US20070000199A1 - Method to bond concrete slab to metal - Google Patents

Method to bond concrete slab to metal Download PDF

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Publication number
US20070000199A1
US20070000199A1 US11/313,767 US31376705A US2007000199A1 US 20070000199 A1 US20070000199 A1 US 20070000199A1 US 31376705 A US31376705 A US 31376705A US 2007000199 A1 US2007000199 A1 US 2007000199A1
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United States
Prior art keywords
concrete
metal
bonding agent
bonding
metal substrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/313,767
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English (en)
Inventor
John Siefken
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US11/313,767 priority Critical patent/US20070000199A1/en
Priority to PCT/US2006/025327 priority patent/WO2007002812A2/fr
Publication of US20070000199A1 publication Critical patent/US20070000199A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
    • C09J5/06—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers involving heating of the applied adhesive
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • E04B5/38—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element
    • E04B5/40—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element with metal form-slabs
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2400/00—Presence of inorganic and organic materials
    • C09J2400/10—Presence of inorganic materials
    • C09J2400/16—Metal
    • C09J2400/163—Metal in the substrate

Definitions

  • the present invention relates to construction methods and composite construction materials. More specifically, the present invention comprises methods of adhesively bonding concrete to a metal substrate, e.g., construction steel, to form a composite material by chemical bonding, precluding the need for mechanical attachment.
  • the present invention extends to a composite construction material formed by the method, e.g., a composite deck having a concrete slab chemically bonded to a metal deck or substrate.
  • Steel (or other metals) and concrete have relatively poor adhesion to one another when fresh concrete is poured upon a metal substrate (e.g., steel construction members, etc.).
  • the relatively weak bond generally separates in short order due to differential thermal expansion between the materials, surface corrosion of the metal, etc. No adhesion between the materials exists at all, when a cured concrete element is placed upon a metal substrate. Accordingly, it is conventional in the construction trade to provide some form of mechanical attachment between the concrete and steel elements, in the form of indentations, protrusions, and/or small passages formed in the steel members that the concrete can flow around and through in its plastic state to adhere to the metal. Such metal elements are known as “Hi-Bond” steel.
  • concrete may be conventionally secured to a metal substrate by studs, anchor bolts and the like passing through the concrete (either before or after curing) and secured to the metal construction member.
  • the present inventor is aware of various methods and systems for adhesively securing construction materials to one another.
  • An example is found in French Patent No. 2,678,658, published on Jan. 8, 1993, describing (according to the drawings and English abstract) different embodiments of composite panels formed of polystyrene cores having “rock wool” (asbestos) insulation applied to the faces thereof.
  • the polystyrene-asbestos composite panels are then adhesively bonded or mechanically secured to a cured concrete slab to provide acoustic and thermal insulation.
  • the method of bonding concrete to a metal substrate is applicable for adhesively bonding either uncured concrete slurry in its wet, plastic state or hardened, cured concrete to a metal substrate, e.g., construction steel.
  • the method involves the application of a bonding agent to the metal substrate and then applying the concrete to the bonding agent coating before the bonding agent cures.
  • the bonding agent is allowed to cure partially before the concrete is poured.
  • the bonding agent is applied to the metal substrate (and/or to the surface of the concrete), and the concrete and metal are joined immediately after the application of the bonding agent to one or both of the components.
  • the bonding agent develops its full adhesive strength between the two materials as it cures.
  • the bonding agent may comprise a two-part epoxy mixture that is mixed immediately before application, the two parts reacting chemically with one another for curing.
  • the cured bonding agent may have sufficient resilience to accommodate any differential expansion between the materials.
  • FIG. 1 is a partially broken away perspective view of a metal panel having an adhesive bonding agent applied thereto in accordance with the method of the present invention, with a concrete slab partially overlying the metal panel.
  • FIG. 2 is a partially broken away perspective view of a cured concrete slab applied to an I-beam and bonded thereto according to the method of the present invention.
  • FIG. 3 is a partially broken away perspective view of a prior art mechanical method of securing concrete to a metal panel.
  • FIG. 4 is a partially broken away perspective view of a prior art mechanical method of securing a cured concrete slab to an I-beam.
  • FIG. 5 is a flowchart describing the basic steps in the method of adhesively bonding a wet, plastic concrete slurry to a metal substrate.
  • FIG. 6 is a flowchart describing the basic steps in the method of adhesively securing a hardened, cured concrete panel to a metal substrate.
  • the present invention comprises various embodiments of a method for adhesively bonding concrete to a metal substrate (e.g., metal deck panel, I-beams, etc.).
  • the method may be applied to either a hardened, cured concrete slab or element, or to the adhesive bonding of a wet, uncured concrete slurry to the metal substrate.
  • the present methods eliminate need for mechanical fastening of the metal to the concrete, thus providing greater economy in the manufacture of the metal and/or the labor involved in the construction of the metal and concrete structure. While the present methods are particularly well adapted for use with construction steel, they may be applied to other metals, e.g., aluminum, copper, etc., as well, for adhesively bonding concrete thereto.
  • the present invention also extends to a composite material useful in the construction trades formed by chemically bonding concrete to metal.
  • a composite material is a composite deck formed by bonding a concrete slab to a metal deck.
  • Such a composite deck may form a floor or ceiling in a building or other structure.
  • the present invention also extends to a joint formed by chemically bonding concrete to metal.
  • a joint formed by chemically bonding concrete to metal.
  • An example of such a joint is a joint between a concrete slab and an I-beam formed by bonding the concrete to the I-beam with a bonding agent that forms bonds to both the concrete and the I-beam.
  • FIG. 1 provides a partially broken away perspective view of a composite concrete panel 10 being adhesively bonded to a metal substrate panel 12 . While the concrete panel 10 is illustrated as a solid slab, it will be seen that the continuous, unbroken metal deck panel 12 below the concrete 10 precludes the flow of a wet, uncured concrete slurry through the panel 12 . Thus, the concrete material 10 may be provided as a wet, uncured slurry, and is shown broken away in FIG. 1 to show the underlying structure and application of the bonding agent. Reinforcing rods 14 (“rebar”) may be placed over the metal substrate panel 12 prior to pouring the concrete 10 for additional strengthening of the composite assembly as desired or required.
  • rebar Reinforcing rods 14
  • the adhesive bonding agent 16 may be any bonding agent capable of forming a bond to both concrete and the particular metal used as the substrate, usually steel.
  • An example of such an adhesive bonding material 16 is a two part epoxy adhesive material manufactured by the Universal Form Clamp Co., known by the brand name of Unibond MV®. The two parts of this bonding material are mixed prior to application and, once mixed, react chemically with one another to cure to a hardened plastic state. However, the bonding material 16 is in a liquid state prior to and immediately after mixing, prior to its curing reaction. The bonding material 16 is relatively thin, permitting it to be applied by means of a spray gun 18 or the like, or by means of a roller 20 or brush 22 .
  • the bonding strength of the adhesive bonding material 16 in its fully cured state may require coating the contact surface(s) 24 of the construction material(s) over only a portion thereof, as shown by the areas of bonding material 16 being applied in FIG. 1 . However, the contact surface(s) of the construction material(s) may be completely coated with the adhesive bonding material 16 , as desired or required.
  • the bonding agent 16 is captured between the concrete material 10 and the metal substrate 12 , and develops an adhesive bond between the two materials 10 and 12 as the bonding agent 16 develops to a fully cured state, thereby producing a laminar concrete and metal composite panel.
  • the bonds formed between the concrete and metal layers have sufficient strength and resilience that the concrete and metal are securely bonded together without slippage between the layers, but will have sufficient stretch that the bonds will not break with expansion and contraction of the layers upon variations in temperature within a range that permits use of the material in the building and construction trades. While there is a small degree of bonding that can occur between concrete and metal without the use of adhesive or a bonding agent, such bonds are brittle and are typically destroyed by any differential movement between the two layers, so that no allowance for such bonding is made in the structural engineering design of buildings and other structures.
  • the composite structures formed according to the methods of the present invention are able to withstand normal expansion and contraction without slippage between the two layers.
  • the method of the present invention is adaptable for adhesively bonding a wet, uncured concrete slurry to a metal substrate, as noted further above. This is accomplished by first coating only the contact surface 24 of the metal substrate 12 with the mixed adhesive bonding agent 16 (either partially or completely coating the contact surface, as noted further above), and allowing the bonding agent material 16 to cure partially.
  • the curing time will depend upon various factors, e.g., the specific bonding agent being used, the temperature, and perhaps humidity and/or other factors. A typical partial cure time might be on the order of three hours or so.
  • the wet concrete slurry 10 is poured over the contact surface 24 of the metal substrate 12 and its adhesive bonding agent coating 16 .
  • the partially cured bonding agent material 16 flows slightly and blends with the immediately adjacent concrete slurry, thereby producing a solid adhesive bond between the concrete and the bonding agent when the two materials are fully cured, and with the bonding agent developing a firm adhesive attachment to the underlying metal substrate when the adhesive agent has fully cured.
  • the method comprises the steps of: coating the metal with adhesive (step 100 ); allowing the adhesive to partially cure (step 102 ); applying concrete slurry to the metal (step 104 ); and allowing the adhesive to cure between the concrete and the metal (step 106 ). Additional strengthening of the composite concrete and metal structure may be accomplished as required by conventional mechanical attachment (e.g., rivets or bolts 26 , or welding) of additional metal supports, e.g., an I-beam 28 , to the metal substrate panel 12 , as shown in FIG. 1 .
  • additional metal supports e.g., an I-beam 28
  • FIG. 2 is an illustration of a somewhat different process, in which the concrete is first cured to a hardened state prior to adhesively bonding the concrete to the metal substrate to form a joint between a concrete slab and an I-beam.
  • a fully cured, hardened concrete slab 30 is bonded to an underlying or adjacent I-beam 28 .
  • the cured slab 30 is supported only by the underlying metal structure 28 , with no completely extensive metal substrate panel being provided in the assembly of FIG. 2 .
  • the concrete slab 30 may be reinforced using rebar elements 14 , as is conventional in reinforced concrete structures.
  • an adhesive bonding agent 16 is used.
  • the bonding material 16 is applied to the contact surface 24 of either the cured concrete slab 30 or the metal support 28 , or both, as both materials provide a hard surface for the application of the liquid adhesive material 16 .
  • the adhesive material 16 may be applied to a part of the contact surface 24 or to the entire surface by any conventional means, e.g., spray, roller, or brush, as shown in FIG. 1 . In this case, it is not necessary to allow the bonding agent 16 to cure partially, as both structural elements 28 and 30 are in a fully hardened state. Thus, the two elements 28 and 30 may be assembled to one another immediately after the bonding agent 16 has been applied to one or the other, or both, of the elements.
  • the juncture of the cured concrete panel 30 and metal support structure 28 is devoid of any form of mechanical attachment or connection, with the adhesive bonding agent 16 providing all of the attachment strength between the two components 28 and 30 .
  • This process of adhesively bonding a fully cured concrete slab or element to a metal structural member is described generally by the flowchart of FIG. 6 . Briefly, the method comprises the steps of: coating the metal with adhesive (step 110 ); applying cured concrete to the freshly coated metal substrate (step 112 ); and allowing the adhesive to cure between the concrete and the metal (step 114 ).
  • FIGS. 3 and 4 illustrate conventional prior art means of securing concrete and metal elements to one another.
  • a “Hi-Bond” construction steel panel S having a series of indentations, protrusions, and/or other irregularities I therein, has a poured reinforced concrete slab C 1 resting thereon.
  • the indentations and/or other irregularities I of the construction steel panel S provide a mechanical grip or “tooth” for the concrete slab Cl to adhere to the panel S as the uncured, fluid concrete flows around and into the irregularities I as it is poured on the panel S.
  • Additional mechanical attachment strength between the concrete slab C 1 and the underlying metal panel S may be provided by studs, bolts or pins P, which pass through the concrete slab C 1 and are anchored in the metal panel S, and/or to the underlying I-beam B.
  • FIG. 4 is an illustration of a prior art assembly of a cured reinforced concrete slab C 2 , which has been mechanically attached to an underlying I-beam B by means of, studs, bolts or pins P. While the reinforced concrete slab C 2 is self-supporting in its cured state, conventional construction relies upon mechanical means for the attachment of concrete elements to structural steel elements, generally as shown in FIG. 4 .
  • the present method of adhesively bonding concrete to a metal substrate greatly simplifies the construction process where concrete and steel structures are formed. This simplification of the construction process results in various economies during construction, as less costly structural steel may be used and less labor is involved due to the elimination of mechanical fasteners.
  • the adhesive bonding agents which may be used in accordance with the present method have been found to provide more than sufficient strength in such applications, and their physical properties can accommodate the thermal expansion and contraction of the adhesively joined or bonded materials as well as other adverse effects. Accordingly, the present method of bonding concrete and metal elements together will prove to be quite beneficial to the building and construction trades, and to other fields where concrete and metal composite structures are used.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Joining Of Building Structures In Genera (AREA)
  • Adhesives Or Adhesive Processes (AREA)
US11/313,767 2005-06-29 2005-12-22 Method to bond concrete slab to metal Abandoned US20070000199A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US11/313,767 US20070000199A1 (en) 2005-06-29 2005-12-22 Method to bond concrete slab to metal
PCT/US2006/025327 WO2007002812A2 (fr) 2005-06-29 2006-06-28 Procede permettant de faire adherer une dalle de beton sur du metal

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US69470005P 2005-06-29 2005-06-29
US11/313,767 US20070000199A1 (en) 2005-06-29 2005-12-22 Method to bond concrete slab to metal

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WO (1) WO2007002812A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080028706A1 (en) * 2004-10-12 2008-02-07 Nicolas Rodet Panel Equipped with Metal Fabric

Citations (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3333517A (en) * 1964-10-27 1967-08-01 Jeerbau Ges Fur Strassenbau M Method of bonding pavements to concrete or steel subsurfaces
US3468090A (en) * 1964-11-25 1969-09-23 Robert L Hermite Constructional element and method of making the same
US3498015A (en) * 1966-11-15 1970-03-03 Paul A Seaburg Poured gypsum roof structure with lower vent means for removing excess moisture
US4132043A (en) * 1977-02-22 1979-01-02 H. B. Fuller Company Structural units
US4274239A (en) * 1976-09-03 1981-06-23 Carroll Research, Inc. Building structure
US4335557A (en) * 1978-08-23 1982-06-22 Verco Manufacturing, Inc. Shear load resistant structure
US4476657A (en) * 1981-05-22 1984-10-16 H. B. Fuller Precast concrete structural units and burial vaults
US4506482A (en) * 1983-02-10 1985-03-26 Pracht Hans J Prefabricated panel for building wall construction and method of making same
US4604841A (en) * 1983-04-01 1986-08-12 Barnoff Robert M Continuous, precast, prestressed concrete bridge deck panel forms, precast parapets, and method of construction
US4615166A (en) * 1982-08-31 1986-10-07 G. Maunsell & Partners Structural panel
US6023806A (en) * 1996-09-30 2000-02-15 Martin Marietta Materials, Inc. Modular polymer matrix composite support structure and methods of constructing same
US6170105B1 (en) * 1999-04-29 2001-01-09 Composite Deck Solutions, Llc Composite deck system and method of construction
US6189287B1 (en) * 1996-08-05 2001-02-20 Lafarge Materiaux De Specialites S.A. Method for producing a floor, and resulting floor
US6455131B2 (en) * 1997-06-02 2002-09-24 West Virginia University Modular fiber reinforced polymer composite deck system
US6588160B1 (en) * 1999-08-20 2003-07-08 Stanley J. Grossman Composite structural member with pre-compression assembly
US6591567B2 (en) * 2000-12-09 2003-07-15 West Virginia University Lightweight fiber reinforced polymer composite modular panel
US6602958B2 (en) * 2001-07-10 2003-08-05 Ips Corporation Adhesives for bonding composites

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3312872B2 (ja) * 1998-04-30 2002-08-12 大塚化学株式会社 エポキシ樹脂用硬化剤
US6769216B2 (en) * 1999-10-18 2004-08-03 Chia-Lung Lu Process of waterproofing construction surface and slit of construction surface
JP4252183B2 (ja) * 2000-02-17 2009-04-08 株式会社ルネサステクノロジ 不揮発性半導体記憶装置、該不揮発性半導体記憶装置からのデータの読み出し方法及び、該不揮発性半導体記憶装置へのデータの書き込み方法

Patent Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3333517A (en) * 1964-10-27 1967-08-01 Jeerbau Ges Fur Strassenbau M Method of bonding pavements to concrete or steel subsurfaces
US3468090A (en) * 1964-11-25 1969-09-23 Robert L Hermite Constructional element and method of making the same
US3498015A (en) * 1966-11-15 1970-03-03 Paul A Seaburg Poured gypsum roof structure with lower vent means for removing excess moisture
US4274239A (en) * 1976-09-03 1981-06-23 Carroll Research, Inc. Building structure
US4132043A (en) * 1977-02-22 1979-01-02 H. B. Fuller Company Structural units
US4335557A (en) * 1978-08-23 1982-06-22 Verco Manufacturing, Inc. Shear load resistant structure
US4476657A (en) * 1981-05-22 1984-10-16 H. B. Fuller Precast concrete structural units and burial vaults
US4615166A (en) * 1982-08-31 1986-10-07 G. Maunsell & Partners Structural panel
US4506482A (en) * 1983-02-10 1985-03-26 Pracht Hans J Prefabricated panel for building wall construction and method of making same
US4604841A (en) * 1983-04-01 1986-08-12 Barnoff Robert M Continuous, precast, prestressed concrete bridge deck panel forms, precast parapets, and method of construction
US6189287B1 (en) * 1996-08-05 2001-02-20 Lafarge Materiaux De Specialites S.A. Method for producing a floor, and resulting floor
US6023806A (en) * 1996-09-30 2000-02-15 Martin Marietta Materials, Inc. Modular polymer matrix composite support structure and methods of constructing same
US6467118B2 (en) * 1996-09-30 2002-10-22 Martin Marietta Materials Modular polymeric matrix composite load bearing deck structure
US6455131B2 (en) * 1997-06-02 2002-09-24 West Virginia University Modular fiber reinforced polymer composite deck system
US6170105B1 (en) * 1999-04-29 2001-01-09 Composite Deck Solutions, Llc Composite deck system and method of construction
US6588160B1 (en) * 1999-08-20 2003-07-08 Stanley J. Grossman Composite structural member with pre-compression assembly
US6591567B2 (en) * 2000-12-09 2003-07-15 West Virginia University Lightweight fiber reinforced polymer composite modular panel
US6602958B2 (en) * 2001-07-10 2003-08-05 Ips Corporation Adhesives for bonding composites

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080028706A1 (en) * 2004-10-12 2008-02-07 Nicolas Rodet Panel Equipped with Metal Fabric
US8141311B2 (en) * 2004-10-12 2012-03-27 GKD—Gebr. Kufferath AG Panel equipped with metal fabric

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Publication number Publication date
WO2007002812A2 (fr) 2007-01-04
WO2007002812A3 (fr) 2007-05-24

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