Fabricated seamless floor and construction technology

Abstract

The fabricated seamless floor comprises a base layer and a plurality of prefabricated slabs laid on the base layer, and is characterized in that the thermal expansion and cold contraction coefficient of the prefabricated slabs is the same as or similar to that of the base layer, a bonding layer is arranged between the base layer and the prefabricated slabs, and the bonding layer is arranged between the base layer and the prefabricated slabs. The prefabricated slabs are tightly attached together, the bonding force between the base layer and the prefabricated slabs is F, the deformation force between the base layer and the prefabricated slabs is G, F = a * G, a is a preset proportion value, and the value range of a is 1-3. The thermal property of the prefabricated panel is the same as or similar to the parameters of the base layer, so that the prefabricated panel and the base layer expand with heat and contract with cold synchronously, the prefabricated panel is prevented from warping and deforming during expansion with heat and contraction with cold, the seamless effect of the floor is ensured, and a real seamless structure can be realized.

Description

Technical Field

[0001] The invention relates to a floor, in particular to an assembled seamless floor and a construction process. Background Art

[0002] In the prior art, the floor is generally completed by cast-in-place or paving construction. The cast-in-place process is to make the surface material of the floor on site, usually by hand. The quality of this method is difficult to control. The density of the handmade surface layer is not enough, which will cause the floor to be non-fouling and color-bleeding pollution in the later stage. The cast-in-place process has a long construction period and is inappropriate under the efficient economic development. The difficulty of on-site management of the cast-in-place process increases, and the on-site environment of cross-construction is very easy to cause floor surface pollution, resulting in irreversible quality problems. When using the paving construction process, such as ceramic tiles, stone materials, artificial stones, etc., due to the thermal expansion and contraction of the board, a gap needs to be left between the boards during paving and installation, which is commonly known as a seam. The size of the seam is reserved according to the size of the board. This seam-leaving process causes the seam to affect the appearance after the floor is paved. On the other hand, the seam will hide dirt and dirt, which is difficult to clean. In places such as hospitals, due to the presence of seams, the seams will not only hide dirt and dirt, but also breed bacteria. Such a seamed floor cannot meet the clean environment requirements of the hospital. Summary of the invention

[0003] The technical problem to be solved by the present invention is to overcome the deficiencies of the above-mentioned prior art and provide a prefabricated seamless floor without gaps and not easy to deform. At the same time, it relates to a construction process for the prefabricated seamless floor.

[0004] According to an assembled seamless floor provided by the present invention, the floor comprises a base layer and a plurality of prefabricated panels laid on the base layer, the thermal expansion and contraction coefficients of the prefabricated panels are the same as or similar to those of the base layer, an adhesive layer is arranged between the base layer and the prefabricated panels, the prefabricated panels are tightly attached to each other, the adhesive force between the base layer and the prefabricated panels is F, the deformation force between the base layer and the prefabricated panels is G, then F=a*G, wherein a is a preset ratio value, and the value range of a is 1-3.

[0005] The assembled seamless floor provided by the present invention also has the following additional technical features:

[0006] It further includes that the bonding layer is a solvent-free epoxy resin putty layer.

[0007] Further comprising: the thickness of the bonding layer is 0.5 mm-3 mm.

[0008] It further includes that the prefabricated board is formed by pressing solvent-free epoxy resin and granular aggregate under high pressure in a vacuum state.

[0009] It further includes that the thickness of the prefabricated board is 10mm-30mm.

[0010] It further includes that the surface of the prefabricated board has a surface layer formed by grinding and polishing.

[0011] According to the present invention, a construction process of an assembled seamless floor comprises the following steps:

[0012] A. Grinding the base layer to form a flat and solid surface;

[0013] B. scraping a layer of solvent-free epoxy resin putty on the base layer;

[0014] C. Placing the prefabricated board on the solvent-free epoxy resin putty, and vibrating the surface of the prefabricated board with a vibrator to drive the prefabricated board to move left and right and up and down, so that the solvent-free epoxy resin putty under the prefabricated board flows and fills the gap between the prefabricated board and the base layer;

[0015] D. Apply solvent-free epoxy resin glue on the facade of the laid prefabricated board, push the next prefabricated board and the previous prefabricated board together tightly, and squeeze the solvent-free epoxy resin glue on the facade from between the prefabricated board pieces to fill the gaps, so that there is no gap between each prefabricated board;

[0016] E. After the solvent-free epoxy resin putty is cured, the prefabricated board is polished and sealed to finally produce an integral seamless floor.

[0017] The construction process of an assembled seamless floor provided by the present invention also has the following subsidiary technical features:

[0018] It further includes that in step A, the slurry and loose layer on the surface of the base layer are cleaned by grinding to expose a solid and clear concrete aggregate texture, and the low-lying parts of the base layer are repaired and leveled with epoxy repair mortar.

[0019] It further includes that the dynamic cracks on the base layer are filled with elastic glue or expansion joints, and the static cracks on the base layer are repaired with epoxy mortar or carbon fiber and epoxy resin and covered by the prefabricated board.

[0020] It may further include that in step E, the grinding includes coarse grinding and leveling, medium grinding and fine grinding.

[0021] The assembled seamless floor provided by the present invention has the following advantages compared with the prior art: First, the thermal properties of the prefabricated board of the present invention are the same or similar to the parameters of the base layer, so that the prefabricated board and the base layer can expand and contract synchronously, ensuring that the prefabricated board will not warp or deform when expanding and contracting, ensuring the seamless effect of the floor, and realizing a truly seamless structure. Secondly, the prefabricated board and the base layer of the present invention form a structure in which the prefabricated board and the base layer are integrated through an adhesive layer, and the adhesive force between the base layer and the prefabricated board is greater than the deformation force of the base layer and the prefabricated board, that is, under the action of external force or the deformation force generated by thermal expansion and contraction, the prefabricated board and the base layer will not crack or warp.

[0022] The construction process of an assembled seamless floor provided by the present invention has the following advantages compared with the prior art: since the present invention adopts prefabricated panels for construction, the construction period is shorter. At the same time, since the prefabricated panels and the base layer are tightly combined into an integrated structure, the prefabricated panels and the base layer will not warp or deform, so a seamless floor can be achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a cross-sectional view of the present invention. DETAILED DESCRIPTION

[0024] In order to clearly illustrate the scheme in the present invention, preferred embodiments are given below and described in detail with reference to the accompanying drawings. The following description is essentially only exemplary and is not intended to limit the application or use of the present disclosure. It should be understood that in all the drawings, corresponding reference numerals represent the same or corresponding parts and features.

[0025] like Figure 1As shown, the present invention provides an assembled seamless floor, comprising a base layer 1 and a plurality of prefabricated panels 2 laid on the base layer 1, the thermal expansion and contraction coefficient of the prefabricated panels 2 being the same or similar to that of the base layer 1, a bonding layer 3 being arranged between the base layer 1 and the prefabricated panels 2, each of the prefabricated panels 2 being tightly attached together, the bonding force between the base layer 1 and the prefabricated panels 2 being F, the deformation force between the base layer 1 and the prefabricated panels 2 being G, then F=a*G, wherein a is a preset ratio value, and the value range of a is 1-3. The prefabricated panels 2 in the present invention are formed by pressing solvent-free epoxy resin and granular aggregate under high pressure in a vacuum state. The specific materials are solvent-free epoxy resin + quartz stone or other crushed stone or sandstone, etc. + colorant such as toner + additives. By adjusting the formula and pressing parameters, the thermal properties of the prefabricated panels 2 can be made the same or similar to the parameters of the concrete of the base layer 1, ensuring that the prefabricated panels 2 and the base layer 1 expand and contract together. Of course, the material of the prefabricated board 2 in the present invention can be solvent-free epoxy resin + quartz stone or other crushed stone or sandstone, etc., without adding colorant. The auxiliary agent can also be added or not, and adjusted according to the process or parameter needs. The prefabricated board 2 is made of epoxy resin. The prefabricated board has a certain flexibility, which is more flexible than materials such as tiles and stones, has good elasticity, and can expand and contract with the base layer 1. The prefabricated board 2 is tightly combined with the base layer 1 through the bonding layer 3 into an integrated structure, forming a synchronous thermal expansion and contraction to ensure that the prefabricated board 2 does not warp or deform. The bonding force between the base layer 1 and the prefabricated board 2 is F, and the deformation force between the base layer 1 and the prefabricated board 2 is G, then F=a*G, where a is a preset ratio value, and the value range of a is 1-3. The value of a in this embodiment is 2, of course, it can also be 1.2, 1.5, 1.8, 2.2, 2.8, etc. The above relationship can ensure that the prefabricated board 2 will not crack or warp under the action of external force or deformation force of thermal expansion and contraction, so that the two can be tightly combined into an integrated structure. Since the two can be tightly combined into an integrated structure, each prefabricated board 2 can be closely attached to each other to form a seamless structure.

[0026] The reason why cast-in-place epoxy terrazzo is prone to cracking is that the surface material has not been compacted under high pressure, the density is insufficient, and there are many voids, resulting in insufficient overall physical performance indicators and easy cracking. Prefabricated epoxy terrazzo panels are prefabricated surface materials produced in an industrialized manner. They are produced under high pressure under a vacuum state and have very superior performance. The bulk density, tensile strength, bending strength, compressive strength and other properties are much higher than cast-in-place epoxy terrazzo. The prefabricated epoxy terrazzo surface layer itself will not crack, and at the same time can resist most of the impacts caused by cracking of the base layer. Physical properties of prefabricated panels: Bulk density: ≥2.42g / cm 3; Water absorption: ≤0.01%; Dry / water saturated compression strength: ≥120MP; Flexural strength: ≥35MP; Anti-slip coefficient: ≥0.6; Mohs hardness: ≥6; Abrasion resistance: ≤30 (g / cm3); Fire resistance: A2 grade; Waterproof: 7 days, no blistering, no falling off, slight discoloration is allowed; Anti-corrosion: Acid resistance: (20% H2SO4, 48 hours): no blistering, no falling off, slight discoloration is allowed; Alkali resistance: (20% NaOH, 72 hours): no blistering, no falling off, slight discoloration is allowed; Salt water resistance: (3% NaCL, 7 days): no blistering, no falling off, slight discoloration is allowed; Oil resistance: (120# gasoline, 72 hours): no blistering, no falling off, slight discoloration is allowed. Thickness of epoxy terrazzo prefabricated board: not less than 10mm.

[0027] See also Figure 1 , further included in the above embodiment given by the present invention, the bonding layer 3 is a solvent-free epoxy resin mortar layer. The solvent-free epoxy resin has no volatiles in the solidification process, and no gap passage of the board is needed to volatilize the solvent after paving. Traditional paving materials such as cement or tile mortar require volatilization of water during the solidification process, and the gap of the board is required as a volatilization passage. If the water cannot evaporate from under the board, it will affect the bonding between the board and the ground base at the least, and the water will form water vapor expansion at the worst, bursting the board and forming cracks. Solvent-free epoxy resin has excellent bonding force, which can produce super strong bonding force and adhesion with the ground base, and can make the prefabricated board 2 and the ground base 1 tightly combined into one, forming synchronous thermal expansion and contraction, so as to ensure that the surface layer does not warp or deform. Solvent-free epoxy resin is used to seamlessly bond the prefabricated board 2 together. Since the solvent-free epoxy resin used is the same material as the epoxy resin used in the production of the board, the board can produce fusion bonding to form a seamless whole.

[0028] See also Figure 1 In the above embodiment of the present invention, the thickness of the adhesive layer 3 is 0.5 mm to 3 mm. In this embodiment, it is 2 mm. The adhesive layer with the above thickness can ensure that the adhesive force F is greater than the deformation force G, satisfying the above formula.

[0029] See also Figure 1 In the above embodiment of the present invention, the thickness of the prefabricated board 2 is 10 mm to 30 mm. In this embodiment, the thickness is 20 mm. The prefabricated board 2 in the present invention has a relatively large thickness, which can meet the strength requirements of the floor in factories or public places, and can meet the needs of most occasions.

[0030] See also Figure 1 In the above embodiment of the present invention, the surface of the prefabricated board 2 has a surface layer formed by grinding and polishing. The surface of the prefabricated board 2 is smoother, without cracks, sand holes and wear marks.

[0031] The assembled seamless floor of the present invention has the following properties after completion: 1. Glossiness: high gloss: 60-80 degrees; semi-gloss: 40-60 degrees; matte: less than 40 degrees. 2. The surface should be smooth, free of cracks, sand holes and wear marks. 3. Surface flatness: tested with a 2-meter ruler and a feeler gauge, the error shall not exceed 3mm. 4. Color: consistent with the sample, with no obvious color difference overall. 5. Aggregate distribution: consistent with the sample, with uniform aggregate distribution. 6. Requirements for seams: except for the expansion joints and structural joints indicated on the drawings, the whole is seamless. 7. Floor seamless standards: Physical seamlessness: after completion, the floor is seamless as a whole, the joints are smooth and flat, and will not hide garbage. Visual seamlessness: hidden seam effect. When standing, no traces of seams can be seen by the naked eye. 8. Bonding strength between prefabricated panels and concrete base: not less than 2.5Mpa.

[0032] The prefabricated panels 2 of the present invention can be spliced ​​into different patterns. Since there are no gaps between the prefabricated panels 2, the spliced ​​patterns are more beautiful and realistic. When the prefabricated panels with textures are spliced, the adjacent textures can be butted together so that the textures on the floor form a whole without being broken due to the presence of gaps. The seamless floor of the present invention has the advantages of cast-in-place flooring and overcomes the disadvantages of the cast-in-place process, and has excellent performance.

[0033] In an embodiment of a construction process of an assembled seamless floor provided by the present invention, the construction process is used to make the seamless floor of the above embodiment, and comprises the following steps:

[0034] A. Grind the base to make it smooth, and the surface of the base forms a flat and solid surface; through grinding, remove all the floating slurry and loose layer on the concrete surface, revealing a solid and clear concrete aggregate texture. In this way, the bonding adhesion between the concrete base and the prefabricated board is guaranteed, and the goal of tight integration is achieved. Requirements after the base treatment is completed before paving: 1. Flatness: 2 meters ruler ≤ 3mm; 2. Surface strength: no hollows, no loose sand, no floating slurry, and exposed concrete aggregate physics. 3. Seams: no irregular cracks (processed and strengthened), maintenance cutting seams are repaired and smooth, and dynamic cracks are filled with elastic glue; 4. Surface: clean and dust-free, oil-free, and free of other pollutants; 5. Moisture content: less than 8%.

[0035] B. Scrape a layer of solvent-free epoxy resin glue on the base layer 1; use a scraper to scrape the epoxy resin glue evenly and flatly. Solvent-free epoxy resin glue is used for paving glue, which has solvent-free volatiles. The solid content of the glue after mixing is ≥96%; the surface curing time is ≤8 hours; the actual curing time is ≤24 hours; the flammability meets the requirements of automatic flame extinguishing; the color of the glue is consistent with the color of the prefabricated board. Ensure that each prefabricated board is equipped with a dedicated epoxy glue, and the color of the glue is the same as the prefabricated board.

[0036] C. Place the prefabricated board on the solvent-free epoxy resin putty, vibrate the surface of the prefabricated board with a vibrator, drive the prefabricated board to move left and right and up and down, so that the solvent-free epoxy resin putty under the prefabricated board flows and fills the gap between the prefabricated board and the base layer to avoid hollowing. The vibrator can be an electric vibrator, or a hand-held vibrator or a knocking tool, such as a small hammer or a rubber hammer.

[0037] D. Apply solvent-free epoxy resin putty on the facade of the prefabricated board 2, push the next prefabricated board and the previous prefabricated board together tightly, and squeeze the solvent-free epoxy resin putty on the facade from between the prefabricated board pieces to fill the gaps, so that there is no gap between each prefabricated board; the prefabricated board paving joint is less than 0.2mm; it is necessary to ensure that epoxy resin putty overflows from the gaps between the prefabricated boards to fill the gaps without leakage; at the same time, it is necessary to ensure that the prefabricated board 2 and the prefabricated board are completely squeezed and fit each other seamlessly. At the same time, it is necessary to ensure that epoxy putty overflows from the gaps between the prefabricated boards to fill the gaps. At the same time, pay attention to ensuring flatness: the flatness of adjacent prefabricated boards is basically the same, and the flatness error does not exceed 1 mm. If the flatness error is too large, use a suction cup to suck up the prefabricated board 2, and add epoxy resin putty at the bottom of the prefabricated board 2 until the flatness error between adjacent prefabricated boards 2 is within 1 mm. If too much epoxy resin mortar overflows after paving, it is necessary to clean it with a putty knife to ensure that the paving site is clean. When paving to the corners of the building, the prefabricated board 2 needs to be cut with a handheld cutting machine to ensure that the size of the cut board matches the required size of the corners before paving.

[0038] Maintenance: After paving is completed, if the temperature is above 10℃, it needs to be cured for more than 48 hours; if the temperature is below 10℃, it needs to be cured for more than 72 hours. During this time, no personnel or any external force is allowed to act on the prefabricated panels. It must be ensured that the paved epoxy putty has been completely cured, and the prefabricated panels and concrete base are firmly bonded and fused together.

[0039] E. After the solvent-free epoxy resin putty is cured, the prefabricated board 2 is polished and sealed to finally produce an integral seamless floor.

[0040] In step A, the floating slurry and the loose layer on the surface of the base layer 1 are cleaned by grinding to expose the solid and clear concrete aggregate texture, and the low-lying parts of the base layer 1 are repaired and leveled with epoxy repair mortar.

[0041] The dynamic cracks on the base layer 1 are filled with elastic glue or expansion joints, and the static cracks on the base layer 1 are repaired with epoxy mortar or carbon fiber and epoxy resin and covered by the prefabricated board.

[0042] Dynamic cracks in the present invention refer to cracks that will expand and contract during future use. They generally refer to concrete joints that are not connected by steel mesh. For example: structural joints, compartment joints, and settlement joints.

[0043] Static cracks: refers to the cracks that will not move in the future use. For example: the curing joints that are cut on the surface to release stress after concrete pouring, and the irregular surface cracks caused by unqualified concrete quality.

[0044] Principles for handling dynamic cracks: For small dynamic cracks, 1) use a cutting machine to cut and straighten the seam, with a cutting depth of more than 15CM and a width of 5-10mm (depending on the area of ​​the entire concrete slab). 2) Clean the seam. 3) Fill the seam with elastic glue. 4) After the elastic glue is dry, mark the position of the seam. 5) Lay the prefabricated floor. 6) After the prefabricated floor is laid, use a cutting machine to cut out the seam at the marked position. 7) Then fill the seam with elastic glue. For large dynamic cracks: After the floor construction is completed, install the finished expansion joint.

[0045] The treatment principle for static cracks is as follows: Cut maintenance joints: fill and repair with epoxy mortar. Irregular cracks on the concrete surface: repair with carbon fiber (150mm wide) and epoxy resin.

[0046] In step E, the grinding includes rough grinding and leveling, medium grinding and fine grinding.

[0047] Rough grinding and leveling: Use a 12-head heavy-duty grinder equipped with a 60# diamond grinding head for grinding, and adjust the grinding machine speed to about 1500 rpm. The purpose of rough grinding is to grind the intersections between prefabricated panels flat. During rough grinding, always check whether the intersections between panels are flat. When grinding, the grinding lines should intersect each other by one-third. Evenly control the grinding speed of the grinder to grind the interface flat. Do not stop arbitrarily to avoid local depression and unevenness. Do not move too fast to cause leakage.

[0048] Intermediate grinding: Use a 12-head heavy-duty grinder equipped with a 120# diamond grinding head for grinding, and adjust the grinding machine speed to about 1500 rpm. The purpose of intermediate grinding is to eliminate the grinding marks left over from rough grinding. At the same time, pay attention to the uneven edges and corners, and use a handheld grinder to smooth them out.

[0049] Fine grinding: Use a 12-head heavy-duty grinder equipped with a water-grinding disc for grinding, from 50 mesh to 300 mesh. The purpose of fine grinding is to eliminate the slight grinding marks left over from the medium grinding. After fine grinding, the ground should have a bright finish.

[0050] Polishing: Clean the floor and blow dry it. Apply polishing liquid and polish with a polishing machine.

[0051] Finished product protection: Lay a layer of soft cloth or carpet, ground protection film, and then cover it with a layer of wood board.

[0052] In summary, the above contents are only embodiments of the present invention, which are only used to illustrate the principles of the present invention and are not used to limit the protection scope of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the protection scope of the present invention.

Claims

1. An assembled seamless floor, comprising a base layer and a plurality of prefabricated panels laid on the base layer, characterized in that: The thermal expansion and contraction coefficient of the prefabricated board is the same as or similar to that of the base layer. A bonding layer is arranged between the base layer and the prefabricated board. Each of the prefabricated boards is tightly attached to each other. The bonding force between the base layer and the prefabricated board is F, and the deformation force between the base layer and the prefabricated board is G. Then F=a*G, wherein a is a preset ratio value, and the value range of a is 1-3.

2. The assembled seamless floor according to claim 1, characterized in that: The bonding layer is a solvent-free epoxy resin mastic layer.

3. The assembled seamless floor according to claim 1, characterized in that: The thickness of the bonding layer is 0.5 mm to 3 mm.

4. The assembled seamless floor according to claim 1, characterized in that: The prefabricated board is formed by pressing solvent-free epoxy resin and granular aggregate under high pressure in a vacuum state.

5. The assembled seamless floor according to claim 1, characterized in that: The thickness of the prefabricated board is 10mm-30mm.

6. The assembled seamless floor according to claim 1, characterized in that: The surface of the prefabricated plate has a surface layer formed by grinding and polishing.

7. A construction process for an assembled seamless floor, characterized in that: The steps include: A. Grinding the base layer to form a flat and solid surface; B. scraping a layer of solvent-free epoxy resin putty on the base layer; C. Placing the prefabricated board on the solvent-free epoxy resin putty, and vibrating the surface of the prefabricated board with a vibrator to drive the prefabricated board to move left and right and up and down, so that the solvent-free epoxy resin putty under the prefabricated board flows and fills the gap between the prefabricated board and the base layer; D. Apply solvent-free epoxy resin glue on the facade of the laid prefabricated board, push the next prefabricated board and the previous prefabricated board together tightly, and squeeze the solvent-free epoxy resin glue on the facade from between the prefabricated board pieces to fill the gaps, so that there is no gap between each prefabricated board; E. After the solvent-free epoxy resin putty is cured, the prefabricated board is polished and sealed to finally produce an integral seamless floor.

8. The construction process of a prefabricated seamless floor as claimed in claim 7, characterized in that: In step A, the floating slurry and loose layer on the surface of the base layer are cleaned by grinding to expose a solid and clear concrete aggregate texture, and the low-lying parts of the base layer are repaired and leveled with epoxy repair mortar.

9. The construction process of a prefabricated seamless floor as claimed in claim 7, characterized in that: The dynamic cracks on the base layer are filled with elastic glue or expansion joints, and the static cracks on the base layer are repaired with epoxy mortar or carbon fiber and epoxy resin and covered by the prefabricated board.

10. The construction process of a prefabricated seamless floor as claimed in claim 7, characterized in that: In step E, the grinding includes rough grinding and leveling, medium grinding and fine grinding.

Images