EP1582654A1 - Concrete surface and its method of production - Google Patents

Abstract

The concrete area (1), in particular, the concrete floor comprises a separation layer (3) which is located on a base (2) and is provided with raised sections (5) and/or depressions (6), so that the thickness of the concrete cover layer (4) varies. Independent claims are also included for: (A) a method for producing the proposed concrete area; and (B) an application of a separation layer for production of concrete areas.

Description

The present invention relates to a concrete surface, in particular a concrete floor, according to the preamble of claim 1 and a method for her Production according to the preamble of claim 12 or 13th Furthermore the present invention relates to a use of a release layer, in particular foil, sheet metal or the like, for producing a concrete surface, in particular a concrete floor, according to the preamble of the claim 15th

In the production of monolithic, one-piece concrete floors occurs during the setting and drying process of the concrete as a result of Volume decrease to an uncontrolled crack or joint formation, in particular in the case of concreting large areas.

The prior art attempts this undesirable property of the concrete in different ways.

Currently, it is believed that the best prevention of (shrinkage, setting) cracks for monolithic concrete floors is that you first between the base layer (= base) and the concrete (= top layer) one Slip layer in the form of a plastic film provides, d. H. the concrete layer is applied to an arranged on the substrate plastic film, and that then (generally the day after concreting) so-called "Dummy joints" in the surface of the concrete layer cuts, in general at a mutual distance of about 5 to 7 m. This will achieve that occurring in any case concrete shortening due to setting or Drying controlled in the dummy joints appears and no uncontrolled Cracking or joint formation takes place in between. Equally will By inserting the plastic film avoids that the water in the Fresh concrete escapes uncontrolled into the underground. This method is so far not efficient, as in the day after concreting still joints in the Concrete must be cut, and then the joints then closed or sealed and later mostly renovated. Of Furthermore, this method places high demands on the flatness of the wing or the substrate, otherwise the plastic film will not slide can, but what is required to the shrinkage or shortening counteract the concrete during setting or drying.

Furthermore, it has been proposed by incorporation of special Plastic fibers of certain dimensions in the concrete mass of formation of (shrinkage, setting) cracks during setting and drying of the concrete counteract (see, for example, European Patent EP 0 448 577 B1 of the company Danaklon A / S or its German equivalent DE 689 10 533 T2). Especially however, this method has little effect on large areas. Of Further, the homogeneous distribution of the fibers over the concrete mass is not always easy to reach. The practical experience with this method are also very limited.

The object underlying the present invention is to provide a method of the type described above, which the Disadvantages of the prior art at least partially avoids.

A further object is to provide a method for producing a concrete surface, in particular a concrete floor, in which the formation uncontrolled cracks due to setting or drying of the concrete largely avoided or at least controlled.

Yet another object is to provide a method for the production of a seamless concrete surface, in particular a jointless one Concrete floor.

The subject of the present invention according to a first aspect of the present invention Invention is thus a concrete surface, in particular a concrete floor, with a release layer disposed on a substrate and one on top of it arranged or applied top layer of concrete, wherein the release layer has a plurality of elevations and / or depressions, so that the thickness of the cover layer varies.

The term "concrete" as used in the invention is very broad to understand and includes both concrete in the strict sense as well concrete-like hydraulic binder of all kinds, such. As cements, mortar or similar.

The term "concrete surface" in the context of the present invention comprises concrete surfaces of any kind, both flat and uneven surfaces. Especially are hereunder concrete floors of any kind to understand.

One of the special features of the concrete surface according to the invention, in particular Concrete floor, it must be seen that the separation layer a variety of elevations and / or depressions, so that the thickness of the concrete cover layer varied. This means that the separating layer is repeated in preferably regularly recurring sections different Has thickness ranges. Consequently, this varies the thickness of the Concrete covering layer over the elevations or depressions of the separating layer, as described in more detail below.

As will be explained in more detail below, the use of a separating layer of the type described above inter alia to avoid uncontrolled Jointing or cracking in the concrete surface, in particular concrete floor, or at least causes the formation of controlled (micro) cracks or (micro-) joints in the concrete, in particular cracks or joints under 0.2 mm width, which are harmless from a structural point of view. Without To commit oneself to a certain theory, the effect can be possibly explain the release layer provided according to the invention by that the release layer during drying of the concrete, cement, mortar or the like of the top layer absorbs shrinkage or evenly distributed over the area and, where appropriate, controlled for training (Micro) cracks or (micro-) joints leads. That will be later further explained. In this way, according to the invention, the provision or Cutting (fake) joints, as required in the prior art is to be avoided.

According to the invention it is preferred if the elevations and / or depressions regularly distributed or arranged distributed over the separating layer are. In this way a maximum effect is achieved.

In general, the release layer has a structured, preferably uniformly structured surface. For example, the release layer frustoconical or truncated pyramidal elevations (eg in the form of bumps, nubs, etc.), preferably in a more uniform manner Distribution.

The separating layer provided according to the invention may be in particular a preferably structured film, in particular plastic or Metal foil, or act a preferably textured sheet. According to the invention it is preferred if the film is water-repellent or waterproof is formed, since it then additionally fulfills a sealing function. Examples for plastic films suitable according to the invention are structured (eg, dimpled) polyolefin films (eg, polyethylene or polypropylene films), as they are available for example in the trade. In the invention provided separation layer may in particular but also to a preferably structured or profiled (eg deep-drawn) sheet ("Profile sheet") act.

According to a particular embodiment of the present invention can the separating layer can be formed by the substrate or can be the separating layer at the same time form the underground.

Depending on the application, the thickness of the topcoat over the elevations or depressions of the separating layer vary within wide ranges. In general The thickness of the cover layer varies over the elevations or depressions the separation layer on average by at least 5%, in particular by at least 10%, preferably by at least 15%, preferably at least by 20%, more preferably by at least 25%, especially preferably at least 30%. This means in other words that the (average) thickness of the concrete cover layer due to the elevations or depressions varies by the above values, d. H. so over the surveys shortened and thickened over the wells.

In the concrete of the top layer fibers, for different purposes, fibers, in particular plastic fibers, such as polyolefin fibers (eg., Polyethylene or Polypropylene fibers), metal fibers, glass fibers or the like incorporated be. The material, the texture, the quantity and the dimensions of such Fibers depend on the particular application and are the person skilled in the art. For example, metal or glass fibers serve as a bar steel or reinforcing steel reinforcement replacement, plastic fiber for the purposes of fire protection or for the additional absorption of Forces from setting and early disappearance are used etc.

Similarly, it is possible in the concrete of the top layer z. As steel inserts, To bring in irons, etc., d. H. the concrete as reinforced concrete or the like train.

The concrete surface according to the invention, in particular concrete floor, is suitable both for indoor and outdoor use, especially for extensive floor areas (eg hall floor, roadway floor, runway for Aircraft or the like). The concrete surface according to the invention, in particular Concrete floor, is generally resilient, especially passable.

In general, the concrete surface according to the invention, in particular concrete floor, cast, in particular cast in one piece, before and is preferably formed monolithic and joint-free.

The inventively provided, a plurality of elevations or depressions having separating layer (eg a "knobbed foil" or "studded plate") made of plastic or metal, a profiled or deep-drawn sheet metal etc.) is intended, among other things, to effect the reduction occurring in each case of the concrete in as many as possible, physically acceptable, controlled or split controlled (micro) cracks or cracking even completely suppress. The separating layer (eg knobbed foil or plate) effects this alike a kind of "gearing" with the ground (the concrete of the Cover layer or cover plate thus remains substantially on the same Place, d. H. Shifts should be consciously avoided.), And on the other hand act the reaching into the concrete elevations ("nubs") or Wells as a kind of "crack indicator" or "crack initiator" (The total thickness of the concrete is weakened locally, resulting in these "vulnerabilities" due the increase in voltage primarily micro or predetermined cracks occur.). Theoretically over long distances trained restraints due Concrete shortening are thus divided into many small forces. Possibly Certain fiber additives (plastic fibers such as polyolefin fibers, z. As polypropylene fibers, or metal fibers, such as. As steel fibers, or Glass fibers) these forces regardless of the fundamental dimension of the Control separation layer. Ideally, it's about the size of it concreted concrete surface independently (eg in the case of large areas such as hall floors, Airfields etc.).

Without wishing to be bound by any theory, the present Invention are described by the following principles:

With regard to the residual stresses of the concrete, the following can be stated: If one wants to become independent of the dimension of the surface, one must all the components causing or causing local movements medium dimensions are considered (dummy joints), forgotten. Around To achieve this situation, one must also local all voltages occurring locally can bind before they accumulate each other and dimensions reach that are no longer manageable. But this is only over the detour To achieve the toothing with the ground. These are flat films, which have too small coefficients of friction, can not be used according to the invention.

By providing a multi-ply release layer (eg, a dimpled foil or plate) between the substrate and the concrete of the cover layer, this release layer prevents local shrinkage from being summed over greater distances. For example, it can be assumed that the temperature coefficient α = 10 ^-5 only takes effect on the locally limited area (eg 5 × 5 to eg 15 × 15 cm); Theoretically, it is possible to recalculate the permissible crack widths (eg: 0.2 mm) with the expected temperature gradient and shrinkage. The big advantage of this is that you no longer need to view a test field two-dimensionally, but that one dimension is sufficient (eg: 1 x 30 m).

With respect to the load voltages, the following can be stated: Since in the inventive Concrete surface, especially concrete floor, spacious joints eliminated, remain in the end only the tensile stresses on the underside of the plate (Field center). In common consideration with the invention provided separation layer (eg. "Noppenfolie / -platte") can be at local Load even assume that at the "bottom" of Trennschicht form no real tensile stresses, but a kind Mini vaults. This is all the more true when the surveys or depressions ("Pimples") are less sustainable than the release layer as such.

The concrete surface according to the invention, in particular concrete floor, is therefore based - in contrast to the conventional production monolithic or one-piece concrete floors (eg steel or fiber reinforced concrete floors), in between Supporting layer (substrate) and construction concrete (covering layer) one Slip film is inserted to allow for shrinkage the fact that the concrete is not given a chance to not to sum up preventing shrinkage movements over longer distances. This is achieved by a between base course (subgrade) and construction concrete interposed special release layer (eg "bubble wrap" or "profile sheet"), which in the Abbindvorgang of the young concrete in the module of Noppenabstandes hinders these movements and forces occurring holds in dimensions which are either of the respective strength state of the Composite concrete are receivable or in case of exceeding this strength the movements in the form of many small, physically acceptable and thus harmless cracks compensated. Like previously described, can the material of the release layer ("knobbed foil" or "profiled sheet") of Plastic up to deep-drawn sheets actually contain all materials, which is stiff or rigid enough, the young concrete a certain To oppose movement resistance. The geometric shape of the dimpled films resembles a drainage foil, when out of a plane (under certain circumstances in raster-shaped module) surveys, for example in the form of z. B. truncated or truncated pyramids, burls, cones or like, stand out. Such dimpled sheets are commercially available. The mode of action of these nubbed foils is then that on the one hand built up against the substrate (base layer) a (higher) static friction On the other hand, on the top, the individual pimples become the (plate) thickness or thickness of the concrete of the top layer weaken and thus small-scale provoke harmless cracks.

Without wishing to be bound by any particular theory, the static Effect of the final product may be explained as follows: If floors are made without joints, they fall at the top of the Concrete surface occurring at the joints tensile stresses according to outer Loads away (It can, for example, on known and usual design methods bedded plates.). At the top of the concrete surface Essentially only tensile stresses from constraining forces remain (Shrinkage, creeping, temperature, etc.), whose deformations in kind of many microcracks are compensated. The ones occurring at the bottom (Last) tensile stresses must be determined with the help of the residual body (within the dimpled foil) of the concrete - possibly with the help of the composite cross-section of the concrete with the dimpled foil - to be recorded. Is the load above one Nub ("weak point", ie lower concrete thickness), then the forwarding the forces as in a vault (support arch) within the concrete in the train zone accomplished. The geometric shape of these nubs and the relative height of the "top" of these knobs to concrete slab thickness must ensure that causes no splitting effect or punching of the concrete becomes. The so provoked, penetrated by microcracks concrete product can for the design sure a lower, d. H. So cheaper elastic modulus than have the un-cracked concrete.

Further advantages of the concrete surface according to the invention, in particular concrete floor, can be summarized as follows:

With favorably chosen dimensions of the structured separating layer ("dimpled foil") This can easily overlap when laying at the joints become; when introducing the concrete, this gearing is by its own weight secured.

The possible static composite effect between structured release layer ("Bubble wrap") and concrete can reduce the structural strength of the concrete. Is the module of the knobs matched to prefabricated reinforcement units (For example, steel mesh grating mats), so this mat can easily fit in it sunk or introduced; Normally, the corrosion protection the optionally added reinforcement by the tightness of Noppenfolie secured, so they can rest directly. The modified composite effect However, reinforcement and concrete without concrete cover must be taken into account.

According to information from soil experts has the not "full-scale" introduction The load forces (pressure) no adverse, but rather an improving Influence on the compression modulus, as long as no "bad" Base layers (cohesive soils, particle sizes <0.2 mm, capillary water withdrawing) Layers) are present.

When placed on thermal insulation Noppenfolien the optionally remaining air space under the knobs in addition as heat-insulating to be viewed as.

The demands on the evenness of the underground are not too big, because Even larger bumps are compensated by the release layer can. The asked in the conventional production of industrial floors high demands on the evenness of the base course or the subfloor, on which the conventionally used slip film is to be effective deleted thus complete. Only the static required plate thickness must be as Minimum requirement to be met.

When laying a planned floor heating, the heating coils can in the correct position and protected, without additional measures, between the pimples or depressions / elevations are introduced, if the nub module allows the inspection during concreting. (The ones through the heating coils partially interrupted transfer surface by fibers must be there be considered statically.)

Are day joints required - z. B. at interruptions of the concreting process over several hours -, so these can be inserted vertically Nubbed mat to be designed shear-proof. The Zugverbund becomes thereby usefully by a below the shuttering inserted in the module the pimples accomplishes matching mild steel mesh strips.

In the meantime, the Applicants have carried out numerous tests, including a composite concrete concrete grade C 25/30 to EN standard as a cover layer concrete, in addition steel fibers and plastic fibers (polypropylene fibers) were admixed. This concrete was applied to a plastic nap foil, in a first experiment over an area of 52 m ² , in a second experiment over an area also 52 m ² and in a third experiment over an area of 20 m ² , wherein in the first (second, third) trial, the concrete thickness varied from 5 cm (10 cm; 23 cm) over the protrusions of the dimpled sheet to 7 cm (12 cm; 25 cm) above the dimples of the dimpled sheet. Within the assessment period of one month, no cracks appeared in the cover layers.

Fig. 1

eine schematische Darstellung einer erfindungsgemäßen Betonfläche, insbesondere eines Betonbodens, mit einer Trennschicht in Form einer Noppenmatte mit hohlen Noppen;

Fig. 2

eine schematische Darstellung einer erfindungsgemäßen Betonfläche, insbesondere eines Betonbodens, mit einer Trennschicht in Form einer Noppenmatte mit Vollnoppen.

Further advantages, properties, aspects and features of the concrete surface according to the invention, in particular of a concrete floor, will become apparent from the following description of a preferred embodiment of the present invention shown in the drawing. It shows:

Fig. 1

a schematic representation of a concrete surface according to the invention, in particular a concrete floor, with a release layer in the form of a dimpled mat with hollow nubs;

Fig. 2

a schematic representation of a concrete surface according to the invention, in particular a concrete floor, with a release layer in the form of a dimpled mat with full knobs.

1 and 2 schematically show a concrete surface 1 according to the invention, in particular a concrete floor, with a arranged on a substrate 2 Separating layer 3 and a covering layer 4 of concrete arranged thereon, wherein the separating layer 3 has a plurality of elevations 5 or depressions 6, so that the thickness of the cover layer 4 varies. As a separating layer 3 may in particular be a dimpled foil (eg made of plastic or plastic) Metal) are used, the surveys 5, z. B. in the form of truncated pyramid or truncated conical bumps, burls or the like. These elevations 5 may be hollow, d. H. between the elevations 5 and the ground 2 is air (Fig. 1), or these surveys 5 consist of the interface material ("full nubs") (Figure 2). The specially designed, provided according to the invention separation layer 3 prevents An uncontrolled joint or crack formation during setting or

Drying the concrete cover layer 4 and optionally leads to training controlled, structurally harmless (micro) cracks.

Subject of the present invention according to another, second Aspect of the present invention is a process for the preparation of the invention Concrete surface, in particular a concrete floor. Another The present invention thus relates to a process for the preparation a concrete surface, in particular a concrete floor, with one on one Substrate arranged separating layer, on which a cover layer of concrete applied (eg, poured), wherein as a release layer, a plurality used by elevations or depressions having separating layer is so that the thickness of the cover layer varies. Likewise, the invention serves Method of avoidance or suppression or at least the control of joint and crack formation in concrete floors.

In other words, it is in the process of the invention a method for producing a concrete surface, in particular a concrete floor, in particular as described above, the concrete surface being seamless is poured concrete and the concrete surface with alternating areas Lesser and greater thickness is poured, so that an uncontrolled Joint or crack formation is avoided or controlled (micro) cracks be formed in the concrete or the areas of lesser thickness Form micro or Sollrißstellen the concrete.

The phrase "alternating areas of lesser and greater thickness" includes, for example, embodiments in which these areas in the Kind of egg carton vary, d. H. the areas of lesser thickness are not connected, but distributed as it were grid-shaped over the concrete surface In particular, each local area of lesser thickness is complete surrounded by a region of greater thickness. If necessary, the concrete surface but also be designed to be complementary.

For further embodiments and embodiments of the method according to the invention can be applied to the above statements on the concrete surface according to the invention, in particular concrete floor, referenced, with respect to the inventive Procedures apply accordingly.

Subject of the present invention according to another, third Aspect of the present invention is the use of a release layer, in particular foil, sheet metal or the like, for the production of an inventive Concrete surface, in particular a concrete floor, with one on one Subsurface arranged separating layer and arranged thereon or applied cover layer of concrete, wherein as a release layer a a variety used by elevations and / or depressions having separating layer is so that the thickness of the cover layer varies.

For further embodiments and embodiments of the use according to the invention can be applied to the above statements on the concrete surface according to the invention, particular concrete floor, referenced in relation to the apply according to the invention.

Further embodiments, modifications and variations of the present The invention will be readily apparent to those skilled in the art upon reading the description recognizable and realizable, without being the scope of the present Invention leaves.

Claims (16)

Concrete surface (1), in particular concrete floor, with a separating layer (3) arranged on a substrate (2) and a covering layer (4) made of concrete applied thereon,
characterized in that the separating layer (3) has a plurality of elevations (5) and / or depressions (6), so that the thickness of the cover layer (4) varies. Concrete surface according to claim 1, characterized in that the separating layer (3) has a plurality of elevations (5) and / or depressions (6) in the concrete to avoid uncontrolled formation of cracks or cracks and / or to form controlled (micro) cracks in the concrete. Concrete surface according to claim 1 or 2, characterized in that the elevations (5) and / or depressions (6) are regularly distributed over the separating layer (3). Concrete surface according to one of the preceding claims, characterized in that the separating layer (3) has a structured, preferably uniformly structured surface and / or that the separating layer (3) has frustoconical or truncated pyramidal elevations (5), in particular in the form of dimples, preferably in even distribution. Concrete surface according to one of the preceding claims, characterized in that the separating layer (3) is designed as a preferably structured foil or sheet, in particular plastic or metal foil, in particular wherein the foil can be water-repellent or waterproof. Concrete surface according to one of the preceding claims, characterized in that the separating layer (3) is formed by the substrate (2). Concrete surface according to one of the preceding claims, characterized in that the average thickness of the covering layer (4) due to the elevations (5) and / or depressions (6) of the separating layer (3) by at least 5%, in particular by at least 10%, preferably by at least 15%, preferably at least 20%, more preferably at least 25%, most preferably at least 30%, varies. Concrete surface according to one of the preceding claims, characterized in that the cover layer (4) and / or the entire concrete surface (1) is formed without joints and / or that the cover layer (4) (micro) cracks and / or (micro) joints having. Concrete surface according to one of claims 1 to 8, characterized in that fibers, in particular plastic fibers, such as polyolefin fibers, metal fibers, glass fibers or the like, are incorporated in the concrete of the cover layer (4). Concrete surface according to one of claims 1 to 8, characterized in that the concrete of the covering layer (4) contains no fibers. Concrete surface according to one of the preceding claims, characterized in that the concrete surface (1) forms a large floor area for indoor or outdoor use, in particular an indoor floor, a roadway floor, a runway for aircraft or the like, and / or that the concrete surface (1) is loadable, in particular passable, and / or that the concrete surface (1) poured, in particular cast in one piece, and / or that the concrete surface (1) is formed monolithic and / or joint-free. Method for producing a concrete surface (1), in particular a concrete floor, in particular according to one of Claims 1 to 11, having a separating layer (3) arranged on a substrate (2), onto which a covering layer (4) of concrete is applied;
characterized in that a release layer (3) having a plurality of protrusions (5) and / or recesses (6) is used so that the thickness of the cover layer (4) varies. Method for producing a concrete surface (1), in particular a concrete floor, in particular according to one of claims 1 to 11, wherein the concrete surface (1) is poured seamlessly from concrete,
characterized in that the concrete surface is cast (1) with alternating regions of lower and greater thickness, so that an uncontrolled crevice or crack formation is prevented and / or controlled (micro) cracks formed in the concrete and / or the regions of lesser thickness microstructure - or Sollrißstellen the concrete form. Method according to claim 12 or 13, characterized by the features of the characterizing part of one or more of claims 1 to 11. Use of a separating layer (3), in particular foil, sheet metal or the like, for producing a concrete surface (1), in particular a concrete floor, in particular according to one of claims 1 to 11, with a separating layer (3) arranged on a substrate (2) and one Applied thereon cover layer (4) made of concrete,
characterized in that a separating layer (3) having a plurality of elevations (5) and / or depressions (6) is used as separating layer (3), so that the thickness of the covering layer (4) varies. Use according to claim 15, characterized by the features of the characterizing part of one or more of claims 1 to 11.

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