SE529224C2 - Floor Concrete device - Google Patents

Abstract

A concrete floor assembly is disclosed including a subfloor element with a floor side and a ground/ceiling side, and a top casting layer. In at least one embodiment, the subfloor element includes a concrete portion on the floor side, which concrete portion has a bottom casting surface with a surface roughness. The top casting layer includes a casting composition, which includes a self-compacting concrete and a shrinkage reducing admixture. The top casting layer is cast on the floor side of the subfloor element so that at least a portion of the bottom casting surface is covered by the top casting layer, the bottom casting surface having such surface roughness that the top casting layer adheres to the bottom casting surface. A method of providing such a concrete floor assembly is also disclosed, as well as a floor assembly.

Description

25 30 35 529 224 2 There are several systems on the market for creating a flat floor on top of a curved floor deck. According to a system, a plurality of studs are first attached at regular intervals over the hollow deck. Then carefully balanced bars are attached to the studs, so that the bars form a horizontal base for a parquet floor or a subfloor in the form of, for example, a chipboard; The mounting height of the studs can be selected so that even electrical or water pipes can fit under the floor. A disadvantage of this system is that it is laborious and time consuming. In addition, it is difficult to achieve high precision, which is why the floor may sag or tilt.

Another system for obtaining a flat surface for floor laying is the application of a so-called leveling compound to the holding deck. A disadvantage of the use of leveling compound is that it is expensive. Therefore, it is not desirable to use leveling compound in layers that are thick enough to pour in electrical or water pipes. In addition, it is difficult to predict how the leveling compound dries out and how long the drying takes when applied in such thicker layers. If the surface is not sufficiently dry when the floor (for example parquet or a plastic mat) is laid, the floor may be damaged by moisture or there may be problems with mold.

Attempts have also been made using ordinary concrete instead of leveling compound. It has been found that if ordinary concrete is cast on a prefabricated hollow core element in layers thinner than 100 mm, problems arise with the concrete adhering to the substrate both centrally and along the edges, so-called "boom" and "edge erection". This is mainly due to the fact that thin layers have a strong moisture gradient, which leads to the surface layer wanting to bend. It is usually not possible to use concrete layers that are sufficiently thick to avoid these problems, as it requires such large volumes that the use of ordinary concrete also becomes too expensive. In addition, it is a problem that thick concrete layers need a long time to dry out, which prolongs and thus makes the construction process more expensive. Summary of the invention The object of the present invention is therefore to provide a floor concrete device which in a cost-effective manner. method enables the laying of a flat floor at the desired height and to provide a method for providing such a floor concrete device and a method for providing a floor device.

These objects are achieved according to the invention by means of a floor concrete device and methods according to claims 1, 14, 23.

The floor concrete device according to the invention thus comprises a subfloor element with a floor side and a ground / roof side, and a pouring layer.

The subfloor element comprises a concrete portion on the floor side and the concrete portion has an exposed surface, and the pouring layer comprises a pouring composition comprising a self-compacting concrete and a shrink-reducing additive. The casting layer is cast on the floor side of the subfloor element so that at least a portion of the exposed surface is covered by the casting layer. Thanks to the exposed surface of the subfloor element, which allows good adhesion, according to the invention it has been found possible to use a pouring composition which is based on a self-compacting concrete if it contains an addition of shrinkage reducer. Such a casting composition is significantly more affordable than known leveling compounds. Due to the good adhesion to the subfloor element and the shrink-reducing additive, it is possible according to the invention to cast a layer which is thick enough to meet the requirements for sound insulation and requirements for the casting of pipes, but not so thick that an unnecessary amount of material is consumed. Furthermore, the pouring composition, which according to the invention is based on a self-compacting concrete, advantageously, unlike ordinary concrete, does not need to be vibrated but lays down substantially horizontally by itself. Thus, a very small work effort is achieved because, according to the invention, it has a flat surface even without leveling compound. Thanks to an affordable casting composition and a rational application method, the floor concrete device according to the invention is thus significantly more cost-effective than the conventional alternatives.

The floor concrete device according to the invention is intended to be part of a floor layer for a building structure, for example buildings such as residential buildings, office or industrial premises, or facilities such as sports facilities, underground rooms or silo buildings.

The floor concrete device according to the invention can be part of or the entire base layer of the floor. It can also form a non-load-bearing part of the floor.

According to the invention, a floor concrete device thus means a portion of a floor layer, which portion forms a substrate which is suitable for floor laying or which can in itself function as a floor.

The term subfloor element refers to a cast-in-place or prefabricated element.

The subfloor element can extend over the entire floor of a room or over the entire floor of a floor, but can also form a slab with a limited extent.

The subfloor element has a floor side and a ground / roof side.

The floor side is the side that in normal use forms part of the base for a floor. The ground / roof side is the side that in normal use faces the roof of a lower floor and the ground, respectively, in the event that the subfloor element belongs to a first floor.

According to an embodiment of the invention, the subfloor element constitutes a supporting, prefabricated V 10 15 20 25 30 35 in 529 224 hollow deck element. Several such perforated deck elements can be joined together so that they extend over an entire floor plan. According to an embodiment of the invention, the subfloor element constitutes a hollow deck element with prestressed reinforcement. Due to the prestress, such perforated deck elements are usually curved, that is, they have an arcuate longitudinal section. By casting the pouring layer according to the invention on the arcuate floor side of the hollow core element, the floor concrete device can be provided with a flat floor side which is suitable as a base for floor laying.

If the subfloor element has a curvature, or in other words an arcuate section, and the pouring layer is such that the floor concrete device has a flat floor side, the thickness of the pouring layer will vary over the section. It has its minimum thickness where the curve of the arc has its maximum. Usually such a subfloor element has its minimum thickness approximately in the middle and its maximum thickness at two opposite edge sides.

The subfloor element according to the invention may be of concrete or reinforced concrete, but may also comprise other materials. According to the invention, at least a portion of the floor side of the subfloor element has a surface of concrete of which at least one portion is exposed.

Exposure in this application refers to the removal of surface skin, surface sludge and fine ballast particles from the concrete surface so that coarser ballast appears.

Such exposed surfaces are known to produce aesthetic effects. According to the invention, however, the prominent ballast is used to increase the surface roughness on the surface of the subfloor element. Increased roughness on the subfloor element surface means increased adhesion between the subfloor element and the casting layer, which reduces the risk of a boom and edge erection. Another positive effect is that the upper surface is also strengthened by removing loose-fitting mortar. Thus, by means of the exposure according to the invention, two properties are obtained for the adhesion of the casting layer to the subfloor element, namely increased surface roughness and strong concrete in the joint.

According to the invention, substantially the entire floor side of the subfloor element can be exposed or only a portion thereof. The casting layer can cover substantially all or a portion of the floor side of the subfloor element, however, at least a portion of the exposed surface is covered.

In some embodiments, the adhesion of the casting layer may be sufficient even if the entire surface of the floor element covered by the casting layer is not exposed.

According to an embodiment of the invention, the concrete portion of floor concrete elements has a deeply exposed surface, i.e. ballast in the concrete surface is exposed to such a depth that the coarser ballast grains appear markedly. The depth can be greater than 1/3 of the maximum size of the surface ballast.

According to an embodiment of the invention, a membrane hardener is applied to the casting layer so that the post-curing takes place under the influence of the membrane hardener.

Membrane hardeners or (membrane hardening liquids) are agents that delay the drying of the concrete during hardening.

The membrane hardener forms a thin film over the freshly cast surface so that it does not usually need to be watered.

Membrane hardeners of different chemical composition, e.g. wax dispersions, acrylate polymers or latex emulsions are commercially available. Preferred. membrane hardeners meet specifications according to ASTM C 309, Liquid Membrane-Forming Compounds for Curing Concrete, e.g. specifications of maximum moisture loss specified therein. Thanks to the application of the membrane hardener to the casting layer, it is ensured that the casting layer does not dry out too quickly during the first hours after casting, whereby advantageous plastic shrinkage formation in the surface layer is avoided. According to an embodiment of the invention, the subfloor element is pre-watered before the casting composition is cast on the subfloor element. This advantageously prevents water from the casting composition from being sucked into the subfloor element, which would impair the strength of the layer in the casting layer which is closest to the subfloor element.

According to an embodiment of the invention, a plurality of subfloor elements are joined to a subfloor unit with or without the aid of connecting material. For example, the subfloor elements can be joined together by joint casting, but it is also possible for the subfloor elements to be laid loosely next to each other so that they are attached to each other or to a substrate. Thereafter, the casting composition is cast so that a casting layer is formed which extends over several subfloor elements, whereby a floor device according to the invention is provided. According to one embodiment, substantially the entire floor side of the subfloor elements is exposed and the casting layer extends over substantially the entire subfloor unit. Thanks to the self-leveling properties of the casting composition, it is hereby possible to provide a flat surface for flooring with a single casting of a layer. In addition, electricity and / or pipelines can be cast into the casting layer.

The pour-on composition according to the invention comprises a self-compacting concrete and a shrink reducer. Self-compacting concrete is compacted homogeneously under the influence of its own weight and fills a mold without the vibration insert required for ordinary concrete. This means opportunities for a rational casting process without vibration, with reduced time and reduced staffing needs. The concrete also becomes self-leveling, which means that it does not need to be coated with leveling compound before laying the floor, which means a large cost saving. Self-compacting concrete and various types thereof are described in The European Guidelines for Self-Compacting Concrete - Specification, 10 15 20 25 30 35 ~ s29 224 8 Production and Use, May 2005, issued by the Self-Compacting Concrete European Project Group, formed by BIBM, CEMBUREAU, ERMCO, EFCA and EFNARC.

Concrete consists mainly of stone material (ballast) of varying grain size which is bonded together by a cement glue (cement paste) consisting of cement and water. A common mixing ratio in volume parts is one part water, one part cement, two parts sand and three parts stone. Additives that modify the properties of the concrete in different directions can also be included. For self-compacting concrete, it is generally the case that the proportion of small aggregate (eg sand and gravel) is greater, and the proportion of large aggregate (eg traditional concrete. It is also common for stone) to be smaller, than in self-compacting concrete use fine-grained materials such as lime or glass filler. A common additive in self-compacting concrete are commercially available floating additives, so-called superplasticizer, which can make the self-compacting concrete easy to move and flexible. According to an embodiment of the invention, the self-compacting concrete has a flow dimension> 520 mm, preferably> 650 mm. Measurement of the buoyancy measure is a survey to assess the buoyancy of self-compacting concrete in the absence of obstacles. It is based on the method described in EN 12350-2. The result is an indication of the filling capacity of the self-compacting concrete. Thus, flow rate is the average diameter of the spread of fresh concrete using a conventional rate cone. Measurement of flow modes is defined in Annex B.l to The European Guidelines for Self-Compacting Concrete - Specification, Production and Use and is summarized below. i - Prepare the cone and base plate as described in EN 12350-2.

- Place the cone coincident with the 200 mm circle of the base plate and hold it in position by standing on the footrests 10 15 20 25 30 35 529 224 9 (or use the collar weight) and ensure that concrete cannot leak under the cone.

- Fill the cone without stirring and wipe off the excess from the top of the cone. Let the cone stand for a maximum of 30 s and during this time remove any concrete spills from the base plate.

Make sure that the base plate is moist over the entire surface but free from excess water.

- Lift the cone vertically in one movement without disturbing the concrete flow. Measure, without affecting the base plate or the concrete, the largest diameter of the poured concrete and the diameter of the poured concrete perpendicular to the largest diameter.

- The flow measure is the average of the two measured diameters.

Self-compacting concrete can become very prone to shrinkage due to small amount of large aggregate and large amount of fine material and / or lime filler, which can be used to make the concrete self-compacting. To reduce shrinkage and thereby reduce the risk of boom and edge erection, shrink-reducing additives are used.

Such shrink reducers include, for example, various types of alcohols. They are assumed to work mainly by lowering the surface tension in the pore water, whereby the shrinkage stresses in the concrete are reduced. Shrink-reducing additives are commercially available and those skilled in the art can select a suitable agent based on the composition of the concrete and the tendency to shrink, etc. A suitable shrink-reducing additive may comprise a polyalcohol, preferably 2,2-dimethylpropane-1,3-diol.

Lime filler contributes to the self-compacting properties of concrete. Lime fillers have also been shown to accelerate dehydration due to their effect on the structure of the pore system. This accelerated drying means that concrete containing lime filler meets the requirements for the relative humidity (RH) of the concrete before carpet laying.

Lime filler is commercially available in several qualities. For use according to the invention, limestone fillers, for example crystalline limestone fillers with an average grain size <0.05 mm, preferably 0.025-0.05 mm, have been found to give the desired combination of contribution to the self-compacting properties of the concrete and contribution to accelerated dehydration.

The high amount of fine material in self-compacting concrete increases the need for water, which further increases the tendency to shrink. Self-compacting concrete for use according to the invention has a water cement number> 0.5, preferably> 0.55.

By utilizing the positive effect of lime fillers on dehydration, according to the invention, rapid dehydration can be obtained without lowering the water cement number, which can otherwise increase the risk of boom and edge erection. Thanks to the rapid drying of the casting composition, the flooring is not delayed and a fast and efficient construction process can be maintained.

Brief description of the drawings The invention will be explained in more detail below with the aid of exemplary embodiments and with reference to the accompanying drawing. Figure 1 is a schematic longitudinal sectional view of a floor concrete device according to the invention.

Figure 2 is a schematic cross-sectional view of a floor concrete device according to the invention.

Figure 3 is a schematic top view of a subfloor element according to the invention. Figure 4 is a schematic top view of a floor device according to the invention, a part of the figure showing joined subfloor elements under the casting layer.

Description of preferred embodiments With reference to Figures 1 and 2, a floor concrete device according to the invention is schematically shown.

The floor concrete device comprises a subfloor element in the form of a prefabricated hollow core element 1.

The hollow deck element 1 comprises longitudinal reinforcing ropes 2 which prestress the hollow deck element 1, whereby it obtains a curved longitudinal section. The prestress and the curvature advantageously result in a good ability to absorb stresses and thus also a good load-bearing capacity.

The hollow core element 1 is further provided with weight-reducing material recesses in the form of longitudinal holes 3.

The hollow deck element 1 according to the example is 10 m x 1.20 m x 0.265 m.

The hollow deck element 1 has a floor side 9 which in use forms an upper side and a ground / roof side 10 which in use forms a lower side.

The holding deck element 1 has an arcuate shape, in which case it is curved upwards during use. If the hollow deck element 1 is laid on a flat surface, the difference between the height of the upper surface 9 of the hollow deck element 1 above the base at the half length of the hollow deck element 1 and at its short ends is 15 mm.

The hollow core element 1 is made of a known concrete mixture also comprising coarser ballast grains 5 with a diameter of approximately 12 mm. The hollow deck element 1 has a concrete surface which covers the entire floor side 9, wherein in the example shown the entire concrete surface on the floor side 9 is exposed, cf. figure 3. The concrete surface is deeply exposed down to a depth corresponding to approximately half the diameter of the coarser ballast. In this example, the exposure is 6 mm deep.

A casting layer 6 is cast on the curved floor side 9 and covers the floor side 9 over its entire exposed surface 4. The casting layer 6 has a substantially planar surface facing away from the exposed surface 7. When using the hollow deck element 1 according to the example shown in a floor, the top 7 of the casting layer 6 horizontal. Furthermore, empty pipes 8 for power lines are cast in the casting layer 6. In the example shown, the casting layer 6 has a thickness of 55 mm in the thinnest 10 in 529 224 12 cross section where the curve formed by the holding deck element 1 has its maximum and a thickness of 70 mm at the short ends of the holding deck element l.

»According to the invention, the pouring layer comprises a pouring composition which is based on a self-compacting concrete. Casting composition may, for example, comprise the following sub-materials.

Part material Quantity (kg / HP) Building cement 250 - 500 Lime filler 50 - 200 Sand 0-2 mm 400 - 700 Gravel O-8 mm 500 ~ 1000 Stone 8-ll mm 400 - 700 Floating additives 0.1 - 10 Shrink-reducing 0.1 - Additives Water 100 - 500 10 15 20 25 529 224 = 13 A preferred casting composition has the following composition.

Part material Quantity Manufacturer / supplier (kg / mh Building cement 385 Cement Lime filler ”Limus 40” 135 Nordkalk Sand O-2 mm (Rö) 586 Skanska Gravel O-8 mm (Enköping) 747 Skanska Sten 8-11 mm (Vällsta) 598 Skanska Moving additives The invention also relates to a floor covering which comprises at least one floor concrete device according to the invention.

Referring to Figure 4, according to the invention, such a floor layer may comprise a floor device according to the invention, which can be provided in the following manner.

First, a subfloor element is produced in the form of a hollow deck element 1 with an exposed surface 4. The hollow deck element 1 is cast from a known concrete and comprises a prestressed reinforcement 2. To provide the exposed surface 4 of the hollow deck element 1, a retarding additive is applied (in liquid form). is delayed down to a depth of 6 mm selected with regard to the fact that the ballast grains have a maximum of 12 before the hollow core element has had time to harden. mm diameter. The hollow deck elements are then high-pressure flushed, which means that the surface layer is "cleaned" of cement paste, ie that the ballast is exposed and a rough and clean surface 4 arises. In this example, the floor side 9 of the entire perforated deck element 1 is exposed.

A plurality of such perforated deck elements are then transported to the desired construction.

The hollow deck elements 1 are joined together on the construction to form a subfloor unit which in this example extends over a floor in 529 224 14 storeys, the floor sides 1 of all the hollow deck elements facing upwards. The hollow deck elements 1 are joined together by joint casting. In other embodiments of the invention, it may be sufficient if the hollow core elements are laid next to each other or if they are attached to each other or to a substrate in some other suitable way. The joined hollow core elements 1 with their curved, arcuate longitudinal sections impart a waveform to the upper side of the subfloor unit. Furthermore, thanks to the exposed floor side 9 of the hollow core elements, the entire floor side of the subfloor unit is exposed.

Then pipelines 8 are placed over the subfloor unit in the desired pattern.

Furthermore, a casting composition is mixed according to the above recipe and delivered to the construction company.

The ready-mixed casting composition is pumped out over the subfloor unit so that the pipes 8 are covered and the desired thickness, for example with respect to sound insulation class, is achieved. Prior to that, the subfloor unit was easily watered.

The casting composition forms a casting layer 6 which covers the top of the entire subfloor unit and the pipes 8.

The casting composition is self-leveling, which means that it is compacted by its own weight so that vibration work can be dispensed with. Furthermore, the casting composition is laid so that the casting layer obtains a substantially horizontal surface.

Laying is done with the help of a laser, for balancing at the desired height, and soldering, to obtain flat and even surfaces. Slotting means that you work on the concrete surface with a so-called sling. Usually a soda consists of a shanked plate or tube of plastic. The surface is easily worked by hand so that a flat and even surface is achieved.

The casting bearing finally has a thickness of 55 mm at its thinnest point and a thickness of 70 mm at the short ends of the holding deck element 1. In other embodiments, balancing and leveling can of course be done by other suitable methods.

Before the casting layer has hardened, a membrane hardener is sprayed on over the surface of the casting layer. This is done immediately after the free water has disappeared from the concrete surface, usually within an hour after casting.

As a result, the post-curing of the casting layer takes place under the influence of the membrane hardener, whereby advantageous plastic shrinkage formation in the surface layer is avoided.

Thanks to the lime fillers of the casting composition, according to the invention rapid drying can be obtained and the set requirements for the relative humidity (RF) of the concrete before carpet laying are met and long waiting times are avoided in the construction process.

According to the invention, an individual floor concrete device can also be provided by means of the method described above.

Claims (27)

10 15 20 25 30 35 529 224 16 Patent claims Floor concrete device comprising one (1) with a floor side (9) and a ground / roof side (10), and a pouring layer (6), VaIVid the subfloor element (1) comprises a concrete portion on the floor side (9), which concrete portion has an exposed surface (4), the subfloor element casting layer (6) comprises a casting composition comprising a self-compacting concrete and a shrink-reducing additive, and the casting layer (6) is cast on the floor side (9) of the subfloor element so that at least a portion of the (exposed) surface is covered by the casting layer (6). 2.. Floor concrete device according to claim 1, wherein coarser ballast grains (5) in the exposed surface (4) of the subfloor element (1) are exposed at a depth> 1/3 of the maximum size of the surface ballast. Floor concrete device according to claim 1 or 2, wherein coarser ballast grains (5) in the exposed surface (4) of the subfloor element (1) are exposed at a depth <1/2 of the maximum size of the surface ballast, preferably approximately 6 mm. Floor concrete device according to one of Claims 1 to 3, in which pipelines (8) or electrical installations are embedded in the pouring layer (6). Floor concrete device according to any one of claims 1 to 4, wherein the exposed surface (4) covers substantially the entire subfloor element (1) (9) - Floor concrete device according to one of Claims 1 to 5, in which the pouring layer (6) is cast on substantially the entire subfloor element (1) (9) - Floor concrete device according to one of Claims 1 to 6, in which the maximum thickness of the casting layer (6) is <100 mm! floor side floor side preferably <70 mm. 10 15 20 25 30 35 529 224 17 Floor concrete device according to one of Claims 1 to 7, in which the minimum thickness of the casting layer (6) is> 40 mm, preferably> 55 mm. IN A floor concrete device according to any one of claims 1 to 8, wherein the casting composition further comprises a lime filler. Floor concrete device according to one of Claims 1 to 9, in which the subfloor element (1) is a prefabricated element. 11. ll. Floor concrete device according to claim 10, wherein the subfloor element (1) is a hollow core element, preferably a reinforced, prestressed, curved hollow core element. Floor concrete device according to one of Claims 1 to 11, in which the self-compacting concrete has a flow dimension> 520 mm, preferably> 650 mm. Floor for construction works comprising a floor concrete device according to any one of claims 1 - 12. A method for providing a floor concrete device comprising the steps of providing a subfloor element (1) with a floor side (9) and a ground / roof side (10), the subfloor element (1) comprising a concrete portion on the floor side (9), which concrete portion has a exposed surface (4), to provide a pouring composition comprising a self-compacting concrete and a shrink-reducing additive, to pour the pouring composition on the floor side of subfloor elements so that a pouring layer (6) is formed which covers at least a portion of the exposed surface (4). The method of claim 14, further comprising the step of applying a membrane hardener to the casting layer (6). The method of claim 14 or 15, further comprising the step of pre-watering the subfloor element (1) prior to the step of pouring the pour-on composition. A method according to any one of claims 14 to 16, further comprising the step of slinging the casting layer (6). A method according to any one of claims 14 ~ 17, wherein the step of providing a subfloor element (1) comprises the steps of casting the subfloor element (1) of a concrete, applying a retarding additive to a surface on the floor side (9) before the subfloor element (1) hardening, and to clear the surface from use after the subfloor element A method according to any one of claims 14 to 18, wherein (1) curing, wherein the surface is exposed. further comprising the step of arranging pipelines (8) or electrical installations on the subfloor element (1) prior to the step of pouring the pouring composition, and wherein the step of pouring the pouring composition comprises embedding pipelines (8) or electrical installations in the pouring layer (6). A method according to any one of claims 14, 19, wherein the casting composition is cast with a thickness which in its thickest place is <100 mm, preferably <70 mm is formed. ' A method according to any one of claims 14 - 20, wherein casting composition is cast so that casting layers (6) are formed with a thickness which in its thinnest place is> 40 mm, preferably> 55 mm. A method according to any one of claims 14 - 21, wherein the self-compacting concrete has a flow dimension> 520 mm, 23. A method of making a floor device preferably> 650 mm. for floors in building works comprising the steps of providing subfloor elements (1) which have a floor side (9) (10), a concrete portion on the floor side (9), which concrete portion has an exposed surface (4), and a ground / roof side and comprises 10 529 224 19 providing a casting composition comprising a self-compacting concrete and a shrink-reducing additive, joining the subfloor elements (1) to a subfloor unit, - casting the casting composition on the subfloor unit by covering at least portions of the exposed layers (on) exposed surfaces ( (6) with a flat top surface which has the desired slope, preferably is substantially horizontal, is formed. The method of claim 23, further comprising the step of arranging pipelines (8) or electrical installations on the subfloor unit prior to the step of pouring the pouring composition, and wherein the step of pouring the pouring composition comprises embedding or electrical installations in the pouring layer (6). A method according to claim 23 or 24, wherein pipelines (8) are poured into the casting composition over substantially the entire subfloor unit. A method according to any one of claims 23 to 25, wherein the step of pouring the pouring composition comprises the step of pumping out the pouring composition over the subfloor unit. A method according to any one of claims 23 to 26, wherein the step of pouring the pouring composition comprises weighing the pouring layer.