METHOD FOR MANUFACTURING A REINFORCED SLAB

Abstract

The invention relates to a method for manufacturing an industrial floor comprising at least one concrete slab, which has a reinforced upper surface, comprising the steps: a) preparing the area to be covered with a concrete slab, b) pouring fluidized concrete onto the area to be covered, c) vibrating the surface of the concrete layer, d) leveling the concrete layer, e) applying an aqueous curing compound to the concrete layer as the process progresses, f) grinding the concrete slab thus obtained and removing by vacuum the layer of sand and fine aggregates formed on the surface of said slab by capillary action during the drying of the concrete, g) applying a liquid hardening compound to the concrete slab, and h) polishing the concrete slab. Figure for the abstract: [Fig 2]

Description

Title of the invention: METHOD FOR MANUFACTURING A REINFORCED SLAB technical field

[0001] The present invention relates to the general technical field of industrial flooring construction. Industrial floors are often subjected to significant mechanical and chemical stresses. They are generally constructed with one or more concrete slabs. Therefore, manufacturing concrete slabs that are more resistant, particularly to wear and abrasion, is a recurring problem.

[0002] In addition, an improvement in the aesthetic appearance of industrial floors may also be sought.

[0003] The invention relates more particularly to a method for manufacturing a concrete slab to create an industrial floor.

[0004] The manufacture of a concrete slab is complex because it involves chemical reactions with water and cement. To prevent the concrete, poured for example into slabs or screeds with a large evaporation surface, from drying out, it is necessary to apply a curing compound to the concrete slab using a known method. This curing compound, for example in aqueous or solvent phase, protects the concrete from drying out by limiting the evaporation of the water contained in the concrete and consequently reduces the risk of cracking.

[0005] Climatic conditions, in particular temperature, wind and humidity, are therefore parameters which influence the chemical reactions during the setting (hardening) of concrete, especially in the first hours following the operation of pouring a concrete slab. Previous technique

[0006] To produce an industrial floor, a process is known for manufacturing a concrete slab comprising a reinforced upper floor, consisting of preparing the area to be covered with a concrete slab, pouring fluidized concrete onto the area to be covered, applying a vibration to the surface of the concrete layer and achieving the planimetry of the concrete layer.

[0007] The known manufacturing process then consists of applying a surface hardener or wearing course to the concrete slab before the concrete has fully set. This layer is approximately 3 mm to 4 mm thick and consists of a mixture of cement and fine aggregate. The concrete slab is then troweled and smoothed before to apply a curing product, for example in aqueous phase. Such a process is not without its drawbacks.

[0008] Indeed, this surface hardener applied to the concrete slab is subject to delamination or delamination. It is very difficult to obtain an optimal consistency to ensure perfect adhesion between the concrete and the constituent layer of the surface hardener.

[0009] Furthermore, during the setting of the concrete, the sand and fine aggregate rise with the water by capillary action in this surface layer. This layer then becomes friable and very poorly resistant to wear and abrasion.

[0010] It should also be noted that the known process, in particular the application of the surface hardener, troweling and smoothing operations, requires a significant workforce and substantially increases the time required to manufacture the concrete slab, also involving night work during cold periods.

[0011] In a global construction context, regulations require a drastic reduction in the amount of carbon needed for building construction. The wear layers and concrete used in construction techniques will therefore need to be significantly modified.

[0012] Regulations require a significant reduction in the CO2 content of cements and concretes, which will make them less and less suitable for industrial flooring work, increase the risk of delamination or delamination and lengthen the working times required to produce slabs.

[0013] Furthermore, working with wear layers generates a significant risk related to working with volatile cement particles. Presentation of the invention

[0014] The object of the invention therefore aims to overcome the drawbacks of the prior art by proposing a new method for manufacturing a reinforced concrete slab, having a surface with improved or equivalent resistance to wear and abrasion.

[0015] Another object of the invention aims to provide an optimized concrete slab.

[0016] Another object of the invention aims to eliminate the risk of accidents induced by the application of the wear layers.

[0017] Another object of the invention aims to enable working with new generation and low carbon materials.

[0018] The objects assigned to the invention are achieved using a method for manufacturing an industrial floor comprising at least one concrete slab, which has a reinforced upper surface, comprising the successive steps: - a) prepare the area to be covered with a concrete slab, - b) pour fluidized concrete onto the area to be covered, - c) vibrate the surface of the concrete layer, - d) level the concrete layer, - el) apply a water-based curing compound to the concrete layer as work progresses. -e2) allow the layer of concrete covered with the curing compound to dry, - f) sand the concrete slab thus obtained and remove by vacuuming the layer of sand and fine aggregates formed on the surface of said slab by capillary action during its concrete drying, - h) polish the concrete slab, and - g) apply a liquid hardening product to the concrete slab.

[0019] The objects assigned to the invention are also achieved using a method for manufacturing an industrial floor comprising at least one concrete slab, which has a reinforced upper face, comprising the successive steps: - a) prepare the area to be covered with a concrete slab, - b) pour fluidized concrete onto the area to be covered, - c) apply a vibration to the surface of the concrete layer, - d) level the concrete layer, - e1) apply an aqueous phase curing compound to the concrete layer as the process progresses, - e2) allow the concrete layer covered with the curing compound to dry, - f) grind the concrete slab thus obtained and remove by vacuum the layer of sand and fine aggregates formed on the surface of said slab by capillary action during the drying of the concrete, - g) apply a liquid hardening compound to the concrete slab, and - h) polish the hardened concrete slab obtained under g).

[0020] According to one embodiment, the process consists of using sodium silicate or a product containing sodium silicate as a hardening agent.

[0021] According to one embodiment, the process consists of using potassium silicate or a product containing potassium silicate as a hardening agent.

[0022] According to one example of implementation, the process consists of using concrete reinforced with metal fibers.

[0023] According to an example of implementation of the process, during step a), metal mesh and construction steel are placed at least locally in the area to be covered.

[0024] The objects assigned to the invention are also reached using a concrete slab for industrial flooring, having an upper face with reinforced resistance to wear and abrasion, characterized in that it is manufactured according to a process as presented above.

[0025] The manufacturing process according to the invention has the enormous advantage, contrary to expectations, in a very large number of cases, of improving the wear and abrasion resistance of the concrete slab, while eliminating the wear layer.

[0026] The manufacturing process according to the invention allows the advantageous use of a liquid hardening product commonly used for aesthetic or decorative purposes, to help form a very resistant and durable surface of the concrete slab, while also improving its care and maintenance.

[0027] Another advantage obtained by the manufacturing process according to the invention lies in the elimination of troweling and smoothing operations. This results in time savings in the production of the slab with less labor.

[0028] The process according to the invention has the advantage of providing a raw concrete slab on which other personnel can walk on the industrial site. The slab is then sanded to remove the film formed by the curing compound, followed by the application of the liquid hardener and final polishing. It is then possible to provide a concrete slab with an optimal level of finish, and in particular, showing no signs of traffic or use before delivery to the customer. Brief description of the figures

[0029] Other features and advantages of the present invention will become more apparent upon reading the following description, made with reference to the accompanying drawings, given by way of non-limiting examples, in which:

[0030] [Fig-1] [Fig.1] is a schematic illustration of a cross-section of an example slab concrete obtained using a prior art manufacturing process,

[0031] [Fig.2] [Fig.2] is a schematic illustration of a cross-section of an example slab in concrete obtained using a manufacturing process according to the invention, and

[0032] [Fig.3] Fig.3 illustrates, in top view, an example of a concrete slab obtained with the manufacturing process according to the invention. Detailed description of the invention

[0033] Structurally and functionally identical or similar elements, present on several distinct figures, are assigned the same numeric or alphanumeric reference.

[0034] The invention relates to a method for manufacturing concrete slabs for industrial flooring. An example of implementing the manufacturing method according to the invention is described below.

[0035] The method according to the invention comprises a step a) relating to the preparation of the area on and in which the concrete slab or a set of juxtaposed slabs is to extend. This preparation step is known as such and will therefore only be described in general terms.

[0036] This preparation step a) includes various standard operations, including the installation of a micro-perforated polyethylene sheet under the slab, the installation of construction joints to stop the panels and openings for pouring and doorways, the installation of steel reinforcement, the placement of wire mesh and structural steel at least locally, the installation of decoupling foam, the installation of thin polyethylene sheeting for protection over adjacent structures, and the installation of various metalwork accessories to protect the sharp edges of the concrete, which could crumble during subsequent use of the structure. These operations are known and commonly carried out on construction sites and will therefore not be described further in this document.

[0037] The manufacturing process according to the invention further comprises a step b) consisting of pouring fluidized concrete onto the area to be covered. This step relates to the placement of the concrete, for example, fluidized concrete directly on site or not, and to the pouring, either directly or via a concrete pump. According to one example of implementing the process, concrete reinforced with metal fibers is used.

[0038] The manufacturing process according to the invention then comprises a step c) consisting of applying a vibration to the surface of the concrete layer, using a vibrating screed and a manual vibrator, for example at joints or doorways. These steps can be carried out using mechanized means, for example, the technology known as "laser screed".

[0039] Next, in step d), the concrete layer is leveled using a cross-screed. These operations in steps c) and d) are also known and therefore not described further herein.

[0040] The manufacturing process then includes a step el) according to which an aqueous phase curing product is applied to the concrete layer as the process progresses.

[0041] The next step e2) consists of allowing the layer of concrete coated with the curing compound to dry. For example, curing compounds are marketed under the names CURESOL or ECOCURE.

[0042] For example, after a period of at least ten days and preferably about 15 days, the manufacturing process then includes a step f) sanding the concrete slab thus obtained and removing the layer of sand and aggregates by suction Fine particles form on the surface of the slab through capillary action during the concrete drying process. This sanding operation is carried out, for example, with a three-headed sander.

[0043] The manufacturing process then includes a step g) in which a liquid hardening product is applied to the concrete slab.

[0044] By way of example, sodium silicate or a product containing sodium silicate is used as a hardening agent. The hardening agent is, for example, a mixture of sodium silicate and water.

[0045] According to another embodiment of the process, potassium silicate or a product containing potassium silicate is used as the hardening agent. The hardening agent is, for example, a mixture of potassium silicate and water.

[0046] The manufacturing process then includes a step h) consisting of polishing the concrete slab. The polishing operation is carried out, for example, using a three-head grinder. The polishing step makes it possible to polish the concrete with finer grits, reducing the pores of the concrete and thus increasing ease of maintenance. The polishing operation is then carried out on a previously hardened slab.

[0047] The drying time of the liquid hardener is generally between twelve and twenty-four hours. For example, the products cure(K) or cure(P) marketed under the HUSQVARNA brand can be cited as liquid hardeners.

[0048] According to another embodiment, the manufacturing process is modified by successively carrying out steps a), b), c), d), e1), e2), f), h) and g). In this other manufacturing process, step g) is carried out in which a liquid hardening product is applied to the concrete slab after step h) which consists of polishing the concrete slab.

[0049] In the context of the implementation of the manufacturing process, preferably all types of concrete containing different types of aggregates and cements are used.

[0050] Figure 1 is a schematic illustration of a cross-section of an example of a concrete slab 1 obtained using a prior art manufacturing process. Such a process consists of producing the concrete slab 1 incorporating a surface hardener in the form of a surface layer 2. This surface layer 2 is formed by the additional deposition of a mixture of cement and fine aggregates and has a thickness of approximately 3 mm to 4 mm. A surface hardener product is, for example, called Achrochape.

[0051] Figure 2 is a schematic illustration of a cross-section of an example of a concrete slab 3 obtained using a manufacturing process according to the invention. The concrete slab 3 is devoid of any additional surface layer, but merely reinforced by a film of a liquid hardening product (not visible in the figures), penetrating and reacting on the surface over several millimeters with the concrete. The concrete slab 3 comprises aggregates 4 dispersed in a cement matrix 5. The aggregates 4 are flush with the surface of the concrete slab 3 and provide said concrete slab 3 with very high resistance to wear and abrasion due to their intrinsic and natural physico-chemical properties.

[0052] Indeed, the contact surface 3a of the concrete slab 3 obtained according to the process according to the invention is thus composed of approximately 87% natural elements, such as aggregates 4, and approximately 13% cementitious surface products 5a. By way of comparison, a concrete slab obtained by a prior art process generally has a contact surface composed of 70% cementitious products and 30% aggregates.

[0053] The surface resistance of the concrete slab 3 obtained by the manufacturing process according to the invention is thus ensured to nearly 87% by the physico-chemical characteristics of the aggregates 4. The durability of such a concrete slab 3 is therefore substantially extended.

[0054] This hardening product has a mechanical function insofar as it increases the resistance to abrasion and chemical attack of the visible parts of cement on the surface of the concrete slab 3.

[0055] Fig. 3 illustrates, in top view, an example of a concrete slab 3 obtained with the manufacturing process according to the invention.

[0056] According to another step in the manufacture of the concrete slabs 3, the latter are sawn using known tools such as a floor saw or a cutting disc.

[0057] It is evident that the present description is not limited to the explicitly described examples, but also includes other embodiments. Thus, a described technical feature may be replaced by an equivalent technical feature without departing from the scope of the present invention as defined by the claims, and a described implementation step may be replaced by an equivalent step without departing from the scope of the present invention as defined by the claims.

Claims

Demands

1. A method for manufacturing an industrial floor comprising at least one concrete slab (3), which has a reinforced upper face, comprising the successive steps: - a) preparing the area to be covered with a concrete slab (3), - b) pouring fluidized concrete onto the area to be covered, - c) applying a vibration to the surface of the concrete layer, - d) leveling the concrete layer, - e1) applying an aqueous phase curing compound to the concrete layer as the process progresses, - e2) allowing the concrete layer covered with the curing compound to dry, - f) grinding the concrete slab (3) thus obtained and removing by vacuuming the layer of sand and fine aggregates formed on the surface of said slab by capillary action during the drying of the concrete, - h) polishing the concrete slab (3), and - g) applying a liquid hardening compound to the concrete slab (3).

2. A method for manufacturing an industrial floor comprising at least one concrete slab (3), which has a reinforced upper face, comprising the successive steps: - a) preparing the area to be covered with a concrete slab (3), - b) pouring fluidized concrete onto the area to be covered, - c) applying a surface vibration to the concrete layer, - d) leveling the concrete layer, - e1) applying an aqueous phase curing compound to the concrete layer as the process progresses, - e2) allowing the concrete layer covered with the curing compound to dry, - f) grinding the concrete slab (3) thus obtained and removing by vacuuming the layer of sand and fine aggregates formed on the surface of said slab by capillary action during the drying of the concrete, - g) applying a liquid hardening compound to the concrete slab (3), and - h) polishing the hardened concrete slab (3) obtained under g).

3. A method according to claim 1 or 2, characterized in that it consists of using sodium silicate or a product containing sodium silicate as a hardening agent.

4. A method according to claim 1 or 2, characterized in that it consists of using potassium silicate or a product containing potassium silicate as a hardening agent.

5. A method according to any one of claims 1 to 4, characterized in that it consists of using a concrete reinforced with metal fibers.

6. A method according to any one of claims 1 to 5, characterized in that it consists, during step a), of placing at least locally in the area to be covered, metal mesh and construction steel.

7. Concrete slab (3) for industrial flooring, having an upper face having reinforced resistance to wear and abrasion, characterized in that it is manufactured according to the process according to any one of claims 1 to 6.

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