Prefabricated Floor Element Layout Without On-Site Screed
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Solution Overview
Problem
Existing methods for producing prefabricated buildings are complex and costly due to the need for on-site application of screed on load-bearing reinforced concrete slabs, which is time-consuming and requires high effort.
Innovation Solution
Prefabricating floor elements with a smooth surface in the factory, allowing them to be turned and applied to the substructure with the smooth side facing away, eliminating the need for on-site screed and enabling direct application of floor coverings, while incorporating reinforcement and insulation for increased strength and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screed is applied to load-bearing reinforced concrete slabs on the construction site, then the floor structure is completed, but the process becomes complex and time-consuming
Solution Approach 1:
The floor element is prefabricated at the factory with a smooth lower surface already prepared, eliminating the need for on-site screed application. The floor element is produced in advance with all necessary surfaces prepared for its final position, including the smooth lower surface that will contact the substructure and the upper surface for floor covering application.
Solution Approach 2:
The floor element combines multiple functions into a single component: it serves as the load-bearing structure, the screed replacement with its smooth lower surface, and the base for floor covering application. By integrating these functions into one prefabricated element, the invention eliminates the need for separate screed application and reduces the number of construction steps.
2Ease of operation
If multiple separate components are used for floor construction, then flexibility is maintained, but assembly effort increases
Solution Approach 1:
The floor element integrates the load-bearing function, the screed function, and the insulation function into a single prefabricated component. This merging of functions reduces the number of separate components that need to be assembled on-site, thereby reducing assembly effort while maintaining the necessary structural complexity through intelligent design.
Solution Approach 2:
The floor element serves multiple purposes simultaneously: it provides structural support, replaces the screed with its smooth lower surface, provides insulation through integrated insulating elements, and serves as the base for floor coverings. This multi-functionality reduces the number of components needed while maintaining the complexity of functions required for a complete floor system.
Data Source
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AI summary
The invention relates to a method for producing a prefabricated building (10), in which formwork (24) for prefabricating floor elements (20, 40, 50, 60, 70, 80, 84) is provided, with a surface (30) a base (28) of the formwork (24) onto which the concrete of the base element (20, 40, 50, 60, 70, 80, 84) is poured during prefabrication is essentially smooth. After the concrete has hardened, the floor element (20, 40, 50, 60, 70, 80, 84) is removed from the formwork (24) and placed on a supporting substructure (18) of a floor (12, 14, 16) of the building (10) applied that the lower smooth side (32) of the floor element (20, 40, 50, 60, 70, 80, 84), which contacted the floor (28) of the formwork (24) during prefabrication, the substructure ( 18) faces away and that the upper side (34) lying opposite the lower smooth side (30) rests on the substructure (18).