Concrete Floor Device

Abstract

A concrete floor assembly is disclosed including a subfloor element with a floor side and a ground/ceiling side, and a top casting layer. In at least one embodiment, the subfloor element includes a concrete portion on the floor side, which concrete portion has a bottom casting surface with a surface roughness. The top casting layer includes a casting composition, which includes 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 roughness that the top casting layer adheres to the bottom casting surface. A method of providing such a concrete floor assembly is also disclosed, as well as a floor assembly.

1 . A concrete floor assembly, comprising:
 a subfloor element with a floor side and a ground/ceiling side; and   a top casting layer, wherein the subfloor element includes a concrete portion on the floor side, the concrete portion including a bottom casting surface with a surface roughness, the top casting layer including a casting composition which comprises a self-compacting concrete and a shrinkage reducing admixture, and wherein 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, 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 determination 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 >⅓ 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 <½ 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 mm. 
   
   
       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 comprising:
 providing a subfloor element having a floor side and a ground/ceiling side, the subfloor element including a concrete portion on the floor side, the concrete portion including a bottom casting surface with a surface roughness;   providing a casting composition which comprises a self-compacting concrete and a shrinkage reducing admixture; 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 roughness 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 surface. 
   
   
       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 wherein the casting of the casting composition comprises 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 structure 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;   providing a casting composition comprising a self-compacting 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 roughness 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  claim 34 , wherein the providing of a 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. 
   
   
       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 inclination 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  claim 35 , wherein the casting of the casting composition comprises pumping out the casting composition over the subfloor unit. 
   
   
       48 . A method as claimed in  claim 35 , wherein the casting of the casting composition comprises leveling of the top casting layer.