Prefabricated finished floor element, floor manufacturing process, and resulting floor

Abstract

The invention relates to a prefabricated finished floor element (1), consisting of a panel made of a structural material (MS), comprising within its thickness reinforcement blocks (5) and reinforcing bars (6, 7), and at least one top layer (14) of structural material. The reinforcement blocks (5) form a grid and define between them a network of ribs (8, 9) extending in two intersecting directions (X, Y). The reinforcing bars (6, 7) are arranged in two parallel layers (10, 11) on either side of the reinforcement blocks (5). They protrude from the edges (4) of the floor element (1) to ensure mechanical continuity with adjacent floor elements (1).A floor (20) is obtained by juxtaposing floor elements (1) separated from each other by a joint zone (ZJ) delimited by an integrated formwork beak (12), and by pouring a very high-performance jointing material (MC) only in the joint zones (ZJ) to seal said floor elements (1) to each other and to the load-bearing elements of a structure, making it possible to create a load-bearing structure for a building without a cast-in-place compression slab. Figure for the abbreviation: Fig 2.

Description

Title of the invention: Prefabricated finished floor element, method of manufacturing a floor and floor obtained Technical field

[0001] The present invention relates to a prefabricated finished floor element, consisting of a panel made of a structural material, defined by a plane, a width, a length, a thickness, a lower face, an upper face, and edges which connect the lower and upper faces, said floor element comprising in its thickness lightening blocks and reinforcements, as well as a network of ribs and at least one upper layer made of said structural material.

[0002] The invention also relates to a method of manufacturing a floor from prefabricated finished floor elements and a floor obtained. Prior art

[0003] Prefabricated finished floor elements have existed for many years in the form of hollow core slabs, made of prestressed concrete or reinforced concrete, for manufacturing dry floors, i.e. floors which do not require a compression slab cast on site. Prefabricated elegis floor elements have also existed for many years for manufacturing semi-finished floors in the same way as floor pre-slabs, requiring a compression slab cast on site. An example is described in publication FR 2 856 092 B1 belonging to the applicant, in which the prefabricated elegis floor elements may include passages to allow the crossing of technical networks.

[0004] Generally speaking, finished or semi-finished prefabricated floor elements must have a surface weight lower than the weight of a solid floor cast in place. This result is achieved by voids (hollow core slab), blocks of lightweight material (elegance), and / or a lightweight structural material. The main disadvantage of hollow core or elegy slab floors is that they only carry in the main direction of the floor. They can only be supported on linear load-bearing elements such as walls or beams, in accordance with publication FR 1 353 463 A. These floors are therefore not usable on point supports, such as posts or pillars, without the use of flat beams called "embedded strips" in the thickness of the floor. In addition, crossing technical networks perpendicular to the direction of span is also problematic in this type of floor, particularly in the case of hollow core slabs.

[0005] Publication GB 1 403 337 A proposes a prefabricated hollow core slab comprising ribs in two perpendicular directions, capable of bearing in two directions and suitable for point supports. However, this solution requires a compression slab cast on site.

[0006] Current solutions of prefabricated finished floor elements, honeycombed or elegis, are therefore not satisfactory. Statement of the invention

[0007] The present invention aims to overcome these drawbacks by proposing a new solution for a finished and prefabricated floor element, which has the advantage of offering a favorable compromise between a significantly reduced total weight of the floor, a quantity of concrete cast in place reduced to its minimum, guaranteed mechanical continuity between the floor elements in two intersecting directions of the floor, and a low-carbon floor. The invention also aims at manufacturing a floor by juxtaposing floor elements, and keying the latter, said finished floor elements comprising the entire structural part of the floor. The invention also aims at the floor obtained, which can be laid with or without props, can bear in one or two directions, can rest indifferently on post heads, beams or walls (walls), and can incorporate technical networks (electricity, low currents, water).

[0008] For this purpose, the invention relates to a floor element of the kind indicated in the preamble, characterized in that said structural blocks are made up of solid blocks having a density lower than that of said structural material and have a width and a length less than the width and the length of said floor element, in that said structural blocks are arranged relative to each other in the plane of said floor element, by means of a predefined interval, so as to define between them said network of ribs made of said structural material, said ribs extending in two intersecting directions of said plane to carry in said two directions,and in that said reinforcements extend in both intersecting directions and project from the edges of said floor element to constitute holding reinforcements and ensure mechanical continuity with adjacent floor elements when juxtaposed to manufacture a floor.

[0009] Thus, the floor element obtained constitutes a complete and finished element, which integrates all the characteristics and performances necessary to constitute a floor having a bearing capacity in two intersecting directions, ready to be laid and ready to be sealed to other identical or similar floor elements, making it possible to considerably shorten the duration of the construction site, by avoiding the laying of reinforcement mesh. additional over the entire floor surface and the pouring of a compression slab on site.

[0010] Depending on the embodiment variants, the ribs forming said network may or may not be perpendicular to each other.

[0011] Said lightening blocks advantageously have a thickness less than the thickness of said floor element, and can be positioned so that they are flush with the lower face of said floor element, or so that they are completely embedded in the thickness of said floor element.

[0012] Said reinforcements may advantageously be arranged in at least two layers parallel to said plane, including a lower layer and an upper layer, said lower layer being able to be located between said lightening blocks or below said lightening blocks in a lower layer made of said structural material, and said upper layer preferably being located above said lightening blocks in said upper layer.

[0013] Said sheets may comprise reinforcements extending in at least two intersecting directions of said plane, and the reinforcements of the two sheets advantageously project from the edges of said floor element to ensure mechanical continuity with adjacent floor elements when they are juxtaposed to manufacture a floor.

[0014] In a preferred form of the invention, said floor element comprises a formwork spoiler extending the lower face of said floor element, on at least two of said edges to create junction zones between adjacent floor elements when they are juxtaposed to manufacture a floor.

[0015] In an alternative embodiment, said floor element may comprise pockets in said edges, to create widened joining zones alternating with narrow joining zones between adjacent floor elements when they are juxtaposed to make a floor.

[0016] Said reinforcements may consist of rigid bars, the projecting part of which may be straight, curved into a hook, provided with an anchoring head which may be attached or obtained by deformation of material, and / or flexible cables, the projecting part of which may form a closed or open loop.

[0017] Depending on the requirements, said floor element may comprise at least one sleeve, which passes perpendicularly through said floor element, to delimit a reservation intended to receive at least one reinforcing bar at the right angle of a load-bearing element of a construction. In this case, said floor element may comprise around said sleeve a support zone full of structural material, without a lightening block.

[0018] The ribs provided in said floor element may have a variable width, preferably increasing in the direction of said sheath or said solid support zone.

[0019] In the same way, said floor element may comprise at least one passage intended to receive a duct or a technical conduit, said passage being produced by a groove and / or a perforation provided in said lighting blocks and by a passage sleeve in said ribs between the adjacent lighting blocks concerned.

[0020] The object of the invention is also achieved by a method of manufacturing a floor consisting of: - juxtaposing floor elements on load-bearing elements of a construction to form the surface of the floor to be manufactured, said floor elements being separated from each other by junction zones comprising the projecting parts of said reinforcements, - interlocking said projecting parts of the reinforcements of the adjacent floor elements in said junction zones, and - pouring a keying material only in said junction areas to seal said floor elements together and to said load-bearing elements of the construction to complete said floor without a compression slab cast on site, said floor bearing in two intersecting directions.

[0021] In this method, said junction zones are advantageously delimited by formwork spoilers integrated into said floor elements and / or may comprise an alternation of widened junction zones and narrow junction zones if the floor elements comprise pockets in their edges.

[0022] The method further provides for pouring a keying material having a very high compressive strength in said junction zones, said material being chosen from the group comprising high-performance concretes or microconcretes, very high-performance concretes or microconcretes, with or without reinforcing fibers, and ultra-high-performance fiber-reinforced concretes or microconcretes. It provides for preferential use of microconcretes, the aggregates of which have a size less than or equal to 10 mm.

[0023] The object of the invention is also achieved by a floor obtained by said manufacturing method, without a compression slab cast on site. Brief description of the drawings

[0024] The present invention and its advantages will appear better in the following description of several embodiments given as non-limiting examples, with reference to the appended drawings, in which:

[0025] [Fig-1] is a perspective view of a prefabricated finished floor element according to the invention,

[0026] [Fig.2] is a cross-sectional view of the floor element of [Fig.l] along section plane II-II,

[0027] [Fig.3] is a cross-sectional view of two floor elements before assembly,

[0028] [Fig.4] is a cross-sectional view of the two floor elements of [Fig.3] after assembly,

[0029] [Fig.5] is a perspective and transparent view of a floor partially represented by six floor elements according to [Fig.l] juxtaposed,

[0030] [Fig.6] is a top view of detail VI of the floor of [Fig.5] showing the projecting reinforcements in the junction area between adjacent floor elements,

[0031] [Fig.7] is an enlarged view of detail VII of [Fig.5] showing a support area on a load-bearing column, provided in a floor element,

[0032] [Fig.8] is a cross-sectional view of the floor element of [Fig.7], at the level of the support zone on the supporting post,

[0033] [Fig.9] is a top view of a floor element provided with ribs of increasing thickness towards the support zone,

[0034] [Fig. 10] is a sectional view of a junction between a floor element and a trumeau,

[0035] [Fig. 11] is a sectional view of the junction side of [Fig. 10],

[0036] [Fig. 12] is a sectional view of two floor elements assembled according to a variant embodiment of [Fig.4],

[0037] [Fig. 13] is a sectional view of two floor elements assembled according to an alternative embodiment of [Fig.l],

[0038] [Fig. 14] is a perspective view of a floor element according to the embodiment variant of [Fig. 13],

[0039] [Fig. 15] is a partial perspective view of the floor element of [Fig. 14],

[0040] [Fig. 16] is a top view of a portion of a floor element provided with reservations for the passage of technical networks in the thickness of the floor,

[0041] [Fig. 17] is a cross-sectional view in a first sectional plane of the floor element of [Fig. 16],

[0042] [Fig. 18] is a cross-sectional view in a second sectional plane of the floor element of [Fig. 16],

[0043] [Fig. 19] is a perspective view of a floor element according to another alternative embodiment of the invention, and

[0044] [Fig.20] is a sectional view of two floor elements of [Fig. 19] assembled. Description of the embodiments

[0045] In the illustrated embodiments, identical elements or parts bear the same reference numbers. Furthermore, terms which have a relative meaning, such as vertical, horizontal, right, left, front, rear, above, below, etc. must be interpreted under normal conditions of use of the invention, and as shown in the figures. The X, Y and Z axes are defined by an orthonormal reference frame illustrated in [Fig.l]. Furthermore, the geometric positions indicated in the description and the claims, such as “perpendicular”, “parallel”, “symmetrical” are not limited to the strict sense defined in geometry, but extend to geometric positions which are close, that is to say which accept a certain tolerance in the technical field considered, without influence on the result obtained.This tolerance is notably introduced by the adverb “sensiblement”, without this term necessarily being repeated before each adjective.

[0046] With reference to Figures 1 to 6, the finished prefabricated floor element 1 according to the invention consists of a panel defined by a general plane in XY, a width in Y, a length in X, a thickness in Z, a lower face 2, an upper face 3, and edges 4 which connect the lower 2 and upper 3 faces. In the example presented, the floor element 1 has a general shape of a rectangular parallelepiped, without this shape being limiting. The shape of the floor element 1 can vary depending on the shape of the floor 20 to be manufactured ([Fig.5]). It is made of an MS structural material, such as ordinary concrete, a concrete with a low carbon dioxide (CO2) footprint, also called low carbon concrete, a fiber concrete, or the like. This MS structural material forms a rigid matrix of high density, of approximately 2.5 for example, without this value being limiting.It is preferably made on a molding bench in a prefabrication factory, or in a fairground prefabrication facility on the construction site or near the construction site. It comprises in its thickness lightening blocks 5 and reinforcements 6, 7 provided for reinforced concrete. The lightening blocks 5 are solid and have a density lower than that of the structural material MS and make it possible to reduce the weight of the floor element 1, and correlatively the overall weight of the floor 20. They also make it possible to reduce the quantity of structural material MS necessary for the manufacture of the floor element 1 and correlatively the quantity of structural material MS of said floor 20, having a positive impact on the reduction of carbon emissions.They can also provide additional functions to the floor element, such as improved fire resistance, as well as better sound and / or thermal insulation depending on the material they are made of. And the reinforcements 6, 7 have the function of reinforcing the structural material MS and giving the element . floor 1 of the mechanical properties of resistance to bending, compression and traction, and thus to replace the compression slab cast on site as described below.

[0047] The lightening blocks 5 have a width and a length less than the width and the length of the floor element 1. For example, the lightening blocks 5 have a width corresponding to *4 of the width of the floor element 1, and a length corresponding to 1 / 6th of the length of the floor element 1, without these values ​​being limiting. The lightening blocks 5 also have a thickness less than the thickness of the floor element 1, and can be completely embedded in the floor element 1 ([Fig. 1] to 12, 16 to 20) or partially embedded to be flush with the lower face of the floor element 1 ([Fig. 13] to 15).

[0048] The shaping blocks 5 are preferably arranged in rows and columns to form a grid. They are separated from each other by a predefined interval I to create between them ribs 8, 9 extending in two intersecting directions of the XY plane, these two directions being able to be perpendicular or not, depending on the shape of the shaping blocks. In the example shown, the shaping blocks 5 are identical, have a general shape of a rectangular parallelepiped and the ribs 8, 9 are perpendicular to each other, without this example being limiting. The network of ribs 8, 9 is obtained by the structural material MS when it is cast on the shaping blocks 5 on the molding bench.This network of ribs 8, 9 gives the floor element 1 mechanical resistance in two intersecting directions, which allows it to be installed on load-bearing elements of a construction, both point and linear, such as posts, beams, walls, or the like.

[0049] The lightening blocks 5 are made up of solid blocks, preferably having a density lower than that of the structural material MS to lighten the floor elements 1, and therefore the total weight of the floor. They can be made of different materials, such as wood pellet concrete, wood fiber concrete or any other bio-sourced fillers such as miscanthus, hemp shiv, wood wool, but also other materials such as rock wool, cellular concrete, polystyrene, or even mixtures of these different materials or similar. The advantage of a bio-sourced material lies in its low carbon footprint which allows for ecological floor solutions.

[0050] The reinforcements 6, 7 are preferably arranged in two layers parallel to the XY plane, including a lower layer 10 and an upper layer 11. The lower layer 10 may be located between the lightening blocks 5 ([Fig. 13] to 15) or below the lightening blocks 5 ([Fig. 1] to 12, 16 to 20), and the upper layer 11 may be located between the lightening blocks 5 or above the lightening blocks 5. The layers 10, 11 each comprise reinforcements 6, 7 which extend at least in two intersecting directions of the XY plane. In the example shown, these two directions are perpendicular to each other, and respectively parallel to the directions of the ribs 6, 7. The reinforcements 6 of the plies 10, 11 extend in a main direction of the floor element 1 along the X axis, and the reinforcements 7 extend in a secondary direction along the Y axis. When the plies 10, 11 cover the lightening blocks 5 on both sides, they form a grid whose meshes are smaller than the grid formed by the lightening blocks 5 ([Fig.6]). The reinforcements 6, 7 of each ply 10, 11 project from the edges 4 of the floor element 1 to constitute waiting reinforcements and ensure mechanical continuity with adjacent floor elements 1. The frames 6, 7 can be made of rigid metal bars, the projecting part of which is straight ([Fig.l] to 4 and 6), curved into a hook ([Fig.12] and 14), in a closed or open loop associated with a connecting cage ([Fig. 19] and 20). They can also be fitted with anchor heads attached to their end or obtained by deformation of material, or made entirely or partly of flexible metal cables, the projecting part of which forms a closed or open loop (not shown).

[0051] The floor element 1 advantageously comprises a rim extending its lower face 2 on at least one of its edges 4, in the case where the floor element 1 is supported on load-bearing elements by two of its opposite edges. In the examples shown, the floor element 1 comprises a rim extending its lower face 2 on at least two of its edges 4, these edges 4 possibly being adjacent. This rim forms a formwork spoiler 12 to delimit junction zones ZJ between adjacent floor elements. These junction zones ZJ comprise the projecting parts of the reinforcements 6, 7 and are intended to receive a keying material MC or sealing material poured on site. The formwork spoiler 12 is preferably provided on two consecutive edges 4 of the floor element 1.Thus, the adjacent floor elements 1 in pairs are automatically spaced apart from each other by a formwork spoiler 12 forming a spacer and belonging to one of the two floor elements 1, when they are juxtaposed to form a floor. In a variant not shown, the floor element 1 may not be equipped with a formwork spoiler 12. In this case, the formwork of the junction zones ZJ is conventionally provided by formwork on site. In addition, the floor elements 1 located at the edge of the floor do not have a formwork spoiler 12 on the free edge 4 or resting on load-bearing elements of a construction.

[0052] In a first embodiment of the invention, the floor element 1 with reference to figures 1 to 12 and 16 to 18 comprises a lower layer 13 of 4 to 7 cm thickness, ribs 8, 9 in the two XY directions of section 7 to 20 cm wide, spaced approximately 50 cm to 100 cm apart along the XY directions by said blocks of lightening 5, and an upper layer 14 of 4 to 10 cm thickness, all in an MS structural material, such as ordinary concrete and preferably low carbon concrete. The values ​​indicated in this example are of course not limiting. The upper layer 14 of MS structural material combined with the upper layer 11 of the reinforcements 6, 7 makes it possible to distribute the loads over the entire floor element 1 and the floor 20 obtained by assembling similar floor elements 1, and to do away with a compression slab cast on site.

[0053] The casting of the MS structural material is carried out in two passes: - a first pass: casting of the lower layer 13, and - a second pass: casting of the ribs 8, 9 and of the upper layer 14. At the end of the first pass, lightening blocks 5, possibly made of wood aggregate concrete, are positioned on the lower layer 13, and preferably on the fresh MS structural material. The lightening blocks 5 made of wood aggregate have the advantage of being very rough and thus of naturally clinging to the fresh MS structural material by sinking the roughnesses. This mechanical clinging thus prevents the lifting of the lightening blocks 5 due to the Archimedes' thrust caused by the MS structural material cast during the second pass.

[0054] The reinforcements 6, 7, such as those used for reinforced concrete, are arranged in the lower layer 13 and in the upper layer 14 in the two perpendicular directions XY. The reinforcements 6, 7 can be reinforced at the right angles to the ribs 8, 9. In a horizontal plane XY, the reinforcements 6, 7 of two consecutive or adjacent floor elements 1 can be arranged in a staggered pattern, that is to say with an offset D relative to each other along the X and Y axes, so as to allow the installation of the floor elements 1 without collision of the reinforcements ([Fig. 3], 4 and 6), in particular when the reinforcements are rigid. The ribs 8 in the main direction X of the floor element 1 may include stiffening lattices (not shown in the figures) in order to increase the resistance to shear force of the ribs, in accordance with standard NF EN 13747.The reinforcements 6, 7 protrude from the floor element 1, in the two XY directions and at each end, that is to say on the four sides 4. At the edge of the floor, the floor elements 1 may also include an integrated chain 15 ([Fig.5]) made of solid concrete surrounding peripheral reinforcements to the floor (not shown).

[0055] Figures 5 and 6 illustrate an example of a rectangular floor 20, partially represented by six juxtaposed rectangular floor elements 1. To do this, the steps of the manufacturing method consist of: - juxtaposing the floor elements 1 on load-bearing elements of a construction to form the surface of the floor 20 to be manufactured, the floor elements 1 being separated from each other by the junction zones ZJ delimited by the formwork spoilers 12, - interlock the projecting parts of the reinforcements 6, 7 of the adjacent floor elements 1 in the junction zones ZJ ([Fig.3], 4 and 6), and - pouring a keying material MC only in the junction zones ZJ to seal the floor elements 1 to each other and to the load-bearing elements of the construction. The floor 20 obtained is finished without having to pour a compression slab in place. In addition, the floor 20 obtained has a load-bearing capacity in both XY directions of the ribs 8, 9.

[0056] The junction and mechanical continuity between the floor elements 1 is achieved by covering the pending reinforcements protruding from the floor elements 1. The space reserved by the formwork spoiler 12 between two adjacent floor elements 1, called the junction zone ZJ, makes it possible to pour on site a keying material MC, which may be a concrete or preferably a microconcrete of the BFUHP type (Ultra High Performance Fiber Reinforced Concrete) or BTHP type (Very High Performance Concrete) or BHP type (High Performance Concrete), with or without reinforcing fibers. These concretes have the advantage of offering a compressive strength of at least between 50 and 90 MPa for BHP type concretes, between 100 and 120 MPa for BTHP type concretes, and greater than or equal to 130 MPa for BFUHP type concretes, thus ensuring the transmission of forces over a very short distance.Furthermore, the advantage of microconcrete lies in the size of the aggregates, which is preferably less than or equal to 10 mm, and allows the reinforcements to be perfectly surrounded in a reduced space. Thus, the quantity of concrete or microconcrete is reduced to its strict minimum compared to a conventional covering in ordinary concrete, at least by a factor of approximately 3 using a BFUHP type concrete and by a factor of approximately 2 using a BTHP type concrete. For example, covering straight reinforcing bars with BFUHP type concrete can be carried out over a length of between 10 and 17 times the diameter of the bars to be covered, whereas in ordinary concrete this length is at least 40 times the diameter of said bars.

[0057] The performance of these MC keying materials makes it possible to absorb the transverse bending moments of the floor 20 in reduced spaces that are the junction zones ZJ, so as to maximize the space occupied by non-structural zones that are the lightening blocks 5. The lightening blocks 5 thus make it possible to reduce the dead weight of the floor 20 by approximately 25 to 50% compared to a solid floor cast in place. They also make it possible to maximize carbon storage, in particular by the use of lightening blocks 5 made of bio-sourced material or based on bio-sourced material, such as a wood aggregate concrete, or any other bio-sourced material, such as miscanthus, hemp shiv, etc. The use of bio-sourced material concrete to make the building blocks 5 also makes it possible to increase the thermal resistance of the floor 20, since the conductivity of bio-sourced material concrete is 10 to 15 times lower than ordinary reinforced concrete.

[0058] Thanks to its ribbed structure in two intersecting directions, the floor element 1 can advantageously bear on a point load-bearing element inducing a high punching load, such as a post 21, a pillar or the like, in accordance with the example shown in Figures 5, 7 to 9. The connection of the floor elements 1 with posts 21 supporting the floor 20 can be carried out by a single reinforcing bar 22 protruding from the lower post 21, passing through the floor element 1 through a sleeve 16 ([Fig.7]) and projecting from the floor element 1 to anchor in the upper post 21. For this purpose, the sleeve 16 is placed on the molding bench to create a through reservation in the floor element 1 during its manufacture. Preferably, the sleeve 16 is arranged perpendicular to the floor element 1 to create a vertical reservation.On site, the sheath 16 is filled with a keying material MC, which can advantageously be the same as that used in the junction zones ZJ, such as a concrete or preferably a microconcrete of the BFUHP, BTHP or BHP type with or without reinforcing fibers. The connection consists of a sheath 16 of square or circular section, the transverse dimension of which can be between 50 and 80 mm, without these values ​​being limiting. A full support zone ZP of structural material MS is then provided around the column head in the floor element 1, in order to incorporate punching reinforcements and upper (hat) bending reinforcements (not shown in the figures). For this purpose, the lightening blocks 5 which surround the sheath 16, comprise a cutout 17 in an arc of a circle, or in any other shape, to release a sufficient full support zone ZP around the sheath 16.In certain cases, it may be useful to widen the ribs 8, 9 of the floor element 1 which converge towards the support zones on the posts 21 when the forces to be transmitted to the posts are particularly significant. [Fig. 9] illustrates an example of ribs 8, 9 of variable width around a support zone provided with a sheath 16 at the right of a post 21, and in particular an increasing width in the direction of said support zone.

[0059] Similarly, and in accordance with the example shown in Figures 10 and 11, the connection between the floor 20 and prefabricated or cast-in-place load-bearing and / or bracing trumeaux 23 is ensured by reinforcing bars 22 projecting from the lower trumeaux 23, passing through the floor elements 1 through sleeves 16, and projecting from the floor elements 1 to be anchored in the upper trumeaux 23. The trumeaux 23 are parts of wall or partition between two bays or French windows, or even interior partition walls. In the same way, the sleeves 16 are integrated into the floor elements 1 during their manufacture to create preferably vertical through-holes. On site, the sleeves are filled with a keying material MC, which can advantageously be the same as that used in the junction zones ZJ, such as a concrete or preferably a micro-concrete of the BFUHP, BTHP or BHP type. The width of the ribs 8, 9 of the floor elements 20 could also be variable in the area where the floor rests on the trumeau 23.

[0060] This floor system 20 with prefabricated finished floor elements 1, associated with prefabricated posts 21 and piers 23, makes it possible to produce the load-bearing structure of a building without pouring construction material on site, except for the keying material MC, the quantity of which is strictly limited to the junctions previously described. This floor system 20 necessarily involves a reduction in the carbon footprint, a restricted workforce on site, a saving of material and time, an optimized overall construction cost, while offering an ecologically sustainable solution.

[0061] In a second embodiment of the invention, the floor element 1' with reference to figures 13 to 15 does not have a lower layer 13, and has ribs 8, 9 in the two XY directions with a section 7 to 20 cm wide, spaced approximately 50 cm to 100 cm apart depending on the directions by said lightening blocks 5, and an upper layer 14 of 4 to 10 cm, all in an MS structural material, such as ordinary concrete and preferably low carbon footprint concrete. The values ​​indicated in this example are of course not limiting.

[0062] The casting of the MS structural material is carried out in two passes: - a first pass: partial casting of the ribs 8, 9 between said support blocks 5 to create the formwork spoiler 12, and - a second pass: pouring of the remaining part of ribs 8, 9 and of the upper layer 14. Prior to the first pass, support blocks 5, possibly made of wood aggregate concrete, are positioned on the bottom of the formwork bench. In this embodiment, the support blocks 5 partly form the lower face 2 of the floor element 1, the formwork spoiler 12 is cast with the ribs 8, 9, as schematically illustrated in Figures 14 and 15, and the reinforcements 6, 7 of the lower layer 10 are arranged only between the support blocks 5. The mechanical continuity in the lower part of the floor 1 is therefore achieved by the reinforcements 6, 7 positioned only at the level of the ribs 8, 9. In this example, the projecting parts of the reinforcements 6, 7 of the upper layer 11 are straight while that those of the reinforcements 6, 7 of the lower layer 10 are curved in an L shape towards the upper layer 11. This example illustrates the possibility of combining different shapes of reinforcements pending in the junction zone ZJ.

[0063] This floor system 20 also makes it easy to provide for the passage of technical networks in the thickness of said floor. Figures 16 to 18 show how to insert a network of passages in the floor 20, without weakening the ribs 8, 9 of the floor elements 1. For this purpose, passage sleeves 17 are put in place between the support blocks 5, before pouring the ribs 8, 9 and the upper layer 14. These passage sleeves 17 are made of compression-resistant materials, such as BFUHP type concrete, steel, etc. The support blocks 5 concerned are machined or cut beforehand to form the passages and may include grooves 18, perforations 19, or any similar recess depending on the needs. The passage sleeves 17 ensure the continuity of the passage network between the lighting blocks 5.Any other means of creating a network of passages in the floor 20, both in the horizontal plane XY and in the vertical axis Z, may be suitable.

[0064] Figures 19 and 20 further illustrate an alternative embodiment of the floor element 1 ' ' designed to further reduce the quantity of keying material MC required for the connection between adjacent floor elements 1” . For this purpose, the floor element 1 ' ' comprises, in the extension of its lower face 2, a half-formwork spoiler 12' on at least two of its sides, and in the example shown on its four sides. It also comprises recesses called U-shaped pockets 24, formed in at least two of its edges 4, and in the example shown in its four edges 4, to delimit enlarged junction zones ZJ. The pockets 24 are arranged in the extension of the ribs 8 and 9 and comprise the projecting parts of the reinforcements 6 and 7. The projecting parts of the reinforcements 6 and 7 have in the example shown a closed loop shape in the vertical direction.The edges 4 of the floor element 1” therefore have a crenellated shape, alternating pockets 24 and solid intervals 25. The solid intervals 25 extend substantially to near the end of the formwork half-beaks 12 and are terminated by a tapered shape to delimit narrow junction zones ZJ. At the edge of the floor, the floor elements 1” may also include an integrated chain, consisting of solid concrete surrounding peripheral reinforcements to the floor (not shown).

[0065] When the 1” floor elements are juxtaposed two by two, they are automatically spaced apart from each other by the half-formwork beaks 12 forming a spacer and belonging to two adjacent 1” floor elements ([Fig.20]). Reinforcing cages 26 are added in the pockets 24 to link the parts projections of the reinforcements 6, 7 between them of the two adjacent 1” floor elements, during the casting of the keying material MC. The 1” floor elements delimit between them junction zones ZI whose width is not constant unlike the previous examples, since they comprise an alternation of narrow junction zones ZI between two full intervals 25, and widened junction zones ZI between two pockets 24 of two adjacent 1” floor elements. The junction zones ZI obtained in this variant embodiment therefore require overall a reduced volume of keying material MC compared to the necessary volume of the junction zones ZI of the previous examples. This embodiment makes it possible to significantly reduce the volume of the keying material MC necessary to ensure the connection and mechanical continuity between the adjacent 1” floor elements.It is then possible to favor very high performance concretes or microconcretes (BTHP) with or without reinforcing fibers, or even ultra high performance fiber-reinforced concretes or microconcretes (BFUHP) which are more expensive.

[0066] The present invention is of course not limited to the embodiments described but extends to any modification and variant obvious to a person skilled in the art within the limits of the appended claims. Furthermore, the technical characteristics of the different embodiments and variants mentioned above may be, in whole or in some cases, combined with each other.

Claims

Claims

1. Prefabricated finished floor element (1, 1', 1”), consisting of a panel made of a structural material (MS), defined by a plane (XY), a width, a length, a thickness, a lower face (2), an upper face (3), and edges (4) which connect the lower and upper faces, said floor element (1, 1', 1”) comprising in its thickness lightening blocks (5) and reinforcements (6, 7), as well as a network of ribs (8, 9) and at least one upper layer (14) made of said structural material (MS), characterized in that said lightening blocks (5) are made of solid blocks having a density lower than that of said structural material (MS) and have a width and a length less than the width and the length of said floor element (1, 1', 1”), in that said lightening blocks (5) are arranged relative to each other in the plane (XY) of said floor element (1, 1', 1”),by means of a predefined interval (I), so as to define between them said network of ribs (8, 9) made of said structural material (MS), said ribs (8, 9) extending in two directions (X, Y) intersecting said plane to bear in said two directions, and in that said reinforcements (6, 7) extend in the two intersecting directions (X, Y) and project from the edges (4) of said floor element (1, 1', 1”) to constitute waiting reinforcements and ensure mechanical continuity with adjacent floor elements (1, 1', 1”) when they are juxtaposed to manufacture a floor (20).,

2. Floor element according to claim 1, characterized in that the ribs (8, 9) forming said network are perpendicular to each other.

3. Floor element according to any one of the preceding claims, characterized in that said lightening blocks (5) have a thickness less than the thickness of said floor element (1, 1', 1”), and are positioned so that they are flush with the lower face (2) of said floor element (1, 1', 1”), or that they are completely embedded in the thickness of said floor element (1, 1', 1”).

4. Floor element according to claim 3, characterized in that said reinforcements (6, 7) are arranged in at least two layers (10, 11) parallel to said plane (XY), including a lower layer (10) and an upper layer (11), and in that said lower layer (10) is located between said lightening blocks (5) or below said lightening blocks (5) in a lower layer (13) made of said structural material (MS), and said upper layer (11) is located between said lightening blocks (5) or above said lightening blocks (5) in said upper layer (14).

5. Floor element according to claim 4, characterized in that said plies (10, 11) comprise reinforcements (6, 7) extending in at least two directions (X, Y) intersecting said plane, and in that the reinforcements (6, 7) of the two plies (10, 11) project from the edges (4) of said floor element to ensure mechanical continuity with adjacent floor elements (1, 1', 1”) when they are juxtaposed to manufacture a floor (20).

6. Floor element according to any one of the preceding claims, characterized in that said floor element (1, 1', 1”) comprises a formwork spoiler (12, 12') extending the lower face (2) of said floor element (1, 1'), on at least one of said edges (4), to create junction zones (ZJ) between adjacent floor elements (1, 1', 1”) when they are juxtaposed to manufacture a floor (20).

7. Floor element according to any one of the preceding claims, characterized in that said floor element (1”) comprises pockets (24) in said edges (4), to create widened junction zones (ZJ) alternating with narrow junction zones (ZJ) between adjacent floor elements (1”) when they are juxtaposed to make a floor (20).

8. Floor element according to any one of the preceding claims, characterized in that said reinforcements (6, 7) are made up of rigid bars, the projecting part of which is straight, curved into a hook, provided with an anchoring head or in a closed loop, and / or flexible cables, the projecting part of which forms a closed or open loop.

9. Floor element according to any one of the preceding claims, characterized in that said floor element (1, 1', 1”) comprises at least one sleeve (16), which passes perpendicularly through said floor element (1, 1', 1”), to delimit a reservation intended to receive at least one bar reinforcement (22) at the right of a load-bearing element (21, 23) of a construction.

10. Floor element according to claim 9, characterized in that said floor element (1, 1', 1”) comprises around said sheath (16) a solid support zone (ZP) of structural material (MS), without a lightening block.

11. Floor element according to any one of claims 9 and 10, characterized in that the ribs (8, 9) have a variable width, preferably increasing in the direction of said sheath (16).

12. Floor element according to any one of the preceding claims, characterized in that said floor element (1, 1', 1”) comprises at least one passage intended to receive a duct or a technical conduit, said passage being produced by a groove (18) and / or a perforation (19) provided in said lightening blocks (5) and by a passage sleeve (17) in the ribs (8, 9) between the adjacent lightening blocks (5) concerned.

13. A method of manufacturing a floor (20) from prefabricated finished floor elements (1, 1', 1”) according to any one of the preceding claims, characterized in that the steps of said method consist of: - juxtaposing floor elements (1, 1', 1”) on load-bearing elements (21, 23) of a construction to form the surface of the floor (20) to be manufactured, said floor elements (1, 1', 1”) being separated from each other by junction zones (ZJ) comprising the projecting parts of said reinforcements (6, 7), - interlocking said projecting parts of the reinforcements (6, 7) of the adjacent floor elements (1, 1', 1”) in said junction zones (ZJ), and - pouring a keying material (MC) only in said junction zones (ZJ) to seal said floor elements (1, 1', 1”) to each other and to said load-bearing elements (21, 23) of the construction to complete said floor (20),without a compression slab cast on site, said floor bearing in two intersecting directions (XY).,

14. Method according to claim 13, characterized in that said junction zones (ZJ) are delimited by formwork spoilers (12, 12') integrated into said floor elements (1, 1', 1”).

15. Method according to any one of claims 13 and 14, characterized in that said junction zones (ZJ) comprise an alternation of widened junction zones (ZJ) and narrow junction zones (ZJ), obtained by pockets (24) provided in the edges (4) of said floor elements (1”).

16. Method according to claim 13, characterized in that it consists of pouring a keying material (MC) having a very high compressive strength in said junction zones (ZJ), said material being chosen from the group comprising high-performance concretes or microconcretes (BHP), very high-performance concretes or microconcretes (BTHP) with or without reinforcing fibers, ultra-high-performance fiber-reinforced concretes or microconcretes (BFUHP).

17. Method according to claim 16, characterized in that it consists of using microconcretes, the aggregates of which have a size less than or equal to 10 mm.

18. Floor (20) obtained by the manufacturing method according to any one of claims 13 to 17, characterized in that it comprises floor elements (1, 1', 1”) according to any one of claims 1 to 12, said floor elements (1, 1', 1”) being juxtaposed to form the surface of said floor (20), and separated from each other by junction zones (ZJ) comprising the projecting parts of said reinforcements (6, 7), in that said projecting parts of the reinforcements (6, 7) of said adjacent floor elements (1, 1', 1”) are nested together in said junction zones (ZJ), and in that only said junction zones (ZJ) are sealed by a keying material (MC) cast in place to seal said floor elements (1, 1', 1”) between them and to said load-bearing elements of the construction to complete said floor (20), without a compression slab cast on site,said floor bearing in two intersecting directions (XY).,

19. Floor according to claim 18, characterized in that said junction zones (ZJ) are delimited by formwork spoilers (12, 12') integrated into said floor elements (1, 1', 1”).

20. Floor according to any one of claims 18 and 19, characterized in that said junction zones (ZJ) comprise an alternation of widened junction zones (ZJ) and narrow junction zones (ZJ), obtained by pockets (24) provided in the edges (4) of said floor elements (1”).

21. Floor according to one of claims 18 to 20, characterized in that said keying material (MC) has a very high compressive strength and is chosen from the group comprising high-performance concretes or microconcretes (BHP), very high-performance concretes or microconcretes (BTHP), and ultra-high-performance fiber-reinforced concretes or microconcretes (BFUHP)

22. Floor according to claim 21, characterized in that the microconcretes have aggregates having a size less than or equal to 10 mm.

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