WO2007002812A2 - Procede permettant de faire adherer une dalle de beton sur du metal - Google Patents

Procede permettant de faire adherer une dalle de beton sur du metal Download PDF

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Publication number
WO2007002812A2
WO2007002812A2 PCT/US2006/025327 US2006025327W WO2007002812A2 WO 2007002812 A2 WO2007002812 A2 WO 2007002812A2 US 2006025327 W US2006025327 W US 2006025327W WO 2007002812 A2 WO2007002812 A2 WO 2007002812A2
Authority
WO
WIPO (PCT)
Prior art keywords
concrete
metal
bonding agent
bonding
metal substrate
Prior art date
Application number
PCT/US2006/025327
Other languages
English (en)
Other versions
WO2007002812A3 (fr
Inventor
John R. Siefken
Original Assignee
Siefken Incorporated
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 Siefken Incorporated filed Critical Siefken Incorporated
Publication of WO2007002812A2 publication Critical patent/WO2007002812A2/fr
Publication of WO2007002812A3 publication Critical patent/WO2007002812A3/fr

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Classifications

    • 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.
  • 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 disclosure is directed to a 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.
  • the disclosure is also directed to the creation of a laminar composite material.
  • the material comprises a layer of concrete, a layer of metal, and a bonding agent joining the layers of concrete and metal.
  • the bonding agent forms adhesive bonds to the concrete and adhesive bonds to the metal.
  • the disclosure is further directed to a composite joint.
  • the joint comprises a slab of concrete, a metal beam, and a bonding agent joining the slab of concrete to the metal beam.
  • the bonding agent forms adhesive bonds to the concrete slab and adhesive bonds to the metal beam.
  • 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. Similar reference characters denote corresponding features consistently throughout the attached drawings.
  • 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
  • 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 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.
  • 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.
  • 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 Cl 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 Cl and the underlying metal panel S may be provided by studs, bolts or pins P, which pass through the concrete slab Cl 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 C2, which has been mechanically attached to an underlying I-beam B by means of, studs, bolts or pins P. While the reinforced concrete slab C2 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. In conclusion, 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)

Abstract

L'invention a trait à un procédé permettant de faire adhérer du béton (10) sur un substrat métallique (12), qui élimine les coûts supplémentaires en temps et en main d'oeuvre ordinairement nécessaires pour obtenir une liaison mécanique entre du béton (10) et des surfaces métalliques (par ex., acier de construction) (12). Le procédé selon l'invention consiste à utiliser un agent liant adhésif (16), qui est appliqué entre les éléments en béton (10) et en métal (12), et qui durcit afin de faire adhérer les deux éléments l'un à l'autre. Le procédé selon l'invention peut servir à produire un support composite laminaire formé d'une dalle de béton collée (10) sur un support métallique (12), un joint composite obtenu par le collage d'une dalle de béton (10) sur une poutre (12) ou une solive métallique, et d'autres structures composites.
PCT/US2006/025327 2005-06-29 2006-06-28 Procede permettant de faire adherer une dalle de beton sur du metal WO2007002812A2 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US69470005P 2005-06-29 2005-06-29
US60/694,700 2005-06-29
US11/313,767 2005-12-22
US11/313,767 US20070000199A1 (en) 2005-06-29 2005-12-22 Method to bond concrete slab to metal

Publications (2)

Publication Number Publication Date
WO2007002812A2 true WO2007002812A2 (fr) 2007-01-04
WO2007002812A3 WO2007002812A3 (fr) 2007-05-24

Family

ID=37587900

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2006/025327 WO2007002812A2 (fr) 2005-06-29 2006-06-28 Procede permettant de faire adherer une dalle de beton sur du metal

Country Status (2)

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US (1) US20070000199A1 (fr)
WO (1) WO2007002812A2 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2876401B1 (fr) * 2004-10-12 2007-02-23 Nicolas Rodet Panneau muni d'une toile metallique

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US6359036B1 (en) * 1998-04-30 2002-03-19 Otsuka Kagaku Kabushiki Kaisha 1-Aminopyrrolidine or its salt as epoxy resin hardener
US6769216B2 (en) * 1999-10-18 2004-08-03 Chia-Lung Lu Process of waterproofing construction surface and slit of construction surface

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4132043A (en) * 1977-02-22 1979-01-02 H. B. Fuller Company Structural units
US6359036B1 (en) * 1998-04-30 2002-03-19 Otsuka Kagaku Kabushiki Kaisha 1-Aminopyrrolidine or its salt as epoxy resin hardener
US6769216B2 (en) * 1999-10-18 2004-08-03 Chia-Lung Lu Process of waterproofing construction surface and slit of construction surface
US6266279B1 (en) * 2000-02-17 2001-07-24 Mitsubishi Denki Kabushiki Kaisha Nonvolatile semiconductor memory device, method for reading data from the nonvolatile semiconductor memory device, and method for writing data into the nonvolatile semiconductor memory device

Also Published As

Publication number Publication date
US20070000199A1 (en) 2007-01-04
WO2007002812A3 (fr) 2007-05-24

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