Composite precast element

Abstract

Composite precast element (1) comprising a tension layer (2) and a concrete layer (3) connected to the tension layer (2), wherein the tension layer (2) has a definable plurality of definable shaped recesses (5) on an inner surface (4) facing the concrete layer (3), into which recesses (5) the concrete layer (3) engages to form a positive connection between the concrete layer (3) and the tension layer (2), wherein the tension layer (2) is designed as a wood layer, characterized in that the tension layer (2) projects laterally beyond the concrete layer (3) on all sides for lateral connection with other composite precast elements by means of wood connectors and for creating channels (14) for laying pipes, and that the tension layer (2) is designed to connect two adjacent composite precast elements (2) by means of wood connectors.

Description

[0001] The invention relates to a composite prefabricated component according to claim 1.

[0002] It is common practice to construct building ceilings using a timber-concrete composite method. In this method, an additional concrete slab is applied to a timber ceiling. Such composite ceilings are frequently used in building renovations and extensions, such as attic conversions, and are also employed in new buildings as part of lightweight construction. In these composite ceilings, the concrete layer absorbs the compressive stresses, while the timber layer absorbs the tensile stresses. Due to the additional mass of the concrete layer, combined with the high internal damping properties of concrete, these composite ceilings exhibit excellent acoustic properties in addition to their low weight.

[0003] The connection between the concrete layer and the wood layer is achieved through a positive fit via projections or recesses in the wood layer or an existing wooden ceiling. These projections or recesses can be formed by fasteners driven into the wood layer, or by grooves or cutouts in the wood layer, commonly referred to as notches, which are milled into the wood layer on site. The concrete layer is poured directly onto the existing or previously constructed wood layer on the construction site.

[0004] The structural advantages of such composite slabs, particularly their high load-bearing capacity at low weight combined with good impact sound insulation, are accompanied by the disadvantage that these composite slabs are complex to manufacture. The production and installation of connectors is elaborate, time-consuming, and associated with high noise levels for workers and residents. Furthermore, the use of large quantities of synthetic resin adhesive to fix the connectors is not uncommon. Pouring the concrete layer on-site requires extensive and careful sealing measures to prevent the still-liquid concrete from penetrating into the rooms below. The concrete layer must also be poured in one continuous pour, at least up to the expansion joints, a task that is arduous and generates a great deal of dust on the construction site.

[0005] Once the concrete layer is complete, it cannot immediately bear full load; it must first cure completely. During this time, no further work can be carried out on the newly constructed slab, which slows down construction progress and increases costs. Furthermore, the wooden ceiling often needs additional support while the concrete is still wet and not yet able to bear weight, further increasing the workload.

[0006] DE 44 20 175 A1, FR 27 74 112 A1, DE 298 16 002 U1, DE 10 2013 106 919 A1, DE 102 54 043 B4, DE 20 2005 003 808 U1 and DE 196 53 809 A1 each disclose a composite prefabricated part with features of the preamble of claim 1.

[0007] The object of the invention is therefore to provide a composite prefabricated element of the type mentioned above, with which the aforementioned disadvantages can be avoided, with which the construction of a building can be simplified and accelerated, and with which a load-bearing floor slab can be formed within a short time.

[0008] According to the invention, this is achieved by the features of claim 1.

[0009] This allows for the construction of a composite slab using dry construction methods. This eliminates the need for a poured concrete layer as part of the load-bearing composite slab, significantly simplifying logistics on the construction site. This also enables the creation of a composite corner that is more load-bearing than conventional composite corners while simultaneously having a lower mass. These precast composite elements can be manufactured in a factory or plant and do not need to be produced on-site or under typical construction site conditions. Higher-quality concrete can be used than would be possible with ready-mix or cast-in-place concrete. Furthermore, the curing conditions can be better controlled in the factory. The individual precast composite elements are then connected to each other or to a timber substructure on-site using standard timber connection techniques.Since there is no need to wait for the concrete to cure, the prefabricated composite elements, once installed and fixed, can bear their full load immediately. This eliminates the need to wait for the concrete layer to be walkable or to provide additional support for the wooden ceiling during curing, thus accelerating construction progress and reducing costs and logistical effort on the construction site. Because no connectors are required, this procedure, which can be a significant inconvenience for any occupants, for example, during a subsequent attic conversion, is also eliminated. A further advantage is that, due to its strength, such a floor slab can be placed directly onto a brick or concrete wall without a conventional wooden support structure, making it easy to install a wooden ceiling even in brick or concrete buildings.

[0010] The dependent claims relate to further advantageous embodiments of the invention.

[0011] Reference is hereby expressly made to the wording of the claims, whereby the claims are incorporated into the description at this point by reference and are deemed to be reproduced verbatim.

[0012] The invention is described in more detail with reference to the accompanying drawings, in which a merely preferred embodiment is shown by way of example. The drawings show: Fig. 1 an axonometric representation of a preferred embodiment of a composite precast element; Fig. 2 a longitudinal section through a composite precast element according to Fig. 1, with parts of a ceiling structure shown in dashed lines; and Fig. 3 a floor slab with composite prefabricated elements according to Fig. 1 in cross-section.

[0013] The Fig. 1 and Fig. Figure 2 shows a composite precast element 1 comprising a tension layer 2 and a concrete layer 3 connected to the tension layer 2, wherein the tension layer 2 is a wood layer and has a definable plurality of definable shaped recesses 5 on an inner surface 4 facing the concrete layer 3, into which recesses 5 the concrete layer 3 engages to form a positive bond between the concrete layer 3 and the tension layer 2.

[0014] This allows for the construction of a composite slab or floor slab 11 using dry construction methods. This eliminates the need for a cast concrete layer as part of the load-bearing composite slab, significantly simplifying logistics on the construction site. This enables the creation of a composite corner that is more load-bearing than conventional composite corners while simultaneously having a lower mass. These precast composite elements 1 can be manufactured in a plant or factory and do not need to be produced on a construction site or under site conditions. Higher-quality concrete can be used than would be possible with ready-mix or cast-in-place concrete. Furthermore, the curing conditions can be better controlled in the factory. The individual precast composite elements 1 can be connected to each other or to a timber substructure on the construction site using standard timber connection techniques.Since there is no need to wait for the concrete to cure, the installed and fixed composite precast elements 1 can bear full load immediately. This eliminates the need to wait for the concrete layer to be walkable or fully load-bearing, or the need for additional support of the wooden ceiling during curing. This accelerates construction progress and reduces costs and logistical effort on the construction site. Because no fasteners, such as metal anchors, are required, this procedure, which can be a significant burden for any occupants, for example, during a subsequent attic conversion, is also eliminated. A further advantage is that such a floor slab 11, due to its strength, can be placed directly onto a brick or concrete wall without a conventional wooden support structure, thus making it easy to install a wooden ceiling even in brick or concrete buildings.

[0015] A composite prefabricated component 1 has a tensile layer 2 and a compression layer. Preferably, the composite prefabricated component 1 has only a tensile layer 2 made of wood and a compression layer.

[0016] The pressure layer is designed as a concrete layer 3. Such a composite precast element 1 therefore preferably has a defined installation position, depending on the direction of the load. When the composite precast element 1 is preferably used as a composite floor slab 9, the concrete layer 3 is to be arranged on top.

[0017] The third concrete layer is preferably designed without reinforcement. This allows the manufacturing effort and costs to be kept low.

[0018] The concrete layer 3 particularly preferably comprises a shrinkage-reduced concrete, in particular a concrete with shrinkage values ​​of less than 0.04%, preferably 0.03%, and most preferably 0.02%. Such low shrinkage values ​​allow the slab deflections to be reduced and thus the permissible spans of the floor slabs 11 to be increased while maintaining the same overall thickness.

[0019] The second tensile layer is designed as a wood layer, preferably as a cross-laminated timber (CLT) panel. This allows for low weight combined with high load-bearing capacity. Furthermore, it enables particularly simple processing on the construction site by using conventional timber connectors such as screws, nails, and gusset plates. In addition, wood is readily available as a renewable resource.

[0020] The concrete layer 3 is positively connected to the tension layer 2. It is provided that the tension layer 2 has a definable plurality of definable shaped depressions 5 on an inner surface 4 facing the concrete layer 3. The depressions 5, which can also be referred to as notches, are preferably designed as blind holes and / or grooves 8. The depressions 5 do not extend through the entire tension layer 2, as is particularly evident in Fig. 2 shown, and are therefore not designed as a through-opening.

[0021] The concrete layer 3 engages in the recesses 5 of the tension layer 2 to form a positive-locking bond between the concrete layer 3 and the tension layer 2. This occurs during the production of the composite precast element 1, whereby liquid concrete is poured onto the tension layer 2. It is therefore also possible that the recesses 5 have at least one undercut.

[0022] It is particularly preferred that the concrete layer 3 engages only in the recesses 5 of the tension layer 2 to form the positive bond between concrete layer 3 and tension layer 2, and that consequently no additional connecting elements are provided in this area, i.e. no additional metal anchors which are arranged in the tension layer 2 before the production of the concrete layer 3.

[0023] Preferably, both the concrete layer 3 and the tensile layer 2 are designed as continuous layers. The only exceptions are openings used for the routing of a supply line, such as a ceiling outlet for connecting a light fixture.

[0024] In preferred embodiments of the composite precast element 1, the tensile layer 2 forms a first outer surface 6 of the composite precast element. According to said preferred embodiment, a second outer surface 7 of the composite precast element essentially forms the concrete layer 3. The tensile layer 2 is therefore not encompassed by the concrete layer 3 or embedded in it.

[0025] It is designed that the tension layer 2 extends beyond the concrete layer 3 on all sides at the composite precast element edges 10. This allows access to the tension layer 2 from both outer surfaces 6, 7 of the composite precast elements, enabling the attachment of timber connectors. This simplifies the processing of the composite precast elements 1 on the construction site. Furthermore, this creates a channel 14 between adjacent composite precast elements 1 and at the edge of a composite precast element 1 during the construction of a floor slab 11. At least one line, in particular an electrical line and / or a fluid line, such as a fresh water line, wastewater line, gas line, and / or a heating pipe, can be laid in this channel 14. This eliminates the need to create such channels 14 subsequently.

[0026] Due to the all-around overlap, it is easy to connect the tensile layers of two adjacent composite precast elements on all sides, allowing several interconnected composite precast elements to easily transfer horizontal tensile forces and thus form a particularly strong bond. This eliminates the need for an additional grid that would otherwise transmit tensile forces across multiple composite precast elements.

[0027] It is particularly preferred that an empty conduit is arranged in the concrete layer 3. The empty conduit can be easily arranged before the concrete layer 3 is cast and thus simply integrated into the concrete layer 3. The empty conduit further simplifies the routing of cables, for example, to a centrally located lighting fixture. The empty conduit can, in particular, be formed in addition to the grid of channels 14.

[0028] The composite precast element 1 may have different geometric shapes. According to a preferred embodiment, the composite precast element 1 is designed as a composite panel, in particular as a composite floor panel 9. It is specifically provided that the composite floor panel 9 is a substantially flat panel. It may be provided, for example to form highly load-bearing floor slabs, that the composite floor panel 9 is internally prestressed and / or deflected when unloaded.

[0029] The Fig. Figures 1 to 3 show a particularly preferred embodiment of a composite precast element 1 in the form of a substantially flat slab. According to the preferred embodiment, the composite precast element 1 has a substantially rectangular base, wherein the base area of ​​the tension layer 2 is larger than the base area of ​​the concrete layer 3. In particular, both the length and the width of the tension layer 2 are larger than the length and width, respectively, of the concrete layer 3. As shown in Figure 1, the tension layer 2 is formed by a slab and a slab. Fig. As shown in Figure 1, a setback is formed on all sides around the concrete layer 3 relative to the tension layer 2. The edges of the concrete layer 3 therefore maintain a distance from the edges of the tension layer 2 along its entire length. This setback makes it particularly easy to create a grid of channels 14 in both the longitudinal and transverse directions.

[0030] The concrete layer 3 is attached to the tension layer 2 only at one surface. Both the tension layer 2, which is designed as a cross-laminated timber layer, and the concrete layer 3 have essentially the same thickness throughout. As is particularly evident in Fig. As can be seen in Figure 2, the tensile layer 2, in the preferred embodiment presented here, has six recesses 5, which are commonly referred to as notches in the industry. A higher or lower number of recesses 5 may also be arranged on the tensile layer 2. The recesses 5 are designed as grooves 8 with a substantially rectangular base area, which have a shallow penetration depth in the tensile layer 2 compared to the thickness of the tensile layer 2. It should be noted that the recesses 5 in question are Fig. 1 are represented only as invisible edges, and that Fig. 2 and Fig. Figure 3 shows a cross-sectional view, whereby the commonly used hatching has been omitted for the sake of clarity.

[0031] As already explained, it is particularly preferred that the composite precast element 1 is designed as a composite floor slab 9. It is therefore intended to form a floor slab 11, in particular a building ceiling and / or a room ceiling, from such composite floor slabs 9. A floor slab 11, in particular a building ceiling and / or room ceiling, comprising composite precast elements 1 is provided.

[0032] The floor slab 11 can be supported in particular by supports 16. The supports 16 can be designed in particular as walls, for example side walls 12 or interior walls 13, or also as freestanding columns, for example in larger rooms.

[0033] In particular, it may be provided that the supports comprise walls made of concrete and / or brick. It has been shown that a direct support of the floor slab 11 on a masonry or concrete wall is easy to install, thus making it possible to easily use a wooden ceiling even in a brick or concrete building.

[0034] In particular, it may be provided that a composite precast element 1 rests on two opposing supports 16, as is the case in Fig. Figure 2 shows that the composite prefabricated elements 1 can, in particular, have a length that corresponds at least to the distance between two opposing walls of a building. This makes it particularly easy to create a stable floor slab 11.

[0035] In particular, it can preferably be provided that the tensile layer 2 has a step 17 on at least one composite precast side edge 10, and a correspondingly symmetrical step 17 on an opposite composite precast side edge 10, wherein both steps 17 can be joined to form a stepped rebate. This stepped rebate reduces sound transmission through the floor slab 11, which is why this type of connection is particularly suitable for a self-supporting area of ​​the floor slab 11. Furthermore, an even better bond between the individual composite precast elements 1 can be achieved when forming a floor slab 11, and the installation of the composite precast elements 1 can be further simplified.

[0036] Furthermore, it can be provided that the tensile layer 2 is planar at least on one composite precast side edge 10. This composite precast side edge 10 can be located, in particular, at an edge of the floor slab 11 and / or above an interior wall 13, since in this case sound transmission through the floor slab 11 is already prevented by the wall.

[0037] The individual composite prefabricated elements 1 are preferably connected to one another using timber fasteners, in particular including nails, screws, and gusset plates. This allows for the very rapid construction of a walkable floor slab 11, eliminating the need for on-site concreting. Such a floor slab 11 can be constructed by carpenters, thus eliminating the need for bricklayers in this construction phase. This saves a trade on the construction site. Since coordination between different trades or companies is no longer necessary, construction progress is further accelerated.

[0038] As in Fig. 2 and Fig. As shown in Figure 3, a channel 14 is formed at the edges of the composite precast elements 1, particularly between the adjacent composite precast elements 1. It is preferably provided that, in the case of the floor slab 11 in question, lines (not shown), in particular an electrical line and / or a fluid line, such as a fresh water line, wastewater line, gas line and / or a heating pipe, are arranged in the channel 14. In the preferred design of the composite precast element 1 according to the Fig. In steps 1 to 3, the formation of the floor slab 11 creates a grid of both longitudinally and transversely running channels 14, allowing for very flexible routing of the cables. The channels 14 can also run along the wall.

[0039] The channels 14 are filled with conventional fill material, which not only covers any pipes but also allows compressive forces to be transferred to the underlying tensile layer 2 in this area, and also allows compressive forces to be transferred between adjacent concrete layers 3.

[0040] On top of the concrete layer 3 there is a screed 15, which is in the Fig. 2 and Fig. 3 is only schematically represented by dashed lines. In particular, it is provided that the screed 15 is designed as a dry screed, which can further accelerate the construction progress, and the entire ceiling structure can be carried out by carpenters or drywallers without the need for masonry work.

[0041] The tension layer 2 has a wooden underside on the first composite precast element's outer surface 6. Therefore, the tension layer 2 can be designed like the underside of the finished floor slab 11 on the first composite precast element's outer surface 6, thus eliminating the need for further work on the underside.

[0042] Particularly preferably, the tension layer 2 may form an underside of the floor slab 11. In particular, a first composite precast outer surface 6 forms the underside of the floor slab 11. The composite precast element 1, especially the tension layer 2, can therefore be designed such that the tension layer 2 already has a fully functional first composite precast outer surface 6, thus eliminating the need for further work on the underside of the floor slab 11 and further reducing the time and effort required to manufacture the floor slab 11.

Claims

[1] Composite precast element (1) comprising a tension layer (2) and a concrete layer (3) connected to the tension layer (2), wherein the tension layer (2) has a definable plurality of definable shaped recesses (5) on an inner surface (4) facing the concrete layer (3), into which recesses (5) the concrete layer (3) engages to form a positive bond between the concrete layer (3) and the tension layer (2), wherein the tension layer (2) is designed as a wood layer, characterized by , that the tension layer (2) extends laterally over the concrete layer (3) on all sides for lateral connection with other composite precast elements by means of wooden connectors and for the creation of channels (14) for the laying of pipes, and that the tension layer (2) is suitable for connecting two adjacent composite precast elements (2) by means of wooden connectors. [2] Composite prefabricated part (1) according to claim 1, characterized by, that to form the positive connection between concrete layer (3) and tension layer (2) the concrete layer (3) only engages in the recesses (5) of the tension layer (2) and that consequently no additional connecting means are provided between concrete layer (3) and tension layer (2). [3] Composite prefabricated part (1) according to claim 1 or 2, characterized by , that the tensile layer (2) forms a first composite precast outer surface (6). [4] Composite prefabricated part (1) according to claim 3, characterized by , that a second composite precast outer surface (7) is essentially formed by the concrete layer (3). [5] Composite prefabricated part (1) according to any one of claims 1 to 4, characterized by , that the depressions (5) are designed as blind holes and / or grooves (8). [6] Composite prefabricated part (1) according to any one of claims 1 to 5, characterized by , that the tensile layer (2) is designed as a cross-laminated timber panel. [7] Composite prefabricated part (1) according to any one of claims 1 to 6, characterized by , that the composite precast element (1) is designed as a composite panel, in particular as a composite ceiling panel (9). [8] Composite prefabricated part (1) according to any one of claims 1 to 7, characterized by , that the concrete layer (3) is formed without reinforcement. [9] Floor slab (11), in particular building slab and / or room slab, comprising composite prefabricated elements (1) according to any one of claims 1 to 8. [10] Floor slab (11) according to claim 9, characterized by , that the composite prefabricated parts (1) are connected to each other by means of wooden fasteners, in particular comprising nails, screws, gusset plates. [11] Floor slab (11) according to claim 9 or 10, characterized by, that a channel (14) is formed at the edges of the composite prefabricated parts (1), in particular between adjacent composite prefabricated parts (1), and that at least one line, in particular a power line and / or a fluid line, is arranged in the channel (14). [12] Floor slab (11) according to one of claims 9 to 11, characterized by , that a screed (15) in particular a dry screed is arranged on the concrete layer (3).

Images