WO2015057152A1

WO2015057152A1 - Method of producing a wetroom floor module, a wetroom floor module and a floor module frame

Info

Publication number: WO2015057152A1
Application number: PCT/SE2014/051225
Authority: WO
Inventors: Magnus Johansson
Original assignee: Racks I Olofström Ab
Priority date: 2013-10-18
Filing date: 2014-10-17
Publication date: 2015-04-23
Also published as: SE1650518A2; SE1351245A1; SE1650518A1; SE537555C2

Abstract

A method of producing a wetroom floor module, which method comprises mounting of a frame (3) having a vertical extent between a lower edge and an upper edge, placement of the frame (3) upside-down into a form which a really fills the space within the frame (3), fixing of at least one floor bushing (7), preparation of a concrete mass, addition of reinforcing metal fibers (21) into the concrete mass, and casting with the concrete mass within the frame (3) at least partially between the upper and lower edge of the frame (3) to form a wetroom floor in the wetroom floor module. The present invention also relates to a wetroom floor module and a floor module frame.

Description

METHOD OF PRODUCING A WETROOM FLOOR MODULE, A WETROOM FLOOR

MODULE AND A FLOOR MODULE FRAME

Technical field

The present invention relates to a method of manufacturing a wetroom floor module.

5 The present invention also relates to a wetroom floor module and a floor module frame.

Prior art

Floor modules are used for the construction of prefabricated room 10 modules which are fitted together in a factory and which are then transported and hoisted into place as finished units, such as, for example, bathroom modules for apartments, hotels, vessels and the offshore industry, which shortens the production time at the actual construction site. In addition, a uniform quality can be obtained.

15 SE 529 418 shows a method for producing a floor module in a

prefabricated wetroom unit. In this method, a surrounding metal frame is formed and a mesh reinforcement is welded to the inner side of the metal frame. The floor module is produced by casting of concrete within the metal frame.

20 This method has the drawback that the material in the metal frame is affected by the welding, which can lead to the introduction of dimensional variations. Construction of a complete room module is thus made more difficult, since connecting module parts, such as, for example, wall modules, require obvious, relatively large dimensional tolerances. In addition, this

25 method has proved to be complicated and expensive.

Summary of the invention

One object of the present invention is to provide a method of manufacturing a wetroom floor module, which method allows simple

30 production of the wetroom floor module. This object is achieved according to the present invention by a method of producing a wetroom floor module, which method comprises mounting of a frame having a vertical extent between a lower edge and an upper edge, placement of the frame upside-down into a form which areally fills the space within the frame, fixing of at least one floor bushing, preparation of a concrete mass, addition of reinforcing metal fibers into the concrete mass, and casting with the concrete mass within the frame at least partially between the upper and lower edge of the frame to form a wetroom floor in the wetroom floor module.

Through the addition of reinforcing metal fibers into the concrete mass, a load-bearing capacity which is comparable with traditional reinforced concrete is obtained. Metal fibers can therefore wholly replace iron

reinforcement and/or mesh reinforcement, which makes the production of a wetroom floor module considerably easier. In addition, one or more floor bushings can be placed freely in the concrete slab. This method comprises few production steps, and is less labor-intensive, in relation to known methods. Simple and cost-effective production of a robust wetroom floor module with high and uniform strength, i.e. high strength also in the region around a floor bushing, is therefore allowed. In addition, dimensional variations can be avoided, since iron reinforcement or mesh reinforcement does not need to be welded to the frame.

Preferably, reinforcing steel fibers are added to the concrete mass, giving very good strength and durability.

Another object of the present invention is to provide an improved wetroom floor module.

This object is achieved according to the present invention with a wetroom floor module for the construction of a wetroom module, which wetroom floor module comprises a cast concrete slab, a frame which at least partially encloses the concrete slab, and a floor bushing arranged in the concrete slab, and is characterized in that the concrete slab comprises concrete containing reinforcing metal fibers, and in that the concrete and the reinforcing metal fibers enclose said at least one floor bushing. The fact that the concrete in the concrete slab contains metal fibers means that it has very high and uniform strength. A robust and strong wetroom floor module with high load-bearing capacity is therefore obtained. In addition, the fiber reinforcement offers wide scope with respect to the placement of one or more floor bushings, without thereby affecting the strength of the concrete slab in the region around which the floor bushing is arranged, since the concrete slab, by virtue of the reinforcing fibers, has very uniform strength. A wetroom floor module designed in this way is also simple and cost-effective to produce.

The concrete slab preferably comprises concrete containing reinforcing steel fibers, giving the reinforced concrete very good strength and durability.

Said at least one floor bushing is preferably an outflow bushing intended for a shower, toilet or washbasin.

In one embodiment, said at least one floor bushing comprises a floor drain.

The wetroom floor module can have a plurality of floor bushings. In one embodiment, the wetroom floor module has a first floor bushing for outflow from a shower, a second floor bushing for outflow from a toilet, and a third floor bushing for outflow from a washbasin.

A wetroom floor module of this kind can be used in a prefabricated wetroom module and allows simple construction thereof.

Another object of the present invention is to provide an improved floor module frame.

This object is achieved according to the present invention with a floor module frame comprising a first beam, which has two flange sections and an intervening web and forms a first line duct, a second beam, which has two flange sections and an intervening web and forms a second line duct, and is characterized by a coupling device which couples together the first and the second beam, which coupling device comprises a first, upper lug and a second, lower lug, which are disposed on the web of the first beam on both sides of a recess disposed in the web of the first beam and are received in one end section of the second beam, wherein said recess interconnects the first and second line duct.

The coupling device allows very simple and flexible mounting of the frame. In addition, the frame can be mounted without the beams incorporated in the frame needing to be welded together. In the mounting of the frame, the lugs of the coupling device form guides, which facilitates the actual connection of the beams. Once the frame has been mounted, the lugs form supports, which preferably are in positive engagement with the second beam, giving a very robust frame having good stability, and which are thus very well suited for casting of a concrete slab. In addition, one or more lines, such as, for example, water pipe lines, outflow pipe lines, electric cables, underfloor heating coils, can be placed in a simple manner and concealed in line ducts formed by the beams of the frame, which allows a space-efficient solution in which one or more lines are reliably protected.

In one embodiment, said lugs are positively received in said end section, giving a very stable solution which is simple to mount in a correct manner.

In one embodiment, said first lug has a shape which is at least partially complementary to an upper part of said end section, and said second lug has a shape which is at least partially complementary to a lower part of said end section, giving a very stable solution which is simple to mount in a correct manner.

In one embodiment, the second beam element is C-shaped, giving very good stiffness. In addition, a C-shaped beam forms a line duct in the form of a line channel, in which lines can be placed in a very reliable manner since at least one of the flanges protects the lines.

In one embodiment, the first and second lug are disposed on a coupling plate, preferably a C-shaped coupling plate, giving a very robust coupling device with few parts which is simple to mount and which allows simple connection of the first and second beam.

In one embodiment, the second beam has a mounting member disposed in the line duct and fixed to one end section of the second beam, which mounting member comprises an upper and a lower mounting flange and an intervening recess which cooperates with the recess in the web of the first beam, making the frame easier to mount.

In one embodiment, the upper and lower mounting flange are disposed on a mounting plate, wherein the mounting plate is preferably C-shaped, giving a very robust coupling device which allows simple connection of the first and second beam.

In one embodiment, the coupling device comprises locking members, such as, for example, screws, which lock together the first and the second beam.

A floor module frame of this kind can be used in a prefabricated wetroom floor module and allows simple construction thereof.

Further advantages and characteristics of the invention emerge from the description below and from the following patent claims.

Brief description of the drawings

The invention shall now be described in greater detail with reference to the appended schematic drawings, which show preferred embodiments of the invention.

Fig. 1 a is a perspective view and shows a wetroom floor module according to one embodiment of the present invention.

Fig. 1 b is a sectional view along the line A-A in fig. 1 a.

Figs. 2a-b illustrate a floor module frame. Description of preferred embodiments

Fig. 1 a shows a wetroom floor module 1 according to one embodiment of the present invention. The wetroom floor module 1 is intended to form part of a wetroom module, such as, for example, a bathroom module, and comprises a frame, in the form of a floor module frame 3, a concrete slab 5, and a floor bushing in the form of a floor drain 7. The floor module frame 3, which surrounds the concrete slab 5, has two mutually parallel longer beams 9 and 13 and two mutually parallel shorter beams 1 1 and 15. Each of the beams 9, 1 1 , 13, 15 incorporated in the frame 3 is constituted by steel profiles of C-shaped cross section. The beams 9, 1 1 , 13, 15 are coupled together in pairs by means of coupling devices 30, one of which is illustrated in detail in fig. 2a, so that four corners are formed.

The cast concrete slab 5 comprises concrete 22 containing reinforcing steel fibers 21 , as is illustrated schematically in figs. 1 a and 1 b. The concrete slab 5 can comprise, for example, concrete containing fibers of the type having end hooks, but it will be appreciated that other types of steel fibers can be used. In this embodiment, the concrete slab 5 is reinforced with steel fibers of the HE type, which are commercially available from ArcelorMittal. The fiber quantity depends on a number of factors, such as fiber type, load

assumptions and application.

The wetroom floor module 1 comprises a wetroom floor 17, which has a descent to the floor drain 7, see fig. 1 b. The descent is configured such that water on the floor surface of the floor 17 runs down into the floor drain 7. The wetroom floor module 1 further comprises a sealing layer (not shown), which constitutes a moisture barrier.

With reference to figs. 2a and 2b, the floor module frame 1 will now be described in greater detail.

Each of the beams 9, 1 1 , 13, 15 incorporated in the frame 3 has two flange sections and an intervening web. A first beam 1 1 therefore has two flange sections 1 1 a and 1 1 b and a web 1 1 c, and a second beam 13 has two flange sections 13a and 13b and a web 13c.

The first beam 1 1 forms a first line duct 23, and the second beam 13 forms a second line duct 25. A recess 27 is disposed in the web 1 1 c of the first beam and interconnects the first 23 and second 25 line duct, as is best illustrated in fig. 2b. The recess 27 configured in the web 1 1 c of the first beam extends from one short end 1 1 d of the first beam 1 1 and forms an opening in the web 1 1 c of the first beam. The edge 27a of the recess 27 is visible in figs. 2a and 2b. Lines 24, such as electric cables and/or water pipe lines, can thus be placed and concealed in the common line duct which is formed by the first 23 and second 25 line duct. The first 1 1 and second 13 beam are coupled together by means of a coupling device 29, which comprises a first, upper, lug 31 and a second, lower lug 33. The lugs 31 , 33 are disposed on the web 1 1 c of the first beam on both sides of the recess 27 disposed in the web 1 1 c of the first beam, as is best illustrated in fig. 2a. In this embodiment, the lugs 31 , 33 are disposed on a coupling plate 29, which also comprises a recess 28 disposed between the lugs 31 , 33, which recess cooperates with the recess 27 disposed in the web 1 1 c of the first beam. The coupling plate 29 is disposed on that side of the beam web 1 1 c which is facing toward the second beam element 13 and is positively received in one end section 13d of the second beam 13. The first 31 and second lug 33 are therefore positively received in an upper 16 and lower 18 part of the end section 13d of the second beam 13. Thus the first lug 31 has an external shape which is complementary with the internal shape of the upper part 16 of the end section 13d, and the second lug 33 has an external shape which is complementary with the internal shape of the lower part 18 of the end section 13d.

The lugs 31 , 33 are therefore configured so as to bear against and cooperate with the web 13c and flanges 13a and 13b of the second beam, giving a very robust and stable connection of the first 1 1 and the second 13 beam. A robust anchorage of the coupling plate 29 is important, since the coupling plate 29 is intended to absorb shearing loads. In this embodiment, the coupling plate 29 is welded to the web 1 1 c of the first beam. Alternatively, the coupling plate 29 can be anchored in the beam web 1 1 c with the aid of, for example, screw joints.

A mounting member in the form of a mounting plate 35, mounting member stands opposite the coupling plate 29, is disposed in the line duct 25 of the second beam. The mounting plate 35 comprises an upper 37 and a lower 39 mounting flange, and an intervening recess which cooperates with the recess 27 in the web 1 1 c of the first beam. The mounting plate 35 is disposed on one end section 13d of the second beam and at a distance, corresponding to the thickness of the coupling plate 29, from the particular short end of the second beam 13, so that the web 1 1 c of the first beam bears against the end face of the second beam 13 once the beams 1 1 , 13 have been coupled together (fig. 2b). The mounting plate 35 can be anchored in the second beam 13, for example by welding or by means of screw joints. In this embodiment, the mounting plate 35 is welded to the web 13c and flanges 13a and 13b of the second beam.

Each of the lugs 31 , 33 has an outer shape which with close tolerance fits together with the inner shape of the second beam 13, giving a very stable and robust connection which is capable of absorbing large shearing loads. In addition, the lugs 31 , 33 facilitate the actual connection of the beams 1 1 , 13, illustrated by the arrow B in fig. 2a, since the lugs 31 , 33 form a guide.

The beams 1 1 , 13 can be locked together by means of locking members, such as, for example, screws, or by means of welding. In this embodiment, screws 41 are arranged for locking together the first 1 1 and the second beam 13. For this purpose, the mounting plate 35 has through holes 43, through which the screws 41 extend. In addition, the coupling plate 29 has threaded screw holes 45, in which the screws 41 are received and screwed tight.

The lugs 31 , 33 of the coupling plate 29 give the frame 3 very good torsional stiffness and capacity to absorb loads of different kinds. When the floor module frame 3 is subjected to load, the lugs 31 , 33 absorb large shearing loads, which largely relieves the load on the screws 41 . The floor module frame 3 is therefore very stable and reliable. In addition, the floor module frame 3 is well suited for casting of a concrete slab 5 within the frame 3.

In this embodiment, the first 31 and second 33 lug are configured on one and the same coupling plate 29, which has the advantage that the number of parts is few and that a very robust connection is obtained.

Alternatively, the first 31 and second lug 33 can be configured on separate coupling plates disposed on both sides of the recess 27 configured in the web 1 1 c of the first beam.

A way in which the wetroom floor module 1 described with reference to fig. 1 can be produced will now be described. In the production of a wetroom floor module according to one

embodiment of the present invention, a frame having a vertical extent between a lower edge and an upper edge is mounted. The parts of the frame are preferably constituted by C-shaped steel profiles and are coupled together, for example, by means of coupling devices.

The mounted frame is placed upside-down into a form which areally fills the space within the frame.

A floor bushing, such as, for example, a floor drain, is fixed. The floor drain is preferably fixed such that its outlet opens out below the lower edge of the frame. Preferably, the floor drain is fixed by means of a tailor-made floor drain collar.

Concrete mass is prepared and reinforcing metal fibers are added to the concrete mass. Preferably, reinforcing steel fibers are added to the concrete mass. By virtue of the fact that reinforcing metal fibers are added to the concrete mass means that a load-bearing capacity which is comparable with traditionally reinforced concrete is obtained, which means that the metal fibers can wholly replace iron reinforcement and/or mesh reinforcement. For example, steel fibers of the type having end hooks are added, but it will be appreciated that other types of steel fibers can be used. The necessary fiber quantity is calculated on the basis of a number of factors, such as fiber type, load assumptions, and application.

Finally, casting with the concrete mass within the frame 3 is realized at least partially between the upper and lower edge of the frame, preferably level with the lower edge of the frame, to form a wetroom floor in the wetroom floor module.

It will be appreciated that many variants of the above-described embodiments are possible within the scope of the appended patent claims.

A wetroom floor module according to the present invention can be provided with underfloor heating coils in order to provide floor heat in the wetroom floor. In this case, the wetroom floor module comprises holders for underfloor heating coils. In the embodiments described above, the metal frame is formed of steel plating. It will be appreciated that other materials can be used for this purpose.

The described beams 7, 9, 1 1 , 13 have a C-shaped cross section. The beams can naturally have different cross-sectional profiles, such as, for example, a rectangular profile, L-profile or U-profile, than the described C- shaped profile.

Claims

1 . A method of producing a wetroom floor module, which method comprises

mounting of a frame (3) having a vertical extent between a lower edge and an upper edge,

placement of the frame (3) upside-down into a form which areally fills the space within the frame (3),

fixing of at least one floor bushing (7),

preparation of a concrete mass

addition of reinforcing metal fibers (21 ) into the concrete mass, and casting with the concrete mass within the frame (3) at least partially between the upper and lower edge of the frame (3) to form a wetroom floor

(17) in the wetroom floor module.

2. The method as claimed in claim 1 , wherein metal fibers in the form of steel fibers (21 ) are added to the concrete mass.

3. A wetroom floor module (1 ) for the construction of a wetroom module, which wetroom floor module (1 ) comprises a cast concrete slab (5), a frame (3) which at least partially encloses the concrete slab (5), and a floor bushing (7) arranged in the concrete slab (5),

characterized in that the concrete slab (5) comprises concrete (22) containing reinforcing metal fibers (21 ), and in that the concrete (22) and the reinforcing metal fibers (21 ) enclose said at least one floor bushing (7).

4. The wetroom floor module as claimed in claim 3, in which the concrete slab (5) comprises concrete (22) containing reinforcing metal fibers (21 ) in the form of steel fibers (21 ).

5. The wetroom floor module as claimed in any one of claims 3-4, in which said at least one floor bushing (7) is an outflow bushing intended for a shower, toilet or washbasin.

6. A floor module frame (3) comprising

a first beam (1 1 ), which has two flange sections (1 1 a, 1 1 b) and an intervening web (1 1 c) and forms a first line duct (23),

a second beam (13), which has two flange sections (13a, 13b) and an intervening web (13c) and forms a second line duct (25),

and characterized by

a coupling device (29) which couples together the first (1 1 ) and the second (13) beam, which coupling device (29) comprises

a first, upper, lug (31 ) and a second, lower, lug (33), which are disposed on the web (1 1 c) of the first beam on both sides of a recess (27) disposed in the web (1 1 c) of the first beam and are received in one end section (13d) of the second beam (13),

wherein said recess (27) interconnects the first (23) and second (25) line duct.

7. The floor module frame (3) as claimed in claim 6, in which said lugs

(31 , 33) are positively received in said end section (13d).

8. The floor module frame (3) as claimed in any one of claims 6-7, in which said first lug (31 ) has a shape which is at least partially complementary to an upper part (16) of said end section (13d), and said second lug (33) has a shape which is at least partially complementary to a lower part (18) of said end section (13d).

9. The floor module frame (3) as claimed in any one of claims 6-8, in which the second beam element (13) has a C-shaped cross section.

10. The floor module frame (3) as claimed in any one of claims 6-9, in which the first (31 ) and second lug (33) are disposed on a coupling plate (29), wherein the coupling plate (29) is preferably C-shaped.

1 1 . The floor module frame (3) as claimed in any one of claims 6-10, in which the second beam (13) has a mounting member (35) disposed in the line duct (25) and fixed to one end section (13d) of the second beam (13), which mounting member (35) comprises an upper (37) and a lower (39) mounting flange and an intervening recess which cooperates with the recess (27) in the web (1 1 c) of the first beam.

12. The floor module frame (3) as claimed in claim 1 1 , in which the upper (37) and lower (39) mounting flange are disposed on a mounting plate (35), wherein the mounting plate (35) is preferably C-shaped.

13. The floor module frame as claimed in any one of claims 6-1 1 , in which the coupling device (30) comprises at least one locking member (41 ) which locks together the first (1 1 ) and the second (13) beam.