US20090301009A1 - Concrete Floor Device - Google Patents

Concrete Floor Device Download PDF

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Publication number
US20090301009A1
US20090301009A1 US12/086,062 US8606206A US2009301009A1 US 20090301009 A1 US20090301009 A1 US 20090301009A1 US 8606206 A US8606206 A US 8606206A US 2009301009 A1 US2009301009 A1 US 2009301009A1
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Prior art keywords
casting
concrete
subfloor
layer
floor assembly
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US12/086,062
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English (en)
Inventor
Jörgen Falk
Thomas Johansson
Markus Peterson
Peter Svenmar
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Skanska Sverige AB
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Skanska Sverige AB
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Assigned to SKANSKA SVERIGE AB reassignment SKANSKA SVERIGE AB ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JOHANSSON, THOMAS, PETERSON, MARKUS, SVENMAR, PETER, FALK, JOERGEN
Publication of US20090301009A1 publication Critical patent/US20090301009A1/en
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    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • 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
    • E04B5/043—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement having elongated hollow cores
    • 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
    • E04B5/17—Floor structures partly formed in situ
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/12—Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floors
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00103—Self-compacting mixtures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • C04B2111/62—Self-levelling compositions

Definitions

  • the present invention relates to a concrete floor device or assembly and to a method of providing such a concrete floor element as well as a method of providing a floor assembly.
  • a floor structure is a substantially horizontal, structural element which separates different storeys of a building, or the ground floor of the house and the ground.
  • a floor structure also includes floor and ceiling.
  • the structural floor is part of the structural framework of a building and its main function is to carry the load of the storey, such as the floor, the ceiling, interior walls and fittings, and to transfer the weight of this load to structural walls and columns.
  • a floor structure must satisfy a number of requirements. It must have the capacity to carry the load of the storey and have sufficient stiffness, so that the deflections (the resilience) are minimised and do not damage, for instance, the interior walls and fittings.
  • a floor structure should furthermore satisfy specific requirements regarding fire resistance and acoustic and thermal insulation. Sometimes it should also have the capacity to include conduits or electrical installations.
  • a prior-art floor structure comprises prefabricated structural concrete elements with longitudinal holes, so-called hollow core slabs.
  • hollow core slabs can be joined to form a hollow core floor.
  • These hollow core slabs have increased stiffness and strength by being provided with pretensioned reinforcement which gives the hollow core slabs a curved shape. Due to this curvature, it is usually not possible to lay a floor directly on top of them.
  • a plurality of pins are first attached at equal distance over the hollow core floor. Then carefully levelled joists are attached to the pins, so that the joists form a horizontal base for a parquet floor or a subfloor in the form of, for instance, chipboard.
  • the mounting height of the joists can be selected so as to leave enough room for electric or water conduits under the floor.
  • One disadvantage of this system is that it requires much work and is time-consuming. In addition, it is difficult to achieve high precision, which may result in a resilient or inclined floor.
  • Another system for providing a flat base for floor laying is application of so-called screed to the hollow core floor.
  • screed One disadvantage of the use of screed is that it is expensive. Thus, it is not desirable to apply screed in layers that are thick enough for the embedment of electric or water conduits. In addition, it is difficult to predict how well the screed will dry out and how long it will take for the screed to dry when applied in such thick layers. If the base is not dry enough when the floor is laid (for instance a parquet or a plastic carpet), the floor can be damaged by the moisture or mildew problems can arise.
  • object of the present invention is to provide a concrete floor assembly, which makes it possible to lay a flat floor in a cost-effective manner and at a desired vertical level, and to provide a method of making such a concrete floor assembly and a method of making a floor assembly.
  • the concrete floor assembly comprises a subfloor element with a floor side and a ground/ceiling side, and a top casting layer.
  • the subfloor element comprises a concrete portion on the floor side and the concrete portion has a bottom casting surface with a surface roughness.
  • the top casting layer comprises a casting composition, which comprises a self-compacting concrete and a shrinkage reducing admixture.
  • the top casting layer is cast on the floor side of the subfloor element so that at least a portion of the bottom casting surface is covered by the top casting layer, the bottom casting surface having such surface roughness that the top casting layer adheres to the bottom casting surface.
  • the invention allows the use of a casting composition based on a self-compacting concrete provided it contains a shrinkage reducing admixture.
  • a casting composition is much more economical than prior-art screed. Due to the good adhesion to the subfloor element and the shrinkage reducing admixture, it is possible, according to the invention, to cast a layer that is sufficiently thick to satisfy the acoustic insulation requirements and the requirements regarding embedment of conduits, but not so thick that unnecessary amounts of material are consumed.
  • the casting composition which according to the invention is based on a self-compacting concrete, advantageously requires little labour input since it does not, as ordinary concrete, have to be vibrated, but spreads itself substantially horizontally. According to the invention, a flat upper surface is thus provided, also without the use of screed. Owing to a cost-effective casting composition and a rational application method, the concrete floor assembly according to the invention is thus much more cost-effective than conventional alternatives.
  • the concrete floor assembly according to the invention is intended to be part of a floor structure for construction works, for instance buildings, such as dwelling houses, office or industrial premises, or structures such as sports centres, underground cavities or silo buildings.
  • the concrete floor assembly according to the invention can be part of or constitute the entire structural floor of the floor structure. It can also be a non-structural part of the floor structure.
  • a concrete floor assembly is thus a portion of a floor structure, which portion forms a base which is suitable for floor laying or which itself can function as a floor.
  • subfloor element here means an element cast on the spot or a prefabricated element.
  • the subfloor element can extend over the entire floor of a room or over the entire floor of a storey, but it can also be a slab with limited extension.
  • the subfloor element has a floor side and a ground/ceiling side.
  • the floor side is the side which in normal use is part of the base of a floor.
  • the ground/ceiling side is the side which in normal use is facing the ceiling of a lower storey or the ground if the subfloor element belongs to the ground floor.
  • the subfloor element is a structural prefabricated hollow core slab. Several such hollow core slabs can be joined together so as to extend over an entire storey.
  • the subfloor element is a hollow core slab with pretensioned reinforcement. Due to the prestress, such hollow core slabs are usually curved, that is they have an arched longitudinal section.
  • the concrete floor assembly can be given a flat floor side that is suitable as a base for floor laying.
  • the thickness of the top casting layer will vary over the cross-section. Its smallest thickness is where the curve of the arch is at its maximum. Usually, such a subfloor element has its smallest thickness approximately at the centre and its greatest thickness at two opposite edge sides.
  • the subfloor element according to the invention can be made of concrete or reinforced concrete, but it can also comprise other materials. According to the invention, at least a portion of the floor side of the subfloor element has a concrete surface of which at least a portion constitutes a bottom casting surface. The bottom casting surface is intended to interact with the casting composition.
  • the bottom casting surface has such surface roughness that the top casting layer adheres to the bottom casting surface.
  • the casting composition forms a top casting layer with desired thickness over at least part of the bottom casting surface of the subfloor element, the top casting layer adhering to the bottom casting surface so that the requirements of the building sector are met, for instance, those referring to loss of bond and edge lifting and those referring to the strength of the adhesion area between the subfloor element and the top casting layer.
  • the bottom casting surface has a surface roughness which, when measured according to the Swedish Standard for determination of surface roughness SIS812005, is preferably S>1.5. Reference is made to this Standard, for instance, in the Swedish concrete code (BBK04).
  • this surface roughness can be obtained by any suitable method.
  • One example is to seed the bottom casting surface with granular material, such as crushed stone material. Examples of particle sizes are 2-4 mm or 4-8 mm.
  • Another example of providing a bottom casting surface with a rough surface structure is, according to the invention, to treat the bottom casting surface by a surface roughing method.
  • a surface roughing method By this is meant any optional method that removes, transfers and/or compacts material unevenly over the surface so as to make the surface rugged or, in other words, rough.
  • the bottom casting surface is brushed or combed.
  • This can suitably be performed in connection with the manufacturing of the subfloor elements, by a brush or comb being attached to a casting machine.
  • it may sometimes be desirable to remove possible loose material originating from the brushing/combing from the bottom casting surface before the casting of the top casting layer.
  • the adhesion properties are further improved.
  • the bottom casting surface is embossed. This can, for instance, be achieved by a rotating cylinder or several rotating wheels which are attached to a casting machine in connection with the manufacturing of the subfloor elements.
  • At least a portion of the floor side of the subfloor element has a concrete surface with a bottom casting surface which has exposed aggregate.
  • exposed aggregate means that surface skin, surface silt and fine aggregate particles have been removed from the concrete surface so that coarse aggregate protrudes.
  • the exposed aggregate is used to increase the surface roughness of the surface of the subfloor element. Increased roughness of the surface of the subfloor element results in improved adhesion between the subfloor element and the top casting layer, which reduces the risk of loss of bond and edge lifting. Another positive effect is that the upper surface is also strengthened since loose mortar is removed.
  • the exposure of aggregate according to this embodiment provides two properties which are beneficial for the adhesion of the top casting layer to the subfloor element, that is increased surface roughness and strong concrete in the joint.
  • substantially the entire floor side of the subfloor element can have exposed aggregate or only a portion thereof.
  • the top casting layer can cover substantially the entire floor side of the subfloor element or a portion thereof, in which case at least a portion of the exposed aggregate surface, i.e. the bottom casting surface, is covered.
  • the adhesion of the top casting layer can be sufficient even if the surface of the subfloor element covered by the top casting layer does not in its entirety have an exposed aggregate finish.
  • the concrete portion of the subfloor element has a surface with a deep exposure of aggregate, i.e. aggregate in the concrete surface is exposed to such depth that the coarse aggregate grains appear clearly.
  • the depth can be greater than 1 ⁇ 3 of the maximum size of the surface aggregate.
  • a membrane curing compound is applied to the top casting layer so that the after-curing proceeds under the effect of the membrane curing compound.
  • Membrane curing compounds or (liquid membrane curing compounds) are compounds that delay the drying out of the concrete during curing.
  • the membrane curing compound forms a thin film over the newly cast surface so that usually it does not have to be moistened.
  • Membrane curing compounds with different chemical compositions, such as wax dispersions, acrylate polymers or latex emulsions, are commercially available.
  • Preferred membrane curing compounds comply with the specifications laid down in ASTM C 309, Liquid Membrane-Forming Compounds for Curing Concrete, for instance the specifications in this document concerning maximum loss of moisture. Thanks to the application of the membrane curing compound to the top casting layer, the top casting layer does not dry out too quickly during the first hours after casting, whereby plastic shrinkage cracking in the surface layer is advantageously avoided.
  • the subfloor element is pre-moistened before the casting of the casting composition on the subfloor element. This advantageously prevents water from the casting composition from being absorbed into the subfloor element, which would reduce the strength of the layer of the top casting layer that is closest to the subfloor element.
  • a plurality of subfloor elements are joined together to form a subfloor unit with or without the aid of interconnecting means.
  • the subfloor elements can, for instance, be joined by grouting but the subfloor elements can also be loosely placed next to each other or be attached to each other or to a base.
  • the casting composition is cast so that a top casting layer forms which extends over several subfloor elements, whereby a floor assembly according to the invention is provided.
  • substantially the entire floor side of the subfloor elements has exposed aggregate and the top casting layer extends over substantially the entire subfloor unit. Owing to the self-levelling properties of the casting composition, it is thus possible to provide a flat base for floor laying by one single casting of a layer.
  • electric and/or water conduits can be embedded in the top casting layer.
  • the inventive casting composition comprises a self-compacting concrete and a shrinkage reducer.
  • Self-compacting concrete is compacted homogenously under its own weight and fills formwork without using the vibratory unit required for ordinary concrete. This makes it possible to obtain a rational casting process without vibrating, which is less time-consuming and requires less manpower.
  • the concrete will also be self-levelling, which means that it does not have to be coated with screed before the floor is laid, which is a great saving in costs.
  • Self-compacting concrete and various types thereof are described in The European Guidelines for Self-Compacting Concrete—Specification, Production and Use, May 2005, issued by the Self-Compacting Concrete European Project Group, with representatives from BIBM, CEMBUREAU, ERMCO, EFCA and EFNARC.
  • Concrete mainly consists of mineral particles (aggregate) of different grain sizes which are bonded by cement paste consisting of cement and water.
  • a common mixing ratio based on parts by volume is one part water, one part cement, two parts sand and three parts coarse aggregate.
  • Admixtures modifying the properties of the concrete in various ways can also be included.
  • the ratio of fine aggregate e.g. sand and gravel
  • coarse aggregate e.g. stone material
  • a common admixture in self-compacting concrete is commercially available water reducing agents, so-called superplasticisers, which can make the self-compacting concrete plastic and workable.
  • the self-compacting concrete has a slump-flow of >520 mm, preferably >650 mm.
  • the measurement of slump-flow is a test to assess the flowability of self-compacting concrete in the absence of obstructions. It is based on the slump test described in EN 12350-2. The result is an indication of the filling ability of the self-compacting concrete.
  • Slump-flow is thus the mean diameter of the spread of fresh concrete using a conventional slump cone.
  • the measuring of slump-flow is defined in Annex B.1 of The European Guidelines for Self-Compacting Concrete—Specification, Production and Use and is summarised below.
  • Self-compacting concrete can have a very high tendency to shrink due to a small amount of coarse aggregate and a large amount of fine material and/or lime filler, which can be used to make the concrete self-compacting.
  • shrinkage reducing admixtures comprise, for instance, various types of alcohols. They are supposed to primarily reduce the surface tension of the pore water, whereby the shrinkage tensions in the concrete are reduced.
  • Shrinkage reducing admixtures are commercially available and a person skilled in the art can choose a suitable agent based on the composition of the concrete and its shrinkage tendency, etc.
  • a suitable shrinkage reducing admixture can comprise a polyalcohol, preferably 2,2-dimethylpropane-1,3-diol.
  • Lime fillers contribute to the self-compacting properties of the concrete. Lime fillers have also been found to accelerate the drying-out process due to their effect on the structure of the pore system. The accelerated drying-out allows concrete comprising lime filler to comply with the relative humidity (RH) requirements on concrete before carpeting. Lime fillers are commercially available in a number of qualities. For the inventive use, it has been found that a lime filler, for instance a crystalline limestone filler, with a mean particle size of ⁇ 0.05 mm, preferably 0.025-0.05 mm, provides the desired combination of contributions to the self-compacting properties of the concrete and to the accelerated drying-out.
  • RH relative humidity
  • Self-compacting concrete for use according to the invention has a water-cement ratio of >0.5, preferably >0.55.
  • an embodiment of a concrete floor assembly comprises a subfloor element with a floor side and a ground/ceiling side, and a top casting layer.
  • the subfloor element comprises a concrete portion on the floor side and the concrete portion has an exposed aggregate surface
  • the top casting layer comprises a casting composition which comprises a self-compacting concrete and a shrinkage reducing admixture.
  • the top casting layer is cast on the floor side of the subfloor element so that at least a portion of the exposed aggregate surface is covered by the top casting layer.
  • a casting composition based on a self-compacting concrete if it contains an admixture of a shrinkage reducer.
  • a casting composition is considerably more economical than prior-art screed.
  • the good adhesion to the subfloor element and the shrinkage reducing admixture make it possible to cast a layer that is sufficiently thick to comply with the requirements on acoustic insulation and the requirements on the embedment of conduits, but not so thick that an unnecessary amount of material is consumed.
  • the casting composition which according to the invention is based on a self-compacting concrete, requires little labour input since it does not, as ordinary concrete, have to be vibrated but spreads itself substantially horizontally.
  • a flat upper surface is provided, also without the use of screed. Thanks to an economical casting composition and a rational application method, the concrete floor assembly according to the invention is thus considerably more cost-effective than the conventional alternatives.
  • an embodiment of a method of making a concrete floor assembly comprises the steps of providing a subfloor element having a floor side and a ground/ceiling side, the subfloor element comprising a concrete portion on the floor side, which concrete portion has an exposed aggregate surface, providing a casting composition which comprises a self-compacting concrete and a shrinkage reducing admixture, casting the casting composition on the floor side of the subfloor element so that a top casting layer forms which covers at least a portion of the exposed aggregate surface.
  • an embodiment of a method of making a floor assembly for a floor structure in construction works comprises according to the invention the steps of providing subfloor elements which have a floor side and a ground/ceiling side and comprise a concrete portion on the floor side, which concrete portion has an exposed aggregate surface, providing a casting composition comprising a self-compacting concrete and a shrinkage reducing admixture, joining the subfloor elements to form a subfloor unit, casting the casting composition on the subfloor unit by covering at least portions of the exposed aggregate surfaces, thereby forming a top casting layer with a flat upper side which has a desired inclination, preferably substantially horizontal.
  • FIG. 1 is a schematic longitudinal section view of a concrete floor assembly according to the invention.
  • FIG. 2 is a schematic cross-section view of a concrete floor assembly according to the invention.
  • FIG. 3 is a schematic top plan view of a subfloor element according to the invention.
  • FIG. 4 is a schematic top plan view of a floor assembly according to the invention, in which part of the Figure shows joined subfloor elements under the top casting layer.
  • the concrete floor assembly comprises a subfloor element in the form of a prefabricated hollow core slab 1 .
  • the hollow core slab 1 comprises longitudinal reinforcement wires 2 that prestress the hollow core slab 1 , whereby it obtains a curved longitudinal section.
  • the prestress and the curved shape advantageously provide a good ability to absorb tensions and thus also a good load-carrying ability.
  • the hollow core slab 1 is furthermore formed with weight-reducing recesses in the form of longitudinal holes 3 .
  • the hollow core slab 1 according to the example is 10 m ⁇ 1.20 m ⁇ 0.265 m.
  • the hollow core slab 1 has a floor side 9 which in use is an upper side and a ground/ceiling side 10 which in use is an underside.
  • the hollow core slab 1 has an arched shape, the curvature being directed upwards in use. If the hollow core slab 1 is placed on a flat base, the difference in height of the upper side 9 of the hollow core slab 1 above the base measured at half the length of the hollow core slab 1 and at its short ends is 15 mm.
  • the hollow core slab 1 is made of a prior-art concrete mix also comprising coarse aggregate grains 5 with a diameter of about 12 mm.
  • the hollow core slab 1 has a concrete surface that covers the entire floor side 9 , and in the shown example the entire concrete surface of the floor side 9 forms a bottom casting surface which has been provided with a desired roughness by aggregate exposure, cf. FIG. 3 .
  • the concrete surface has deep aggregate exposure, down to a depth corresponding to about half the diameter of the coarse aggregate. In this example, the depth of aggregate exposure is 6 mm.
  • a top casting layer 6 is cast on the arched floor side 9 and covers the floor side 9 over its entire exposed aggregate surface 4 .
  • the top casting layer 6 has a substantially flat upper side 7 facing away from the exposed aggregate surface.
  • the upper side 7 of the top casting layer 6 is horizontal.
  • conduits 8 for electric cables are embedded in the top casting layer 6 .
  • the top casting layer 6 has a thickness of 55 mm at the smallest cross-section where the curve formed by the hollow core slab 1 has its maximum and a thickness of 70 mm at the short ends of the hollow core slab 1 .
  • the top casting layer comprises a casting composition based on a self-compacting concrete.
  • the casting composition can, for instance, comprise the following materials:
  • a preferred casting composition has the following composition:
  • the invention also relates to a floor structure comprising at least one concrete floor assembly according to the invention.
  • a floor structure can, according to the invention, comprise a floor assembly according to the invention, which can be obtained in the following manner.
  • a subfloor element is manufactured in the form of a hollow core slab 1 with an exposed aggregate surface 4 .
  • the hollow core slab 1 is cast in prior-art concrete and comprises a prestressed reinforcement 2 .
  • a retarding admixture in liquid form is applied before curing of the hollow core slab. This means that curing is delayed down to a depth of 6 mm, which has been selected in consideration of the fact that the aggregate grains have a maximum diameter of 12 mm.
  • the hollow core slabs are then high-pressure washed, which means that the surface layer is “cleaned” of cement paste, i.e. the aggregate is exposed and a rough and clean surface 4 appears.
  • the entire floor side 9 of the hollow core slab 1 has exposed aggregate.
  • a plurality of such hollow core slabs are subsequently transported to the desired building site.
  • the hollow core slabs 1 are joined together on site to form a subfloor unit, which in this example extends over a storey and in which all the floor sides 1 of the hollow core slabs are upwardly directed.
  • the hollow core slabs 1 are joined by grouting. In other embodiments of the invention, it may be sufficient to place the hollow core slabs adjacent to each other or to attach them to each other or to a base in some other convenient manner.
  • the curved, arched longitudinal section of the joined hollow core slabs 1 gives the upper side of the subfloor unit a waveform. Furthermore, owing to the exposed aggregate floor side 9 of the hollow core slabs, the entire floor side of the subfloor unit has exposed aggregate.
  • conduits 8 are placed over the subfloor unit in a desired pattern.
  • a casting composition according to the above formula is mixed and supplied to the building site.
  • the ready-mixed casting composition is pumped out over the subfloor unit so that the conduits 8 are covered and the desired thickness, for instance with regard to acoustic insulation class, is obtained.
  • the subfloor unit has been slightly pre-moistened.
  • the casting composition forms a top casting layer 6 which covers the entire upper side of the subfloor unit and the conduits 8 .
  • the casting composition is self-levelling, which means that it compacts under its own weight, which makes vibration unnecessary.
  • the casting composition spreads so that the top casting layer obtains a substantially horizontal surface.
  • Bull floating means that the concrete surface is treated by a so-called bull float.
  • a bull float consists of a board or a plastic tube provided with a handle. The surface is easy to work manually so that a plane and smooth surface is obtained.
  • the top casting layer finally has a thickness of 55 mm at its thinnest point and a thickness of 70 mm at the short ends of the hollow core slab 1 .
  • a membrane curing compound is injected over the surface of the top casting layer. This is done immediately after the free water has disappeared from the concrete surface, usually within an hour after casting. Owing to this, the after-curing of the top casting layer proceeds under the action of the membrane curing compound, whereby plastic shrinkage cracking in the surface layer is advantageously avoided.
  • a separate concrete floor assembly can also be provided by the above-described method.

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  • Working Measures On Existing Buildindgs (AREA)
US12/086,062 2005-12-06 2006-12-05 Concrete Floor Device Abandoned US20090301009A1 (en)

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WO2016189373A1 (en) * 2015-05-26 2016-12-01 Holcim Technology Ltd Concrete composition with reduced drying time once hardened
CN111141616A (zh) * 2020-01-08 2020-05-12 东北石油大学 一种模拟缝网改造地层套管变形的实验装置及实验方法
US20210017078A1 (en) * 2019-07-18 2021-01-21 Central South University Of Forestry And Technology Mildewproof and antirot high-strength cement particle board and preparation method thereof

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CN103726656B (zh) * 2014-01-02 2016-02-10 国核工程有限公司 一种模块墙体内自密实混凝土连续浇筑的信息化施工方法
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WO2016189373A1 (en) * 2015-05-26 2016-12-01 Holcim Technology Ltd Concrete composition with reduced drying time once hardened
US10308554B2 (en) 2015-05-26 2019-06-04 Holcim Technology Ltd. Concrete composition
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US11702362B2 (en) * 2019-07-18 2023-07-18 Central South University Of Forestry And Technology Mildewproof and antirot high-strength cement particle board and preparation method thereof
CN111141616A (zh) * 2020-01-08 2020-05-12 东北石油大学 一种模拟缝网改造地层套管变形的实验装置及实验方法

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NO20082528L (no) 2008-09-04
EP1966449A1 (en) 2008-09-10
SE529224C2 (sv) 2007-06-05

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