Composite element and composite element assembly

Abstract

A composite element (1) for use as a floor, ceiling, or roof element comprises at least one slab-shaped concrete element (2) arranged on one or more wooden elements (3) and connected to the wooden element (3) or at least one of the wooden elements (3) via at least one connection (4). The concrete element (2) has an upward-facing top surface (O) and a downward-facing bottom surface (U) with which it rests on the wooden element(s) (3). The composite element (1) comprises at least one anchoring element (8) which is partially embedded in the concrete element (2) and partially projects upward beyond the top surface (O) of the concrete element (2).

Description

[0001] The invention relates to a composite element for use as a floor, ceiling or roof element, wherein the composite element comprises at least one plate-shaped concrete element arranged on one or more wooden element(s) and connected to the wooden element or at least one of the wooden elements via at least one connection, wherein the concrete element has an upwardly directed top and a downwardly directed bottom with which it rests on the wooden element(s).

[0002] The invention also relates to a composite element assembly consisting of several composite elements according to the invention which are arranged next to and / or behind one another, as well as in a manner connecting them to one another, and to a manufacturing method for this assembly.

[0003] Timber-concrete composite structures are used in building construction as well as bridge construction. In particular, ceilings made of timber-concrete composite elements represent an efficient and resource-saving alternative to conventional ceiling systems made entirely of timber or concrete.

[0004] Timber-concrete composite elements comprise one or more timber elements connected to a concrete element. These composite elements offer the advantage that the top concrete layer, which is subjected to compression when the composite element deflects, is particularly resistant to compression, while the bottom timber layer, which is subjected to tension when the composite element deflects, is particularly resistant to tension.

[0005] To create a composite wood-concrete ceiling, ceiling joists already integrated into a building can be connected to a concrete slab supported by them. This is achieved by placing a formwork made of wooden boards on the joists and attaching it to them using fasteners (e.g., screws), so that the fasteners protrude slightly above the formwork. Concrete is then poured onto the formwork, and after the concrete has hardened, the protruding sections of the fasteners are embedded in the concrete slab, creating a strong bond between the wooden joists and the concrete. The disadvantage of this method is that such a composite wood-concrete ceiling must be constructed on-site.

[0006] In this way, ceilings or floors made of a wood-concrete composite can be produced during the expansion or renovation of existing buildings or during the construction of new buildings.

[0007] When constructing new buildings, it can be advantageous to use prefabricated timber-concrete composite elements (hung, laid, fastened, installed, etc.). Firstly, this effectively saves construction time on site, as the concrete of the timber-concrete composite elements does not need to cure on-site, but is already hardened and fully load-bearing. Secondly, no complex sealing measures are required to prevent unwanted flow of the liquid concrete.

[0008] Conventional, prefabricated timber-concrete composite elements typically comprise a substructure made of one or more timber elements and an attached concrete slab. The concrete slab can be cast separately and mounted to the substructure, for example, by screwing screws through screw channels in the concrete element into the timber structure. Alternatively, the concrete slab can be cast directly onto the substructure (for example, by using the substructure as part of a formwork for the concrete slab), with the hardened concrete slab being firmly connected to the timber structure via anchor elements (shear transfer elements) fixed in the timber structure, which then bond into the hardened concrete.

[0009] A disadvantage of conventional timber-concrete composite elements is that they generally need to be quite thick to achieve sufficient flexural stiffness. This is particularly true since the concrete element is also quite thick (usually at least 120 mm). mm preferably more than 120 mm Since conventional timber-concrete composite elements (e.g., 130 mm) are required, they are quite heavy. Because the transport costs for these factory-made timber-concrete composite elements to the building where they are to be installed are directly related to their weight, these transport costs are quite high for conventional, relatively heavy timber-concrete composite elements.

[0010] Another disadvantage of conventional timber-concrete composite elements is that they generally require connection points or elements. These connection points or elements serve to join the timber-concrete composite elements to one another once they are arranged side-by-side and / or one behind the other on-site in a building to construct a floor, ceiling, or roof. This is necessary for structural and fire safety reasons. However, the production of such connection points or elements and the on-site connection of the timber-concrete composite elements via these connection points or elements is quite complex.

[0011] The invention is based on the objective of providing a composite element (more precisely, a wood-concrete composite element) that does not exhibit the disadvantages of the prior art. In particular, a composite element is to be provided that is easier to transport than conventional composite elements, without reducing the load-bearing capacity of a ceiling / floor / roof constructed from several such composite elements. Likewise, a composite element is to be provided that is easier to manufacture and can be more easily connected on-site with other such composite elements to construct a ceiling, floor, or roof (or at least a base thereof).

[0012] This problem is solved according to the invention with a composite element having the features of claim 1, a composite element assembly having the features of claim 9, and a manufacturing method having the features of claim 12.

[0013] Preferred and advantageous embodiments of the invention are the subject of the dependent claims.

[0014] According to the invention, the composite element has at least one anchoring element which is partially embedded in the concrete element and partially projects upwards above the top of the concrete element.

[0015] In the state of the composite element according to the invention, the top of the concrete element is oriented upwards and the bottom downwards.

[0016] A reinforcement element, such as a reinforcement cage or reinforcement mesh, can preferably serve as the anchoring element, where only part(s) are embedded in the concrete element and part(s) protrude upwards from the concrete element. Multiple reinforcement elements can also be provided, at least some or all of which, in addition to the connection via the concrete element, are directly or indirectly connected to each other, or which, in addition to the connection via the concrete element, are not connected to each other (i.e., only connected via the concrete element).

[0017] The anchoring element(s) can also be components other than reinforcement elements, i.e., components that do not additionally perform a (further) static function in the composite element or in the composite element assembly formed from composite elements according to the invention.

[0018] Preferably, the anchoring element(s) is / are made of metal, in particular structural steel (reinforcing steel). However, the anchoring element(s) can also be made of other materials, e.g., fiber-reinforced plastic.

[0019] If only one anchoring element is provided, it preferably has several rod- or bar-shaped sections, at least partially (especially in the area of ​​the top of the concrete element), that project out of the concrete element. If several anchoring elements are provided, they preferably each have one or more rod- or bar-shaped sections, at least partially (especially in the area of ​​the top of the concrete element), that project out of the concrete element. The anchoring element(s), or at least a part of the anchoring elements, is / are embedded in the concrete element over at least 5%, preferably at least 10%, of its total height. The part of the anchoring element projecting beyond the concrete element...The height of the anchoring elements, or at least a part of the anchoring elements, is in particular at least 50%, preferably at least 60% of its total height.

[0020] The composite elements according to the invention are preferably assembled at the factory, then transported to the installation site and arranged there. Preferably, several composite elements according to the invention are arranged side by side and / or one behind the other, as well as adjoining each other, to form a floor, a ceiling or a roof (or the base therefor). Subsequently, a layer of uncured concrete can be applied on site to the composite elements, which form a closed plane at the bottom, so that after the concrete layer has cured, the anchoring elements of the composite elements are received and anchored in the concrete layer.

[0021] A particular advantage of the composite element according to the invention is that, compared to conventional composite elements, it has a reduced weight and thickness. As a result, the transport costs incurred for a single composite element are significantly lower than for conventional composite elements.

[0022] Furthermore, composite elements according to the invention can be easily connected on site without the need for special connection points or elements, e.g., by connecting the anchoring elements of adjacent composite elements directly or indirectly (e.g., via reinforcing mats) and applying a common, continuous layer of concrete over all composite elements. This saves additional costs and labor.

[0023] Composite elements, such as the composite element according to the invention, can also be referred to as hybrid elements, wood-concrete elements, wood-concrete composite elements or wood-composite elements.

[0024] The composite element according to the invention comprises, in particular, a single plate-shaped concrete element arranged on one or more wooden elements and connected to the wooden element or at least one of the wooden elements. However, the composite element according to the invention can also comprise several plate-shaped concrete elements, which, for example, are directly adjacent to one another and arranged on and connected to the wooden element(s).

[0025] In an advantageous embodiment, the concrete element is connected to the wooden element(s) via at least one connection designed as a screw connection, preferably more than one connection designed as a screw connection. Such connections between the concrete element and the wooden element(s) are particularly resistant to tensile and shear forces.

[0026] In such screw connections, the screw connection(s) can be formed by a screw that is guided through a screw channel in the concrete element and screwed into the underlying wooden element, with its head pressed against a shoulder of the concrete element from above. It is particularly preferable to create the screw channel(s) during the production of the concrete element (e.g., by placing placeholder elements at the locations of the future screw channels during the casting process). Forming concrete elements with a screw channel during production is less complex and simplifies the creation of screw connections between the concrete element and the wooden element(s).

[0027] If the concrete element has one or more screw channels, these can be formed wholly or partially by a connecting element that is part of the concrete element and located wholly or partially within a concrete body of the element. In composite elements with such concrete elements, the screw head is pressed from above against a shoulder of the connecting element and / or the concrete body. Inserting connecting elements into the formwork for the concrete element allows for the particularly quick and easy creation of suitable screw channels.

[0028] In another, equally advantageous embodiment, the concrete element is connected to the wooden element(s) via at least one connection designed as an adhesive bond. The concrete element can be bonded to the wooden element(s) (each) over its entire surface or section by section, at several points. Adhesive bonds are particularly simple and cost-effective to produce and exhibit especially good force transmission properties. In embodiments with beam-shaped wooden elements, for example, an adhesive bond can be provided along the entire length of each wooden beam between the upper surface of the wooden beam facing the concrete element and the underside of the concrete element.

[0029] Other connection options between the concrete element and the wooden element(s) are also possible, for example by filling a through hole in the concrete element and a corresponding recess in the wooden element below with concrete.

[0030] The wooden element(s), or at least some of the wooden elements, can also be connected to the concrete element via several different types of connections (especially as described above) (e.g. screwed and glued).

[0031] Within the scope of the invention, it can be provided that at least one reinforcement element is arranged in the concrete element, which is preferably connected to the anchoring element(s) projecting from the concrete element. If the anchoring element(s) is / are already a reinforcement element, a further reinforcement element or elements may be additionally present, but this is not absolutely necessary.

[0032] The composite element can comprise a beam-shaped or panel-shaped wooden element and / or several beam-shaped or panel-shaped wooden elements, each spaced apart from one another or arranged adjacent to one another. The wooden element(s) can, in particular, consist of glued laminated timber or laminated veneer lumber.

[0033] In embodiments where the composite element comprises one or more longitudinally extending wooden elements (e.g., beam-shaped wooden elements or narrow, plate-shaped wooden elements), the anchoring element(s) can extend transversely to the longitudinal extent of this wooden element(s). Preferably, however, in such embodiments, the anchoring element(s) extend in the direction of the longitudinal extent of the wooden element(s), in particular parallel to it.

[0034] Preferably, the plate-shaped concrete element is a concrete slab with a thickness of ≤ 120 mm, preferably ≤ 90 mm, and particularly ≤ 60 mm. Such concrete slabs may be thicker or thinner in certain areas, but must maintain this thickness over a large portion (for example, ≥ 50%) of their surface area. Concrete slabs with the thickness specified above are sufficiently strong and resistant to withstand manufacturing and transport to the installation site of the composite element without damage, but are significantly lighter than the concrete elements of conventional composite elements.

[0035] The overall height of the anchoring element can be ≥ 40 mm, in particular ≥ 50 mm, preferably ≥ 60 mm. Such a high anchoring element ensures sufficiently strong anchoring of the anchoring element in the concrete layer to be placed above it.

[0036] The invention also relates to a composite element assembly for forming a floor, a ceiling or a roof (or at least a base thereof), wherein the composite element assembly comprises at least two, preferably more than two, composite elements according to the invention, according to one of the embodiments described above.

[0037] In the composite element assembly according to the invention, the composite elements are arranged side by side and / or one behind the other, as well as abutting each other. Adjacent composite elements are connected to one another, and a layer of concrete is arranged on each of the concrete elements of the composite elements. The parts of the anchoring elements protruding from the concrete elements are received in the concrete layer arranged above each of the composite elements, so that a strong and force-transmitting bond is formed between the concrete element and the concrete layer arranged above it.

[0038] The concrete layer is particularly thick or high enough that the parts of the anchoring elements protruding from the concrete elements of the composite elements are completely embedded in the concrete layer. Preferably, there is a gap of at least 10 mm, and in particular at least 15 mm or at least 20 mm, between a surface of the concrete layer and an upper end of each of the anchoring elements.

[0039] The composite element assembly according to the invention provides a structure, namely a floor, a ceiling, or a roof, or at least the base of a floor, a ceiling, or a roof, which has the same static strength and the same static properties as such a structure consisting of conventional composite elements. Since the composite elements according to the invention can be transported to the installation site much more cost-effectively than conventional composite elements, costs can be saved in the production of a composite element assembly according to the invention.

[0040] A floor, ceiling or roof (or at least a base thereof) made from a single composite element according to the invention, onto which a layer of concrete is applied on site, in which - after hardening - the part(s) of the anchoring element protruding from the concrete element is / are embedded, is also possible within the scope of the invention.

[0041] A particularly preferred embodiment of the composite element assembly according to the invention is one in which adjacent composite elements are connected to one another by directly or indirectly connecting the anchoring elements of adjacent composite elements. In such a composite element assembly according to the invention, the concrete layers arranged on the concrete elements form a continuous concrete layer covering the concrete elements of all composite elements of the composite element assembly. A monolithic concrete layer is particularly preferred.Such a concrete layer can be easily formed by applying, in particular pouring, uncured concrete onto the composite elements after they have been arranged and connected according to the invention. This concrete is distributed essentially uniformly over all the composite elements and, when cured, encloses all the parts of the anchoring elements that protrude from the composite elements. A composite element assembly with a common concrete layer is particularly easy and cost-effective to produce and is also highly load-bearing.

[0042] In this preferred embodiment, at least one anchoring element of each composite element is connected to at least one anchoring element of the adjacent composite element. The anchoring elements can be connected directly (e.g., via spot welds or connecting wires, clamps, or clips) or indirectly (e.g., via a reinforcing mat or mesh).

[0043] In an alternative embodiment, adjacent composite elements of the composite element assembly are connected to one another by directly or indirectly connecting (for example, screwing) the wooden elements of adjacent composite elements. In this embodiment, a separate layer of concrete, essentially separated from the concrete layers of adjacent composite elements, is arranged on each of the concrete elements. When manufacturing such a composite element assembly, formwork elements are placed between the composite elements before, during, or after the arrangement and connection (via the wooden elements) of the composite elements according to the invention, and then the uncured concrete is applied to the composite elements, in particular by pouring. The uncured concrete can be applied separately to each of the composite elements (or to several assemblies of composite elements).In particular, the formwork elements have openings, or the concrete is applied to just above the height of the formwork elements, so that before hardening the concrete is distributed essentially evenly over all the composite elements. After the concrete has hardened, the concrete layers of the individual composite elements, while essentially separate from one another, are connected to each other via thin / small fracture surfaces. After the concrete has hardened, the formwork elements preferably remain between the concrete layers / composite elements. Such a composite element assembly is particularly efficient to dismantle, decommission, and recycle.

[0044] Furthermore, the invention relates to the production of a composite element assembly according to the invention for forming a floor, a ceiling, or a roof. Particularly preferably, two, and preferably more than two, composite elements according to the invention are first arranged side by side and / or one behind the other, and connected to each other. Subsequently (or simultaneously), anchoring elements of adjacent composite elements are connected to one another. After all necessary connections between adjacent composite elements have been made, a common layer of concrete is poured onto the concrete elements of the composite elements. This layer of concrete is distributed over all composite elements of the assembly, so that the parts of the anchoring elements projecting upwards from the concrete elements are contained within the concrete layer.After the concrete layer has hardened, it is firmly connected to the composite elements arranged below via the anchoring elements.

[0045] A possible, though not preferred, implementation of the method is also possible in which the composite elements according to the invention are only finished on site when the composite element assembly according to the invention is produced, by attaching factory-finished, thin concrete slabs with protruding anchoring elements to wooden elements on site, e.g. by screwing or gluing them.

[0046] Further details, features and advantages of the invention will become apparent from the following description of preferred embodiments with reference to the accompanying drawings. These show: Fig. 1 is an isometric view of a composite element according to the invention, and Fig. 2 is a detail of a composite element assembly according to the invention in a sectional view.

[0047] Fig. 1 Figure 1 shows a composite element 1 according to the invention in an isometric view from a top oblique angle. A composite element assembly according to the invention, as shown in Figure 1, is shown in Figure 1. Fig. 2 shown in a sectional view, comprises several such composite elements 1 according to the invention, wherein in Fig. 1 However, only a section or detail of a single composite element 1 is shown. The composite elements 1 of the composite element assembly can be arranged side by side, one behind the other, and adjacent to each other.

[0048] Each composite element 1 according to the invention has a plate-shaped concrete element 2, with a top surface O facing upwards in the intended use (in the state of use) and a bottom surface U facing downwards.

[0049] In the illustrated embodiment, the concrete element 2 is arranged with its underside U on several beam-shaped wooden elements 3, i.e. it rests on them.

[0050] Fig. 2 Figure 1 shows a section through a segment or detail of one of the composite elements 1 of the composite element assembly according to the invention. The section plane is essentially orthogonal to the longitudinal axes of the wooden elements 3.

[0051] The concrete element 2 is connected to the wooden elements 3 via several connections 4.

[0052] In Fig. 1 The concrete element 2 is connected to the wooden elements 3 via connections 4 designed as adhesive joints. These adhesive joints are in Fig. 1 not visible, but are located between the concrete element 2 and the wooden elements 3. Preferably, the connection 4, which is designed as an adhesive connection, extends substantially over the entire length of each of the wooden elements 3, but several, shorter or even spot-shaped adhesive connections can also be provided for each wooden element 3.

[0053] In the Fig. 2 In the illustrated embodiment, the connections 4 are designed as screw connections, with several such connections 4 being provided along the longitudinal extent of the wooden elements 3.

[0054] To create the screw connections 4, connecting elements 5 are arranged in the concrete element 2, each forming a screw channel 6. The connecting elements 5 can, for example, be inserted into the formwork of the concrete element 2 before the concrete element 2 is manufactured (cast).

[0055] Each of the connecting elements 5 forms a shoulder against which the head of a screw 7 is pressed, which is guided through the screw channel 6 and screwed into the underlying wooden element 3.

[0056] Several anchoring elements 8, designed as reinforcement cages, are arranged in the concrete element 2, such that only a portion of the anchoring elements 8 are embedded in the concrete element 2, while a portion of the anchoring elements 8 project upwards above the top surface O of the concrete element 2. The anchoring elements 8, designed as reinforcement cages, extend essentially transversely to the longitudinal axes of the timber elements 3.

[0057] In addition to the anchoring elements 8, the concrete element 2 incorporates a reinforcement element 9 designed as a reinforcement mat, which is connected to the anchoring elements 8 in particular by spot welding.

[0058] The concrete elements 2 of adjacent composite elements 1 according to the invention of the composite element assembly are preferably connected to each other.

[0059] A continuous layer of concrete 10 is arranged on the concrete elements 2 of the composite elements 1 according to the invention of the composite element assembly, as shown from Fig. 2 as is evident.

[0060] The continuous concrete layer 10 is formed monolithically by applying, in particular pouring, a not yet hardened concrete onto the composite elements 1 after the composite elements 1 had been arranged next to and behind each other.

[0061] The upwardly projecting parts of the anchoring elements 8 of the composite elements 1 are enclosed by the continuous concrete layer 10, wherein the concrete layer 10 - as in the illustrated embodiment - is in particular designed to be so thick that the upwardly projecting parts of the anchoring elements 8 are completely enclosed by the concrete layer 10.

[0062] During the Figs. 1 and 2In the illustrated embodiment, the anchoring elements 8 extend transversely to a longitudinal extent L of the wooden elements 3. Preferably, however, in such an embodiment, the anchoring elements 8 extend in the direction of the longitudinal extent L of the wooden elements 3, in particular parallel to the longitudinal extent L of the wooden elements 3. Reference symbol list

[0063] 1 Composite element 2 Concrete element 3 Timber element 4 Connection 5 Connecting element 6 Screw channel 7 Screw 8 Anchoring element 9 Reinforcement element 10 Concrete layer OTop of concrete element UBottom of concrete element LLongitudinal extension of wooden element

Claims

1. Composite element (1) for use as a floor, ceiling or roof element, wherein the composite element (1) comprises at least one plate-shaped concrete element (2) arranged on one or more wooden element(s) (3) and connected to the wooden element (3) or at least one of the wooden elements (3) via at least one connection (4), wherein the concrete element (2) has an upwardly directed top (O) and a downwardly directed bottom (U) with which it rests on the wooden element(s) (3), characterized by the fact that the composite element (1) has at least one anchoring element (8) which is partially incorporated in the concrete element (2) and partially extends upwards above the top (O) of the concrete element (2).

2. Composite element according to claim 1, characterized by the fact thatthe concrete element (2) is connected to the wooden element (3) or wooden elements (3) via at least one connection (4) designed as a screw connection, preferably more than one connection (4) designed as a screw connection.

3. Composite element according to claim 2, characterized by the fact that the connection (4) designed as a screw connection is formed by a screw (7) which is guided through a screw channel (6) in the concrete element (2) and screwed into the underlying wooden element (3) and is pressed with its head from above against a shoulder of the concrete element (2), or that the connections (4) designed as screw connections are formed by several such screw connections connecting the concrete element (2) with one or possibly several of the wooden elements (3).

4. Composite element according to claim 3, characterized by the fact thatthe screw channel (6) is formed wholly or partly by a connecting element (5) which is part of the concrete element (2) and is arranged wholly or partly in a concrete body of the concrete element (2), and that the head of the screw (7) is pressed from above against a shoulder of the connecting element (5) and / or the concrete body (2).

5. Composite element according to one of claims 1 to 4, characterized by the fact that the concrete element (2) is connected to the wooden element (3) or wooden elements (3) via at least one connection (4) designed as an adhesive connection.

6. Composite element according to one of claims 1 to 5, characterized by the fact that in the concrete element (2) at least one reinforcement element (9) is arranged, which is preferably connected to the anchoring element(s) (8) projecting from the concrete element (2).

7. Composite element according to one of claims 1 to 6, characterized by the fact thatthe composite element (1) comprises a beam-shaped or plate-shaped wooden element (3) and / or several beam-shaped or plate-shaped wooden elements (3), each spaced apart from one another or lying next to one another.

8. Composite element according to one of claims 1 to 7, characterized by the fact that the plate-shaped concrete element (2) is a concrete slab with a thickness of ≤ 120 mm, preferably ≤ 90 mm, in particular ≤ 60 mm.

9. Composite element assembly for forming a floor, a ceiling or a roof, wherein the composite element assembly comprises at least two, preferably more than two, composite elements (1) according to any one of claims 1 to 8, which are arranged side by side and / or one behind the other, and in a manner that connects to one another, characterized by the fact thatadjacent composite elements (1) are connected to each other, such that a layer of concrete (10) is arranged on each of the concrete elements (2) of the composite elements (1), and that the parts of the anchoring elements (8) protruding from the concrete elements (2) are each received in the layer of concrete (10).

10. Composite element assembly according to claim 9, characterized by the fact that adjacent composite elements (1) are connected to each other by directly or indirectly connecting the anchoring elements (8) of adjacent composite elements (1), and that the concrete layers (10) arranged on the concrete elements (2) form a continuous, in particular monolithic, concrete layer (10) covering the concrete elements (2) of all composite elements (1) of the composite element assembly.

11. Composite element assembly according to claim 9, characterized by the fact thatadjacent composite elements (1) are connected to each other by directly or indirectly connecting wooden elements (3) of adjacent composite elements (1), and that a separate layer of concrete (10) is arranged on each of the concrete elements (2), separate from the layers of concrete (10) of adjacent composite elements (1).

12. Method for producing a composite element assembly for forming a floor, a ceiling or a roof, wherein first two, preferably more than two, composite elements (1) according to one of claims 1 to 8 are arranged side by side and / or one behind the other, and connecting anchoring elements (8) of adjacent composite elements (1) are connected to each other, and subsequently a layer of concrete (10) is poured onto the concrete elements (2) of the composite elements (1), so that the parts of the anchoring elements (8) projecting upwards from the concrete elements (2) are received in the concrete layer (10).

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