FR2488303A1 - Insulating floor with self supporting base - has insulation forming lost shutter for cast concrete floor beams - Google Patents

Abstract

The floor beams are web beams in reinforced or prestressed concrete that span between and rest upon support walls and are connected to each other by a concrete key. Each beam is cast onto a piece of insulation shaped to form the beam, to key the insulation to the web, and to come up to the top surface of the beam. When the concrete has set, the top of the insulation is broken off to reveal notches (17,18). These act as retainers for concrete (23). The beams are placed side by side and concrete is poured to complete the floor.

Description

Technical area.

 The present invention relates to a method of constructing insulating floors based on self-supporting elements. It also relates to the elements as well as the floors that are used in said process.

Problem.

 It is a question of making floors based on reinforced or prestressed concrete which comprise an effective insulation. Indeed, the need to improve the thermal insulation of homes-made necessary the development of new techniques of application of insulation.

The search for the improvement of the cost price leads to consider prefabricated floors that include this insulation.

State of the art and disadvantages.

 Insulated floor assemblies must meet current home insulation (G-improvement) requirements that are currently in use and that employ two basic techniques - the incorporation of inter-wall or plate insulation specifically between resistant ribs, made of reinforced or pre-stressed concrete, - the fixing on the underside or on the surface of a conventional floor, with a specific insulation that is protected by a floating slab when it is fixed on the surface.

 These provisions have the following disadvantages - the need for a special operation of laying the insulation, - obtaining thermal bridges imperfectly corrected to the right of the resistant ribs, - convection current between juxtaposed elements, - need for application of special rules of calculation due to the total absence of mechanical resistance of the specific insulators.

 The present invention aims to overcome these difficulties in that it consists of the realization of prefabricated insulating floors consist of laying side by side elements, all identical, both insulating and resistant.

Presentation of the invention.

The process of the invention is characterized by the combination of the following operations: a) the manufacture of beams by means of a lost formwork of thermally insulating material having an outer shape, roughly parallelepipedic with a flat base, faces symmetrical lateral with longitudinal moldings or bosses in relief and, in the upper part, a longitudinal groove with a V-shaped or I-shaped profile constituting a rupture primer, - a generally T-shaped cross-sectioned recessed top whose lateral surfaces have recessed longitudinal grooves, the widest part of the T-section being at the bottom of the longitudinal groove in V or in I, said formwork receiving a concrete with reinforcements in the lowest part of the recess and having a planar upper face, b) the preparation of the beams by hardening and setting the concrete and then removing the upper corners of the formwork is olant above the longitudinal grooves in
V or in I> c) the laying of the beams side by side so that the longitudinal moldings or embossed protrusions of the insulating material are joined in a substantially watertight manner, d) the casting of a concrete or keying mortar in the longitudinal grooves formed between two adjacent beams.

 To apply this method, self-supporting elements are used which are characterized by a) a lower and lateral envelope of insulating material, cellular or not, having an outer shape, roughly parallelepiped with a flat base, - symmetrical side faces with longitudinally extending moldings or bosses, and in the upper part, a longitudinal groove with a V-shaped or I-shaped profile constituting a fracture primer; - a generally T-shaped cross-section recessed top with lateral surfaces recessed longitudinal grooves, the widest part of the T-section being at the bottom of the longitudinal groove in V or in I, b) the recess of the top of the casing filled with reinforced concrete whose reinforcements are, in particular, at the base of T.

 According to a preferred embodiment is provided two longitudinal moldings or relief bosses located in the middle portion of the side faces, which project the same projection on these faces and which are separated by a central depression. These bosses are provided to rely on the corresponding bosses of the adjacent element and to seal between the two elements by limiting the possibility of air convection movement between them. The upper bosses serve to retain the keying mortar.

 According to another preferred embodiment, the ends of the horizontal bar of the T of the concrete part each have a deep longitudinal groove which is intended to achieve proper anchoring of the keying mortar. To the longitudinal groove can be added notches with vertical axes which serve to immobilize mortar keying keys in the longitudinal direction to allow the semi-recessed work elements of the invention intermediate span.

 On their sides, the blanks of the vertical bar of the T of the concrete part each have at least one longitudinal molding or notch designed to anchor one to the other the concrete part of the element to the part made of insulating material. , especially to prevent it from becoming detached vertically from that one.

 For the realization of the concrete element, the pre-stressed concrete technique can advantageously be used by stressing the reinforcements prior to pouring, hardening and setting the concrete.

Solution to the problem, benefits and industrial result.

 The elements of the invention make it possible to rapidly produce a concrete floor incorporating the insulation.

It eliminates the special operation of laying the insulation.

As it occupies the entire surface of the floor, it eliminates any thermal bridge, especially to the right of the resistance ribs (vertical bar of the T).

 In the interstices between the elements, there is practically no convection current and risk of heat loss.

 Finally, the insulating material can participate in the mechanical strength of the elements. The material of these insulating materials may be chosen depending on the insulation and the degree of fire resistance retained, such as polystyrene, flame-retarded polystyrene, phenolic foam, polyurethane foam, etc. The choice of this material can be determined by its mechanical strength. The arsenal of recent chemistry allows or will allow to choose materials with interesting performances both from the point of view of isolation and from the point of view of mechanical resistance.

 The invention will be better understood from the following description which shows a non-limiting example of practical embodiment and which is illustrated by the accompanying drawings.

Brief description of the figures.

In these drawings
FIG. 1 is a partial perspective view of the lost formwork of thermally insulating material alone,
FIG. 2 is a partial perspective view of an element of the invention as it has just been manufactured after pouring the concrete into the lost formwork;
FIG. 3 is a view similar to that of FIG. 2 in which the beam prepared by eliminating the upper corners of the insulating form,
FIG. 4 is a view similar to that of FIG. 3, showing a part of the element of the invention where there are provided, in the ends of the horizontal bar of the T, notches with vertical axes;
FIG. 5 is a cross-section of the element of the invention at the moment when the concrete is beech poured into the lost formwork, as in FIG. 2, but on a larger scale,
Figure 6 is a cross section according to the elements of the invention showing several of these elements being assembled to form a floor.

Description of an embodiment

 The lost formwork 1, which is an integral part of the element of the invention> is made of thermally insulating material, for example polystyrene, flame-retarded polystyrene, phenolic foam, polyurethane foam or any other material of the same kind. I1 has an outer shape, roughly parallelepipedic with a flat base 2, side faces 3, 4 symmetrical with longitudinal moldings or bosses 5, 6 in relief separated by a central portion 7 curved. In the upper part of the lateral faces is formed a longitudinal groove 8 with a V-shaped profile, intended to constitute a rupture primer as will be seen later.

 The top of the formwork 1 is recessed and has a generally T-shaped cross-section with side surfaces having recessed longitudinal moldings 9, 10> 11, 12. The widest part of the T-section is at the bottom of the box. the groove 9 and at the longitudinal groove V 8, that is to say that at this level, the lost formwork 1 has the minimum thickness, which ensures the beginning of rupture already mentioned and whose role will be explained later. The formwork may have, on either side of the vertical bar of the T, longitudinal recesses which open at one end of the element and are closed at the other end, where protrusions of the same section as the recesses protrude and which are intended to engage in the corresponding recesses of the element Juxtaposé, put in end.

 The upper groove of the formwork 1 makes it possible to receive concrete 13 with reinforcements 14, 15 in the lower part of course. Concrete 13 has a flat superior race 16 which is leveled at the upper level of the lost formwork 1.

 The longitudinal molding 9 contributes to producing a longitudinal groove 17, 18 in the edges of the ends of the horizontal bar 26 of the T of the concrete part 13. These grooves 17 and 18 have a utility which will be explained later with respect to the constitution of the key of keying of two adjacent elements.

 The lost formwork 1 may comprise vertical notches (not shown) for making notches with corresponding vertical axes in the ends of the flanges 26 of the T of the concrete part 13.

 The manufacture of the elements of the inventlon, as represented in FIGS. 1, 2 and 5, is generally carried out in a workshop to constitute elements whose length corresponds to the range of the floors to be made, that is to say that their length is equal to the distance between two support walls to which the length of the supports is added, moreover elements of greater length can be provided with intermediate supports whose dimensioning is in any case determined by the calculation according to efforts to undergo.

 Before the elements, as represented in FIGS. 1, 2 and 5, support sent to the building site, the beams are prepared by eliminating the upper corners 20 and 21, which is facilitated by the breaking initiation formed by the longitudinal moldings 8 and 9, 12.

On the site, each of the elements is placed side by side (Figure 6) on the two supports such as 22 by resting them either at the low level of the lost formwork 1> or at the lower part of the vertical bar 23 of the T concrete part 13. Concrete spandrels
Prefabricated of adapted form realize these two kinds of support.

 Just as the ends of the horizontal bar 26 of the T of the concrete part 13 have a deep longitudinal groove 17, 18, the blanks of the vertical bar 23 of the T of the concrete part each have a notch molding 24, 25 designed to anchor the lost formwork 1 to the concrete part 13. These notches achieve a ba: e of the enlarged T and prevent, in particular, the spacing down the lost formwork 1.

 The vertical bar 23 is connected to the horizontal bar 26 by oblique surfaces 27, 28 which eliminate the connections at sharp angles between the bars 23 and 26.

 When elements such as 29, 30> 31, 32 (Figure 6) are juxtaposed, it remains to pour a thin concrete or keying mortar 33 to form keys ensuring the connection between each of the elements and the floor conti nightd. The vertical anchoring of these keys is provided by the grooves 17, 18. - Their longitudinal anchoring is provided by the notches 19 (to ensure the continuity if necessary).

Claims (8)

REVENDICATIOIiS  1. A method of constructing insulating floors based on self-supporting elements consisting of reinforced or prestressed concrete core beams and an insulating layer, said beams resting on load-bearing walls and being connected by a keying concrete, characterized by the combination of the following operations: a) the manufacture of beams by means of a lost formwork 1 made of thermally insulating material having an outer, roughly parallelepipedal shape with a flat base 2> - lateral faces 3, 4 symmetrical with embossed longitudinal moldings or bosses 5, 6 and, in the upper part, a longitudinal groove with a V-shaped or IM profile constituting a rupture primer, - a recessed top with a generally T-shaped cross-section whose side surfaces have recessed longitudinal grooves 9, 10, the widest part of the T-section being at the bottom of the V longitudinal groove or at I 8, said formwork receiving a concrete 13 with one or more reinforcements 14, 15 in the lowest part of the recess and having a flat top face 16, b) the preparation of the beams by hardening and setting the concrete then by removal of the upper corners of the insulating form over the longitudinal grooves in V u in I, c) laying the beams side by side so that the relief longitudinal moldings or protuberances 5> 6 of the insulating material join in a substantially watertight manner, d) casting a concrete or keying mortar 33 in the grooves upper longitudinal formed between two adjacent beams.  2. self-supporting element or beam, characterized by a) a lower and lateral envelope 1 of insulating material having an outer shape, roughly parallelepiped with a plane base 2 - symmetrical lateral faces 3, 4 with moldings or bosses 5, 6 and in the upper part, a longitudinal groove profile V or I 8 constituting a beginning of rupture, - a recessed top generally T-shaped cross section whose side surfaces have longitudinal grooves recessed 9, the widest part of T-section being at the bottom of the longitudinal groove V or I, b) the recess of the top of the casing filled with reinforced concrete 13 whose frame or the reinforcements 14, 15 are in particular at the base of the T.  3. Element, as defined in claim 2, characterized in that the longitudinal moldings or relief bosses are located, two in number, in the middle part of the side faces, they are the same protrusion on these faces and that they are separated by a central depression.  4. Element as defined in either of claims 2 or 3, characterized in that the ends of the horizontal bar of the T of the concrete part each have a deep longitudinal groove.  5. Element, as defined in any one of claims 2, 3 or 4, characterized in that the blanks of the vertical bar of the T of the concrete part each have at least one designed ridge molding to anchor one to another the concrete part i the part made of insulating material0  6. Element as defined in any one of claims 2 to 5, characterized in that the horizontal and transverse bars of the T are connected to each other by oblique surfaces eliminating connections to sharp angles.  An element as defined in any of claims 2 to 6, wherein the reinforcements of the concrete portion are pre-stressed prior to casting, curing and setting.  8. Element as defined in claim 7, wherein the ends of the horizontal bar of the T have, both in the formwork and in the concrete, notches with vertical axes.