be obtained via the joints.