EP1422356B1 - Prefabricated insulated panel with heating pipes embedded in concrete and method of manufacturing - Google Patents

Abstract

Building panel comprises two reinforced concrete plates (12, 14). These are held apart by support grids (16) which are embedded in the concrete. The space between the plates is filled with thermal insulation (24) and the upper plate contains embedded pipes (22) for an underfloor heating system.

Description

The invention relates to a prefabricated component for the construction technique in the form of a plate in which two slices of reinforced concrete are held by a plurality of lattice girders at a distance from each other. The respective lattice girder is embedded in the upper and lower disc. The space between the panes is filled with insulating material. Furthermore, the invention relates to a method for producing such a prefabricated component.

From the EP-A-1 106 745 The same applicant is known a prefabricated component according to the preamble of claim 1. Between the two reinforced concrete slices, the room is filled with foamed polyurethane. Such prefabricated component can be used as a ceiling element in prefabricated houses. These ceiling elements can be manufactured as prefabricated large-sized and can be relatively easily and quickly mounted on a construction site. Elaborate concreting work is thus avoided. On the construction site screed in the form of a layer of mortar or mastic asphalt of a few centimeters thick is applied to the upper concrete slab. This screed serves as a floor construction and can be provided with a floor publishing. The screed is laid by hand.

It is an object of the invention to provide a prefabricated component for the construction technique and a manufacturing method thereof, which brings improved technical applications with a simple production and increases cost-effectiveness.

This object is achieved for a prefabricated part of the type mentioned above in that the upper disc of reinforced concrete in concrete embedded heating cables of underfloor heating.

In the invention, a floor heating is included as an integral unit in the plate, which can be used as a ceiling element, floor plate or basement ceiling, immediately. In this way, a still required by hand in a conventional plate application of screed and any necessary embedding of the heating cables can be omitted in this screed. The plate produced as prefabricated part has a high economy. The overall required work steps are reduced because the installation of screed is eliminated when mounting on site. In addition, such a plate for the user of a prefabricated house has a high level of comfort.

The integration of the heating in the upper concrete slab achieves a double technical effect. On the one hand, it serves the comfort of humans by warming the floor. On the other hand, the existing through the heating of the upper concrete disc heat to the fact that insulating material remains dry in the space and penetrated moisture is not critical.

Furthermore, according to the invention, a method for producing a prefabricated component for the construction technique in the form of a plate is specified. In this manufacturing process, an edge formwork is erected on the smooth surface of a steel plate. Within this edge formwork a lattice girder layer as well as the necessary longitudinal and transverse reinforcement is arranged. By filling concrete into the edge formwork and hardening the concrete, a lower pane made of reinforced concrete is produced. Subsequently, heating cables for underfloor heating are fastened to the pre-consolidated longitudinal and transverse reinforcement above the lattice girders. On the smooth surface of the same steel plate or another steel plate then an edge formwork for the upper concrete slab is placed. Within the edge formwork concrete is poured. The previously manufactured lower concrete disc is rotated by 180 ° immersed in the liquid concrete and this hardened. The two concrete slabs are at a distance from each other with space exclusively through the lattice girders held. Other spacers that absorb static forces to maintain the distance between the two concrete slabs are not required.

• Fig. 1 einen Querschnitt durch einen perspektivisch dargestellten Aufbau einer Bodenplatte, und
• Fig. 2 den Verfahrensablauf in Form eines Flußdiagramms beim Herstellen des Fertigbauteils.

Embodiments of the invention are explained below with reference to the drawing. It shows

• Fig. 1 shows a cross section through a perspective construction of a bottom plate, and
• Fig. 2 shows the process flow in the form of a flow chart in the manufacture of the prefabricated component.

Fig. 1 shows a schematic, perspective view of a cross section through a prefabricated component, which can be used as a floor slab, floor slab or basement ceiling. The prefabricated component 10 has a lower concrete disc 12, as well as an upper concrete disc 14, which is generally thicker than the lower concrete disc 12. In the lower concrete disc 12, the end portions of lattice girders 16 are concreted together with a direction indicated by a transverse bar 18 reinforcement. Other reinforcing bars are not shown for reasons of clarity.

End sections of the same lattice girders 16 are also embedded in the upper concrete disc 14 together with a reinforcement, indicated by a transverse bar 20. Above the lattice girders 16 are on the reinforcement 20 heating cables 22 a floor heating. They are also embedded in the upper concrete slab 14. The lattice girders 16 hold the two concrete slabs 12, 14 at a distance from each other. Additional spacers are not required.

In the space between the concrete slabs 12, 14 insulating material 24 is filled. As an insulating material, for example, in the production polyurethane foam filled and cured. The cured PU foam can support the stability of the entire prefabricated part 10 to some extent. Alternatively, polystyrene beads may also be used as the insulating material. Cellulose flakes and / or mineral wool flakes are used. The loose insulating material can be poured, blown in or sucked in.

The outwardly facing surface 26 is smooth, so that on this surface 26 directly a floor covering can be applied. As a floor covering z. As tiles, parquet or plastic floor can be used.

Typical dimensions for the finished part are z. B. for the length I about 5 m to 13 m and for the width b 2.5 m to 3.5 m. The lower concrete disc 12 may have a typical thickness d3 of 40 mm to 60 mm, preferably about 50 mm; the distance d2 between the two concrete slabs 12, 14 and thus the thickness of the space for the insulating material is in the range of 130 mm to 170 mm, preferably at about 150 mm; the thickness d1 of the upper concrete disk 14 is in the range of 80 mm to 100 mm, preferably about 90 mm.

Further details about the structure of the plate 10 are the EP-A-1 106 745 the same applicant, for example, information about the reinforcement and other fasteners. The content of this patent application is hereby incorporated by reference into the disclosure of the present application.

FIG. 2 shows the method sequence during the production of a prefabricated component according to FIG. 1 in the form of a flowchart. In step S1, a steel pallet of a pallet circulation system is provided. In the following step S2, an edge formwork is erected on the smooth surface of the steel pallet.

In step S3, lattice girders and optionally the lower reinforcement are arranged and connected to one another within the edge formwork.

In step S4 concrete is poured into the edge formwork, so that the lower end portions of the lattice girders and the lower reinforcement are embedded in concrete.

In the next step S5, the pallet is conveyed to a drying oven and the concrete is cured. Thus, the lower disc made of reinforced concrete is completed.

In the next step S6, the upper reinforcement and the heating pipes for underfloor heating are fastened to the lattice girders. This reinforcement layer serves as a support plane for fixing the heating cables.

In a further step S7, an edge formwork for the upper concrete pane is arranged on the smooth surface of the steel plate of another pallet.

In the next step S8 concrete is poured within this edge formwork.

The prefabricated concrete disc is rotated by 180 °, so that the cast-in lattice girders can be immersed with their outboard end portions in the liquid concrete (step S9).

Subsequently, in step S10, the pallet is conveyed into the drying oven and the concrete is cured. It thus creates a plate in which the two concrete slabs are held at a distance from each other with space through the lattice girders.

In the space can now be filled by filling, blowing or sucking loose insulating material, such as polystyrene beads, cellulose flakes or mineral wool flakes. Alternatively, PU foam can be filled in and cured. It is also possible that after making the lower concrete slab filled with PU foam and this is cured. Only then do the work steps mentioned above in step S6 take place.

Claims (26)

1. Prefabricated component for structural engineering in the form of a panel,
   wherein two panels (12, 14) of steel reinforced concrete are held at a distance (d2) from each other by a plurality of lattice beams (16),
   the respective lattice beam (16) is concreted in the upper and lower panel (12, 14),
   and wherein the space between the panels (12, 14) is filled with insulating material (24),
   characterised in that the upper panel (14) contains heating pipes (22), embedded in concrete, of underfloor heating.
2. Prefabricated component according to claim 1, characterised in that at least one of the panels, preferably both panels (12, 14), contain(s) a steel reinforcement (18, 20).
3. Prefabricated component according to claim 1 or 2, characterised in that polyurethane foam is used as insulating material.
4. Prefabricated component according to claim 1 or 2, characterised in that polystyrene balls, cellulose flocks and / or mineral wool flocks are provided as insulating material.
5. Prefabricated component according to one of the preceding claims, characterised in that the surface (26) of the upper concrete panel (14) is formed in such a way that a floor covering is applied directly thereto.
6. Prefabricated component according to claim 5, characterised in that tiles, carpet, parquet flooring or plastic flooring is / are used as floor covering.
7. Prefabricated component according to one of the preceding claims, characterised in that it is used as a ceiling element.
8. Prefabricated component according to one of the preceding claims, characterised in that it is used in housing without a cellar as a floor panel.
9. Prefabricated component according to one of the preceding claims, characterised in that it is used as a cellar ceiling.
10. Prefabricated component according to one of the preceding claims, characterised in that it has a width of 2.5 to 3.5 m.
11. Prefabricated component according to one of the preceding claims, characterised in that it has a length of 5 m to 13 m.
12. Prefabricated component according to one of the preceding claims, wherein the upper panel (14) with the heating pipes (22) is thicker than the lower panel (12).
13. Prefabricated component according to one of the preceding claims, characterised in that the lower panel (12) has a thickness of 40 mm to 60 mm, preferably around 50 mm.
14. Prefabricated component according to one of the preceding claims, characterised in that the upper panel (14) has a thickness of 80 mm to 100 mm, preferably around 90 mm.
15. Prefabricated component according to one of the preceding claims, characterised in that the distance (d2) between the two panels lies in the region of 130 mm to 170 mm, preferably around 150 mm.
16. Prefabricated component according to one of the preceding claims, characterised in that the heating pipes (22) lie on the upper reinforcement for the upper panel (14).
17. Process for producing a prefabricated component for structural engineering in the form of a panel,
    wherein an edge shuttering is provided on the smooth surface of a steel panel,
    lattice beams (16) are arranged within the edge shuttering,
    a lower panel (12) of steel reinforced concrete is produced by filling concrete into the edge shuttering and curing,
    heating pipes (22) for underfloor heating are fixed above the lattice beam (16),
    an edge shuttering for the upper concrete panel (14) is arranged on a smooth surface of a steel panel,
    concrete is poured within the edge shuttering,
    and wherein the lower concrete panel (12) is immersed, rotated by 180°, in the liquid concrete and this is cured,
    wherein the two concrete panels (12, 14) are held at a distance (d2) from each other with intermediate space by the lattice beams (16).
18. Method according to claim 17, characterised in that the lattice beams (16) in the lower region and / or in the upper region are provided with a steel reinforcement (18, 20).
19. Method according to claim 17, characterised in that after the concreting and curing of the lower concrete panel (12) polyurethane foam is applied thereto and cured.
20. Method according to one of the preceding claims, characterised in that after the concreting of the lower and the upper concrete panel (12, 14) insulating material is arranged in the intermediate space between the two concrete panels (12, 14).
21. Method according to claim 20, characterised in that polystyrene balls, cellulose flocks, mineral wool flocks or polyurethane foam are used as insulating material.
22. Method according to one of the preceding claims, characterised in that the prefabricated component is used as a ceiling element, a floor panel or a cellar ceiling.
23. Method according to one of the preceding claims, characterised in that a floor covering is applied directly to the surface (26) of the upper concrete panel (14).
24. Method according to claim 23, characterised in that tiles, carpet, parquet flooring or plastic flooring is / are used as a floor covering.
25. Method according to one of the preceding claims, characterised in that the steel panel is part of a pallet which is transported in a pallet circulation system.
26. Method according to claim 25, characterised in that the pallet circulation system supplies the pallet to a drying oven, in which the concrete is cured and dried.

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