Construction technology for radiant heating self-leveling composite terrace

Abstract

The invention discloses a radiant heating self-leveling composite terrace construction technology, and relates to the field of building low-temperature hot water heating terraces, and a terrace main body is of a three-layer composite structure: two gypsum-based self-leveling steel wire mesh sandwiched composite layers are overlapped with a surface waterproof curing layer. The construction process comprises the following steps: backfilling the first-layer self-leveling material until the first-layer self-leveling material submerges the heating radiating pipe to prevent the heating radiating pipe from floating and bending After the first layer is cured, steel wire meshes are laid on the surface and fixed to the heating radiating pipes through U-shaped clamps, and then a second layer of self-leveling material is backfilled; and after the second layer is subjected to self-leveling and final setting, a third waterproof curing layer is poured and uniformly scraped, and the water resistance and surface hardness of the backfill layer are improved after capillary crystallization of the third waterproof curing layer. According to the technology, self-leveling of a backfill material is achieved, the risks of upward floating of a heating radiating pipe and cracking of a backfill layer are solved through layered construction, and the defect of water resistance of a traditional gypsum-based material is overcome through sealing of a surface waterproof curing layer; after construction is completed, the flatness of the surface layer is smaller than or equal to 1.5 mm, the requirement for the direct floor laying process can be met, the waterproof requirement after face bricks are laid can also be met, and the technical problems of backfill leveling, pipe floating prevention, cracking prevention, waterproof sealing, strength hardening and the like can be effectively solved.

Description

Technical Field

[0001] This invention falls under the category of low-temperature hot water heating flooring in the field of building construction, specifically a radiant heating self-leveling composite flooring construction technology. Background Technology

[0002] With the increasing demand for comfortable heating and efficient space utilization in the construction industry, radiant heating systems (underfloor heating) have seen a significant increase in popularity in residential and commercial buildings due to their advantages of uniform heat distribution and space saving. However, underfloor heating systems place stringent requirements on the flatness, leak-proofness, and structural stability of the floor backfill layer, and traditional floor construction techniques have gradually revealed many shortcomings, making it difficult to meet these needs.

[0003] Traditional underfloor heating systems often use cement mortar for backfilling. This mortar has poor self-leveling properties, requiring repeated manual compaction and leveling, resulting in low construction efficiency. Furthermore, the flatness of the finished surface often exceeds 3mm, making it unsuitable for direct floor installation and necessitating secondary leveling, increasing construction time and costs. Some projects have attempted to use ordinary gypsum-based self-leveling materials, which improved flatness. However, gypsum-based materials have poor water resistance and low surface hardness, making them prone to powdering and peeling upon prolonged exposure to moisture. This limits their application, especially in damp areas like bathrooms and kitchens.

[0004] More importantly, in traditional construction, heating pipes are easily buoyed and bent by the buoyancy of backfill materials, leading to uneven heat dissipation. The wire mesh laid to prevent cracking of the backfill layer often shifts due to improper fixing, losing its crack-resistant function. This results in cracks appearing in the floor later, affecting not only aesthetics but also potentially damaging the heating pipes and shortening the system's lifespan. Existing technologies struggle to simultaneously address the four core issues of backfill leveling, pipe buoyancy prevention, crack resistance, and waterproofing. There is an urgent need for a new floor construction technology that balances ease of construction with performance stability, which is the core background driving the development of this invention. Summary of the Invention

[0005] This invention addresses the shortcomings of traditional backfilling and leveling mortar construction techniques in radiant heating systems. In particular, to overcome the drawbacks of traditional cement slurry backfill layers, such as poor self-leveling properties, heavy weight, and poor flatness requiring secondary leveling, this invention replaces traditional cement slurry backfill layers with gypsum-based leveling materials. Furthermore, to address the issues of poor water resistance, low surface hardness, and easy powdering and detachment of gypsum-based leveling materials due to prolonged exposure to moisture, this invention employs an improved construction process involving two layers of gypsum-based composite material with a steel wire mesh sandwiched incorporating an organosilicon waterproofing agent, followed by a surface waterproofing and curing layer. This effectively solves problems related to backfilling and leveling, preventing pipe floating, preventing cracking, waterproofing and sealing, and strength hardening.

[0006] The main structure of this flooring is a three-layer composite structure, consisting of two layers of gypsum-based self-leveling compound, a layer of integral crack-resistant wire mesh, and a surface waterproofing and curing layer. Performance optimization is achieved through scientific layering design and construction. The specific construction procedures are as follows: First layer backfill: Use gypsum-based self-leveling material (containing silicone waterproofing agent: active silica, silica fume, etc.) for the first layer backfill. Precisely control the backfill height so that it just submerges the heating pipes of the radiant heating system. This fixes the position of the heating pipes and prevents them from floating and bending. At the same time, the self-leveling properties help to initially solve the problem of backfill leveling.

[0007] Wire mesh installation and second-layer backfilling: After the first layer of gypsum-based self-leveling material has cured (judgment criteria: no surface depressions, no obvious marks from pressing, and no deformation of the material when laying the wire mesh), a wire mesh is laid on its surface and fixed to the heating radiator pipes with U-shaped clips. The wire mesh forms an integral crack-resistant support structure, evenly distributed between the two layers of gypsum-based self-leveling backfill material, which can enhance the rigidity of the backfill layer and inhibit cracking caused by temperature changes and material shrinkage. Subsequently, the second layer of backfilling is carried out using gypsum-based self-leveling material.

[0008] Surface Waterproofing and Curing: After the second layer of gypsum-based self-leveling material has fully cured (judgment criteria: the material has completely lost its plasticity, and the surface hardness can withstand the construction load of the waterproof curing layer), a waterproof curing layer (containing acrylic resin and silicone) is poured and applied to its surface. This waterproof curing layer has a penetrating crystallization function, which can improve the water resistance of the backfill layer to zero after construction, and the surface hardness meets the requirements of daily foot traffic and decorative construction, making up for the waterproofing defects of traditional gypsum-based materials.

[0009] This technology achieves self-leveling of the backfill material and effectively solves the risks of heating pipe floating and backfill layer cracking. Simultaneously, surface curing addresses the issues of insufficient water resistance and strength in gypsum-based materials. After construction, the surface flatness of the floor is ≤1.5mm, meeting the requirements for direct floor installation. After surface curing and the application of decorative tiles, it also achieves moisture and water resistance. This invention comprehensively overcomes challenges related to backfill leveling, preventing pipe floating, preventing cracking, waterproofing, and strength hardening. Attached Figure Description

[0010] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0011] Figure 1 The cross-sectional view of the radiant heating self-leveling composite floor using solid wood composite board is shown. From bottom to top, the structure includes: concrete floor slab (1), thermal insulation and sound insulation board (2), reflective film (3), first layer gypsum-based self-leveling floor containing silicone waterproofing agent (4) (the heating radiator pipe (5) is included in this layer), two-way steel wire mesh (6) (fixed to the heating radiator pipe (5) by U-shaped clips (7)), second layer gypsum-based self-leveling floor containing silicone waterproofing agent (8), acrylic resin and silicone waterproof curing layer (9), plastic padding layer (10), and solid wood composite board (11).

[0012] Figure 2The cross-sectional view of the self-leveling composite flooring structure for radiant heating using facing bricks is shown. The structure from bottom to top includes: concrete floor slab (1), thermal insulation and sound insulation board (2), reflective film (3), first layer gypsum-based self-leveling floor containing silicone waterproofing agent (4) (the heating radiator pipe (5) is included in this layer), two-way steel wire mesh (6) (fixed to the heating radiator pipe (5) by U-shaped clips (7)), second layer gypsum-based self-leveling floor containing silicone waterproofing agent (8), acrylic resin and silicone waterproof curing layer (9), floor tile structural adhesive (12), and facing bricks (13). Detailed Implementation

[0013] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below with reference to specific illustrations.

[0014] It should be understood that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding and reading. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the disclosed technical content. Furthermore, the terms "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention. The invention will now be described in detail with reference to the accompanying drawings.

[0015] To clearly present the technological logic and key operational points of the radiant heating self-leveling composite flooring construction technology of this invention, the following detailed implementation instructions are provided from four aspects: construction preparation, core procedures, subsequent paving, and quality control, in conjunction with actual engineering scenarios.

[0016] I. Pre-construction preparation 1. Substrate pretreatment: First, clean the surface of the concrete floor slab (1), remove dust, oil stains and protruding debris, and repair defects such as cracks and pits to ensure that the substrate is flat and free of looseness. Then lay the thermal insulation and sound insulation board (2). When laying, ensure that the boards are tightly bonded and the joints are treated with a special sealing method. Cover the thermal insulation and sound insulation board (2) with a reflective film (3). During the laying process, straighten and flatten it. The joints of the reflective film (3) are overlapped to prevent heat loss.

[0017] 2. Materials and tools ready: Prepare gypsum-based self-leveling material (including special waterproofing components), wire mesh, U-shaped clips, waterproof curing coating, and tools needed for mixing, scraping, and leveling. Inspect the heating pipes in advance to ensure they are undamaged and the joints are secure. Then, initially fix them according to the design route to lay the foundation for subsequent backfilling.

[0018] II. Implementation of Core Processes 1. First layer backfill construction (key process for preventing pipe floating): First, mix the gypsum-based self-leveling material evenly according to the process requirements to ensure that the material is free of lumps and has the required fluidity. After mixing, quickly pour the material onto the base layer. During the pouring process, use auxiliary tools to guide the flow of the material and accurately control the backfill range and height of the first layer of gypsum-based self-leveling material containing silicone waterproofing agent (4) so ​​that the material just submerges the heating radiator pipe (5). Use the material's own weight and fluidity to fix the pipe position and prevent the pipe from floating and deflecting. When the first layer of gypsum-based self-leveling material containing silicone waterproofing agent (4) is naturally cured until there are no depressions on the surface, no obvious marks when pressed, and the subsequent laying of wire mesh (6) will not cause the material to deform, the first layer is considered to be cured.

[0019] 2. Wire mesh laying and second-layer backfilling (key process for preventing cracking): After the first layer (4) has cured, wire mesh (6) is laid on its surface. When laying, ensure that the mesh is flat and without warping, and that the mesh overlaps and is firmly fixed. Then, use U-shaped clips (7) to connect and fix the wire mesh (6) to the heating radiator pipe (5), so that the wire mesh (6) is evenly distributed between the two layers of self-leveling material (4) and (8) to form a crack-resistant support structure. After fixing, repeat the first-layer mixing process to prepare gypsum-based self-leveling material and backfill the second layer (8) to ensure that the material completely covers the wire mesh and achieves initial surface flatness by means of the self-leveling properties. When the material has been cured until it has completely lost its plasticity and the surface hardness is sufficient to withstand the construction load of the subsequent waterproof curing layer, the second layer is considered to have finally set.

[0020] 3. Surface Waterproofing and Curing (Key Process for Waterproofing and Strength Enhancement): After the second layer (8) has fully cured, first clean the surface dust, and then mix the acrylic resin and silicone waterproof curing coating evenly. Use a special scraper to evenly apply the coating to the surface of the second layer (8). During the scraping process, ensure that the coating covers all areas without omissions and has a consistent thickness. If multiple coats are required, wait for the previous coat to dry before applying the next coat. After the coating is applied, take advantage of its penetrating and crystallizing properties to allow the coating to fully penetrate into the pores of the self-leveling material (8) and encapsulate the hardened gypsum crystals. After the coating is fully cured, a closed acrylic resin and silicone waterproof curing layer (9) is formed, achieving a dual improvement in the waterproofing and surface hardness of the backfill layer.

[0021] III. Subsequent Surface Finishing Layer Installation 1. Solid wood composite board installation: If solid wood composite board (11) is to be installed, after the waterproof curing layer (9) has been fully cured, a plastic underlayment layer (10) shall be laid on its surface. The underlayment layer shall be laid flat and without wrinkles, and the joints shall overlap. Then, the solid wood composite board (11) shall be installed according to the installation specifications. During installation, ensure that the board (11) and the underlayment layer (10) are tightly fitted. A reasonable expansion joint shall be reserved between the boards (11) to avoid deformation of the board (11) due to temperature changes.

[0022] 2. Laying facing bricks: If laying facing bricks (13), special floor tile structural adhesive (12) needs to be applied to the surface of the waterproof curing layer (9). When applying, control the thickness of the adhesive layer (12) to be uniform. Then lay the facing bricks (13) according to the design pattern. During the laying process, adjust the brick joints to be uniform and tap the brick surface with a tool to ensure that the brick body (13) and the structural adhesive (12) are fully bonded. After the structural adhesive (12) has cured, the facing construction is completed.

[0023] IV. Key Points of Quality Control Quality checks must be carried out simultaneously throughout the construction process: After the first layer of gypsum-based self-leveling compound containing silicone waterproofing agent (4) is backfilled, check whether the position of the heating pipe (5) is fixed to avoid displacement; after the wire mesh (6) is laid, confirm that the U-shaped clip (7) is firmly fixed and the mesh (6) is not displaced; the waterproof curing layer (9) should be poured as a whole and scraped multiple times to ensure the waterproof effect; before laying the finishing layer (11) or (13), check the surface flatness of the waterproof curing layer (9) to ensure that it meets the requirements of the subsequent paving process and finally achieve the overall performance of the floor.

[0024] The above-mentioned process, through layered design and precise operation, solves problems such as traditional floor backfilling and leveling, anti-floating pipe, anti-cracking, waterproofing, and insufficient strength in sequence, adapting to different finishing layer requirements and ensuring construction quality and usage effect. Example

[0025] A residential building project originally planned to use cement mortar backfill for radiant heating in the individual apartment floors. However, after research, analysis, and sample testing, it was found that this method was inefficient due to the poor self-leveling properties of cement mortar, requiring repeated manual vibration for leveling. Furthermore, the resulting floor flatness did not meet the requirements for direct floor installation, necessitating secondary leveling and increasing construction time and costs. Following thorough analysis of the technology, cost, timeline, and sample testing, it was decided to adopt the radiant heating self-leveling composite flooring construction technology provided by this invention.

[0026] The original floor slab, from top to bottom, consists of: solid wood composite board, soft foam plastic padding, 20mm thick 1:2.5 cement mortar leveling, 50mm thick C25 fine stone concrete poured and smoothed immediately (with Φ0.8@25 bidirectional steel wire mesh inside, heating pipes are included in this layer), Φ16×2.0 heating pipes, 0.2mm thick vacuum aluminized polyester film, 20mm thick MZL thermal insulation and sound insulation board, and concrete floor slab.

[0027] After adjustment and optimization, the sand-free self-leveling composite flooring provided by this invention has the following top-to-bottom filling structure: solid wood composite board, soft foam plastic padding, 5mm waterproof curing layer containing acrylic resin and silicone, 20mm gypsum-based self-leveling layer containing silicone waterproofing agent, Φ0.8@25 bidirectional steel wire mesh (fixed to the heating radiator pipe by U-shaped clips), 15mm gypsum-based self-leveling layer containing silicone waterproofing agent (the heating radiator pipe is included in this layer), Φ16×2.0 heating radiator pipe, 0.2mm thick vacuum aluminized polyester film, 20mm thick MZL thermal insulation and sound insulation board, and concrete floor slab.

[0028] The specific construction steps for this embodiment are as follows: 1. Construction of base layer and insulation layer: After cleaning the surface of concrete floor slab, lay 20mm thick MZL thermal insulation and sound insulation board, and seal the board joints with special glue; then fully cover it with 0.2mm thick vacuum aluminized polyester film, with an overlap width of ≥50mm, and fix it with tape to prevent heat loss.

[0029] 2. First layer self-leveling compound and pipe fixing: Mix the gypsum-based self-leveling material containing organosilicon waterproofing agent according to the ratio, and pour it after ensuring there are no lumps. Control the thickness to 15mm, so that the material just submerges the Φ16×2.0 heating radiator pipe. Allow it to cure naturally until there are no obvious marks when pressed on the surface, thus completing the anti-floating fixing of the pipe.

[0030] 3. Steel wire mesh laying and second layer self-leveling: Lay Φ0.8@25 bidirectional steel wire mesh on the first layer of cured surface, and use U-shaped clips to clamp the mesh and fix the heat dissipation pipe; then mix the same type of gypsum-based self-leveling material, pour a 20mm thick covering mesh, and cure until the surface can withstand the weight of construction personnel (final setting state).

[0031] 4. Waterproof curing layer construction: Clean the surface dust of the second layer of self-leveling compound, stir the waterproof curing coating containing acrylic resin and silicone, apply it evenly with a scraper, control the thickness to 5mm, and cure until the coating is completely dry and forms a film.

[0032] 5. Finishing layer installation: Lay soft foam plastic padding (joint overlap ≥50mm), then lay solid wood composite board according to the design layout, leaving 2-3mm expansion joints between the boards, and fix with special adhesive. No secondary leveling is required to complete the installation.

[0033] Implementation Effect Analysis: The construction period for this self-leveling composite flooring is only 1 day, allowing for completion on the first day and accessibility on the second day, saving 3 days compared to cement mortar construction. Due to the one-time molding of the gypsum-based self-leveling compound, the maximum flatness measured by a 2m straightedge and feeler gauge is 1.5mm. The self-leveling subcontractor can directly hand over the finished product to the interior decoration unit after completion, significantly improving construction efficiency. Furthermore, the third-party evaluation of floor flatness shows a clear advantage, passing the flatness test on the first attempt. Cost calculations also indicate that replacing the original 50mm thick fine aggregate concrete filling with a 40mm thick gypsum-based self-leveling compound can save 800,000 yuan. Material testing results show that the filler has a compressive strength of 9.4MPa and a flexural strength of 31.8MPa, significantly exceeding the industry standard "Gypsum-Based Self-Leveling Mortar" (JC / T1023-2007) requirements of ≥7.5MPa compressive strength and 20MPa flexural strength. Meanwhile, the gypsum-based self-leveling construction process adopted in this invention exceeds the relevant specifications in terms of technical standards and performance parameters, and has a significant advantage in terms of cost.

[0034] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A construction technology for radiant heating self-leveling composite flooring, characterized in that, Includes the following steps: (1) First layer backfill: Use gypsum-based self-leveling material for the first layer backfill, and control the backfill height to just submerge the heating pipes of the radiant heating system to prevent the heating pipes from floating and bending. (2) Steel wire mesh laying and second layer backfilling: After the first layer of gypsum-based self-leveling material in step (1) has cured, steel wire mesh is laid on its surface, and the steel wire mesh is fixed to the heating radiator pipe by U-shaped clips. Then, the second layer of backfilling is carried out using gypsum-based self-leveling material. (3) Surface waterproofing and curing: After the second layer of gypsum-based self-leveling material in step (2) has finally set, a waterproof curing layer is poured and scraped onto its surface. The waterproof curing layer achieves waterproof curing and sealing of the backfill layer through penetration and crystallization.

2. The construction technology according to claim 1, characterized in that: The gypsum-based self-leveling material contains an organosilicon waterproofing agent; the criteria for "curing of the first layer of gypsum-based self-leveling material" in step (2) are: the surface of the first layer of material has no depressions, no obvious marks when pressed, and the material does not deform when the wire mesh is laid subsequently; the wire mesh laid in step (2) forms a crack-resistant support structure, and after being fixed to the heating pipe by a U-shaped clip, it is evenly distributed between the two layers of gypsum-based self-leveling backfill material, which can enhance the rigidity of the backfill layer, suppress the cracking of the backfill layer caused by temperature changes and material shrinkage, and realize the crack-resistant function of the overall backfill layer.

3. The construction technology according to claim 1, characterized in that: The criteria for determining "final setting of the second layer of gypsum-based self-leveling material" in step (3) are: the second layer of material completely loses its plasticity and the surface hardness reaches the requirements for bearing the construction load of the waterproof curing layer; the waterproof curing layer mentioned in step (3) contains acrylic resin and organosilicon, and is a coating layer with penetrating crystallization function, which can effectively fill the pores of the self-leveling material and wrap the hardened gypsum crystals. After construction, the water resistance of the backfill layer can be improved to a state of no water seepage, and the surface hardness can be improved to meet the requirements of daily stepping and decoration construction.

4. The construction technology according to any one of claims 1-3, characterized in that: After the construction of step (3) is completed, the flatness of the floor surface is ≤1.5mm, and the floor not only meets the flatness requirements for direct floor installation, but also achieves waterproof function after the decorative panel is laid.

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