FI20215153A1 - Concrete slab and method for manufacturing a concrete floor - Google Patents

Abstract

A concrete slab (100), the first and second surfaces (21, 22) of which are substantially square, rectangular or polygonal, and of which the profiles (y) of certain adjacent sides covering half a circle (P) are compatible with the ends, the other half circle (P) with the profiles (z) of the covering sides, so that said concrete slab can be connected to another concrete slab (100) with a bridge connection, and which comprises the frame (10) that borders it, the concrete (20) filling said frame and attached to it with anchors (5), its first and second interlocking lock profiles (6a, 6b) formed on the projection (100.1, 100.2) which are adapted to form a lock (6) in the bridge joint (J) between the concrete slabs (100) to prevent longitudinal (X) movement between said concrete slabs and a locking element (7) to the concrete slab (100) to lock the second concrete slab (100) fixed with said pontoon joint in place and the gap between said concrete slabs vertical (Y) to prevent movement.

Description

CONCRETE FLOORING AND METHOD FOR PREPARING A CONCRETE FLOOR The object of this invention is a concrete slab and a method for producing a concrete floor. The concrete slab according to the invention can be joined together with other concrete slabs and thus a uniform floor surface can be formed from them. The method according to the invention is a means of forming a concrete floor from concrete slabs according to the invention. The purpose of the invention is to speed up the production of high-quality concrete floors by increasing the degree of pre-fabrication. The purpose of the invention is also to significantly reduce the manufacturing costs of concrete floors by rationalizing all the necessary work steps so that each of them can be carried out under the most favorable conditions. It is well known that in the construction industry, prefabrication is always cheaper than construction on site, whenever possible.

Applications of the invention include all concrete floors. The wider the floor, the greater the benefit achieved by using the invention. Examples of advantageous uses of the invention include industrial, sports, event, retail, etc. floors. The invention is also suitable for the production of concrete floors in smaller spaces, such as small houses.

Concrete floors are produced in accordance with known technology as castings on site. The wet concrete is moved from the concrete truck onto the compacted sand base and insulation layer, on which the reinforcement is installed. The concrete is compacted and the desired layer strength and the necessary inclinations are realized with the help of controls and measurements. If necessary, N 25 seams are made in the casting, such as expansion joints, and the surface of the casting is sanded smooth. The casting can N be patterned during the casting project and the casting is watered for several days after the casting S. After watering and drying, the surface of the casting can be rubbed smooth or it 2 can be polished.

i a © 30 The above-described concrete floors in accordance with known technology and their production are presented, e.g. On the Internet, on the websites of numerous companies in the field. Various structures are known to be made from concrete slabs, such as the bases of terraces, etc., but there is no material describing the production of a high-quality concrete floor from them.

this. For this reason, the invention makes it possible to bring a completely new technology to the market. The biggest drawbacks of the known technology are related to the fact that the manufacturing stages of the concrete floor, such as reinforcement, concrete application, sealing and surface finishing, must always be carried out at the installation site. There is no method on the market to transfer these work steps to pre-fabrication. The work performed at the installation site is the worst option in terms of costs, but the known technologies do not provide other competitive implementations. Various structures formed from concrete slabs are made in abundance in the construction industry, examples of which include hollow and mass slab sub-bases, but the above-ground floors of all buildings are today cast in place. An obstacle to development in such solutions can be considered the fact that it has not been possible to develop a method that prevents the movement of tiles and the formation of notches at their joints when the floor is loaded. It is very important that the floor surface remains completely flat throughout its life cycle, and this cannot be compromised to save costs. The purpose of this invention is to provide a concrete slab and a method for producing a concrete floor that avoids the disadvantages of known technology. The inventive solution is characterized by what is presented in the distinguishing parts of patent claims 1 and 10. The greatest advantage of the invention compared to known technology can be considered its cost efficiency. The concrete floor according to the invention is produced as preforms, and the concrete slabs obtained at that time are assembled into a concrete floor at the construction site. The concrete slabs according to the invention S can be completely prepared as a pre-fabrication and connected N together at the construction site in such a way that they remain motionless and attached to each other 0 even under load. The concrete floor according to the invention is able to meet E: all the same quality requirements as the traditional concrete floor. e 30

LO D> In this document, a pontoon joint is a joint formed by compatible protrusions and recesses, where the seam does not follow a single line or curve through a certain structure assembled from parts.

The invention is described in more detail in the accompanying drawings, where figure 1 shows a concrete slab according to the invention three-dimensionally, figures 2a and 2b show the frame belonging to the previous one three-dimensionally and cut in the middle (A-A), figure 3 shows two concrete slabs according to the invention joined together three-dimensionally, figure 4 shows the above said tile as seen directly from above, figure 5, shows the arrangement in figure 4 cut from point B-B, figures 6-8, show points C, D and E of figure 5 enlarged, figure 9, shows a concrete floor produced by the method according to the invention, figures 10a-10c, show a mechanism for connecting concrete slabs to each other, figure 11, shows an embodiment of the invention different from the previous ones. In the following, the structure and details of an advantageous application of the invention are explained with reference to the figures mentioned above. Figure 1 shows a concrete slab 100 according to the invention. It is prefabricated and comprises a rectangular frame 10 that surrounds said slab and defines the extent of its surface, and reinforced concrete 20 that extends to said frame inside it. In this example, the first surface 21 of the concrete slab, which is its upper surface, and the second surface 22, which is its lower surface, are planar and are in the planes of the upper and lower surfaces of the frame 10. The width a and length b of the concrete slab 100 can be from less than a meter to several meters, and these dimensions can be determined to be equal to the overall dimensions of the floor or they can be standardized. The thickness of the concrete slab € can be adjusted = 25 to always fit the situation, e.g. taking into account the future load of the floor or S can also be standardized.

S 0 In figure 2a, the frame 10 is depicted three-dimensionally, and in figure 2b its section from point A-A of the previous figure. The frame 10 therefore determines the width a, the length b of the concrete slab and, in this example, also the thickness €. The mentioned frame is composed of the first, second, third and fourth sides 1-4, which are profiled sheets shaped to certain shapes along the entire length of the sides. The mentioned sides form the circle P of the frame and they are connected together as shown in the figure: the corner joints of the frame are tight, so that the concrete poured inside it stays inside the frame. You mentioned-

anchors 5 are attached to the supporting sides, to the inside of the frame, with which the frame is attached to the concrete poured inside it.

Figure 3 shows three-dimensionally two concrete slabs 100 joined together, in Figure 4 the same from directly above and in Figure 5 the longitudinal section B-B of this combination.

The profiles y of the first and second sides 1, 2 are identical to each other and the profiles z of the third and fourth sides are identical to each other.

In this example, the lower parts of the profiles y form the first projections 100.1 on the concrete slab 100 and the upper parts of the profiles z form the second projections 100.2 on the concrete slab. Thus, the first and second sides 1, 2 of the concrete slab 100 of this example are y-shaped and have said first protrusions, and the third and fourth sides 3, 4 are z-shaped and have said second protrusions.

Figure 6 is a cross-sectional view C of the section B-B, the profile y of the first and second sides 1, 2 is described in more detail in it.

Figure 7 is a sectional view D of the section B-B, the profile z of the third and fourth sides 3, 4 is depicted in it.

Figure 8 is a section view E of the section B-B, it shows the compatibility of the profiles y and z, with which the concrete slabs 100 can be connected to each other with a pontoon joint J.

When the projection 100.2 of the third or fourth side 3, 4 of the latter concrete slab 100 in the installation sequence is slid or pressed into place over the projection 100.1 of the first or second side 1, 2 of the previous concrete slab 100 in the installation sequence so that the profiles y and z converge, then the bottom of the profile z the flexible locking element 7 in the part bends and squeezes closer to the profile z and when the butt seam J meets the profiles y and z, it springs back to its original position and pushes into the depth = 25 stretch 8 at the bottom edge of the previous concrete slab 100 in the installation sequence, so that the end of the locking element 7.1 (shown in figure 7 ) is placed against the counter surface 8.1 (shown in Fig. 6) of the recess or in its immediate vicinity.

N In this example, the angle a> between the counter surface 8.1 and the second surface 22 of the concrete slab is the same as the angle B between the bottoms of the recesses m/ projections of the opposite lock profiles 6a and 6b in the middle of the joint, and the second surface 22 of the concrete slab.

Surfaces m, n and g are plane surfaces a in this example.

The mentioned lock profiles form a lock 6, which prevents the longitudinal X movement S between the concrete slabs, and the locking element 7 prevents the vertical Y movement between them.

The locking between the concrete slabs 100 according to the invention can also be implemented in a way other than that shown above. From the point of view of the invention, it is essential that the lock 6 and the locking element 7 or other shapes and/or elements performing the same task prevent the longitudinal X movement between the concrete slabs 100 and the vertical Y movement perpendicular to it.

Figure 9 shows a part of a concrete floor 200 assembled from one of the concrete slabs 100 according to the invention. The method of manufacturing the floor according to the invention in this example works in such a way that the concrete slabs 100 are produced as pre-made products as described above and the concrete floor 200 is assembled at the construction site as follows: a base 50, such as, for example, a compacted and leveled sand base is installed on top of in certain divisions L determined by the length of the concrete slabs, the guide members 51, whose width S is smaller than their division L.

the concrete slabs 100 are installed against the upper surfaces 51.1 of the guide elements, in which case the mentioned upper surfaces determine the direction line of the lower, first or second surfaces 21, 22 of the concrete slabs and the sufficient height H of the guide elements ensures that the concrete slab does not touch the base 50 between the guide elements and that between the base 50 and the concrete slabs 100 there is enough space for insulation. Adjacent and successive concrete slabs 100 are attached and locked to each other with the help of locks 6 and locking elements 7. When the surface of the concrete floor 200 is finished, the spaces 52 between the base 50, the guide elements 51 and the concrete slabs 100 are filled with filler 53. As an example of the guide elements 51, boards of a certain thickness can be mentioned, such as e.g. polyurethane boards and the filler 53 is polyurethane foam.

Figures 10a-10c describe the joining of profiles x, y and the operation of the locking element 7 = 25 when assembling a concrete floor according to the invention. The surface g connecting the bottom m of the recess of each lock profile 6a, 6b and the surface n of the projection is adapted to such an angle ö N with respect to the first and second ends 100.3, 100.4 of the concrete slab that the locking element 7 is able, when flexible, to settle into its final position in accordance with the above figures - E : in 8. In this example, the ends 100.3, 100.4 are vertical and the angle 8 is 20 °. ™ 30 The value of the mentioned angle is determined according to the other properties of the concrete slab and = at least values of 10°- 45 © can be considered as an advantageous value of angle 3.

S The guide members 51 are arranged so that they support the pontoon joints J at least during installation. They can be fitted under the mentioned joints or between the match. Finished cookie-

the concrete slabs 100 of the normal concrete floor 200 and the pontoon joints J between them are all supported from below, so the position of the control elements 51 has no significant effect on it.

The frames and their compatible, pairs-locking sides 1-4, as in the above example 1 and 3, 1 and 4, 2 and 3, 2 and 4 can be realized and shaped in many different ways, but it is essential for them in terms of the invention that they can to connect the next installed concrete slab 100 according to the invention to the previously installed concrete slab 100 according to the invention tightly and to lock the achieved connection so that said slabs cannot move relative to each other. The most advantageous shape of the frame is essentially a rectangle, i.e. a shape corresponding to a square or a rectangle, but even polygons are not excluded from the use of this invention, although their cost-effectiveness can be considered lower than the first mentioned.

The tight joining of the profiles y, z also includes an application where the shapes of the mentioned profiles have a certain installation tolerance, which enables their inexpensive installation. The movements between the concrete slabs 100 allowed by the tolerance are not the mentioned longitudinal and vertical X, Y movements.

Profiles y and z can be implemented within the scope of the inventive idea in many ways. In terms of durability, projections 100.1, 100.2 of essentially the same height and the bottoms of the recesses of the lock profiles 6a, 6b and the surfaces of the projections m, n, which are parallel in this example and form the first and second ends of the concrete slab 100.3, 100.4, can be considered as the most advantageous implementation option in terms of durability = less than 25 90 * angle o, but also other related solutions may come into question in some applications of the invention. From the point of view of the invention, it is advantageous that angle a and N angle B are the same size, but the invention is not limited only to this embodiment.

= a ™ 30 The assembly of sides 1-4 into a frame 10 requires the shaping of each of their ends in order to make the corners of the S frame compact. Pages 1-4 can each be made from one or several parts. In terms of the invention, the most advantageous way is to make them in one piece, e.g. in a sheet metal processing center or with a sheet metal working machine. The design of the mentioned pages in the corners of the frame 10 can be implemented in many ways. One inexpensive way is to pre-cut the ends of the blank so that after folding the ends have a suitable shape. Another way is to cut the shape after folding. All other manufacturing options that give a favorable end result from the point of view of the invention also implement the invention. Alternatively, the frames can also be left unsealed at the corners and the sealing can be done with molds for pouring the concrete.

The concrete slab 100 can be very large in extent, and its maximum possible size is determined by its transportability. The thickness of the concrete slab can be any practical thickness. As an example, width a can be mentioned as 3 m, length b 6 m and thickness c 100 mm. Any known method suitable for moving and transporting the concrete slabs 100 can be used. Figure 11 shows the concrete slab 100 according to the invention, whose circle P is a regular hexagon. Other regular polygons with an even number of sides 1-n also fall within the scope of the invention. In these cases, it is essential that half of the adjacent sides contained in the circuit P comprise the profile y and the rest the profile x. The slopes of the surface of the concrete floor produced by the method according to the invention can be realized by making them on the 100 surface of the concrete slabs during pre-production. In this case, one inclination can extend to the entire extent of the first surface 21 of the concrete slab, or said surface can contain at least two parts of the surface in different directions. Tilts can also be implemented in some cases in connection with the manufacture/installation of the base 50, control elements 51. One application option of the invention is a concrete slab 100 thicker than the frame 10, at least in some parts. In this case, the parts of the thickness of the concrete slab that exceed the edges of the frame can be S molded. On the other hand, if the concrete slab contains inclines, the heights of sides 1-4 can be adjusted according to the surface of the concrete 20.

D E One application option of the invention is to install the first projections 0 30 100.1 of the concrete slabs on top of the second projections 100.2, whereby the second surfaces 22 of the slabs are their = upper surfaces and form the surface 201 of the floor.

S Any usable material can be used as the material of the frame 10 and the anchors 5. An inexpensive example of such a material can be mentioned steel,

whose coefficient of thermal expansion is close to the corresponding coefficient of concrete. One proven product suitable as a material for frame 10 is steel plate PL 1.5. All other inexpensive wall thicknesses on pages 1-4 also implement the invention. The anchors 5 can be shaped and attached to the frame 10 in many ways. It is essential that they are able to connect the concrete 20 to the frame 10 sufficiently well. The visible surface of the concrete 20 can be treated in pre-fabrication as desired. Patterning, grinding, grinding, etc. can be performed before the concrete slabs 10 are installed in place. The treatment of the dried concrete 20 after the installation of the concrete floor 200 according to the invention is also not excluded from the application of the invention. Through-holes and/or cuts can already be made in the concrete slab according to the invention during its manufacture. It should be noted that although this explanation has been limited to one type of implementation example favorable to the invention, it is by no means intended to limit the use of the invention to only this type of example, but many modifications are possible within the scope of the inventive idea defined by the patent claims. = 25

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Claims (15)

Patent Claims 1. A concrete slab (100), the first and second surfaces (21, 22) of which are essentially square, rectangular or polygonal, and the profiles (y) of certain adjacent sides covering half a circle (P) are compatible with the ends, with the profiles (z) of the sides covering the second half of the circuit (P) so that said concrete slab can be connected to another concrete slab (100) with a bridge connection (J), characterized by the fact that it comprises: a. the frame (10) that borders it, b. said frame concrete (20) filling and attached to it with anchors (5), c. the interlocking lock profiles (6a, 6b) formed on its first and second projections (100.1, 100.2), which are adapted to form the longitudinal (X) of the lock (6) between said concrete slabs in the pontoon joint (J) between the concrete slabs (100) to prevent movement, d. the locking member (7) to lock the second concrete slab (100) attached to the concrete slab (100) with said pontoon joint in place and to prevent the vertical (Y) movement between said concrete slabs. 2. A concrete slab (100) according to claim 1, characterized in that the bottoms (m) of the recesses of the lock profiles (6a, 6b) and the surfaces (n) of the projections are flat surfaces and parallel to each other and that they and the first or second end of the concrete slab (100.3 , 100.4) the angle (o) between is less than 90 °. = 25 3. A concrete slab (100) according to claim 1 or 2, characterized in that the surface (g) connecting the bottom (m) of the recess and the surface N (n) of the projection in N each lock profile (6a, 6b) is adapted to such a position in the first 2 and the second in relation to the head 100.3, 100.4, that the angle (8) between them is 10 °- 45 °. ? Oh 30 4. A concrete slab (100) according to one of claims 1-3, characterized in that the locking element (7) is attached to the frame (10) or is a part of it. 5. A concrete slab (100) according to one of claims 1-4, characterized in that the locking element (7) is a projection adapted to flex concrete slabs (100) when installed together and its end (7.1) is adapted to be placed against the opposite surface (8.1) of the adjacent concrete slab recess (8) or in its immediate vicinity. 6. A concrete slab (100) according to one of claims 1-5, characterized in that the concrete (20) is reinforced. 7. A concrete slab (100) according to one of claims 1-6, characterized in that the concrete (20) is attached to the frame (10) with anchors (5). 8. A concrete slab (100) according to one of the patent claims 1-7, characterized in that the height of the frame (10) is at least partially lower than the thickness (c) of the concrete slab of the circle (P). 9. A concrete slab (100) according to one of the patent claims 1-8, characterized in that its upper surface, which is the first or second surface (21, 22), has a region in a different direction compared to the lower surface. 10. A method for the production of a concrete floor (200), according to which the said floor is assembled from concrete slabs to be connected with pontoon joints (J), known for including the following steps: a. concrete slabs (100) defined in one of the patent claims 1-9 are produced, b. on top of the base (50) N guide members (51) with a certain advantageous height (H) are installed at a certain preferred division (L) determined by the length of the mentioned concrete slabs = 25, whose upper surfaces (51.1) determine the lower, first or the line of the other surfaces (21, 22). which is 0 in all respects above the bottom (50), E c. the width (S) of the guide member (51) is smaller than their division (L) and they are arranged in such a way that they support the pontoon joints (J) at least during installation, = d. concrete slabs (100) are attached and locked together with locks (6) and locking elements (7), €. the spaces (52) between the base 50, the guide elements (51) and the concrete slabs (100) are filled with filler (53). 11. The method according to claim 10, characterized in that the locking element (7) is fitted to the recess (8) of the adjacent concrete slab (100) in such a way that its end (7.1) is placed against the opposite surface (8.1) of the recess or in its immediate vicinity. 12. The method according to claim 10 or 11, characterized in that the base (50) is formed from sand. 13. The method according to one of claims 10-12, characterized in that the control elements (51) are formed from polyurethane sheets. 14. The method according to one of claims 10-13, characterized in that polyurethane foam is used as the filler (53) filling the space (52). 15. The method according to claim 14, characterized in that the filler is installed in stages, as the completion of the concrete floor (200) progresses. = O OF N > LO I a a 0) Lo « = OF O OF