JPH1018491A - Composite light-weight floor board and manufacture and installation method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a composite light-weight floor slab having excellent structural performance, fire-resistive performance and sound-insulating performance in spite of light weight by forming a mortar layer on the underside of a reinforcing truss, a light-weight concrete layer on a top face and a foamed mortar layer in an intermediate section. SOLUTION: Reinforcing trusses 20, 20 consisting of top chord bars 22, 22, lower chord bars 24, 24 and lattice bars 26, 26 are installed into forms, and mortar is placed and a mortar layer 12 is formed. Foamed mortar having specific gravity of approximately 0.5 is poured and cured immediately after the placing of mortar, and a foamed mortar layer 16 is formed. The foamed mortar layer 16 is cured, light-weight concrete is placed and a light-weight concrete layer 14 is formed, and the composite light-weight floor slab 10A is manufactured. The composite light-weight floor slab 10A has structural performance, fire-resistive performance, sound-insulating performance, etc., equivalent to or higher than that of the conventional reinforced concrete floor slab in spite of light weight. A beam is laid on the floor slab 10A, concrete is placed in a joint section, and adjacent floor slabs 10A and beams are integrated at the time of the execution of works.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite lightweight floor panel used as a floor panel of a building, and more particularly to a composite lightweight floor panel capable of reducing the weight of the floor, and a method of manufacturing and installing the composite lightweight floor panel.

[0002]

2. Description of the Related Art Generally, floor boards of buildings have the following roles. (1) To provide a comfortable living space by supporting vertical loads and preventing vertical vibration interference. (2) Deformability of the building during an earthquake is improved by the in-plane rigidity of the floor. (3) By integrating the floor with the beam, the beam can be evaluated as a T-shaped cross-section beam, thereby increasing the rigidity of the beam against a vertical load, eliminating vibration disturbance, and improving comfort. (4) Cut off the sound of the upper and lower floors. (5) It exhibits excellent fire resistance to prevent fires on the upper and lower floors in the event of a fire.

In order for the floor panel to have the above functions, it must have excellent in-plane rigidity, sound insulation performance, and fire resistance in addition to bending strength against a vertical load. Therefore, most of the floorboards used for ordinary buildings are made of reinforced concrete, with some exceptions, in order to satisfy the above conditions. That is, the reinforced concrete floorboard has high rigidity, and also has excellent sound insulation performance and fire resistance performance.

[0004] However, in order to satisfy all the above-mentioned performances in a reinforced concrete floor plate, the thickness and the weight of the floor plate are extremely large. For this reason, the fixed load of the floor occupies a large specific gravity in the whole building,
The effect on building costs was significant.

[0005]

As described above, the conventional reinforced concrete floorboard is excellent in structural performance, fire resistance, and sound insulation performance, and is a structure suitable for floorboards. During construction, there were the following disadvantages.

(1) The weight of the floor increases the weight of the whole building. (2) In order to cope with a long span, the thickness of the floorboard becomes larger and the design becomes more difficult. For this reason, a long beam requires a small beam. (3) During construction, there are many man-hours, including formwork, rebar construction, concrete casting, and the work cannot be dismantled until the specified concrete strength is developed, so it takes a lot of time to complete. However, it greatly affects the construction period of the entire frame. Accordingly, an object of the present invention is to provide a floor panel having structural performance, fire resistance performance, sound insulation performance, and the like that are equal to or higher than those of the related art and capable of achieving weight reduction, and a method of manufacturing and performing the same.

[0007]

In order to achieve the above object, a composite lightweight floor panel according to the present invention comprises a mortar layer or a lightweight concrete layer provided on a lower surface of a reinforced truss, and an upper surface of the reinforced truss. A non-combustible, lightweight, and foamed material provided between the provided lightweight concrete layer, the mortar layer or the lightweight concrete layer on the lower surface of the reinforced truss, and the lightweight concrete layer on the upper surface of the reinforced truss. And a foamed layer that has been formed. Further, the present invention is characterized in that a mortar layer or a lightweight concrete layer on a lower surface of the reinforced truss is joined to a lower chord material of the reinforced truss. Further, the present invention is characterized in that the lightweight concrete layer on the upper surface of the reinforced truss is joined to the upper chord of the reinforced truss.
Further, the present invention is characterized in that reinforcing bars are arranged on at least one of an upper surface and a lower surface of the reinforcing bar truss. Further, the present invention is characterized in that the specific gravity of the foam layer is about 0.5. Further, the present invention is characterized in that the foam layer is made of foam mortar.

In the method for manufacturing a composite lightweight floor panel according to the present invention, a mortar layer or a lightweight concrete layer is poured into a lower surface of a reinforced truss to provide a mortar layer or a lightweight concrete layer. Property, light weight, foam material obtained by foaming a material having strength is continuously poured into a predetermined thickness to provide a foam layer, and after the foam layer is cured, on the upper surface of the foam layer and on the upper surface of the reinforcing steel truss. Lightweight concrete is cast to provide a lightweight concrete layer. Further, the construction method of the composite lightweight floor panel according to the present invention is to provide a mortar layer or a lightweight concrete layer on the lower surface of the reinforced truss and foam a nonflammable, lightweight, strength material as an intermediate layer on the upper surface. After placing the composite lightweight floor panel as a semi-finished product provided with the foamed layer on the beam and placing the composite lightweight floor panel on the beam, a lightweight concrete layer is struck on the upper surface of the foam layer and on the upper surface of the reinforced truss. It is characterized in that it is provided.

Further, the present invention is characterized in that the lightweight concrete layer on the upper surface of the foam layer is cast over a plurality of composite lightweight floor boards as semi-finished products. Further, the present invention, by casting the lightweight concrete layer over the composite lightweight floorboard as a plurality of semi-finished products, through a joint provided on a beam arranged at the joint of each composite lightweight floorboard It is characterized by joining each composite lightweight floor panel and beam.

In the present invention, a mortar layer or a lightweight concrete layer is provided on the lower surface of the reinforced truss, a lightweight concrete layer is provided on the upper surface, and a foam layer is provided in the middle. The mortar layer or lightweight concrete layer provided on the upper and lower surfaces resists, and the fire resistance and sound insulation are prevented by the combination of the mortar layer or lightweight concrete layer and the foam layer. According to the present invention, compared to the conventional reinforced concrete floorboard, sufficient structural performance,
Fire resistance and sound insulation performance can be obtained, and significant weight reduction can be achieved. The composite lightweight floor panel having such a structure can be manufactured in a factory as a finished product having a three-layer structure of a mortar layer or a lightweight concrete layer on the lower surface, an intermediate foam layer, and a lightweight concrete layer on the upper surface. In this case, only the work of placing concrete at the joint between the composite lightweight floorboards is performed at the site, so that the construction work at the construction site can be simplified and the construction period can be shortened. In addition, it can be produced in a factory as a semi-finished product consisting of only two layers, a mortar layer or a concrete layer on the lower surface and a foam layer in the middle, and a lightweight concrete layer on the upper surface can be post-punched at the construction site,
This is advantageous in increasing the integration between the composite lightweight floor panel and the beams and the mutual integration between the composite lightweight floor panels.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment of a composite lightweight floor panel according to the present invention will be described. FIG. 1 is a sectional view showing an example of a composite lightweight floor panel according to the present invention, and FIG. 2 is a sectional view showing a manufacturing process of the composite lightweight floor panel. The composite lightweight floor slab 10A of this example has a high strength mortar layer 12 on the lower surface of the reinforced truss 20 and an ultralight concrete layer 14 on the upper surface of the reinforced truss 20, and the mortar layer 12 and the ultralight concrete layer 14 It has a three-layer structure in which a foam mortar layer 16 is provided in the middle. The foam mortar layer 16 is formed by mixing water, cement, and a foaming agent to foam.

On both upper and lower sides of the reinforcing bar truss 29, wire mesh bars 2 for reinforcing cracks are provided as necessary.
A and 2B are arranged. Further, in this example, a part of the lattice 26 and the lower chord 24 are embedded in the mortar layer 14 on the lower surface, and a part of the upper chord 22 and the lattice 26 of the reinforcing bar truss 20 are formed on the ultralight concrete layer on the upper surface. Embedded in the mortar layer 12 and the foam mortar layer 16
And the super lightweight concrete layer 14 are integrated. This floor panel 10A has a thickness of about 15 cm to 20 cm, for example.
cm, width about 180cm ~ 240cm, length about 4m ~ 6m
To the extent possible, determine the allocation according to the building and adjust the width and length. The super-lightweight concrete layer 14 on the upper surface and the mortar layer 12 on the lower surface have a specific gravity of 1.0-1.
It is made of an ultra-lightweight concrete of about 5 with a thickness of about 1 cm to 3 cm.
Are integrated by filling a material having a specific gravity of about 0.5.
Thereby, the weight of the floor panel 10A is 12 per m ² .
It will be about 0-150 kg. Therefore, compared with a conventional reinforced concrete floor panel, the weight of the floor panel is reduced from one-half to one-third, and the weight of the entire structural body can be significantly reduced by reducing the weight of the floor panel itself.

FIGS. 3 and 4 are perspective views showing specific examples of the reinforcing truss 20 used for the floor panel 10A of the present embodiment.
This reinforcing bar truss 20 has a large diameter upper chordal bar 22 and a lower chordal bar 24.
Are spot-welded with a small-diameter lattice stitch 26 bent obliquely in a waveform. Generally, as shown in FIG. 3, there are a three-dimensional configuration using two lower chords 24, and a ladder-like configuration as shown in FIG. Is also good.

Next, the manufacturing process of the composite lightweight floor panel 10A as described above will be described. First, after the reinforced truss 20 shown in FIGS. 3 and 4 is created, it is installed at a predetermined interval.
Attach a horizontal streak not shown if necessary. Then, the unit rebar assembled in this manner is installed in a mold (not shown). Note that a wire mesh bar 2B is arranged on the lower surface of the reinforcing bar truss 20. In this state, FIG.
As shown in (1), a mortar layer 12 is formed by casting mortar with a thickness of about 1 cm to 3 cm. Immediately after the mortar layer 12 is cast, a foamed mortar having a specific gravity of about 0.5 is poured onto the mortar layer 12 to a predetermined thickness and cured as shown in FIG. I do. The reason why the foamed mortar layer 16 is formed by pouring the foamed mortar immediately after the mortar layer 12 is cast is that by pouring the foamed mortar layer 16 before the mortar layer 12 is hardened, the mortar layer 12 and the foamed mortar layer 16 can be formed more easily. This is for firm bonding. In this example, in this state, a part of the upper chord reinforcing bar 22 and the lattice bar 26 protrudes from the upper surface of the foam mortar layer 16 in this state. And
After the foamed mortar layer 16 is hardened, wire mesh bars 2A are arranged on the upper surface of the reinforcing bar truss 20, and as shown in FIG.
The ultra-lightweight concrete layer 14 is formed, and the composite lightweight floorboard 10A is completed as one.

Next, FIG. 5 to FIG. 7 are cross-sectional views showing specific examples when the composite lightweight floor panel 10A as described above is joined to a beam. FIG. 5 shows an example in which the composite lightweight floor panel 10A described above is joined to the steel beam 30. The peripheral edge of the vertically formed composite lightweight floor panel 10A is laid so as to be in contact with the beam flange 30a of the steel beam 30, and joints are formed. Post-cast concrete 3 to 40
2, the composite lightweight floor panel 10A and the steel beam 30 are integrated. In addition, a cotter, a dowel or the like (not shown) is provided on the periphery of the ultralight concrete layer 14 of the composite lightweight floor panel 10A, and a stud dovetail 34 is provided on the upper surface of the steel beam 30, so that the post-cast concrete 32 is used. Sufficient in-plane rigidity is obtained. In the figure, reference numeral 3002 denotes a reinforcing material.

FIG. 6 also shows an example in which the composite lightweight floor panel 10A is joined to the steel beam 30.
By forming the periphery of the composite lightweight floorboard 10A into an inclined surface, the periphery of the composite lightweight floor panel 10A is
From the beam flange 30
The composite concrete floor plate 10A and the steel beam 30 are integrated by casting a post-cast concrete 32 into the joint portion 40 so as to involve the a. In addition, also in this example, a cotter, a dowel, or the like is provided on the periphery of the composite lightweight floor panel 10A,
A stud dowel 34 is provided on the upper surface of the steel beam 30. With such a structure, higher rigidity can be obtained.

FIG. 7 shows an example in which the composite lightweight floor panel 10A is joined to the reinforced concrete beam 36. The periphery of the composite lightweight floor panel 10A is laid on the beam main reinforcement 36a of the beam 36 at a predetermined interval. A post-cast concrete 38 is cast, and the composite lightweight floor panel 10A and the beam 36 are integrated.
In addition, at the time of such a joint work of the joint portions 42, a concrete pouring operation into the formwork 36A of the reinforced concrete beam 36 may be performed at the same time. In addition, as a beam which joins the composite lightweight floor panel 10A of this example, in addition to the above-described steel structure or reinforced concrete structure, a steel-frame reinforced concrete structure may be used, and various types may be employed.

In the above-described structure, the mortar layer 1 provided on the upper and lower surfaces of the reinforced truss 20 is not affected by a vertical load.
2 and the concrete layer 14, and fire resistance and sound insulation are prevented by the combination of the mortar layer 12, the concrete layer 14, and the foam mortar layer 16. For the in-plane rigidity, joints 40 and 42 of floor plate 10A and beams 30 and 36 are provided.
The concrete is filled with concrete 32 and 38, and is secured by being integrated via a joint provided on the peripheral portion of the floor plate 10A and the beam 30 to secure rigidity of the entire floor. As a result, sufficient structural performance, fire resistance performance, and sound insulation performance can be obtained and a significant reduction in weight can be achieved as compared with the conventional reinforced concrete floor panel.

As described above, since the weight of the floor occupies a large part in the building, if the floor is light, the weight of the building can be greatly reduced, and the foundation can be positively affected. Also, when the building weight is reduced, the horizontal load acting upon the earthquake is reduced, and the cross sections of columns and beams can be reduced. In addition, since the floorboards are lightweight, the transportation cost per sheet when manufactured in a factory is reduced, and the size of the lifting machine required at the time of assembly can be reduced. As described above, there are many factors for cost reduction due to weight reduction of floorboards, and overall frame cost can be significantly reduced. In addition, the composite lightweight floor panel of this example can be completed by laying the factory-produced floor panel on horizontal members such as beams and then processing the joints to complete the floor work. Only temporary parts are needed, and no temporary materials such as supports are required, and labor on site can be saved, and the construction period can be significantly reduced.

In the above example, the case where the composite lightweight floor panel 10A having a three-layer structure is laid on a beam in a completed state has been described. However, the mortar layer 12 on the lower surface and the intermediate foam mortar layer 16 are semi-finished products. Composite lightweight floorboard 1
After forming 0B and laying it on the beam, the ultra-lightweight concrete layer 16 on the upper surface may be cast. That is, at the stage of factory production, the semi-finished product is manufactured as shown in FIG. Then, at the construction site, after the semi-finished composite lightweight floor panel is laid on a horizontal member such as a beam, the concrete layer on the upper surface and the concrete on the joint are integrally formed.

FIGS. 8 and 9 are cross-sectional views showing a specific example in which such a semi-finished composite lightweight floor panel 10B is joined to a beam. In the example of FIG. 8, the composite lightweight floor panel 10B is laid so as to be in contact with the beam flange 44a of the steel beam 44, and two adjacent composite lightweight floor panels 10B and a joint 46 between them are straddled to form a post-cast concrete. By casting 48, the concrete layer 14 on the upper surface of each composite lightweight floor panel 10B is formed, and the joint portions 46 are joined and integrated. A stud dowel 50 is provided on the upper surface of the steel beam 44. Further, a reinforcing member 44 </ b> A is provided in a lower half portion of the steel beam 44.

FIG. 9 shows an example in which the periphery of the composite lightweight floor panel 10B is laid on the beam main reinforcement 52a of the reinforced concrete beam 52 at a predetermined interval, and two adjacent composite lightweight floor panels 1B are laid.
0B and a post-cast concrete 56 over the joints 54 between the composite lightweight floorboards 1B.
While forming the concrete layer 14 of the upper surface of 0B,
The joint portions 54 are joined to be integrated. As described above, the semi-finished composite lightweight floor panel 10B also has sufficient structural performance, fire resistance performance, and sound insulation performance as compared with the conventional reinforced concrete floor panel, similarly to the case of the above-described completed composite lightweight floor panel 10A. At the same time, significant weight reduction can be achieved, and various advantages can be obtained by reducing the weight of the floorboard. Further, the composite lightweight floor panel 10B as a semi-finished product can be factory-produced, which can save labor and shorten the construction period of the on-site work as compared with the related art, and also enables the formation of the concrete layer on the upper surface of the floor panel 10B and the treatment of joints. In addition to being able to be performed in an integrated operation, the operation process can be simplified, and there is an advantage that a high rigidity can be obtained by an integral concrete layer straddling each floor plate.

In each of the above examples, the case where the mortar layer 12 is provided on the lower surface of the reinforcing truss 20 has been described, but a lightweight concrete layer may be provided instead.
Further, in each example, the case where the foamed layer is formed using foamed mortar has been described, but a material having nonflammability, light weight, and strength other than mortar may be foamed.

[0024]

As described above, the composite lightweight floor panel of the present invention has a structure in which a mortar layer or a lightweight concrete layer is provided on the lower surface of a reinforced truss, a lightweight concrete layer is provided on the upper surface, and a foam layer is provided in the middle. did. for that reason,
Compared with the conventional reinforced concrete floor panel, sufficient structural performance, fire resistance and sound insulation performance can be obtained, and a great reduction in weight can be achieved, which can contribute to cost reduction and the like. Also,
The composite lightweight floorboard of the present invention can be manufactured as a finished product by factory production, and when the finished product is produced by factory production, the work on site is only the work of casting concrete at joints between the composite lightweight floorboards. Therefore, the construction work can be simplified, and the construction period can be shortened. In addition, it is also possible to produce at the factory as a semi-finished product of only two layers, a mortar layer or a concrete layer on the lower surface and a foam layer in the middle, and postpone the lightweight concrete layer on the upper surface at the construction site. This is advantageous in increasing the integration between the composite lightweight floor panel and the beam and the mutual integrity of the composite lightweight floor panel.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an example of a composite lightweight floor panel according to the present invention.

FIG. 2 is a sectional view showing a manufacturing process of the composite lightweight floor panel of FIG.

FIG. 3 is a perspective view showing an example of a reinforcing truss.

FIG. 4 is a perspective view showing another example of a reinforcing truss.

FIG. 5 is a cross-sectional view showing an example of a laid state of the composite lightweight floor panel of FIG.

FIG. 6 is a sectional view showing another example of a laid state of the composite lightweight floor panel of FIG. 1;

FIG. 7 is a sectional view showing still another example of a laid state of the composite lightweight floor panel of FIG. 1;

FIG. 8 is a sectional view showing an example of a laid state of a composite lightweight floor panel as a semi-finished product.

FIG. 9 is a cross-sectional view showing another example of a laid state of a composite lightweight floor panel as a semi-finished product.

[Explanation of symbols]

 10A, 10B Composite lightweight floor panel 12 Mortar layer 14 Ultra-light concrete layer 16 Foamed mortar layer 20 Reinforced truss 30,44 Steel beam 32,38,48,56 Back-cast concrete 36,52 Reinforced concrete beam 40,42,46,54 Joint

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor: Ryoaki Kondo 300, Onagi, Yokkaido, Chiba Pref.

Claims (10)

[Claims] 1. A mortar layer or a lightweight concrete layer provided on a lower surface of a reinforced truss arranged, a lightweight concrete layer provided on an upper surface of the reinforced truss, and a mortar layer or lightweight concrete on a lower surface of the reinforced truss. And a foam layer formed by foaming a nonflammable, lightweight, and strong material provided between the lightweight concrete layer on the upper surface of the reinforced truss. . 2. The composite lightweight floor panel according to claim 1, wherein a mortar layer or a lightweight concrete layer on a lower surface of the reinforcing truss is joined to a lower chord of the reinforcing truss. 3. The lightweight concrete layer on the upper surface of the reinforced truss is joined to the upper chord of the reinforced truss.
Or the composite lightweight floor panel according to 2. 4. The composite lightweight floor panel according to claim 1, wherein a reinforcing bar is provided on at least one of an upper surface and a lower surface of the reinforcing bar truss. 5. The composite lightweight floor panel according to claim 1, wherein the specific gravity of the foam layer is about 0.5. 6. The composite lightweight floor panel according to claim 1, wherein the foam layer is made of foam mortar. 7. A mortar or lightweight concrete layer is poured into the lower surface of a reinforced truss by a predetermined thickness to provide a mortar layer or a lightweight concrete layer. The foamed material obtained by foaming the foamed material is continuously poured into a predetermined thickness to form a foamed layer, and after the foamed layer is hardened, light-weight concrete is poured on the upper surface of the foamed layer and on the upper surface of the reinforcing steel truss to form a lightweight concrete layer. A method for manufacturing a composite lightweight floor panel. 8. A semi-finished product in which a mortar layer or a lightweight concrete layer is provided on the lower surface of a reinforced truss, and a foam layer formed by foaming a material having noncombustibility, light weight, and strength as an intermediate layer is provided on the upper surface. After arranging the composite lightweight floor panel on the beam, and arranging the composite lightweight floor panel on the beam, a lightweight concrete layer is cast on the upper surface of the foam layer and on the upper surface of the reinforced truss. The construction method of the composite lightweight floorboard. 9. The method according to claim 8, wherein the lightweight concrete layer on the upper surface of the foam layer is cast over a plurality of composite lightweight floor boards as semi-finished products. 10. The light weight concrete layer is cast over the plurality of composite lightweight floorboards as semi-finished products, so that each of the composite lightweight floorboards is connected via a joint provided on a beam arranged at a joint portion of each composite lightweight floorboard. The method for constructing a composite lightweight floor panel according to claim 9, wherein the composite lightweight floor panel and the beam are joined.