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EP1217140A1 - Precast flooring "MARVEL-ITHIC" - Google Patents

Precast flooring "MARVEL-ITHIC" Download PDF

Info

Publication number
EP1217140A1
EP1217140A1 EP00311506A EP00311506A EP1217140A1 EP 1217140 A1 EP1217140 A1 EP 1217140A1 EP 00311506 A EP00311506 A EP 00311506A EP 00311506 A EP00311506 A EP 00311506A EP 1217140 A1 EP1217140 A1 EP 1217140A1
Authority
EP
European Patent Office
Prior art keywords
slab
mould
slabs
mixture
cement mixture
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.)
Granted
Application number
EP00311506A
Other languages
German (de)
French (fr)
Other versions
EP1217140B1 (en
Inventor
designation of the inventor has not yet been filed The
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 DE60028795T priority Critical patent/DE60028795T2/en
Priority to ES00311506T priority patent/ES2265880T3/en
Priority to AT00311506T priority patent/ATE330084T1/en
Priority to EP00311506A priority patent/EP1217140B1/en
Publication of EP1217140A1 publication Critical patent/EP1217140A1/en
Application granted granted Critical
Publication of EP1217140B1 publication Critical patent/EP1217140B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • E04B5/12—Load-carrying floor structures formed substantially of prefabricated units with wooden beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • 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

Definitions

  • This invention relates to flooring construction, to a novel pre-formed flooring slab, and to methods of laying flooring using pre-formed flooring slabs.
  • the invention stems from work to simplify the on-site laying of flooring which traditionally comprises a screed laid in situ.
  • a method of constructing a floor comprises mixing a sand and cement mixture, which mixture may comprise an aggregate, and casting a flooring slab from said mixture in a mould, the slab having a substantial width to thickness ratio, transporting the flooring slab to a site where the floor is to be constructed, and arranging the slab on horizontally spaced-apart supports to form the floor.
  • the slab has a width to thickness ratio of at least fifty.
  • a typical polymer coating is available as Ronacrete TM from Ronacrete Limited. The polymer is applied in liquid form on the surface of the concrete floor and sets to form a smooth finish.
  • the cast flooring slab is coated on one side with a polymer coating, whereby the pre-formed flooring slab delivered to the site already carries the polymer coating, on the side that is uppermost in use.
  • the void defined between the supports and beneath the slabs may be filled with grout under pressure, if desired, and it should be noted that the upper surface of the slab *Will still be usable whilst the grout is setting.
  • the flooring slabs are typically of thickness in the range 70 mm to 100 10 mm and are typically of width 3 meters. However, the slabs may have a thickness as small as 20 mm or 25 mm, for example.
  • the slabs are preferably laid with a small gap between adjacent edges, and the gap is then filled with a suitable grout.
  • the slabs are preferably laid on joists or on other horizontally spaced15 apart slab support members.
  • the joists may be of concrete, metal or wood.
  • fixing for 20 the slabs may be arranged to extend into the void for entrapment by the grout so as to secure the slabs once the grout has set.
  • the joists may be provided with ducts and with openings in their upper surfaces, the ducts being employed to supply grout under pressure through said openings to fill the gaps between the slabs.
  • the duct is preferably supplied with grout through a suitable fitting, preferably located at one end of the joist.
  • the supports may be local supports which engage with a corner region of the slabs, such as concrete pillars.
  • the slab may incorporate a reinforcing medium such as fibres or flakes, or steel rod or wire reinforcement.
  • a reinforcing medium such as fibres or flakes, or steel rod or wire reinforcement.
  • the fibre is preferably a suitable glass fibre.
  • a method of casting a slab which is suitable for use in the method of the first aspect, comprises pouring a cement mixture into a mould defined by a mould base and upstanding mould side strips, tamping the cement mixture down to the level of the top of the side strips, raising the side strips by a predetermined amount corresponding to a thickness of a polymer layer to be applied, applying a liquid polymer mixture on the surface of the cement mixture, and then allowing the materials to set at least, to a condition in which the slab can be removed from the mould.
  • the upper surface of the slabs may be provided with mosaic or other decorative finish, such as a parquet finish, which can be applied during moulding of the slab or subsequently.
  • the rear side of the slabs may be provided with an insulation layer, such as a layer of expanded polystyrene, which may be positioned in the mould prior to casting of the slab, or which may be applied to the cast slab.
  • an insulation layer may be provided at an intermediate depth of the slab by spreading a layer of sand/cement mixture in the mould, inserting the insulation layer and then spreading further sand/cement mixture on top of the insulation layer in the mould.
  • the sand/cement mixture may incorporate a bulk density reducer such as Vermiculite or Lytag' material.
  • the slabs may be cast with internal ducts to accommodate wires or pipes, for example to provide underfloor heating.
  • insulation or grout may be forced into any voids remaining in the ducts.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Floor Finish (AREA)
  • Buffer Packaging (AREA)

Abstract

A method of constructing a floor comprising mixing a sand and cement mixture, and casting a flooring slab from said mixture in a mould, the slab having a substantial width to thickness ratio, transporting the flooring slab to a site where the floor is to be constructed, and arranging the slab on horizontally spaced-apart supports to form the floor.

Description

  • This invention relates to flooring construction, to a novel pre-formed flooring slab, and to methods of laying flooring using pre-formed flooring slabs.
  • The invention stems from work to simplify the on-site laying of flooring which traditionally comprises a screed laid in situ.
  • When a screed floor has to be laid which is capable of being used a relatively short time thereafter it is necessary to employ a fast-setting composition which considerably increases the cost of the floor.
  • According to one aspect of the present invention a method of constructing a floor comprises mixing a sand and cement mixture, which mixture may comprise an aggregate, and casting a flooring slab from said mixture in a mould, the slab having a substantial width to thickness ratio, transporting the flooring slab to a site where the floor is to be constructed, and arranging the slab on horizontally spaced-apart supports to form the floor.
  • Preferably the slab has a width to thickness ratio of at least fifty.
  • When a solid floor is required to have a smooth durable surface it is common practice to lay a polymer topping on top of the main flooring material. A typical polymer coating is available as Ronacrete TM from Ronacrete Limited. The polymer is applied in liquid form on the surface of the concrete floor and sets to form a smooth finish.
  • According to a preferred feature of the present invention, the cast flooring slab is coated on one side with a polymer coating, whereby the pre-formed flooring slab delivered to the site already carries the polymer coating, on the side that is uppermost in use.
  • The void defined between the supports and beneath the slabs may be filled with grout under pressure, if desired, and it should be noted that the upper surface of the slab *Will still be usable whilst the grout is setting.
  • The flooring slabs are typically of thickness in the range 70 mm to 100 10 mm and are typically of width 3 meters. However, the slabs may have a thickness as small as 20 mm or 25 mm, for example.
  • The slabs are preferably laid with a small gap between adjacent edges, and the gap is then filled with a suitable grout.
  • The slabs are preferably laid on joists or on other horizontally spaced15 apart slab support members. The joists may be of concrete, metal or wood.
  • When the slabs are laid on wooden joists they may be secured in position with screws driven into the wood.
  • When the void between the supports is to be filled with grout, fixing for 20 the slabs may be arranged to extend into the void for entrapment by the grout so as to secure the slabs once the grout has set.
  • The joists may be provided with ducts and with openings in their upper surfaces, the ducts being employed to supply grout under pressure through said openings to fill the gaps between the slabs.
  • The duct is preferably supplied with grout through a suitable fitting, preferably located at one end of the joist.
  • The supports may be local supports which engage with a corner region of the slabs, such as concrete pillars.
  • The slab may incorporate a reinforcing medium such as fibres or flakes, or steel rod or wire reinforcement. When a fibre is employed the fibre is preferably a suitable glass fibre.
  • According to a second aspect of the invention a method of casting a slab, which is suitable for use in the method of the first aspect, comprises pouring a cement mixture into a mould defined by a mould base and upstanding mould side strips, tamping the cement mixture down to the level of the top of the side strips, raising the side strips by a predetermined amount corresponding to a thickness of a polymer layer to be applied, applying a liquid polymer mixture on the surface of the cement mixture, and then allowing the materials to set at least, to a condition in which the slab can be removed from the mould.
  • The upper surface of the slabs may be provided with mosaic or other decorative finish, such as a parquet finish, which can be applied during moulding of the slab or subsequently.
  • The rear side of the slabs may be provided with an insulation layer, such as a layer of expanded polystyrene, which may be positioned in the mould prior to casting of the slab, or which may be applied to the cast slab. In the case of a relatively thick slab, an insulation layer may be provided at an intermediate depth of the slab by spreading a layer of sand/cement mixture in the mould, inserting the insulation layer and then spreading further sand/cement mixture on top of the insulation layer in the mould.
  • The sand/cement mixture may incorporate a bulk density reducer such as Vermiculite or Lytag' material.
  • The slabs may be cast with internal ducts to accommodate wires or pipes, for example to provide underfloor heating.
  • Where wires or pipes have been, inserted into the laid slabs, insulation or grout may be forced into any voids remaining in the ducts.

Claims (17)

  1. A method of constructing a floor comprising mixing a sand and cement mixture, which mixture may comprising an aggregate, and casting a flooring slab from said mixture in a mould, the slab having a substantial width to thickness ratio, transporting the flooring slab to a site where the floor is to be constructed, and arranging the slab on horizontally spaced-apart supports to form the floor.
  2. A method as claimed in claim 1 in which the slab has a width to thickness ratio of at least fifty.
  3. A method as claimed in claim 1 or claim 2 in which the cast flooring slab is coated on one side with a polymer coating, whereby the pre-formed flooring slab delivered to the site already carries the polymer coating, on the side that is uppermost in use.
  4. A method as claimed in any of the preceding claims in which thevoid defined between the supports and beneath the slabs is filled with grout under pressure.
  5. A method as claimed in any of the preceding claims in which the flooring slabs are of thickness in the range 70 mm to 100 mm.
  6. A method as claimed in any of the preceding claims in which the slabs are laid with a small gap between adjacent edges, and the gap is then filled with a suitable grout.
  7. A method as claimed in any of the preceding claims in which the slabs are laid on elongate horizontally spaced-apart slab support members.
  8. A method as claimed in claim 7 in which the slabs are laid on wooden joists and are secured in position with screws driven into the wood.
  9. A method as claimed in claim 7 in which the support members are in the form of joists provided with ducts and with openings in their upper surfaces, the ducts being employed to supply grout under pressure through said openings to fill the gaps between the slabs.
  10. A method as claimed in any one of claims 1 to 6 in which the supports are local supports which engage with a corner region of the 10 slabs.
  11. A method as claimed in any of the preceding claims comprising incorporating a reinforcing medium such as fibres or flakes, or steel rod or wire reinforcement into the material of the slab.
  12. A method as claimed in claim 3 or any of claims 4 to 11 each as appended to claim 3 in which the casting of the slab, which is suitable for use in the method of the first aspect, comprises pouring a cement mixture into a mould defined by a mould base and upstanding mould side strips, tamping the cement mixture down to the level of the top of the side strips, raising the side strips by a predetermined amount corresponding to a thickness of a polymer layer to be applied, applying a liquid polymer mixture on the surface of the cement mixture, and then allowing the materials to set, at least to a condition in which the slab can be removed from the mould.
  13. A method as claimed in any of the preceding claims comprising positioning a layer of insulation material in the mould prior to casting of the slab.
  14. A method as claimed in any one of claims 1 to 12 in which an insulation layer is provided at an intermediate depth of the slab by spreading a layer of sand/cement mixture in the mould, inserting the insulation layer into the mould, and then spreading further sand/cement mixture on top of the insulation layer in the mould.
  15. A method of constructing a floor substantially as described herein.
  16. A method of casting a slab comprising pouring a cement mixture into a mould defined by a mould base and upstanding mould side strips, tamping the cement mixture down to the level of the top of the side strips, raising the side strips by a predetermined amount corresponding to a thickness of a polymer layer to be applied, applying a liquid polymer mixture on the surface of the cement mixture, and then allowing the materials to set at least to a condition in which the slab can be removed from the mould.
  17. A method of placing the materials in moulds or frames where the mixture is vibrated and levelled from the top to form the underside of the slab, after the materials have been left to set for a sufficient period of time, whereby the finish is determined by the design of the floor or bottom of the frame of the mould.
EP00311506A 2000-12-20 2000-12-20 Precast flooring "MARVEL-ITHIC" Expired - Lifetime EP1217140B1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
DE60028795T DE60028795T2 (en) 2000-12-20 2000-12-20 Prefabricated ceiling element "Marvel-Ithic"
ES00311506T ES2265880T3 (en) 2000-12-20 2000-12-20 PREFABRICATED FLOOR COATING "MARVEL-ITHIC".
AT00311506T ATE330084T1 (en) 2000-12-20 2000-12-20 PREFABRICATED CEILING ELEMENT ßMARVEL-ITHICß
EP00311506A EP1217140B1 (en) 2000-12-20 2000-12-20 Precast flooring "MARVEL-ITHIC"

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP00311506A EP1217140B1 (en) 2000-12-20 2000-12-20 Precast flooring "MARVEL-ITHIC"

Publications (2)

Publication Number Publication Date
EP1217140A1 true EP1217140A1 (en) 2002-06-26
EP1217140B1 EP1217140B1 (en) 2006-06-14

Family

ID=8173475

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00311506A Expired - Lifetime EP1217140B1 (en) 2000-12-20 2000-12-20 Precast flooring "MARVEL-ITHIC"

Country Status (4)

Country Link
EP (1) EP1217140B1 (en)
AT (1) ATE330084T1 (en)
DE (1) DE60028795T2 (en)
ES (1) ES2265880T3 (en)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH171619A (en) * 1934-02-14 1934-09-15 Hossdorf Josef Ribbed ceiling.
US3194724A (en) * 1961-06-29 1965-07-13 Burns & Russell Co Coated blocks
FR2058768A5 (en) * 1969-09-25 1971-05-28 Sommerard Henri
US4088808A (en) * 1976-01-16 1978-05-09 Cornwell Charles E Shaped articles of hydraulic cement compositions with a glossy reflective surface and reinforced with fiber glass
DE4007977A1 (en) * 1989-03-16 1990-10-11 43 Sz Allami Epitoeipari Valla Concrete panels for ceilings - have moulded ducts to receive electric cables
DE9017564U1 (en) * 1990-12-29 1991-03-28 Werner, Hartmut, Dipl.-Ing., 7521 Dettenheim Wood or wood-based concrete composite ceiling as a prefabricated element or in-situ concrete construction with a composite made by reinforced concrete studs and profiled head studs
DE29818408U1 (en) * 1998-10-15 1999-01-28 Cohrs, Helmut, Dipl.-Ing., 75228 Ispringen Concrete ceiling and prefabricated wall parts with integrated insulation made of foam plastic panels with simultaneous hollow body effect

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH171619A (en) * 1934-02-14 1934-09-15 Hossdorf Josef Ribbed ceiling.
US3194724A (en) * 1961-06-29 1965-07-13 Burns & Russell Co Coated blocks
FR2058768A5 (en) * 1969-09-25 1971-05-28 Sommerard Henri
US4088808A (en) * 1976-01-16 1978-05-09 Cornwell Charles E Shaped articles of hydraulic cement compositions with a glossy reflective surface and reinforced with fiber glass
DE4007977A1 (en) * 1989-03-16 1990-10-11 43 Sz Allami Epitoeipari Valla Concrete panels for ceilings - have moulded ducts to receive electric cables
DE9017564U1 (en) * 1990-12-29 1991-03-28 Werner, Hartmut, Dipl.-Ing., 7521 Dettenheim Wood or wood-based concrete composite ceiling as a prefabricated element or in-situ concrete construction with a composite made by reinforced concrete studs and profiled head studs
DE29818408U1 (en) * 1998-10-15 1999-01-28 Cohrs, Helmut, Dipl.-Ing., 75228 Ispringen Concrete ceiling and prefabricated wall parts with integrated insulation made of foam plastic panels with simultaneous hollow body effect

Also Published As

Publication number Publication date
EP1217140B1 (en) 2006-06-14
DE60028795T2 (en) 2007-02-08
ATE330084T1 (en) 2006-07-15
ES2265880T3 (en) 2007-03-01
DE60028795D1 (en) 2006-07-27

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