DE202023107246U1 - Prefabricated ceiling component and the ceiling made from prefabricated ceiling components - Google Patents

Abstract

The prefabricated ceiling component (1) which includes at least one wooden longitudinal beam (2) and at least one concrete slab (3) connected to the wooden longitudinal beam (2) and provided with the inserted steel reinforcement (7), characterized in that the concrete slab (3) rests with its lower side on the upper side of the wooden longitudinal beam (2) and is connected to it by the connecting strip (5) which is fastened to the wooden longitudinal beam (2) and at the same time protrudes into the concrete slab (3).

Description

Area of technology

The technical solution concerns the field of construction, specifically the prefabricated ceiling structures of wooden buildings.

State of the art

Wooden structures made from the enclosing frames that form the walls are often built as low-rise buildings, because the design of the wall panels is carried out only with regard to the load-bearing capacity of the roof structure and roof covering. The ceiling is made from the wooden frame, lightweight plasterboard and lightweight insulation materials. This saves a significant amount of material and simplifies and speeds up the assembly.

The situation is more complicated in multi-storey buildings. Taking into account the requirements for the acoustic, static, fire-protection and heat-insulating function of the roof structure, wood or lightweight insulating materials such as plasterboard cannot be used, but it is necessary to use heavier materials that have the required properties. One option is to create a reinforced concrete ceiling, which is poured directly on site into the formwork and coupling elements prepared in advance. Thanks to the concreting, the entire ceiling structure becomes monolithic. Such a ceiling structure entails complications in the form of the aforementioned formwork of the components, the support of the ceilings, the binding of the reinforcement on site and the complicated pouring of the ceilings with the wet concrete mix. Hundreds of liters of water are thus poured into the wooden dry construction, and the water must then evaporate and the ceiling structure must dry out so that construction can continue. The entire construction is therefore dependent on climatic conditions, the construction of the concrete ceiling is often very time-consuming due to the technological hardening process, the construction of the wooden structure is extended and consequently more expensive, and in addition it is a very robust and heavy ceiling construction.

Taking into account the above-mentioned fact, requirements are imposed on the relief of the ceiling structures, namely by creating prefabricated wood-concrete composite ceilings. The wood-concrete connection is formed in various ways, the most common of which are grooves in the wood and springs inserted in the transverse direction or connections using connecting screws. This connection is also carried out on the construction site, where the concrete is poured into the already finished structure. This relieves the ceiling structure, but does not eliminate the disadvantages arising from pouring the wet concrete mixture into the wooden ceiling structure directly on the construction site, the manipulation of which above the wooden structure is impractical, time-consuming and complicated, given the need for formwork.

That is why prefabricated concrete elements have recently been produced, which are the latest known variant of connected ceiling elements available. The ceiling element has plastic-steel brackets cast in concrete, with the help of which the final connection of the ceiling is carried out on the construction site by screwing the concrete element and the wooden beam using special static screws. This variant does not require the wet concreting process on site, but it is time-consuming and complicated. And it is not able to repair inaccuracies during construction. Another disadvantage of these connected wood-concrete elements is the robustness of the concrete slab, which ensures the appropriate thermal insulation and acoustic properties, and the connection of the ceiling slab to the supporting structures of the wooden building, since these elements create holes between the load-bearing wall and the ceiling slab. These holes must be sealed, but there is still a risk of thermal bridges forming, which makes construction more expensive and slows down.

A similar solution is for example in CZ2021-552 where the exposed ceiling panel made of wood concrete is described for the assembly of the monolithic composite static ceiling structure made of wood concrete for passive wooden buildings, which consists of two or three parallel longitudinal wooden beams, to which wooden cross beams are attached perpendicularly. The longitudinal beams rest against the reinforced concrete slab and are provided with partially drilled screws, which are then cast into the concrete slab. When making the exposed ceiling panel, the longitudinal and cross beams are first assembled, screws are drilled into the longitudinal beams to connect them to the concrete slab, and then a steel checkerboard is laid on them as the reinforcement of the concrete slab. This entire structure is placed in the mold, into which the concrete mix is then poured, after which the panel is hardened and removed from the mold. From these exposed ceiling panels A monolithic composite static ceiling structure made of wood concrete for passive wooden buildings is then formed. The disadvantages of this solution are mainly that the connection between the wood and the concrete slab is only ensured by means of screws, which can be broken relatively easily, so that the connection is not strong enough and does not have sufficient quality. The ceiling is formed from a flat slab on the visible side, which can be a disadvantage in some cases if the owner of the wooden building wants to have visible supporting beams in the room.

The task of the technical solution is therefore to create such a prefabricated ceiling element and the finished ceiling from these prefabricated ceiling elements, which would eliminate the above-mentioned shortcomings, the use of which would accelerate the construction of hybrid wood-concrete structures, which would eliminate the wet processes in the dry construction of hybrid and wooden structures, which would improve the fire protection and acoustic properties of the ceiling structure, and which would enable the formation of a connected wood-concrete slab that would sit precisely on the load-bearing structures of the wooden structure without creating thermal bridges and would be strong enough and suitable for the rapid construction of concrete ceilings on the lower visible side of which the wooden beams are visible.

Essence of the technical solution

The task is solved by means of the prefabricated ceiling component according to this technical solution. The ceiling component includes at least one longitudinal wooden beam and at least one concrete slab connected to the longitudinal wooden beam and provided with the inserted steel reinforcement.

The essence of this technical solution is that the concrete slab rests with its lower side on the lower side of the wooden beam and is connected to it by the connecting strip, which is attached to the wooden beam and at the same time protrudes into the concrete slab. The connecting strip, attached to the wooden beam and cast in the concrete slab, represents a solid and high-quality connection of the wooden beam with the concrete slab, which ensures a perfect connection of the wooden beam with the concrete slab after pouring and hardening of the concrete mixture around the connecting strip.

In the advantageous embodiment, the wooden longitudinal beam is provided on its upper side at least in one part with at least one longitudinal groove in which the lower part of the connecting strip is fixed by the adhesive connection in the longitudinal direction. Gluing the connecting strip into the wooden longitudinal beam using a suitable adhesive for metal and wood, the so-called chemical anchor, represents a high-strength connection in which there is no possibility of the wooden longitudinal beam being damaged or torn out of the concrete slab.

In another advantageous embodiment, the wooden longitudinal beam is provided with two parallel longitudinal grooves on its upper side at least in one part, with the lower part of the connecting strip being fixed in one groove by means of an adhesive connection, and the other groove is filled with adhesive for connection to the second concrete slab. This embodiment speeds up the installation of the ceiling panels themselves, thanks to the possibility of quick connection by gluing the groove and connecting the adjacent ceiling element. With a larger span of the ceiling element, only one support in the middle of the wooden longitudinal beam on which the connection point is formed is sufficient during installation. The support can be removed 20 minutes after the connection point has been made.

In the advantageous design, the connecting strip is provided with recesses in its upper part for the placement of steel reinforcement at the required height, the so-called concrete cover. Each recess is advantageously provided with a profile lock in order to prevent the steel reinforcement from moving and to keep it in one place when pouring concrete to form the reinforced concrete slab, thus preventing the steel reinforcement from moving during concreting, which allows the precise positioning of the steel reinforcement inside the concrete slab to be maintained.

The steel reinforcement is the most advantageous version of the Kari mat, which is used to reinforce the entire concrete slab or the entire ceiling component. It is a commercially available and reasonably priced reinforcement that fulfils its function perfectly.

In the advantageous design, the connecting strip is provided with height holes in its lower part for the placement of the height pins for adjusting the installation height of the connecting strip relative to the wooden longitudinal member. After adjusting the selected height of the connecting strip relative to the wooden longitudinal member, the adhesive is applied, i.e. the connecting strip is glued into the groove of the wooden longitudinal member.

In a further advantageous embodiment, the connecting strip is provided in its upper part with shear holes for the placement of the protruding shear pins, as far as this is required by the static calculation.

In another advantageous embodiment, the connecting strip is provided with additional holes in its upper part for the placement of additional load-bearing elements for connecting the external and internal structures and for breaking the thermal bridge. The additional load-bearing element is understood to be, for example, the so-called "Isokorb" or "Tronsole". The Isokorb and other similar elements enable the connection of external concrete structures, such as balconies, arcades and staircases, and internal concrete staircases while maintaining the thermophysics and breaking the thermal bridge. It is also possible to connect the external concrete structures during the manufacture of the ceilings or to screw them on site at the construction site. The Tronsole and other similar elements are used to connect concrete structures, such as balconies, arcades and staircases. Thanks to the additional load-bearing elements built directly into the ceiling structure, correct acoustic properties can be achieved and thus the transmission of sound and impact noise into the ceiling structure can be prevented.

The connecting bar is preferably made of steel.

The concrete slab is advantageously equipped with plastic bushings to ensure the passage of technological penetrations, it can contain built-in fire protection penetrations, passages for water and waste pipes, air conditioning and electrical installations, which are laid in absolutely precise positions. This fact also allows for the speeding up of work on the construction site and improves the fire resistance of the ceiling structures.

In the advantageous embodiment, the prefabricated ceiling component can include two wooden longitudinal beams, where one wooden longitudinal beam is connected to the concrete slab by means of the connecting strip and the other wooden longitudinal beam is connected to the concrete slab by means of the adhesive connection.

The concrete slab advantageously has alternating projections on at least one of its sides, which form the shape of the interlocking; these are unique profile locks that fall into one another.

The concrete slab, formed from a well-defined concrete mix and connected with longitudinal wooden beams, is significantly lighter and thinner than standard concrete ceilings, while maintaining its load-bearing capacity, thus saving weight while maintaining the load-bearing capacity. The ceiling component can be connected to the surrounding wooden structure using standard wooden fasteners, such as static and other screws, thanks to the longitudinal wooden beams arranged on the lower side of the concrete slab.

The subject of the technical solution is also the ceiling made from the prefabricated ceiling components described above according to this technical solution. The essence of the technical solution is that the ceiling consists of at least two ceiling components arranged next to each other, the concrete slabs of which are provided with alternating projections on their adjacent sides, which fall into each other. The gap between the two concrete slabs arranged next to each other is filled with the casting compound in order to form the monolithic ceiling. All adjacent ceiling components thus form the monolithic reinforced concrete slab, which can be assumed in the static calculation of the timber structure.

The advantages of the prefabricated ceiling element and the ceiling made of these prefabricated ceiling elements according to this technical solution are mainly that their use accelerates the construction of hybrid wood-concrete buildings, eliminates the wet processes in the dry construction of hybrid and wooden buildings, improves the fire protection and acoustic properties of the ceiling structure, and enables the formation of a connected wood-concrete slab that sits precisely on the supporting structures of the wooden structure without creating thermal bridges and is strong enough and suitable for the rapid construction of concrete ceilings on the lower visible side of which the wooden beams are visible.

Explanation of the drawings

• die Ansicht der Verbindungsleiste darstellt,
• die Ansicht der eingeklebten Verbindungsleiste im Holzlängsträger darstellt,
• die Ansicht der eingelegten Stahlbewehrung in der Verbindungsleiste darstellt,
• die Seitenansicht des Deckenbauteils darstellt,
• die Draufsicht des Deckenbauteils darstellt,
• die Draufsicht der zwei nebeneinander angeordneten Deckenbauteile darstellt.

The technical solution mentioned is explained in more detail in the following figures, where:

• represents the view of the connection bar,
• shows the view of the glued-in connecting strip in the wooden longitudinal beam,
• shows the view of the inserted steel reinforcement in the connection bar,
• shows the side view of the ceiling component,
• represents the top view of the ceiling component,
• the top view of the two ceiling components arranged next to each other.

Example of the realization of the technical solution

The prefabricated ceiling component 1 according to this technical solution includes the wooden longitudinal beam 2, the connecting strip 5 and the concrete slab 3. In the the connecting element is made of steel, i.e. the connecting bar 5 with a length of 7860 mm and a thickness of 3 mm. In another example of the design, the connecting bar 5 can have other dimensions. In its upper part, specifically on its upper edge, recesses 6 are formed in the connecting bar 5, which in this case are 100 mm apart (this depends on the selected reinforcement). In each recess 6, a profile lock 8 is formed, into which the steel reinforcement 7 fits, and further it does not move over the connecting bar 5. In the upper part of the connecting bar 5, shear holes 10 are also formed, into which the required number of shear pins with a diameter of 8 mm, in this case fifty shear pins, are then placed. In the lower part of the connecting bar 5, height holes 9 are formed, into which the height pins are then placed, which enable its precise height adjustment relative to the wooden longitudinal beam 2. Furthermore, additional holes 13 are formed in the connecting bar 5 for the introduction of the reinforcement for binding the additional load-bearing elements, such as the Isokorb or the Tronsole.

In the the connecting strip 5, which is fitted in the wooden longitudinal beam 2, is shown. On the upper side of the wooden longitudinal beam 2, the longitudinal groove 4 with a thickness of 10 mm is milled out along its entire length. The HILTI HIT-RE 500 V4/500 adhesive is introduced into the groove 4. The lower part of the connecting strip 5 with height and shear pins, which are placed perpendicular to the longitudinal groove 4, is then inserted into the groove 4 with the adhesive. The height pins hit the wooden longitudinal beam 2, and this sets the height of the connecting strip 5. After the adhesive has hardened and the strong adhesive bond has been formed between the connecting strip 5 and the wooden longitudinal beam 2, it is necessary to prepare the formwork for the concrete slab 2, including the insertion of the release film. In the prepared formwork with the separating film inserted, steel reinforcement 7, namely the Karimatte with the size of 6x100x100, is placed in the upper part of the connecting strip 5, specifically in the recess 6 with the profile lock 8. In another example of execution, another Karimatte with corresponding dimensions is used. When connecting the Karimatte, it is necessary to ensure its overhang of 30 to 50 cm. The lower part of the Karimatte is inserted so that the lower wires are perpendicular to the connecting strip 5, as shown in the After placing the Karimatte, it is necessary to control the position of the profile formwork to ensure the formation of alternating projections 11, which form the shape of the teeth on one side surface of the concrete slab 2. Further, it is necessary to insert the plastic bushings to ensure the passage for the technological penetrations.

After ensuring the preparatory steps described above, the prepared high-strength mixture, the so-called UHPC concrete, is poured into the formed formwork. It is necessary to allow the concrete mixture to set by means of vibrations through the cari mat. After the concrete mixture has hardened, the concrete slab 3 is created with the connected wooden longitudinal beam 2. The concrete slabs 3 can have different dimensions depending on the requirements for the size of the ceiling, in this example of the design the concrete slab 3 has a length of 5000 mm, a width of 1590 mm and a thickness of 80 mm.

In the two ceiling components 1 arranged next to one another are shown, of which one ceiling component 1 has two arranged wooden longitudinal beams 2 on the lower side of the concrete slab 3. On one wooden longitudinal beam 2, a groove 4 is formed on its upper side for gluing the connecting strip 5, and on the other wooden longitudinal beam 2, two parallel longitudinal grooves 4 are formed on its upper side. The lower part of the connecting strip 5 is fastened in one groove 4 by the adhesive connection, and the other groove 4 is filled with the adhesive for the connection to the other concrete slab 3. The second ceiling component 1 is therefore connected to the first ceiling component 1 by the adhesive connection.

In the the ceiling component 1 is shown, the side surface of the concrete slab 3 of which has the toothing, which is formed by alternately occurring projections 11, which fall into the alternately occurring projections 11 of the concrete slab 3 of the second ceiling component 1, as in the shown. After the ceiling components 1 have been installed, the SikaGrout 212 casting compound 12 is introduced into the gap between the adjacent concrete slabs 3, which connects the entire ceiling made from the ceiling components 1 described above, or makes it monolithic. The ceiling components 1 connected in this way form the monolithic ceiling, which is then simply installed on the load-bearing walls of the timber structure via the longitudinal timber beams 2 and screwed on with standard screws.

The example described above is only an illustrative example of concrete values; in other exemplary designs, individual components of the ceiling with different dimensions can be used.

Industrial applicability

The prefabricated ceiling component as well as the ceiling constructed from prefabricated ceiling components according to this technical solution can be used as a ceiling structure in the construction of wooden buildings.

Overview of reference symbols

1

Ceiling component

2

Wooden longitudinal beams

3

Concrete slab

4

Groove

5

Connection bar

6

Recess

7

Steel reinforcement

8th

Profile lock

9

Height hole

10

Scherloch

11

head Start

12

Casting compound

13

Additional hole

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• CZ2021552 [0006]

Claims (14)

The prefabricated ceiling component (1) which includes at least one wooden longitudinal beam (2) and at least one concrete slab (3) connected to the wooden longitudinal beam (2) and provided with the inserted steel reinforcement (7), characterized in that the concrete slab (3) rests with its lower side on the upper side of the wooden longitudinal beam (2) and is connected to it by the connecting strip (5) which is fastened to the wooden longitudinal beam (2) and at the same time protrudes into the concrete slab (3). The prefabricated ceiling component (1) after the Claim 1 , characterized in that the wooden longitudinal support (2) is provided on its upper side at least in one part with at least one longitudinal groove (4), in which the lower part of the connecting strip (5) is fastened by the adhesive connection. The prefabricated ceiling component (1) after the Claim 1 , characterized in that the wooden longitudinal member (2) is provided on its upper side at least in one part with two longitudinal grooves (4), wherein the lower part of the connecting strip (5) is fastened in one groove (4) by the adhesive connection, and the other groove (4) is filled with the adhesive mass. The prefabricated ceiling component (1) according to one of the Claims 1 until 3 , characterized in that the connecting bar (5) is provided in its upper part with recesses (6) for the placement of the steel reinforcement (7). The prefabricated ceiling component (1) after the Claim 4 , characterized in that each recess (6) is provided with a profile lock (8) for preventing the movement of the steel reinforcement (7). The prefabricated ceiling component (1) according to one of the Claims 1 until 5 , characterized in that the steel reinforcement (7) is the Karimatte. The prefabricated ceiling component (1) according to one of the Claims 1 until 6 , characterized in that the connecting bar (5) is provided in its lower part with height holes (9) for the placement of the height pins for the height adjustment of the connecting bar (5) relative to the wooden longitudinal member (2). The prefabricated ceiling component (1) according to one of the Claims 1 until 7 characterized in that the connecting strip (5) is provided in its upper part with shear holes (10) for the placement of the shear pins protruding into the concrete slab (3). The prefabricated ceiling component (1) according to one of the Claims 1 until 8th , characterized in that the connecting strip (5) is provided in its upper part with additional holes (13) for the placement of the additional supporting elements for the connection of the external and internal structures and for the interruption of the thermal bridge. The prefabricated ceiling component (1) according to one of the Claims 1 until 9 , characterized in that the connecting bar (5) is made of steel. The prefabricated ceiling component (1) according to one of the Claims 1 until 10 , characterized in that the concrete slab (3) is provided with plastic bushings for the purpose of ensuring the passage for the technological penetrations. The prefabricated ceiling component (1) according to one of the Claims 1 until 11 , characterized in that it includes two wooden longitudinal beams (2). The prefabricated ceiling component (1) according to one of the Claims 1 until 12 , characterized in that the concrete slab (3) has alternating projections (11) on at least one of its side surfaces. The ceiling made from the prefabricated components (1) according to one of the Claims 1 until 13 , characterized in that it consists of at least two ceiling blocks (1) arranged next to one another, the concrete slabs (3) of which are provided on their adjacent sides with alternating projections (11) which fall into one another, the gap between adjacent concrete slabs (3) being filled with the casting compound (12) for the purpose of forming the monolithic ceiling.