US 200903 01009 A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2009/0301009 A1
Falk et al. (43) Pub. Date: Dec. 10, 2009
(54) CONCRETE FLOOR DEVICE Publication Classification
(76) Inventors: Jörgen Falk, Malmo (SE); Thomas (51) Int. Cl.
Johansson, Solna (SE); Markus
Peterson, Solna (SE); Peter
Et, : ( .01)
CR
Svenmar, Lund (SE) (52) U.S. C. .. 52/220.1; 52/250; 52/745.05:52/742.14
Correspondence Address:
HARNESS, DICKEY & PIERCE, P.L.C. (57) ABSTRACT
P.O. BOX8910 A concrete floor assembly is disclosed including a Subfloor
RESTON, VA 20195 (US) element with a floor side and a ground/ceiling side, and a top
casting layer. In at least one embodiment, the Subfloor ele
(21) Appl. No.: 12/086,062 ment includes a concrete portion on the floor side, which
(22) PCT Filed: Dec. 5, 2006 concrete portion has a bottom casting Surface with a Surface
e a9 roughness. The top casting layer includes a casting composi
(86). PCT No.: PCT/SE2006/OO1385 tion, which includes a self-compacting concrete and a shrink
age reducing admixture. The top casting layer is cast on the
S371 (c)(1), floor side of the subfloor element so that at least a portion of
(2), (4) Date: Sep. 4, 2008 the bottom casting Surface is covered by the top casting layer,
the bottom casting Surface having Such Surface roughness that
(30) Foreign Application Priority Data the top casting layer adheres to the bottom casting Surface. A
method of providing Such a concrete floor assembly is also
Dec. 6, 2005 (SE) .................................... 0502666-1 disclosed, as well as a floor assembly.

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Patent Application Publication Dec. 10, 2009 Sheet 2 of 2 US 2009/030.1009 A1
US 2009/03 01009 A1
CONCRETE FLOOR DEVICE
TECHNICAL FIELD OF THE INVENTION
0001. The present invention relates to a concrete floor
device or assembly and to a method of providing such a
concrete floor element as well as a method of providing a floor
assembly.
TECHNICAL BACKGROUND OF THE
INVENTION
0002. A floor structure is a substantially horizontal, struc
tural element which separates different storeys of a building,
or the ground floor of the house and the ground. In addition to
a structural element, the so-called structural floor, a floor
structure also includes floor and ceiling. The structural flooris
part of the structural framework of a building and its main
function is to carry the load of the storey, such as the floor, the
ceiling, interior walls and fittings, and to transfer the weight
of this load to structural walls and columns.
0003. A floor structure must satisfy a number of require
ments. It must have the capacity to carry the load of the storey
and have sufficient stiffness, so that the deflections (the resil
ience) are minimised and do not damage, for instance, the
interior walls and fittings. A floor structure should further
more satisfy specific requirements regarding fire resistance
and acoustic and thermal insulation. Sometimes it should also
have the capacity to include conduits or electrical installa
tions.
0004. A prior-art floor structure comprises prefabricated
structural concrete elements with longitudinal holes,
so-called hollow core slabs. Several hollow core slabs can be
joined to form a hollow core floor. These hollow core slabs
have increased stiffness and strength by being provided with
pretensioned reinforcement which gives the hollow core slabs
a curved shape. Due to this curvature, it is usually not possible
to lay a floor directly on top of them.
0005. There are several systems on the market for provid
ing a flat floor on top of a curved hollow core floor. According
to one system, a plurality of pins are first attached at equal
distance over the hollow core floor. Then carefully levelled
joists are attached to the pins, so that the joists form a hori
Zontal base for a parquet floor or a subfloor in the form of, for
instance, chipboard. The mounting height of the joists can be
selected so as to leave enough room for electric or water
conduits under the floor. One disadvantage of this system is
that it requires much work and is time-consuming. In addi
tion, it is difficult to achieve high precision, which may result
in a resilient or inclined floor.
0006 Another system for providing a flat base for floor
laying is application of so-called screed to the hollow core
floor. One disadvantage of the use of screed is that it is
expensive. Thus, it is not desirable to apply screed in layers
that are thick enough for the embedment of electric or water
conduits. In addition, it is difficult to predict how well the
screed will dry out and how long it will take for the screed to
dry when applied in such thick layers. If the base is not dry
enough when the floor is laid (for instance a parquet or a
plastic carpet), the floor can be damaged by the moisture or
mildew problems can arise.
0007 Experimental studies have also been carried out
using ordinary concrete instead of Screed. They have shown
that if ordinary concrete is cast on a prefabricated hollow core
slab in layers thinner than 100 mm, problems arise in the
Dec. 10, 2009
adhering of the concrete to the base both centrally and along
the edges due to loss of bond and edge lifting, respectively.
This is above all due to the fact that thin layers have a high
moisture gradient, which causes the Surface layer to bend. In
most cases, it is not possible to use concrete layers with
sufficient thickness to avoid these problems, since this
requires Such large Volumes that also the use of ordinary
concrete would be too expensive. It is also a problem that
thick concrete layers need alongtime to dry out, which delays
the construction process, thus also making it more expensive.
SUMMARY OF THE INVENTION
0008. Therefore object of the present invention is to pro
vide a concrete floor assembly, which makes it possible to lay
a flat floor in a cost-effective manner and at a desired vertical
level, and to provide a method of making Such a concrete floor
assembly and a method of making a floor assembly.
0009. According to the invention, these objects are
achieved by a concrete floor assembly and methods according
to claims 1, 20 and 34.
0010. The concrete floor assembly according to the inven
tion comprises a subfloor element with a floor side and a
ground/ceiling side, and a top casting layer. The Subfloor
element comprises a concrete portion on the floor side and the
concrete portion has a bottom casting Surface with a Surface
roughness. The top casting layer comprises a casting compo
sition, which comprises a self-compacting concrete and a
shrinkage reducing admixture. The top casting layer is cast on
the floor side of the subfloor element so that at least a portion
of the bottom casting Surface is covered by the top casting
layer, the bottom casting Surface having Such Surface rough
ness that the top casting layer adheres to the bottom casting
Surface.
0011. Owing to a sufficient surface roughness of the bot
tom casting Surface of the Subfloor element, good adhesion is
obtained. Thereby, the invention allows the use of a casting
composition based on a self-compacting concrete provided it
contains a shrinkage reducing admixture. Sucha casting com
position is much more economical than prior-art Screed. Due
to the good adhesion to the subfloor element and the shrink
age reducing admixture, it is possible, according to the inven
tion, to cast a layer that is sufficiently thick to satisfy the
acoustic insulation requirements and the requirements
regarding embedment of conduits, but not so thick that unnec
essary amounts of material are consumed. Furthermore, the
casting composition, which according to the invention is
based on a self-compacting concrete, advantageously
requires little labour input since it does not, as ordinary con
crete, have to be vibrated, but spreads itself substantially
horizontally. According to the invention, a flat upper Surface
is thus provided, also without the use of screed. Owing to a
cost-effective casting composition and a rational application
method, the concrete floor assembly according to the inven
tion is thus much more cost-effective than conventional alter
natives.
0012. The concrete floor assembly according to the inven
tion is intended to be part of a floor structure for construction
works, for instance buildings, such as dwelling houses, office
or industrial premises, or structures such as sports centres,
underground cavities or silo buildings.
0013 The concrete floor assembly according to the inven
tion can be part of or constitute the entire structural floor of
the floor structure. It can also be a non-structural part of the
floor structure.
US 2009/03 01009 A1
0014. According to the invention, a concrete floor assem
bly is thus a portion of a floor structure, which portion forms
a base which is suitable for floor laying or which itself can
function as a floor.
0.015 The term subfloor element here means an element
cast on the spot or a prefabricated element. The subfloor
element can extend over the entire floor of a room or over the
entire floor of a storey, but it can also be a slab with limited
extension. The subfloor element has a floor side and a ground/
ceiling side. The floor side is the side which in normal use is
part of the base of a floor. The ground/ceiling side is the side
which in normal use is facing the ceiling of a lower storey or
the ground if the subfloor element belongs to the ground floor.
0016. According to an embodiment of the invention, the
subfloor element is a structural prefabricated hollow core
slab. Several such hollow core slabs can be joined together so
as to extend over an entire storey.
0017. According to an embodiment of the invention, the
subfloor element is a hollow core slab with pretensioned
reinforcement. Due to the prestress, such hollow core slabs
are usually curved, that is they have an arched longitudinal
section. By casting the top casting layer according to the
invention on the arched floor side of the hollow core slab, the
concrete floor assembly can be given a flat floor side that is
Suitable as a base for floor laying.
0.018. If the subfloor element has a curvature, or in other
words an arched cross-section, and the top casting layer is
such that the concrete floor assembly has a flat floor side, the
thickness of the top casting layer will vary over the cross
section. Its smallest thickness is where the curve of the arch is
at its maximum. Usually, such a subfloor element has its
Smallest thickness approximately at the centre and its greatest
thickness at two opposite edge sides.
0019. The subfloor element according to the invention can
be made of concrete or reinforced concrete, but it can also
comprise other materials. According to the invention, at least
a portion of the floor side of the subfloor element has a
concrete Surface of which at least a portion constitutes a
bottom casting Surface. The bottom casting Surface is
intended to interact with the casting composition.
0020. According to the invention, the bottom casting sur
face has such surface roughness that the top casting layer
adheres to the bottom casting Surface. This means that the
casting composition forms a top casting layer with desired
thickness over at least part of the bottom casting Surface of the
Subfloor element, the top casting layer adhering to the bottom
casting Surface so that the requirements of the building sector
are met, for instance, those referring to loss of bond and edge
lifting and those referring to the strength of the adhesion area
between the subfloor element and the top casting layer.
0021. According to an embodiment of the invention, the
bottom casting Surface has a Surface roughness which, when
measured according to the Swedish Standard for determina
tion of surface roughness SIS812005, is preferably S>1.5.
Reference is made to this Standard, for instance, in the Swed
ish concrete code (BBK04).
0022. According to the invention, this surface roughness
can be obtained by any suitable method. One example is to
seed the bottom casting Surface with granular material. Such
as crushed stone material. Examples of particle sizes are 2-4
mm or 4-8 mm.
0023. Another example of providing a bottom casting sur
face with a rough surface structure is, according to the inven
tion, to treat the bottom casting Surface by a surface roughing
Dec. 10, 2009
method. By this is meant any optional method that removes,
transfers and/or compacts material unevenly over the Surface
So as to make the Surface rugged or, in other words, rough.
0024. According to an embodiment of the invention, the
bottom casting Surface is brushed or combed. This can Suit
ably be performed in connection with the manufacturing of
the subfloor elements, by a brush or comb being attached to a
casting machine. In such a method, it may sometimes be
desirable to remove possible loose material originating from
the brushing/combing from the bottom casting Surface before
the casting of the top casting layer. By this means, the adhe
sion properties are further improved.
0025. According to an embodiment of the invention, the
bottom casting Surface is embossed. This can, for instance, be
achieved by a rotating cylinder or several rotating wheels
which are attached to a casting machine in connection with
the manufacturing of the subfloor elements.
0026. According to an embodiment of the invention, at
least a portion of the floor side of the subfloor element has a
concrete Surface with a bottom casting Surface which has
exposed aggregate.
0027. In this application, "exposed aggregate’ means that
Surface skin, Surface silt and fine aggregate particles have
been removed from the concrete surface so that coarse aggre
gate protrudes.
0028 Such exposed aggregate Surfaces are known to pro
vide aesthetical effects. However, according to the embodi
ment of the invention, the exposed aggregate is used to
increase the surface roughness of the surface of the subfloor
element. Increased roughness of the surface of the subfloor
element results in improved adhesion between the subfloor
element and the top casting layer, which reduces the risk of
loss of bond and edge lifting. Another positive effect is that
the upper Surface is also strengthened since loose mortar is
removed. Thus, the exposure of aggregate according to this
embodiment provides two properties which are beneficial for
the adhesion of the top casting layer to the subfloor element,
that is increased Surface roughness and strong concrete in the
joint.
0029. According to the invention, substantially the entire
floor side of the Subfloor element can have exposed aggregate
or only a portion thereof. The top casting layer can cover
substantially the entire floor side of the subfloor element or a
portion thereof, in which case at least a portion of the exposed
aggregate Surface, i.e. the bottom casting Surface, is covered.
In some embodiments, the adhesion of the top casting layer
can be sufficient even if the surface of the subfloor element
covered by the top casting layer does not in its entirety have an
exposed aggregate finish.
0030. According to an embodiment of the invention, the
concrete portion of the subfloor element has a surface with a
deep exposure of aggregate, i.e. aggregate in the concrete
Surface is exposed to such depth that the coarse aggregate
grains appear clearly. The depth can be greater than /3 of the
maximum size of the Surface aggregate.
0031. According to an embodiment of the invention, a
membrane curing compound is applied to the top casting
layer so that the after-curing proceeds under the effect of the
membrane curing compound. Membrane curing compounds
or (liquid membrane curing compounds) are compounds that
delay the drying out of the concrete during curing. The mem
brane curing compound forms a thin film over the newly cast
Surface so that usually it does not have to be moistened.
Membrane curing compounds with different chemical com
US 2009/03 01009 A1
positions, such as wax dispersions, acrylate polymers or latex
emulsions, are commercially available. Preferred membrane
curing compounds comply with the specifications laid down
in ASTMC 309, Liquid Membrane-Forming Compounds for
Curing Concrete, for instance the specifications in this docu
ment concerning maximum loss of moisture. Thanks to the
application of the membrane curing compound to the top
casting layer, the top casting layer does not dry out too
quickly during the first hours after casting, whereby plastic
shrinkage cracking in the Surface layer is advantageously
avoided.
0032. According to an embodiment of the invention, the
subfloor element is pre-moistened before the casting of the
casting composition on the Subfloor element. This advanta
geously prevents water from the casting composition from
being absorbed into the subfloor element, which would
reduce the strength of the layer of the top casting layer that is
closest to the subfloor element.
0033 According to an embodiment of the invention, a
plurality of subfloor elements are joined together to form a
subfloor unit with or without the aid of interconnecting
means. The Subfloor elements can, for instance, be joined by
grouting but the Subfloor elements can also be loosely placed
next to each other or be attached to each other or to a base.
Subsequently, the casting composition is cast so that a top
casting layer forms which extends over several subfloor ele
ments, whereby a floor assembly according to the invention is
provided. According to an embodiment, substantially the
entire floor side of the Subfloor elements has exposed aggre
gate and the top casting layer extends over Substantially the
entire subfloor unit. Owing to the self-levelling properties of
the casting composition, it is thus possible to provide a flat
base for floor laying by one single casting of a layer. In
addition, electric and/or water conduits can be embedded in
the top casting layer.
0034. In some construction projects, use is made of pre
fabricated wall elements in which windows are already
mounted. Furthermore, the construction process is some
times such that also the ceiling is applied before a method of
providing a flat base is initiated. In Such constructions, it is
possible, according to an embodiment of the invention, to seal
door openings and bushings, if any, in the wall elements, for
instance, by means of plastics So that a relatively airtight room
is obtained. Only thereafter, the top casting layer is applied.
Hereby, the moisture evaporated from the top casting layer
can be maintained in the sealed room, which delays the drying
out of the top casting layer. Owing to the slower drying-out
process, plastic shrinkage cracking in the top casting layer
can be avoided. It is often sufficient to keep the room airtight
for about 24 hours.
0035. The inventive casting composition comprises a self
compacting concrete and a shrinkage reducer. Self-compact
ing concrete is compacted homogenously under its own
weight and fills formwork without using the vibratory unit
required for ordinary concrete. This makes it possible to
obtain a rational casting process without vibrating, which is
less time-consuming and requires less manpower. The con
crete will also be self-levelling, which means that it does not
have to be coated with screed before the floor is laid, which is
a great saving in costs. Self-compacting concrete and various
types thereof are described in The European Guidelines for
Self-Compacting Concrete—Specification, Production and
Use, May 2005, issued by the Self-Compacting Concrete
Dec. 10, 2009
European Project Group, with representatives from BIBM,
CEMBUREAU, ERMCO, EFCA and EFNARC.
0036 Concrete mainly consists of mineral particles (ag
gregate) of different grain sizes which are bonded by cement
paste consisting of cement and water. A common mixing ratio
based on parts by Volume is one part water, one part cement,
two parts sand and three parts coarse aggregate. Admixtures
modifying the properties of the concrete in various ways can
also be included. In general, in the case of self-compacting
concrete, the ratio of fine aggregate (e.g. sand and gravel) is
greater, and the ratio of coarse aggregate (e.g. Stone material)
is Smaller, than in traditional concrete. It is also common to
use fine-particle material in self-compacting concrete. Such
as lime or glass filler. A common admixture in self-compact
ing concrete is commercially available water reducing agents,
so-called Superplasticisers, which can make the self-com
pacting concrete plastic and workable.
0037 According to an embodiment of the invention, the
self-compacting concrete has a slump-flow of>520 mm, pref
erably >650 mm. The measurement of slump-flow is a test to
assess the flowability of self-compacting concrete in the
absence of obstructions. It is based on the slump test
described in EN 12350-2. The result is an indication of the
filling ability of the self-compacting concrete. Slump-flow is
thus the mean diameter of the spread of fresh concrete using
a conventional slump cone. The measuring of slump-flow is
defined in Annex B.1 of The European Guidelines for Self
Compacting Concrete—Specification, Production and Use
and is Summarised below.
0.038 Prepare the cone and baseplate as described in EN
12350-2.
0039 Place the cone coincident with the 200 mm circle
on the baseplate and hold in position by standing on the
foot pieces (or use the weighted collar), ensuring that no
concrete can leak from under the cone.
0040 Fill the cone without any agitation or rodding, and
strike off surplus from top of the cone. Allow the filled
cone to stand for not more than 30 s. During this time
remove any spilled concrete from the baseplate. Ensure
the baseplate is damp all over but without any surplus
Water.
0041 Lift the cone vertically in one movement without
interfering with the flow of concrete. Without disturbing
the baseplate or the concrete, measure the largest diam
eter of the concrete flow and measure the diameter of the
flow spread at right angles to the largest diameter.
0042. The slump-flow is the mean of the two measured
diameters.
0043. Self-compacting concrete can have a very high ten
dency to shrink due to a small amount of coarse aggregate and
a large amount offine material and/or lime filler, which can be
used to make the concrete self-compacting. To reduce shrink
age and thus the risk of loss of bond and edge lifting, shrink
age reducing admixtures are used. Such shrinkage reducing
admixtures comprise, for instance, various types of alcohols.
They are Supposed to primarily reduce the Surface tension of
the pore water, whereby the shrinkage tensions in the concrete
are reduced. Shrinkage reducing admixtures are commer
cially available and a person skilled in the art can choose a
Suitable agent based on the composition of the concrete and
its shrinkage tendency, etc. A Suitable shrinkage reducing
admixture can comprise a polyalcohol, preferably 2,2-dim
ethylpropane-1,3-diol.
US 2009/03 01009 A1
0044) Lime fillers contribute to the self-compacting prop
erties of the concrete. Lime fillers have also been found to
accelerate the drying-out process due to their effect on the
structure of the pore system. The accelerated drying-out
allows concrete comprising lime filler to comply with the
relative humidity (RH) requirements on concrete before car
peting. Lime fillers are commercially available in a number of
qualities. For the inventive use, it has been found that a lime
filler, for instance a crystalline limestone filler, with a mean
particle size of <0.05 mm, preferably 0.025-0.05 mm, pro
vides the desired combination of contributions to the self
compacting properties of the concrete and to the accelerated
drying-out.
0045. The high amount offine material in self-compacting
concrete increases the water requirement, which further
increases the shrinkage tendency. Self-compacting concrete
for use according to the invention has a water-cement ratio of
>0.5, preferably >0.55.
0046 By exploiting the positive effect of lime fillers on the
drying-out process, quick drying-out can be achieved accord
ing to the invention without reducing the water-cement ratio,
which could have increased the risk of loss of bond and edge
lifting. Owing to the quick drying-out of the casting compo
sition, the floor laying is not delayed and a quick and efficient
construction process can be maintained.
0047 Thus, an embodiment of a concrete floor assembly
according to the invention comprises a Subfloor element with
a floor side and a ground/ceiling side, and a top casting layer.
The subfloor element comprises a concrete portion on the
floor side and the concrete portion has an exposed aggregate
Surface, and the top casting layer comprises a casting com
position which comprises a self-compacting concrete and a
shrinkage reducing admixture. The top casting layer is cast on
the floor side of the subfloor element so that at least a portion
of the exposed aggregate Surface is covered by the top casting
layer.
0048. Due to the exposed aggregate surface of the subfloor
element, which allows good adhesion, it has been found pos
sible, according to this embodiment of the invention, to use a
casting composition based on a self-compacting concrete if it
contains an admixture of a shrinkage reducer. Such a casting
composition is considerably more economical than prior-art
screed. According to the invention, the good adhesion to the
Subfloor element and the shrinkage reducing admixture make
it possible to cast a layer that is sufficiently thick to comply
with the requirements on acoustic insulation and the require
ments on the embedment of conduits, but not so thick that an
unnecessary amount of material is consumed. Advanta
geously, the casting composition, which according to the
invention is based on a self-compacting concrete, requires
little labour input since it does not, as ordinary concrete, have
to be vibrated but spreads itself substantially horizontally.
Thus, according to the invention, a flat upper Surface is pro
vided, also without the use of screed. Thanks to an economi
cal casting composition and a rational application method, the
concrete floor assembly according to the invention is thus
considerably more cost-effective than the conventional alter
natives.
0049. Furthermore, an embodiment of a method of mak
ing a concrete floor assembly according to the invention com
prises the steps of providing a Subfloor element having a floor
side and a ground/ceiling side, the Subfloor element compris
ing a concrete portion on the floor side, which concrete por
tion has an exposed aggregate Surface, providing a casting
Dec. 10, 2009
composition which comprises a self-compacting concrete
and a shrinkage reducing admixture, casting the casting com
position on the floor side of the subfloor element so that a top
casting layer forms which covers at least a portion of the
exposed aggregate Surface.
0050 Finally, an embodiment of a method of making a
floor assembly for a floor structure in construction works
comprises according to the invention the steps of providing
subfloor elements which have a floor side and a ground/
ceiling side and comprise a concrete portion on the floor side,
which concrete portion has an exposed aggregate surface,
providing a casting composition comprising a self-compact
ing concrete and a shrinkage reducing admixture, joining the
Subfloor elements to form a subfloor unit, casting the casting
composition on the Subfloor unit by covering at least portions
of the exposed aggregate surfaces, thereby forming a top
casting layer with a flat upper side which has a desired incli
nation, preferably substantially horizontal.
BRIEF DESCRIPTION OF THE DRAWINGS
0051. The invention will now be described in more detail
by way of examples and with reference to the accompanying
drawings.
0.052 FIG. 1 is a schematic longitudinal section view of a
concrete floor assembly according to the invention.
0053 FIG. 2 is a schematic cross-section view of a con
crete floor assembly according to the invention.
0054 FIG. 3 is a schematic top plan view of a subfloor
element according to the invention.
0055 FIG. 4 is a schematic top plan view of a floor assem
bly according to the invention, in which part of the Figure
shows joined Subfloor elements under the top casting layer.
DESCRIPTION OF PREFERRED
EMBODIMENTS
0056. With reference to FIGS. 1 and 2, a concrete floor
assembly according to the invention is schematically shown.
The concrete floor assembly comprises a subfloor element in
the form of a prefabricated hollow core slab 1. The hollow
core slab 1 comprises longitudinal reinforcement wires 2 that
prestress the hollow core slab 1, whereby it obtains a curved
longitudinal section. The prestress and the curved shape
advantageously provide a good ability to absorb tensions and
thus also a good load-carrying ability. The hollow core slab 1
is furthermore formed with weight-reducing recesses in the
form of longitudinal holes 3. The hollow core slab 1 accord
ing to the example is 10 mx 1.20mx0.265 m.
0057 The hollow core slab 1 has a floor side 9 which in use
is an upper side and a ground/ceiling side 10 which in use is
an underside. The hollow core slab 1 has an arched shape, the
curvature being directed upwards in use. If the hollow core
slab 1 is placed on a flat base, the difference in height of the
upper side 9 of the hollow core slab 1 above the base mea
sured at half the length of the hollow core slab 1 and at its
short ends is 15 mm.
0058. The hollow core slab 1 is made of a prior-art con
crete mix also comprising coarse aggregate grains 5 with a
diameter of about 12 mm. The hollow core slab 1 has a
concrete surface that covers the entire floor side 9, and in the
shown example the entire concrete surface of the floor side 9
forms a bottom casting surface which has been provided with
a desired roughness by aggregate exposure, cf. FIG. 3. The
concrete Surface has deep aggregate exposure, down to a
US 2009/03 01009 A1 Dec. 10, 2009

depth corresponding to about half the diameter of the coarse paste, i.e. the aggregate is exposed and a rough and clean
aggregate. In this example, the depth of aggregate exposure is surface 4 appears. In this example, the entire floor side 9 of the
6 mm. hollow core slab 1 has exposed aggregate.
0059 A top casting layer 6 is cast on the arched floor side 0064. A plurality of such hollow core slabs are subse
9 and covers the floor side 9 over its entire exposed aggregate quently transported to the desired building site.
Surface 4. The top casting layer 6 has a Substantially flat upper 0065. The hollow core slabs 1 are joined together on site to
side 7 facing away from the exposed aggregate Surface. When form a subfloor unit, which in this example extends over a
using the hollow core slab 1 according to the shown example storey and in which all the floor sides 1 of the hollow core
in a floor structure, the upper side 7 of the top casting layer 6 slabs are upwardly directed. The hollow core slabs 1 are
is horizontal. Furthermore, conduits 8 for electric cables are joined by grouting. In other embodiments of the invention, it
embedded in the top casting layer 6. In the shown example, may be sufficient to place the hollow core slabs adjacent to
the top casting layer 6 has a thickness of 55 mm at the Smallest each other or to attach them to each other or to a base in some
cross-section where the curve formed by the hollow core slab other convenient manner. The curved, arched longitudinal
1 has its maximum and a thickness of 70 mm at the short ends section of the joined hollow core slabs 1 gives the upper side
of the hollow core slab 1. of the subfloor unit a waveform. Furthermore, owing to the
0060 According to the invention, the top casting layer exposed aggregate floor side 9 of the hollow core slabs, the
comprises a casting composition based on a self-compacting entire floor side of the Subfloor unit has exposed aggregate.
concrete. The casting composition can, for instance, comprise 0066. Subsequently, conduits 8 are placed over the sub
the following materials: floor unit in a desired pattern.
0067 Furthermore, a casting composition according to the
above formula is mixed and supplied to the building site.
0068. The ready-mixed casting composition is pumped
Materials Amount (kg/m) out over the subfloor unit so that the conduits 8 are covered
Building cement 2SO-SOO and the desired thickness, for instance with regard to acoustic
Lime filler SO-200 insulation class, is obtained. Before that, the subfloor unit has
Sand 0-2 mm 400-700 been slightly pre-moistened. The casting composition forms
Gravel 0-8 mm SOO-1OOO a top casting layer 6 which covers the entire upper side of the
Stone material 8-11 mm 400-700
Water reducing agent O.1-10 Subfloor unit and the conduits 8. The casting composition is
Shrinkage reducing admixture O.1-10 self-levelling, which means that it compacts under its own
Water 100-500 weight, which makes vibration unnecessary. Moreover, the
casting composition spreads so that the top casting layer
0061 A preferred casting composition has the following obtains a Substantially horizontal Surface.
composition: 0069. When spreading, use is made of a laser, to obtain the
desired vertical level, and by bull floating, to obtain plane and
Smooth Surfaces. Bull floating means that the concrete Surface
is treated by a so-called bull float. Usually, a bullfloat consists
Amount Manufacturer? of a board or a plastic tube provided with a handle. The
Materials (kg/m) supplier Surface is easy to work manually so that a plane and Smooth
Building cement 385 Cementa Surface is obtained. The top casting layer finally has a thick
Lime filler “Limus 40 135 Nordkalk ness of 55 mm at its thinnest point and a thickness of 70 mm
Sand 0-2 mm (R6) S86 Skanska at the short ends of the hollow core slab 1.
Gravel 0-8 mm (Enköping) 747 Skanska 0070. In other embodiments, it is, of course, possible to
Stone material 8-11 mm (Vällsta) 598 Skanska perform levelling and Smoothing by other suitable methods.
Water reducing agent “Evo 26 2.7 Sika
Shrinkage reducing admixture 5.8 Sika 0071. Before the top casting layer has cured, a membrane
“Control 40 curing compound is injected over the Surface of the top cast
Water 2O7 ing layer. This is done immediately after the free water has
disappeared from the concrete Surface, usually within an hour
0062. The invention also relates to a floor structure com after casting. Owing to this, the after-curing of the top casting
prising at least one concrete floor assembly according to the layer proceeds under the action of the membrane curing com
invention. With reference to FIG.4, such a floor structure can, pound, whereby plastic shrinkage cracking in the Surface
according to the invention, comprise a floor assembly accord layer is advantageously avoided.
ing to the invention, which can be obtained in the following 0072. Due to the lime fillers of the casting composition, it
a.
is possible, according to the invention, to obtain quick drying
out and the relative humidity (RH) requirements on concrete
0063 First, a subfloor element is manufactured in the form before carpeting can be complied with and long waiting times
of a hollow core slab 1 with an exposed aggregate surface 4. in the construction process are avoided.
The hollow core slab 1 is cast in prior-art concrete and com 0073. According to the invention, a separate concrete floor
prises a prestressed reinforcement 2. To obtain the exposed assembly can also be provided by the above-described
aggregate surface 4 of the hollow core slab 1, a retarding method.
admixture (in liquid form) is applied before curing of the
hollow core slab. This means that curing is delayed down to a 1. A concrete floor assembly, comprising:
depth of 6 mm, which has been selected in consideration of a Subfloor element with a floor side and a ground/ceiling
the fact that the aggregate grains have a maximum diameter of side; and
12 mm. The hollow core slabs are then high-pressure washed, a top casting layer, wherein the Subfloor element includes a
which means that the surface layer is “cleaned” of cement concrete portion on the floor side, the concrete portion
US 2009/03 01009 A1
including a bottom casting Surface with a surface rough
ness, the top casting layer including a casting composi
tion which comprises a self-compacting concrete and a
shrinkage reducing admixture, and wherein the top cast
ing layer is cast on the floor side of the subfloor element
So that at least a portion of the bottom casting Surface is
covered by the top casting layer, and wherein the bottom
casting Surface has such surface roughness that the top
casting layer adheres to the bottom casting Surface.
2. A concrete floor assembly as claimed in claim 1, wherein
the Surface roughness of the bottom casting Surface, when
measured according to the Swedish Standard for determina
tion of surface roughness SIS812005, is S>1.5.
3. A concrete floor assembly as claimed in claim 1, wherein
the bottom casting Surface is seeded with granular material.
4. A concrete floor assembly as claimed in claim 1, wherein
the bottom casting Surface is treated by a surface roughening
method.
5. A concrete floor assembly as claimed in claim 4, wherein
the bottom casting Surface is brushed and/or combed.
6. A concrete floor assembly as claimed in claim 4, wherein
the bottom casting Surface is embossed.
7. A concrete floor assembly as claimed in claim 4, wherein
the bottom casting Surface has exposed aggregate.
8. A concrete floor assembly as claimed in claim 7, wherein
coarse aggregate grains in the exposed aggregate Surface of
the subfloor element are exposed at a depth of >/3 of the
maximum size of the Surface aggregate.
9. A concrete floor assembly as claimed in claim 7, wherein
coarse aggregate grains in the exposed aggregate Surface of
the subfloor element are exposed at a depth of </2 of the
maximum size of the Surface aggregate.
10. A concrete floor assembly as claimed in claim 1,
wherein at least one of conduits and electrical installations are
embedded in the top casting layer.
11. A concrete floor assembly as claimed in claim 1,
wherein the bottom casting Surface covers Substantially the
entire floor side of the subfloor element.
12. A concrete floor assembly as claimed in claim 1,
wherein the top casting layer is cast on Substantially the entire
floor side of the subfloor element.
13. A concrete floor assembly as claimed in claim 1,
wherein the maximum thickness of the top casting layer is
<100 mm.
14. A concrete floor assembly as claimed in claim 1,
wherein the minimum thickness of the top casting layer is >40
. wherein the casting of the casting composition comprises
15. A concrete floor assembly as claimed in claim 1,
wherein the casting composition further comprises a lime
filler.
16. A concrete floor assembly as claimed in claim 1,
wherein the subfloor element is a prefabricated element.
17. A concrete floor assembly as claimed in claim 16,
wherein the subfloor element is a hollow core slab.
18. A concrete floor assembly as claimed in claim 1,
wherein the self-compacting concrete has a slump-flow of
>520 mm.
19. A floor structure for construction works comprising a
concrete floor assembly as claimed in claim 1.
20. A method of making a concrete floor assembly com
prising:
providing a Subfloor element having a floor side and a
ground/ceiling side, the Subfloor element including a
Dec. 10, 2009
concrete portion on the floor side, the concrete portion
including a bottom casting Surface with a Surface rough
neSS,
providing a casting composition which comprises a self
compacting concrete and a shrinkage reducing admix
ture; and
casting the casting composition on the floor side of the
Subfloor element so that a top casting layer forms which
covers at least a portion of the bottom casting Surface,
the bottom casting Surface having such surface rough
ness that the top casting layer adheres to the bottom
casting Surface.
21. A method as claimed in claim 20, further comprising
applying a membrane curing compound to the top casting
layer.
22. A method as claimed in claim 20, further comprising
pre-moistening the Subfloor element before the step of casting
the casting composition.
23. A method as claimed in claim 20, further comprising
bull floating the top casting layer.
24. A method as claimed in claim 20, wherein the providing
of a Subfloor element comprises seeding the bottom casting
Surface with granular material.
25. A method as claimed in claim 20, wherein the providing
of a Subfloor element comprises treating the bottom casting
Surface by a Surface roughening method.
26. A method as claimed in claim 25, wherein the treating
of the bottom casting Surface by a surface roughening method
comprises at least one of brushing and combing the bottom
casting Surface.
27. A method as claimed in claim 25, wherein the treating
of the bottom casting Surface by a surface roughening method
comprises embossing the bottom casting Surface.
28. A method as claimed in claim 25, wherein the treating
of the bottom casting Surface by a surface roughening method
comprises exposing the aggregate of the bottom casting Sur
face.
29. A method as claimed in claim 28, wherein the providing
of a Subfloor element comprises casting the Subfloor element
in concrete, applying a retarding admixture to a surface of the
floor side before curing of the subfloor element, and cleaning
the surface of mortar after curing of the subfloor element, thus
exposing the aggregate of the Surface.
30. A method as claimed in claim 20, further comprising
arranging conduits or electrical installations on the Subfloor
element before the casting of the casting composition, and
embedding of conduits or electrical installations in the top
casting layer.
31. A method as claimed in claim 20, wherein the casting
composition is cast with a thickness of <100 mm at its thickest
point.
32. A method as claimed in claim 20, wherein the casting
composition is cast with a thickness of>40 mm at its thinnest
point.
33. A method as claimed in claim 20, wherein the self
compacting concrete has a slump-flow of >520 mm.
34. A method of making a floor assembly for a floor struc
ture in construction works comprising:
providing subfloor elements which have a floor side and a
ground/ceiling side and comprise a concrete portion on
the floor side, the concrete portion including a bottom
casting Surface with a surface roughness;
US 2009/03 01009 A1
providing a casting composition comprising a self-com
pacting concrete and a shrinkage reducing admixture;
joining the subfloor elements to form a subfloor unit;
casting the casting composition on the Subfloor unit by
covering at least portions of the bottom casting Surfaces,
the bottom casting Surfaces having Such surface rough
ness that the top casting layer adheres to the bottom
casting Surface, thereby forming a top casting layer with
a flat upper side which has a desired inclination.
35. A method as claimed in claim34, wherein the providing
ofa Subfloor element comprises exposing the aggregate of the
bottom casting Surface.
36. A method as claimed in claim 34, further comprising
arranging conduits or electrical installations on the Subfloor
unit before the casting of the casting composition, and
wherein the casting of the casting composition comprises
embedding of conduits or electrical installations in the top
casting layer.
37. A method as claimed in claim 34, wherein the casting
composition is cast over Substantially the entire Subfloor unit.
38. A method as claimed in claim 34, wherein the casting of
the casting composition comprises pumping out the casting
composition over the subfloor unit.
39. A method as claimed in claim 34, wherein the casting of
the casting composition comprises levelling of the top casting
layer.
Dec. 10, 2009
40. A concrete floor assembly as claimed in claim 1,
wherein the bottom casting Surface is seeded with granular
material.
41. A concrete floor assembly as claimed in claim 1,
wherein the bottom casting Surface is treated by a Surface
roughening method.
42. A method as claimed in claim 21, further comprising
pre-moistening the Subfloor element before the step of casting
the casting composition.
43. A method as claimed in claim 21, further comprising
bull floating the top casting layer.
44. The method of claim 34, wherein the desired inclina
tion is horizontal.
45. A method as claimed in claim 35, further comprising
arranging conduits or electrical installations on the Subfloor
unit before the casting of the casting composition, and
wherein the casting of the casting composition comprises
embedding of conduits or electrical installations in the top
casting layer.
46. A method as claimed in claim 35, wherein the casting
composition is cast over Substantially the entire Subfloor unit.
47. A method as claimed in claim35, wherein the casting of
the casting composition comprises pumping out the casting
composition over the subfloor unit.
48. A method as claimed in claim35, wherein the casting of
the casting composition comprises leveling of the top casting
layer.