AU2013200496B2 - Systems for forming insulated thermal mass concrete slabs - Google Patents

Abstract

Disclosed herein is an insulated concrete thermal mass ground slab (101). Construction of the slab (101) is facilitated by a slab forming system (11) comprising a first, outer slab edge insulation layer (12), a second insulation layer defined by an under slab insulation module (18), and a third, outer under beam insulation layer (19). The outer slab edge insulation layer (12) and the outer under beam insulation layer (19) are laid around the perimeter of the concrete ground slab, and the under slab insulation module (18) is laid in a grid pattern within the perimeter of the concrete ground slab, such that the entire underside and edges of the slab (10)1 are encapsulated in insulation. 11, 101 12 12 25 27 27- -__18 18b 18b 16c 16 18a 18 12, 16a 16c 18b 18b t\-6b 18b Ill ll Il / Ill IllIll 18b Figure 1

Description

1 AUSTRALIA Patents Act 1990 AMBE ENGINEERING PTY LTD COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Systems for forming insulated thermal mass concrete slabs The following statement is a full description of this invention including the best method of performing it known to us: - 2 The present disclosure relates to systems for forming insulated thermal mass concrete slabs, such as basement slabs, ground slabs, suspended slabs, inter floor slabs, roof slabs, and the like, for residential, commercial and industrial buildings, but it will be appreciated that they may also be used for forming slabs in specialized buildings, such as 5 data centres, cold storages, aircraft hangers and the like. Thermal mass is a property that enables building materials to absorb and store thermal energy, and later slowly release the stored energy. An insulated thermal mass slab acts like a thermal battery. In order to derive maximum benefit, the thermal mass should be placed on the building interior side of the insulation. 10 In winter, a building with an insulated thermal mass slab absorbs and stores thermal energy from sunlight entering through open windows during the day, and from other direct and indirect sources, and slowly releases the stored thermal energy at night to keep the house warm. In summer, the thermal mass slab is cooled by relatively cooler conditions within the building during the day, with thermal energy stored in the slab being slowly 15 released outside the building at night through convection and through open windows. In summer, the exterior insulation inhibits thermal energy outside the building from entering the building or accumulating in the thermal mass slab. Drawing the curtains on windows in summer also inhibits sunlight from entering the building and thereby inhibits thermal energy from sunlight accumulating in the thermal mass slab. 20 One of the most important benefits of an insulated thermal mass slab is its ability to moderate temperature extremes, which helps to create an internal environment that is more comfortable to live in. The surface temperature of an insulated concrete thermal mass slab also tends to be more stable, which makes condensation less likely to occur. A common high thermal mass material used in building construction is concrete. It 25 is readily available, relatively inexpensive and can provide structurally strong buildings with wind resistance, weather proofing, moisture protection, air leakage resistance, sound resistance, fire resistance, termite resistance and earthquake resistance, while still maintaining a healthy indoor air quality. Solar passive design of buildings may require the thermal mass to be exposed to the 30 interiors of the building in areas with good solar orientation and direct solar access and may also require that the thermal mass is not directly exposed to the interiors of the building in areas with poor solar orientation or no solar access in order to promote overall moderation and comfort. Capturing free energy from the sun means that insulated thermal mass buildings are 35 more energy passive which can result in significantly lower heating and cooling costs.

3 Studies have shown that approximately 80 percent of heat loss occurs through the perimeter edges of the concrete slabs and the balance of heat loss is through the top and bottom of the concrete slabs. Therefore, a thermal mass concrete slab should be fully insulated around all its perimeter edges as well as around its entire bottom surface but the 5 entire top surface should be left free of thermal insulation so that the entire embodied heat is re-directed via the exposed top surface of the concrete slab to the interiors of the building. That is, in order to derive maximum benefit, only the top surface of the concrete thermal mass slab should be exposed to the interior of the building and all other sides including the slab perimeter edges and the slab bottom should be wrapped in insulation to 10 ensure that there is no thermal break or passage of heat/energy between the concrete thermal mass slab and the foundation and other surrounding areas of the building. Present systems of forming insulated concrete ground slabs include using either removable formwork or stay in place slab edge insulation or stay in place insulating void formers or waffle pods, all of which suffer from severe drawbacks and may not always be 15 appropriate for meeting the objectives of modern energy conservation practices. There are several known removable formwork systems for forming insulated concrete ground slabs that use conventional scaffolding or formwork which is erected around the perimeter of the building and then polystyrene insulation is laid on the edges and bottom of the perimeter prior to pouring the concrete. However, all these known 20 systems involve extensive site labour to initially set up the formwork and also to later on strip, remove, wash and store the inside formwork. Accordingly, these conventional formwork systems are very uneconomical to use. There are also several known stay in place slab edge insulation systems for forming insulated concrete ground slabs that generally consist of a layer of polystyrene insulation 25 panels with metal or plastic ties that are laid around the perimeter of the building after which the polystyrene bottom insulation or polystyrene insulating void formers are laid prior to pouring the concrete in such a manner that the ties get embedded in the concrete and secure the insulation. However, all these known systems still involve extensive bracing or formwork to temporarily hold the slab edge insulation in place till the concrete is 30 poured, some systems even require the ties to be temporarily secured to ground using stakes until the concrete is poured. Accordingly, these formwork systems are very cumbersome and uneconomical to use. Further, there are several known stay in place insulating void formers or waffle pods systems for forming insulated concrete ground slabs. Such systems generally consist 35 of several polystyrene insulating cubes or polystyrene pods that are laid and interlocked in a grid pattern with metal or plastic ties for insulating the bottom of the concrete slab after 3148371_.doc 4 which the polystyrene edge insulation is separately placed and secured by erecting conventional formwork either stand alone or in conjunction with metal or plastic ties until the concrete is poured. However, all these known systems involve a two separate steps for laying the slab bottom insulation and the slab edge insulation and still involve extensive 5 bracing or formwork to temporarily hold the slab edge insulation in place till the concrete is poured. Accordingly, these formwork systems are very cumbersome and uneconomical to use. A problem with known stay in place slab edge insulation systems and stay in place insulating void formers or waffle pods systems is that neither of the two systems provides 10 an integral means to insulate both the edges as well as the bottom of the slab in one single operation. The stay in place slab edge insulation systems are primarily designed to insulate the edges of the slabs with the bottom insulation added as a secondary operation and the stay in place insulating void formers or waffle pod systems are primarily designed to insulate the bottom of the slabs with the edge insulation added as a secondary operation. 15 Accordingly, none of these two systems do the complete job of insulating the slab and require a lot of time as well as skilled labour to set up on site, which makes them very expensive to use. Another drawback of known stay in place slab edge insulation systems and stay in place insulating void formers or waffle pods systems is that the slab edge insulations and 20 the slab bottom insulations are not linked or attached to each other, which makes it very difficult to accurately set up, align, secure and hold together the two types of insulation on site to prevent them from moving and buckling under the enormous pressure that is generated in the pouring and curing of concrete slab. Another drawback of known stay in place slab edge insulation systems and stay in 25 place insulating void formers or waffle pods systems is that they are not completely stand alone systems and depend upon extensive additional bracing or formwork to temporarily hold the insulations in place until the concrete slab is poured. Another drawback of known stay in place slab edge insulation systems and stay in place insulating void formers or waffle pods systems is that they do not provide any 30 integral means to create a set-down or rebate in the concrete slab for setting down a concrete wall into the edge of the concrete slab to prevent the ingress of water through the joint between the slab and the walls. Most present systems of forming insulated concrete suspended slabs generally use either removable formwork or stay in place deck-type insulating concrete forms, all of 35 which suffer from severe drawbacks and may not always be appropriate for meeting the objectives of modern energy conservation practices. 3148371_.doc 5 There are several known removable formwork systems for forming insulated concrete suspended slabs that use conventional scaffolding or formwork that is erected around the perimeter and under the bottom of the suspended slab, after which polystyrene insulation is laid on the edges and bottom of the suspended slab prior to pouring the 5 concrete. However, all these known systems involve extensive site labour to initially set up the formwork and also to later on strip, remove, wash and store the inside formwork. Accordingly, these formwork systems are very uneconomical to use. There are also several known types of stay in place deck-type insulating concrete forms that generally consist of several long insulating forms made of polystyrene with built 10 in embedded steel beams that are laid across the walls after which the polystyrene edge insulation is separately placed and secured by erecting conventional formwork around the walls either stand alone or in conjunction with metal or plastic ties prior to pouring the concrete. However, all these known systems involve multiple steps for laying the insulating forms and the slab edge insulation and still involve extensive bracing or formwork to 15 temporarily hold them together until the concrete is poured. Accordingly, these formwork systems are very cumbersome and uneconomical to use. A problem with known stay in place deck-type insulating concrete forms is that the steel beams that are embedded within the polystyrene insulation act as cold conductive bridges for heat energy to pass through, thus reducing the overall effectiveness of the 20 insulation. Another drawback of known stay in place deck-type insulating concrete forms is that the polystyrene insulation does not have any secondary reinforcement and is itself not strong enough to hold the substantial weight of construction workers, equipment and concrete. Accordingly, the safety of the system depends entirely upon the ability of the 25 construction workers to step upon and put their weight only over the steel beams and one wrong step can result in a worker's foot penetrating through the polystyrene and causing serious injury. Another drawback of known stay in place deck-type insulating concrete forms is that they do not provide a services cavity that is free of thermal insulation for the 30 installation of the various electrical, plumbing and other services under the bottom of the suspended slab. Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the 35 field relevant to the present invention as it existed before the priority date of each claim of this application. 3148371_.doc 6 Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. 5 A first aspect of the present disclosure provides a system for forming an insulated concrete thermal mass ground slab, said system comprising: a first insulation layer for insulating an outer edge of the slab; a second insulation layer, spaced apart from the first insulation layer, for insulating an underside of the slab; and 10 first frame members extending between the first and second insulation layers and engageable with each of the first and second insulation layers to interlock the first and second insulation layers together so as to maintain the space therebetween for receiving uncured concrete to form an outer perimeter ring beam of the slab, wherein the first and second insulation layers, and the engagement therebetween via 15 the frame members, have sufficient strength to support the forces applied by the uncured concrete. The second insulation layer may form part of an inner under slab insulation module. The inner under slab insulation module may comprise a third insulation layer for insulating an inner side of the peripheral ring beam. The inner under slab insulation module may 20 comprise a fourth insulation layer for insulating at least part of a base of the peripheral ring beam. The inner under slab insulation module may comprise a planar top surface and peripheral sidewalls extending generally perpendicularly from the top surface. The fourth insulation layer may comprise a peripheral flange extending outwardly from the sidewalls at an end of the sidewalls opposite the top surface. A plurality of the inner under slab 25 insulation modules may be connected together to insulate an entire underside area of the slab. Channels may be defined by the sidewalls and peripheral flanges of adjoining inner under slab insulation modules, the channels being configured to form inner grid beams of the slab. Second frame members may extend between adjoining inner under slab insulation modules and engage each of the adjoining inner under slab insulation modules to interlock 30 the adjoining inner under slab insulation modules together so as to maintain the space there between for receiving uncured concrete to form the slab, wherein the inner under slab insulation modules, and the engagement therebetween via the second frame members, have sufficient strength to support the forces applied by the uncured concrete. A fifth insulation layer may be provided for insulating at least part of a base of a 35 peripheral ring beam of the slab. The fifth insulation layer may be engageable with the inner under slab insulation module. Tongue and groove formations and/or ship lap 3148371_.doc 7 formations may be provided to facilitate the engagement between the fifth insulation layer and the inner under slab insulation module. A slab set-down forming flange may extend substantially vertically from the first frame members at a position intermediate the first and second insulation layers, a top end 5 of the slab set-down forming flange being positioned above the height of the first and second insulation layers so as to create a set-down or rebate around a perimeter edge of the slab. The slab set-down forming flange may slidably engage the first frame members. The slab set-down forming flange may be defined by a vertical flange of an elongate L-shaped channel that extends generally parallel to the first insulation layer. The vertical flange of 10 the L-shaped channel may form the web of a C-shaped channel extending away from an interior of the L-shaped channel. Vertical corner reinforcement brackets may slidably engage the C-shaped channel to reinforce mitred joints of external and internal corners of the slab set-down forming channel. One or more longitudinally extending projections may extend from a horizontal flange of the slab set-down forming channel in a direction away 15 from an interior of the L-shaped channel. The projections may have a T-shaped transverse cross section. The slab set-down forming channel may be formed from recycled plastics, virgin plastics, fibreglass reinforced composite plastics, flame retardant plastics, or the like, and may be formed using an extrusion process. The slab set-down forming flange may serve as stay in place formwork for the set-down or rebate around the perimeter edge of the 20 slab. A protective casing may encapsulate and interlock over the first insulation layer. The casing may be in the form of a channel having a C-shaped cross section. The casing may comprise an upper portion and a lower portion that are separable to facilitate installation of the casing around the outer slab edge insulation layer. The casing may be 25 formed from a rigid material. An outer surface of the casing may be textured to facilitate application of tiles, renders and other external finishes. The first insulation layer may comprise slots for slidably receiving correspondingly shaped first anchors of the first frame members to engage the first insulation layer to the first frame members. The inner under slab insulation module may comprise slots for 30 slidably receiving correspondingly shaped first anchors of the first frame members and/or second anchors of the second frame members to engage the inner under slab insulation module to the first frame members and/or to the second frame members. Each of the first frame members may comprise a pair of elongate, spaced apart, substantially parallel, studs and a plurality of spacers interconnecting the pair of studs. The 35 studs may comprise outer studs for connection to the first insulation layer and inner studs for connection to the second insulation layer. The outer studs may extend generally parallel 3148371_.doc 8 to a plane of the first insulation layer. The connection between the spacers and at least some of the studs may be a welded connection. The connection between the spacers and at least some of the studs may be a mechanical connection. The studs may be pre-fabricated with connecting formations at predetermined intervals for engagement by corresponding 5 connecting formations on at least some of the spacers to mechanically interconnect these spacers and studs. The spacers may comprise at least one slot for positioning reinforcement for concrete to be poured between the first insulation layer and the inner under slab insulation module to form a peripheral ring beam of the slab. A plurality of the slots may be provided. 10 The slots may be of different depths and may be provided at different axial positions on the first frame members to facilitate a tailored arrangement of the reinforcement. The spacers may be formed from fire-rated steel. The outer studs may each comprise an outer flange extending substantially parallel to a plane of the first insulation layer. The first insulation layer may include slots for 15 slidably receiving the outer flanges of the outer studs, such that engagement of the outer flanges in the slots secures the first insulation layer to the outer studs against relative movement in a direction perpendicular to a plane of the first insulation layer. The inner studs may each comprise an inner flange extending substantially perpendicular to a plane of the second insulation layer. The inner under slab insulation 20 module may include slots for slidably receiving the inner flanges of the inner studs, such that engagement of the inner flanges in the slots secures the inner under slab insulation module to the inner studs against relative movement in a direction parallel to a plane of the inner under slab insulation module (i.e. perpendicular to the slots). The top spacer of the first frame member may comprise slots for slidably receiving 25 and interlocking with corresponding projections extending from the slab set-down forming flange, wherein engagement of the projections in the slots secures the slab set-down forming flange to the top spacer and the first frame member. The slots may be provided on a raised flange extending from the top spacer. The slots may have a necked opening for captively retaining an enlarged head portion of the projections. The slots and projections 30 may be T-shaped in transverse cross-section. Keyed openings, or slots, may be defined between the projections extending from the slab set-down forming flange. Horizontal corner reinforcement brackets may slidably engage the keyed openings to reinforce mitred joints of external and internal corners of the slab set-down forming flange. Each of the second frame members may comprise a pair of elongate, spaced apart, 35 substantially parallel, first and second studs and a plurality of spacers interconnecting the first and second studs. The first and second studs may be slidably engageable with 3148371_.doc 9 correspondingly shaped slots in the second insulation layer to facilitate connection of the second frame members with the second insulation layer. The slots may be T-shaped in transverse cross-section. The connection between the spacers and at least some of the studs may be a welded connection. The connection between the spacers and at least some of the 5 studs may be a mechanical connection. The studs may be pre-fabricated with connecting formations at predetermined intervals for engagement by corresponding connecting formations on at least some of the spacers to mechanically interconnect these spacers and studs. One or more of the spacers of the second frame members may comprise at least one 10 slot for positioning reinforcement for concrete to be poured for the inner grid beams. A plurality of the slots may be provided. The slots may be of different depths and may be provided at different axial positions on the second frame members to facilitate a tailored arrangement of the reinforcement. The spacers may be formed from fire-rated steel. The first studs of the second frame members may each comprise end flanges on 15 their opposite ends, the end flanges extending substantially perpendicular to a plane of the second insulation layer. The second insulation layer may include slots for slidably receiving the end flanges of the first studs, such that engagement of the end flanges in the slots secures the adjoining second insulation layers to the second frame members against relative movement in a direction parallel to a plane of the inner under slab insulation 20 module. The studs, spacers and flanges of the first frame members and the second frame members may be integrally formed in one-piece construction. The studs, spacers and flanges of the first frame members and the second frame members may be formed from recycled plastics, virgin plastics, flame retardant plastics, fibreglass reinforced composite 25 plastics, or the like, using processes such as injection moulding, structural foam moulding or gas assist moulding. The casing for the first insulation layer may comprise a C-channel with a central joint that divides the channel into top and bottom portions that may be interlocked via a tongue and groove arrangement, elongate dovetail joint, or similar. The top portion may 30 encapsulate the top half of the first insulation layer. The top portion may terminate in a lip that is adapted to engage a corresponding groove in the top spacer of the first frame member to secure the casing, and thereby the first insulation layer, to the first frame member, and thereby to the second insulation layer. The bottom portion may encapsulate the bottom half of the outer slab edge insulation layer. Vertical corner reinforcement 35 brackets, comprising a first sidewall extending perpendicular to a second sidewall, may 3148371_.doc 10 slidably engage a gap between the return flanges of the casing channel and the and the first insulation layer to reinforce mitred corner joints of the first insulation layer. The casing for the first insulation layer may be formed from recycled plastics, virgin plastics, fibreglass reinforced composite plastics, flame retardant plastics, or the like, 5 and may be formed using an extrusion process. The first insulation layer may serve as stay in place formwork for the concrete slab. The second insulation layer may serve as stay in place formwork for the concrete slab. The third insulation layer may serve as stay in place formwork for the concrete slab. The fourth insulation layer may serve as stay in place formwork for the concrete slab. The fifth 10 insulation layer may serve as stay in place formwork for the concrete slab. In a second aspect of the present disclosure provides a system for forming an insulated concrete thermal mass suspended slab, said system comprising: a first insulation layer for insulating an underside of the suspended slab; a reinforcing layer supporting an underside of the first insulation layer, the 15 reinforcing layer being in modular form and comprising a plurality of modules that extend along the length and width of the slab; and a plurality of longitudinally extending spaced apart support beams connected to an underside of the reinforcing layer, each of the support beams being positioned under a joint between the modules of the reinforcing layer, 20 wherein, if the insulation layer alone was supported on the support beams, the insulation layer would have insufficient strength to support the weight of uncured concrete for the slab, but wherein the insulation layer and reinforcing layer together, when spanning the support beams, have sufficient strength to support the weight of uncured concrete for the slab. 25 The modules of the reinforcing layer may each comprise a base and walls extending from the base to define an array of rectangular cells above the base. The modules of the reinforcing layer may be embedded in the first insulation layer. The modules of the reinforcing layer may each be integrally formed in one-piece construction, from recycled plastics, virgin plastics, flame retardant plastics, fibreglass reinforced composite plastics, or 30 the like, and may be formed using processes such as injection moulding, structural foam moulding, gas assist moulding or compression moulding. The first insulation layer may be in modular format and may comprise modules having a base shaped to correspond with the shape of the top of the modules of the reinforcing layer. The modules of the first insulation layer may each comprise a thicker 35 central portion, extending in a longitudinal direction from one end of the modules to the other, and thinner side portions extending transversely from a lower extremity of the 3148371_.doc 11 central portion, the side portions extending in the longitudinal direction from one end of the modules to the other. The central portion may have a planar upper surface to support the underside of a main portion of the slab. The upper surface of the modules may, however, be profiled to increase bonding with the concrete of the slab. The side portions may 5 comprise tongue and groove formations to facilitate connection with tongue and groove formations of an adjoining module of the first insulation layer. When adjoining modules of the first insulation are connected, longitudinally extending recesses may be defined between the interconnected side portions and the sidewalls of their central portions, the longitudinally extending recesses being adapted to receive uncured concrete for forming 10 internal beams of the slab. The central portion may have a wider transverse width portion at a position spaced above the side portions so as to facilitate keying of the internal beams with the modules of the first insulation layer. The modules of the first insulation may have a transverse cross section that has a filled Q shape. The modules of the first insulation layer may be formed or moulded from a foam 15 based insulation product, such as extruded or expanded polystyrene foam, phenolic foam, polyurethane foam, polysulfone foam, or the like. The support beams may comprise pairs of C-section steel sections connected back to back to form I-beams. The C-sections may be light weight steel sections, such as those used as studs in the walls of buildings. A lining layer may be connected to an underside of 20 the support beams to define a cavity between the support beams, the lining layer and the reinforcing layer, the cavity being free from insulation and thereby adapted to receive services, such as electrical, plumbing and/or telecommunications services. Openings may be provided in the support beams to facilitate passing of services through the support beams. 25 The beam end insulation inserts may be formed or moulded from a foam-based insulation product, such as extruded or expanded polystyrene foam, phenolic foam, polyurethane foam, polysulfone foam, or the like. The beam end insulation inserts may comprise slots on for engaging and interlocking into the ends of the steel support beams. The beam end insulation inserts may be adapted to insulate the ends of the support beams. 30 The beam end insulation inserts may be adapted to act as a stay in place insulated edge formwork to hold the uncured concrete in place at the ends of the support beams. The first insulation layer, reinforcing layer and support beams may serve as stay in place formwork for the concrete slab. In a third aspect, there is provided a system for forming an insulated concrete 35 thermal mass ground slab, said system comprising: 3148371_.doc 12 a first insulation layer for insulating an outer edge of the slab and acting as stay in place formwork for the outer edge of the slab; a N-twarV-- seon r aeor layer, spaced apart from the first insulation layer, for 5 underside of the slab first frame members extending between the first insulation layer and the w ge el omie layer and engageable with each of the first insulation layer and the koweriNCecond nsgadBn layer to interlock the first insulation layer and the numw*n :"Sgianz layer together so as to maintain the space therebetween for receiving 10 uncured concrete to form an outer perimeter ring beam of the slabvheinirstand a stay in place slab set-down forming flange extending substantially vertically from the first frame members at a position intermediate the first insulation layer and the 15 namwan*econd i ma layer, a top end of the slab set-down forming flange being positioned above the height of the first insulation layer and the *umwe-secondias;ason layer so as to create a set-down or rebate around a perimeter edge of the slab. second insulation layer 0ia: glue o or more of the eres of te ove-defned 20 einboe eais the seconansadon layer accraingzt the first aspect-alxwe. The presently disclosed systems for forming an insulated concrete thermal mass slab may be fully integrated with applicant's previous invention entitled 'System for forming an insulated concrete thermal mass wall' (International PCT Publication No WO 2011/134008) in a contiguous and seamless manner so as to create an insulated concrete 25 thermal mass building that is substantially fully insulated from the external environment in order to derive maximum benefit of the embodied thermal mass. The present disclosure has several features in common with the invention disclosed in International PCT Publication No WO 2011/134008, where corresponding reference numerals indicate corresponding features with corresponding functionality. The entire disclosure of International PCT 30 Publication No WO 2011/134008 is incorporated herein by way of reference. Embodiments of the presently disclosed system for forming an insulated concrete thermal mass slab will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a top view of a first embodiment of an insulated concrete thermal mass 35 ground slab constructed with a first embodiment of the presently disclosed system; 3148371_.doc 13 Figure 2 is a sectional view of the insulated concrete thermal mass ground slab of Figure 1; Figure 3 is a sectional view of an embodiment of an insulated concrete thermal mass suspended slab constructed with a second embodiment of the presently disclosed 5 system; Figure 4 is a perspective view of an outer frame member of the system for forming an insulated concrete thermal mass ground slab as shown in Figures 1 and 2; Figure 5 is a perspective view of an inner frame member of the system for forming an insulated concrete thermal mass ground slab as shown in Figures 1 and 2; 10 Figure 6 is a perspective top view of an inner under slab insulation module of the system for forming an insulated concrete thermal mass ground slab as shown in Figures 1 and 2; Figure 7 is a perspective bottom view of the inner under slab insulation module of Figure 6; 15 Figures 8a and 8b are perspective views of an outer under beam insulation layer of the system for forming an insulated concrete thermal mass ground slab as shown in Figures 1 and 2; Figure 9 is a sectional view of an outer under beam insulation layer sub-assembled and interlocked with inner under slab insulation modules of the system for forming an 20 insulated concrete thermal mass ground slab as shown in Figures 1 and 2; Figure 10 is a perspective view of an outer slab edge insulation layer of the system for forming an insulated concrete thermal mass ground slab as shown in Figures 1 and 2; Figure 11 is a perspective view of an outer protective casing channel for the outer slab edge insulation layer of Figure 10; 25 Figure 12 is a perspective view of a vertical corner reinforcement bracket for use with the outer protective casing channel of Figure 11 and the outer slab edge insulation layer of Figure 10; Figure 13 is a perspective view of a vertical corner reinforcement bracket of Figure 12, shown interlocked into the outer protective casing channel of Figure 11 and the outer 30 slab edge insulation layer of Figure 10 for reinforcement of mitred internal and external corners of the system for forming an insulated concrete thermal mass ground slab as shown in Figures 1 and 2; Figure 14 is a perspective view of a slab set-down forming channel for creating a set-down or rebate in the edges of the concrete slab of Figures 1 and 2; 35 Figure 15 is a perspective view of a horizontal corner reinforcement bracket for use with the slab set-down forming channel of Figure 14; 3148371_.doc 14 Figure 16 is a perspective view of a vertical corner reinforcement bracket for use with the slab set-down forming channel of Figure 14; Figure 17 is a perspective view of the vertical corner reinforcement bracket of Figure 16 and horizontal corner reinforcement brackets of Figure 15 interlocked into the 5 slab set-down forming channel of Figure 14 for reinforcement of mitred internal and external corners of the slab set-down forming channel; Figure 18 is a perspective view of a partial sub-assembly showing the outer protective casing channel of Figure 11, outer slab edge insulation layer of Figure 10, under outer beam insulation layer of Figures 8a and 8b, outer frame member of Figure 4, slab set 10 down forming channel of Figure 14 and the under slab insulation module of Figures 6 and 7, all interlocked together to form an outer ring beam of the system for forming an insulated concrete thermal mass ground slab as shown in Figures 1 and 2; Figure 19 is a perspective view of an alternative inner under slab insulation module that provides earth coupling to a concrete ground slab; 15 Figure 20 is a sectional view of an alternative embodiment of an insulated concrete thermal mass ground slab incorporating the inner under slab insulation module of Figure 19 to provide earth coupling; Figure 21 is a perspective view of an under slab insulation reinforcement grid module of the system for forming an insulated concrete thermal mass suspended slab as 20 shown in Figure 3; Figure 22 is a perspective view of an under slab integral beam insulation module of the system for forming an insulated concrete thermal mass suspended slab as shown in Figure 3; Figure 23 is a perspective view of an under slab steel support beam of the system 25 for forming an insulated concrete thermal mass suspended slab as shown in Figure 3; Figure 24a is a perspective view of a beam end insulation insert and an associated reinforcement bracket for connection to the under slab steel support beam of Figure 23; Figure 24b is a sectional view taken along line A-A of Figure 3 and Figure 26, which shows the placement of the beam end insulation insert and reinforcement bracket of 30 Figure 24a; Figure 25 is a perspective view of an alternative under slab flat insulation module for a system for forming an insulated concrete thermal mass suspended slab Figure 26 is a sectional view of an alternative embodiment of an insulated concrete thermal mass suspended slab including the under slab flat insulation module of Figure 25; 35 Figure 27 is a sectional view of an insulated concrete thermal mass ground floor slab, insulated concrete thermal mass suspended concrete slab with flat insulation module, 3148371_.doc 15 insulated concrete thermal mass suspended concrete slab with integral beam insulation module, as well as an insulated concrete thermal mass wall, all integrated together to construct an insulated concrete thermal mass concrete building using embodiments of the presently disclosed system for the formation of an insulated concrete thermal mass slab, as 5 well as embodiments of the wall system disclosed in International PCT Publication No WO 2011/134008. Referring to the drawings, and initially to Figures 1 and 2, there is shown a top view and sectional view, respectively, of a first embodiment of an insulated concrete thermal mass ground slab 101. Construction of the slab 101 is facilitated by a slab forming system 10 11comprising a first, outer slab edge insulation layer 12, a second insulation layer defined by an under slab insulation module 18, and a third, outer under beam insulation layer 19. The outer slab edge insulation layer 12 and the outer under beam insulation layer 19 are laid around the perimeter of the concrete ground slab, and the under slab insulation module 18 is laid in a grid pattern within the perimeter of the concrete ground slab, such that the 15 entire underside and edges of the slab 101 are encapsulated in insulation. First, outer frame members 16, which are shown in detail in Figure 4, extend between the outer slab edge insulation layer 12 and the under slab insulation module 18 to interlock the outer slab edge insulation layer 12 and the outer under beam insulation layer 19 to the inner under slab insulation module 18 in such a manner so as to maintain a space 20 there between for receiving uncured concrete 23 to form outer slab perimeter ring beams 103 of the insulated concrete thermal mass ground slab 101. The interlocking provided by the outer frame members 16 secures the outer slab edge insulation layer 12, the outer under beam insulation layer 19 and the inner under slab insulation module 18 against forces generated by the pouring and weight of the uncured concrete. 25 Second, inner frame members 16', which are shown in detail in Figure 5, extend between adjoining inner under slab insulation modules 18 to interlock all such modules together in a grid pattern in such a manner so as to maintain a space there between for receiving uncured concrete 23 to form inner grid beams 105 of the insulated concrete thermal mass ground slab 101. The interlocking provided by the inner frame members 16' 30 secures the inner under slab insulation modules 18 against forces generated by the pouring and weight of the uncured concrete. Slab set-down forming channel 27, which are shown in detail in Figure 14, slides in and interlocks into the top of the outer frame members 16 in such a manner so as to create a set-down or rebate around the perimeter edge of the concrete ground slab 101, thus forming 35 a positive set-down base for the installation of the concrete walls and to prevent the ingress of water through the joint between the slab 101 and the walls. 3148371_.doc 16 Outer protective casing channel 25, which is shown in detail in Figure 11, encapsulates and interlocks over the outer slab edge insulation layer 12 in such a manner so as to provide a protective sheath around the entire slab edge insulation and also act as a rigid surface for soil backfilling as well as a textured base surface for application of tiles, 5 renders and other external finishes. As best seen in Figure 4, each of the outer frame members 16 comprises a pair of elongate, spaced apart, substantially parallel, studs 16a, 16b and a plurality of spacers 16c interconnecting the pair of studs. The studs comprise outer studs 16a for connection to the outer slab edge insulation layer 12 and inner studs 16b for connection to the inner under 10 slab insulation module 18. The studs 16a, 16b extend generally parallel to a plane of the outer slab edge insulation layer 12 and generally perpendicularly to a plane of the slab 101. The spacers 16c have a generally T-shaped cross-section, comprising a web 16c1 and a flange 16c2 extending normal to the web. A plurality of slots 16c3 are formed in the web for securely positioning and supporting horizontally oriented reinforcement 20 for 15 concrete 23 to be poured in the space between the inner insulation module 18 and outer insulation layer 12 to form the outer slab perimeter ring beam 103 of the insulated concrete thermal mass ground slab 101. Slots 16c3 are provided at different axial positions to facilitate a tailored arrangement of the reinforcement 20. The outer studs 16a each comprise an anchor, in the form of an outer flange 16al 20 extending substantially parallel to a plane of the outer insulation layer 12, and an inner flange 16a4 also extending substantially parallel to a plane of the outer insulation layer 12. As shown, the outer flange 16a1 and the inner flange 16a4 are joined together by a web 16a2. The web 16a2 may also be provided with rectangular apertures 16a3 for weight and cost reduction. As shown in the embodiments of Figures 1, 2, 10, 18 and 20, the outer slab 25 edge insulation layer 12 includes slots 12a for slidably receiving the flanges 16al of the outer studs, such that engagement of the flanges 16al in the slots 12a anchors the outer insulation layer 12 to the outer studs 16a against relative movement in a direction perpendicular to a plane of the outer insulation layer 12. The inner flanges 16a4 also help to further secure the outer insulation layer 12, as well as helping to prevent the entry of 30 concrete into the slots 12a of the outer insulation layer 12. Each outer frame member module 16 may either be 400mm or 16 inches long or may have a custom length to suit the desired height of the concrete slab and the site soil conditions. Referring again to Figure 4, the inner studs 16b each comprise an outer flange 16b1 extending substantially parallel to a side plane of the inner under slab insulation module 18 35 and an inner flange 16b4 also extending substantially parallel to the side plane of the inner under slab insulation module 18. As shown, the outer flange 16b1 and the inner flange 3148371_.doc 17 16b4 are joined together by a web 16b2. The web 16b2 may be provided with rectangular apertures 16b3 for weight and cost reduction. As shown in the embodiments of Figures 1, 2, 6, 7, 18, 19 and 20, the inner under slab insulation module 18 includes slots 18a for slidably receiving the flanges 16b1 of the inner studs, such that engagement of the flanges 5 16b1 in the slots 18a secures the inner under slab insulation module 18 to the inner studs 16b against relative movement in a direction perpendicular to the plane of the flanges 16b 1, 16b4. The inner flanges 16b4 also help to further secure the inner under slab insulation module 18, as well as helping to prevent the entry of concrete into the slots 18a of the inner under slab insulation module 18. 10 Referring again to Figure 4, the top spacer 16c of the outer frame member 16 may additionally be provided with a raised flange 16d with integral T-slots 16d2 for slidably receiving and interlocking correspondingly shaped horizontal T-tracks 27b1 of the slab set down forming channel 27. The T-slots 16d2 extend generally perpendicular to the plane of the top web 16c1, such that the engagement of the T-tracks 27b1 in the T-slots 16d2 15 secures the slab set-down forming channel 27 to the top of the outer frame member 16 against relative movement in a direction perpendicular to the plane of the outer slab edge insulation layer 12 as well as against relative translational movement in the plane of the top web 16c1. Vertical webs 16d1 may be provided opposite ends of the raised flange 16d for providing additional rigidity to the raised flange 16d, as well as rectangular apertures 16d3 20 for weight and cost reduction and to promote distribution of uncured concrete around the raised flange 16d. As shown in the embodiments of Figures 1, 2, 4, 14, 18 and 20, the slab set-down forming channel 27 slides in and interlocks into the top of the outer frame members 16 in such a manner so as to create a set-down or rebate around the perimeter edge of the concrete ground slab 101 thus forming a positive set-down base for the 25 installation of the concrete walls and to prevent the ingress of water through the joint between the slab and the walls. Referring again to Figure 4, the top spacer 16c of the outer frame member 16 may additionally be provided with a built in recessed groove 16e for receiving and interlocking a curved lip 25a2 of the outer protective casing channel 25 in such a manner so as to further 30 protect and secure the outer slab edge insulation layer 12 and secure it against movement due to pressure generated during the pouring of the concrete 23. As shown in the embodiments of Figures 1, 2, 11, 18 and 20, the outer protective casing channel 25 encapsulates and interlocks over the outer slab edge insulation layer 12 in such a manner so as to protect the insulation from damage and also provides a rigid surface for soil 35 backfilling as well as a textured base surface for application of tiles, renders and other external finishes while acting as a positive barrier against ingress of pests and termites. 3148371_.doc 18 Referring again to Figure 4, the bottom spacer 16c of the outer frame member 16 may additionally be provided with a extended flange 16c4 and a horizontal web 16c5, which together hold down the outer under beam insulation layer 19 and secure it against movement due to pressure generated during the pouring of the concrete 23. The extended 5 flange 16c4 may also be provided with rectangular apertures 16c6 for weight and cost reduction and to promote distribution of uncured concrete around the extended flange 16c4. As best seen in Figure 5, each of the inner frame members 16' comprises a pair of elongate, spaced apart, substantially parallel, studs 16a, 16b and a plurality of spacers 16c interconnecting the pair of studs. The studs comprise outer studs 16a for connection to one 10 side of the inner under slab insulation module 18 and inner studs 16b for connection to one side of the adjacent inner slab insulation module 18 to interlock all the modules together in a grid pattern in such a manner so as to maintain a space there between for receiving uncured concrete 23 to form the inner grid beams 105 of the insulated concrete thermal mass ground slab 101. 15 The spacers 16c have a generally T-shaped cross-section, comprising a web 16cl and a flange 16c2 extending normal to the web. A plurality of slots 16c3 are formed in the web for securely positioning and supporting horizontally oriented reinforcement 20 for concrete 23 to be poured between the inner insulation modules 18 to form the inner grid beams 105 of the insulated concrete thermal mass ground slab 101. Slots 16c3 are provided 20 at different axial positions to facilitate a tailored arrangement of the reinforcement 20. The outer studs 16a each comprise an outer flange 16al extending substantially parallel to the side plane of the inner under slab insulation module 18 and an inner flange 16a4 also extending substantially parallel to the side plane of the inner under slab insulation module 18. As shown, the outer flange 16a1 and the inner flange 16a4 are joined 25 together by web 16a2. The web 16a2 may also be provided with rectangular apertures 16a3 for weight and cost reduction. As shown in the embodiments of Figures 1, 2, 6, 7, 18, 19 and 20, the inner under slab insulation module 18 includes slots 18a for slidably receiving the flanges 16a1 of the outer studs, such that engagement of the flanges 16a1 in the slots 18a secures the inner under slab insulation module 18 to the outer studs 16a against relative 30 movement in a direction perpendicular to a plane of the flanges 16a1. The inner flanges 16a4 also help to further secure the inner under slab insulation module 18, as well as helping to prevent the entry of concrete into the slots 18a of the inner under slab insulation module 18. Each inner frame member module 16' may either be 400mm or 16 inches long or may have a custom length to suit the height of the concrete slab and the site soil 35 conditions. 3148371_.doc 19 Referring again to Figure 5, the inner studs 16b each comprise an outer flange 16b1 extending substantially parallel to the side plane of the adjacent inner under slab insulation module 18 and an inner flange 16b4 also extending substantially parallel to the side plane of adjacent the inner under slab insulation module 18. As shown, the outer flange 16b1 and 5 the inner flange 16b4 are joined together by web 16b2. The web 16b2 may also be provided with rectangular apertures 16b3 for weight and cost reduction. As shown in the embodiments of Figures 1, 2, 6, 7, 18, 19 and 20, the inner under slab insulation module 18 includes slots 18a for slidably receiving the flanges 16b1 of the inner studs, such that engagement of the flanges 16b1 in the slots 18a secures the inner under slab insulation 10 module 18 to the inner studs 16b against relative movement in a direction perpendicular to a plane of the flanges 16bl. The inner flanges 16b4 also help to further secure the inner under slab insulation module 18, as well as helping to prevent the entry of concrete into the slots 18a of the inner under slab insulation module 18. Referring again to Figure 5, the bottom spacer 16c of the outer frame member 16' 15 may additionally be provided with a extended flange 16c4 and a horizontal web 16c5 which together hold down the extended ship lap formations 18b on the bottom of inner under slab insulation module 18 and secure it against movement due to pressure generated during the pouring of the concrete 23. The extended flange 16c4 may also be provided with rectangular apertures 16c6 for weight and cost reduction and to promote distribution of 20 uncured concrete around the extended flange 16c4. The outer frame members 16, and the inner frame members 16', may be integrally formed in one-piece construction, preferably from recycled plastics, virgin plastics, flame retardant plastics, fibreglass reinforced composite plastics, or the like, using processes such as injection moulding, structural foam moulding or gas assist moulding. However, the 25 frame members 16 and 16' may also be formed, for example, from combinations of plastics and metals, or other materials that are resistant to the chemical environment of curing concrete, and connected by welding or by appropriate mechanical fasteners, such as screws or bolts. As best seen in Figures 6 and 7, the inner under slab insulation module 18 30 comprises a thick foam based insulation module with a built-in combined ship lap 18b, and tongue 18c, and groove 18d, formations on the bottom of all four sides that engage and interlock into corresponding combined ship lap 18b, and tongue 18c and groove 18d, formations of the adjacent inner under slab insulation modules 18, or the adjacent outer under beam insulation layer 19, in such a manner that all the insulation modules are laid 35 out and interconnected to each other in a grid pattern so as to seamlessly insulate the undersides of all the inner grid beams 105 as well as the undersides of all the outer 3148371_.doc 20 perimeter ring beams 103. As discussed above, the inner under slab insulation module also includes slots 18a for slidably receiving the inner flanges 16b of the outer frame members 16, and the outer flanges 16a and inner flanges 16b of the inner frame members 16'. Engagement of the flanges in the slots secures and interlocks all the inner under slab 5 insulation modules 18 and the outer slab edge insulation layers 12 as well as the outer under beam insulation layers 19 to each other in a grid pattern in such a manner so as to resist relative movement and withstand the substantial pressures that are generated during the pouring and subsequent curing of the concrete 23. The inner under slab insulation module 18 may also be provided with additional voids 18e at the bottom for weight and 10 cost reduction. The inner under slab insulation module 18, may be moulded from a foam based insulation product, such as expanded polystyrene foam, phenolic foam, polyurethane foam, polysulfone foam, or the like, depending upon the desired performance criteria for the particular application and climate. 15 As best seen in Figures 8a and 8b, the outer under beam insulation layer 19 comprises a thick foam-based insulation sheet or panel with a built-in combined ship lap 19a, and groove 19c or tongue 19b, formations on one side that engage and interlock into corresponding combined ship lap 18b, and tongue 18c or groove 18d, formations of the adjacent inner under slab insulation modules 18 in such a manner so as to insulate the 20 undersides of the outer perimeter ring beam 103 of the concrete thermal mass ground slab 101. The outer under beam insulation layer 19 may be formed from a thick sheet or panel based foam insulation product, such as extruded or expanded polystyrene foam panels, phenolic foam panels, polyurethane foam panels, polysulfone foam panels, or the like, 25 depending upon the desired performance criteria for the particular application and climate. Figure 9 shows a sectional view of the outer under beam insulation layer 19, and inner under slab insulation modules 18, with their respective combined ship laps 19a and l8b, and tongue 18c and groove 19c and 18d, formations sub-assembled and interlocked together for use below the concrete thermal mass ground slab 101. 30 As best seen in Figure 10, the outer slab edge insulation layer 12, comprises a thick foam-based sheet or panel with built in T-slots 12a on the inner side for slidably receiving the outer flanges 16al of the outer frame members 16 such that engagement of the flanges 16a1 in the slots 12a secures the outer insulation layer 12 to the outer studs 16a against relative movement in a direction perpendicular to a plane of the outer insulation layer 12 35 and thereby to insulate the perimeter edges of the insulated concrete thermal mass ground slab 101. The outer slab edge insulation layer 12 also has tongue 12b and groove 12c 3148371_.doc 21 formations for enhancing interlocking of the adjoining sheets or panels for reducing thermal bridging and improving overall insulation and weatherproofing performance. The outer slab edge insulation layer 12 may be formed from a thick sheet or panel based foam insulation product, such as extruded or expanded polystyrene foam panels, 5 phenolic foam panels, polyurethane foam panels, polysulfone foam panels, or the like, depending upon the desired performance criteria for the particular application and climate. As best seen in Figures 11, 12 and 13, the outer protective casing channel 25 for the outer slab edge insulation layer 12 comprises a top C-channel 25a and a bottom C-channel 25b, which are interlocked to each other using a keyed tongue 25a1 and groove 25b1 10 arrangement. The top C-channel 25a encapsulates the top half of the outer slab edge insulation layer 12 and its terminal end has a curved lip 25a2 that engages and interlocks into the corresponding recessed groove 16e in the top spacer of the outer frame member 16 to further protect and secure the outer slab edge insulation layer 12 and secure it against movement due to pressure generated during the pouring of the concrete. The bottom C 15 channel 25b encapsulates the bottom half of the outer slab edge insulation layer 12 and protects it against damage. As shown in Figures 12 and 13, corner reinforcement brackets 26 are provided for the casing channel 25 to facilitate forming mitred corners in the outer slab edge insulation. The top and bottom ends of the brackets 26 have serrated teeth 26a that slide into the gap 20 between an inner side of the lips of the top and bottom C-channels 25a and 25b and an inner side of the outer slab edge insulation panels 12 for providing additional reinforcement to mitred corner joints in the outer slab edge insulation. The serrated teeth 26a facilitate providing a tight friction fit between the corner reinforcement bracket 26 and the casing channel 25. 25 The outer protective casing channel 25, may be formed from recycled plastics, virgin plastics, fibreglass reinforced composite plastics, flame retardant plastics, or the like, using an extrusion process to provide the requisite rigidity and strength to perform its function to protect the outer slab edge insulation layer. As best seen in Figures 14, 15, 16 and 17, the slab set-down forming channel 27, 30 comprises an elongate L shaped channel having a vertical surface 27a and a horizontal surface 27b both of which extend generally parallel to the outer slab edge insulation layer 12. The horizontal surface 27b is provided with a series of horizontal T-tracks 27b1, as discussed above, which slide and interlock into the corresponding T-slots 16d2 on the top spacers 16c of the outer frame members 16 in such a manner so as to create a set-down or 35 rebate around the perimeter edge of the concrete ground slab 101. This set-down or rebate provides a positive set-down base for the installation of concrete walls and also helps to 3148371_.doc 22 prevent the ingress of water through the joint between the slab 101 and the walls. The vertical surface 27a is provided with a vertical C-channel 27a1. As shown in Figures 15 and 16, horizontal corner reinforcement brackets 28 and vertical corner reinforcement brackets 29 are provided to facilitate forming mitred corners 5 in the slab set-down forming channel 27. The horizontal corner reinforcement brackets 28 have built-in serrated teeth 28a and slidably engage the horizontal T-tracks 27b1 on the horizontal surface 27b of the slab set-down forming channel 27, as shown in Figure 17. The vertical corner reinforcement brackets 29 have built-in serrated teeth 29a and slidably engage the vertical C-channels 27al on the vertical surface 27a of the slab set-down 10 forming channel 27, as shown in Figure 17. Together, the brackets 28 and 29 provide additional reinforcement to mitred corner joints in the slab set-down bracket 27. The serrated teeth 28a and 29a facilitate providing a tight friction fit between the corner reinforcement brackets 28 and 29 and the slab set-down forming channel 27. The slab set-down forming channel 27, may be formed from recycled plastics, 15 virgin plastics, fibreglass reinforced composite plastics, flame retardant plastics, or the like, using an extrusion process to provide the requisite rigidity and strength to perform its function to create a set-down or rebate in the concrete slab. Figure 18 is a perspective view of a partial sub assembly of the slab system 11 showing the outer protective casing channel 25, outer slab edge insulation layer 12, outer 20 under beam insulation layer 19, outer frame member 16, slab set-down forming channel 27 and the under slab insulation module 18, all interlocked together to form the outer ring beam 103 of the insulated concrete thermal mass ground slab 101. To form an insulated concrete thermal mass ground slab 101 using the slab forming system 11, the following sequence of steps are followed: 25 Step 1 - outer slab edge insulation layer panels 12 are first inserted and interlocked into the bottom half 25b of the outer protective channels 25 and laid out to form the perimeter of the slab 101. The internal and external mitred corners of the outer slab edge insulation layer 12 are formed and interlocked by inserting the corner reinforcement brackets 26 in the gap between the inner side of the lips of the bottom C-channel 25b and 30 the inner side of the outer slab edge insulation panels 12; Step 2 - outer under beam insulation layer modules 19 are laid on the inside perimeter of the slab 101, abutting the bottom C-channels 25b of the outer protective channels 25; Step 3 - inner under slab insulation modules 18 are laid in a grid pattern within the 35 perimeter defined by the outer under beam insulation layer modules 19. The inner under slab insulation modules 18 are interlocked with each other with the built-in combined ship 3148371_.doc 23 lap 18b, and tongue 18c and groove 18d, formations to form the inner grid beams 105 and are also interlocked with the outer under beam insulation layer modules 19 with the built-in ship lap 18b, 19a, and tongue 18c and groove 19c, formations to form the outer ring beam 103 of the insulated concrete thermal mass ground slab 101; 5 Step 4 - the outer slab edge insulation layer panels 12 are connected and secured to the inner under slab insulation modules 18 using the outer frame members 16; Step 5 - the inner under slab insulation modules are further connected and secured to each other in a grid pattern using the inner frame members 16'; Step 6 - steel reinforcement bars 20 are placed in the slots 16c3 of the outer frame 10 members 16, along with steel reinforcement ring ligatures 21, to reinforce the outer ring beams 103 of the slab 101 and steel reinforcement bars 20 are also placed in the slots 16c3 of the inner frame members 16' to reinforce the inner grid beams 105 of the slab 101; Step 7 - the slab set-down forming channels 27 are engaged with the outer frame members 16 by sliding the horizontal T-tracks 27b1 into the corresponding T-slots 16d2 on 15 the top spacers 16c of the outer frame members 16. The internal and external mitred corners of the channels 27 are formed and interlocked by inserting the vertical corner reinforcement brackets 29 into the vertical C-channels 27al and the horizontal corner reinforcement brackets 28 into the horizontal T-tracks 27b1; Step 8 - the top half 25a of the outer protective channels 25 are laid over the outer 20 slab edge insulation layer panels 12 and interlocked to the bottom half 25b by inserting the tongue 25al into the corresponding groove 25bl. The top half 25a of the outer protective channels 25 is further secured by inserting and interlocking its inner curved lip 25a2 into the corresponding recessed groove 16e in the top spacer 16c of the outer frame member 16 in such a manner so as to secure the outer slab edge insulation layer 12 against movement 25 due to pressure generated during the pouring of the concrete 23; Step 9 - steel reinforcement bars 20 are placed in a grid pattern above the entire top surface of the inner under slab insulation module and all the steel reinforcement is fully inspected and certified, after which uncured concrete 23 is poured to create an insulated concrete thermal mass ground slab 101. 30 Figure 19 is a perspective view of an alternative inner under slab insulation module 18, which does not have any insulation below the inner grid beams 105, so as to provide earth coupling to the insulated concrete ground slab 101 for additional strength and stability for particular soil types, such as reactive soils and unstable soils. Figure 20 is a sectional view of an alternative embodiment of an insulated concrete 35 thermal mass ground slab 101 that does not have any insulation below the perimeter ring 3148371_.doc 24 beams 103 or the inner grid beams 105, so as to provide earth coupling for additional strength and stability for particular soil types, such as reactive soils and unstable soils. Referring to Figure 3, there is shown a sectional view of an embodiment of an insulated concrete thermal mass suspended slab 201. Construction of the slab 201 is 5 facilitated by a slab forming system 51 comprising a first insulation layer 55 for insulating an underside of the slab 201 and a reinforcing layer 54 supporting an underside of the first insulation layer 55. The first insulation layer 55 and reinforcing layer 54 are in modular form and comprise a plurality of interconnectable modules for spanning the length and width of the slab 201. The base of the modules of the first insulation layer 55 have a shape 10 corresponding with the shape of the top of the modules of the reinforcing layer 54. Longitudinally extending spaced apart steel support beams 65 are connected to an underside of the reinforcing layer 54 at locations corresponding with joints between the modules of the reinforcing layer. If the insulation layer 55 alone was supported on the beams 65, the insulation layer would have insufficient strength to support the weight of 15 uncured concrete for the slab 201. However, the insulation layer 55 and reinforcing layer 54 together, when spanning the support beams 65, have sufficient strength to support the weight of uncured concrete 23 for the slab 201, along with the weight of construction workers and weight of construction equipment, and can also withstand the substantial pressures that are generated during the pouring and subsequent curing of the slab 201. 20 As best seen in Figure 21, modules of the reinforcing layer 54 each comprise a base 14b and walls 14a extending from the base to define an array of rectangular cells above the base 14b. The modules of the reinforcing layer 54 may each be integrally formed in one piece construction, from recycled plastics, virgin plastics, flame retardant plastics, fibreglass reinforced composite plastics, or the like, using processes such as injection 25 moulding, structural foam moulding, gas assist moulding or compression moulding. As best seen in Figure 22, the first insulation layer modules 55 comprises a thicker central portion 55d, extending in a longitudinal direction from one end to the other, and thinner side portions 55c extending transversely from a lower extremity of the central portion 55d, the side portions 55c also extending in the longitudinal direction from one end 30 to the other. The central portion 55d has a planar upper surface to support the underside of a main portion of the slab 201. The upper surface of the modules may be profiled to increase bonding with the concrete of the slab 210. The side portions 55c comprise tongue 55a and groove 55b formations to facilitate connection with tongue 55a and groove 55b formations of an adjoining first insulation layer module 55. The tongue 55a and groove 55b 35 formations enhance the interlocking of the adjoining modules 55 for improving the overall 3148371_.doc 25 insulation and weatherproofing performance of the insulated concrete thermal mass suspended slab 201. When adjoining modules 55 are connected, longitudinally extending recesses are defined between the interconnected side portions 55c and the sidewalls of their central 5 portions 55d. The longitudinally extending recesses are adapted to receive uncured concrete 23 and steel reinforcement 20 for forming internal beams 205 of the slab 201, as shown in Figure 3. The central portion 55d has a wider transverse width portion at a position spaced above the side portions 55c so as to facilitate keying of the internal beams 205 with the modules of the first insulation layer 55. The modules of the first insulation 10 layer 55 thus have a transverse cross section that has a filled Q shape. The internal beams 205 allow the slab 201 to bridge or cantilever over large spans whilst reducing the overall weight and quantity of the concrete and reinforcement steel, thereby reducing the overall cost of the suspended slab 201. 1. The first insulation layer modules 55 may be formed or moulded from a foam-based 15 insulation product, such as extruded or expanded polystyrene foam, phenolic foam, polyurethane foam, polysulfone foam, or the like, depending upon the desired performance criteria for the particular application and climate. The reinforcing layer modules 54 may be inserted or in-situ embedded into the first insulation layer modules 55 during the moulding and manufacturing stage, or they may be simply laid under the insulation modules 55 on 20 site. As best seen in Figure 23, the under slab steel support beams 65 comprise standard light weight C-channel steel framing studs 65a placed together and back to back and connected together to form I beams 65. The steel support beams 65are laid below the first insulation layer modules 55 and reinforcing layer modules 54 to perform the dual function 25 of carrying the temporary construction loads as well as facilitating the forming of a full services cavity 69 for the installation of various services, such as electrical, plumbing, air conditioning, data and other services, under the bottom of the suspended slab 201. The light weight C-channel steel framing studs 65a have built-in flanged holes 65b to facilitate installation of services through their webs. Whilst not shown, the under slab steel support 30 beams 65 are provided with additional temporary propping and shoring supports to withstand the substantial weight of concrete 23 for the slab 201 until it is fully cured. Shown in Figure 24a is a beam end insulation insert 67 comprising a thick foam based insulation module with built-in profiled slots 67a, 67b on both sides for engaging and interlocking into the ends of the slab support beams 65. As best seen in Figure 24b, a 35 bracket 68 facilitates connection of the beam end insulation inserts 67 to the ends of the slab support beams 65. The insulation inserts 67 perform the dual function of providing 3148371_.doc 26 insulation to the ends of the steel beams 65 and acting as a stay-in-place insulated edge formwork to hold the concrete 23 in place until it cures. The bracket 68 has longitudinally extending ribs 68a to increase its rigidity and strength to facilitate withstanding the forces generated by the pouring and weight of uncured concrete of the slab 201. The beam end 5 insulation inserts 67 may be formed or moulded from the same foam-based insulation product as the first insulation layer modules 55. The bracket 68 may be formed from metal, such as steel. Figure 25 is a perspective view of an alternative under slab flat insulation module 55' that does not provide for any internal beams 205. Figure 26 is a sectional view of an 10 embodiment of an insulated concrete thermal mass suspended slab 201' constructed using the alternative under slab flat insulation module 55'. The reduced overall height of the insulation modules 55' and resulting slab 201' are useful for application where vertical space is limited or the height of a room is to be maximised. Figures 3, 25 and 26 have a number of features in common with those discussed above with respect to Figures 1, 2 and 15 4 to 24b, where corresponding reference numerals indicate corresponding features with corresponding functionality. Figure 27 is a sectional view of an insulated concrete thermal mass ground floor slab 101, insulated concrete thermal mass suspended concrete slab 201' with flat insulation modules 55', insulated concrete thermal mass suspended concrete slab 201 with insulation 20 modules 55, as well as an insulated concrete thermal mass wall 100, all integrated together to construct a insulated concrete thermal mass concrete building using embodiments of the presently disclosed slab forming system as well as embodiments of our insulated concrete thermal mass wall system, which is disclosed in PCT Publication No WO 2011/134008. To form an insulated concrete thermal mass suspended slab 201 and 201', as shown 25 in Figure 27, using the slab forming systems 51 and 51', the following sequence of steps is followed: Step 1 - an insulated concrete thermal mass ground slab 101 of the building is completed using system 11 as described above. Insulated concrete thermal mass walls are then completed using the system disclosed in PCT Publication No WO 2011/134008. 30 Initially, the concrete 23 is poured in the walls 100 only up to the bottom line of the suspended concrete slab 201', such that the outer insulation layer 12 of the wall 100 acts as a stay-in-place insulated edge formwork for the insulated concrete thermal mass suspended slab 201'; Step 2 - several under slab steel support beams 65 are placed over the top of the 35 partly poured wall 100 at a distance equal to the width of each first insulation layer module 55'. The under slab steel support beams 65 are then provided with additional temporary 3148371_.doc 27 propping and shoring supports to withstand the substantial weight of concrete 23 of the slab 201' until it is cured sufficiently to be self-supporting; Step 3 - the beam end insulation inserts 67 are then inserted between the ends of the under slab support beams 65 and the profiled slots 67a and 67b are interlocked into the 5 corresponding profiles of the beams 65 and the brackets 68 are secured to the support beams 65 using bolts or other appropriate fasteners in such a manner that the beam end insulation inserts 67 perform the dual function of providing insulation to the ends of the steel beams 65 and acting as a stay-in-place insulated edge formwork to hold the concrete 23 of the suspended slab 201' in place until it is cured sufficiently to be self-supporting; 10 Step 4 - reinforcing layer modules 54, along with first insulation layer modules 55', are placed over the under slab steel support beams 65, and interlocked with each other by engaging the tongues 65b and grooves 65c, such that the modules 54, 55' fully cover all the under slab steel support beams 65 without any gaps to provide seamless insulation and weather proofing performance to the insulated concrete thermal mass suspended slab 201'; 15 Step 5 - steel reinforcement bars 20 are placed in a grid pattern over the entire top surface of the first insulation layer modules 55'; Step 6 - all the steel reinforcement 20 of slab 201' is fully inspected and certified after which uncured concrete 23 is poured to create insulated concrete thermal mass suspended slab 201'; 20 Step 7 - concrete 23 is poured in the walls 100 up to the bottom line of the suspended concrete slab 201, such that the outer insulation layer 12 of the wall 100 acts as a stay-in-place insulated edge formwork for the insulated concrete thermal mass suspended slab 201; Step 8 - several under slab steel support beams 65 are placed over the top of the 25 poured wall 100 at a distance equal to the width of each first insulation layer module 55. The under slab steel support beams 65 are then provided with additional temporary propping and shoring supports to withstand the substantial weight of concrete 23 of the slab 201 until it is cured sufficiently to be self-supporting; Step 9 - the beam end insulation inserts 67 are then inserted between the ends of the 30 under slab support beams 65 and the profiled slots 67a and 67b are interlocked into the corresponding profiles of the beams 65 and the brackets 68 are secured to the support beams 65 using bolts or other appropriate fasteners in such a manner that the beam end insulation inserts 67 perform the dual function of providing insulation to the ends of the steel beams 65 and acting as a stay-in-place insulated edge formwork to hold the concrete 35 23 of the suspended slab 201 in place until it is cured sufficiently to be self-supporting; 3148371_.doc 28 Step 10 - reinforcing layer modules 54, along with first insulation layer modules 55, are placed over the under slab steel support beams 65, and interlocked with each other by engaging the tongues 65b and grooves 65c, such that the modules 54, 55 fully cover all the under slab steel support beams 65 without any gaps to provide seamless insulation and 5 weather proofing performance to the insulated concrete thermal mass suspended slab 201; Step 11 - steel reinforcement bars 20 are placed in the longitudinally extending recesses defined between the adjoining first insulation layer modules 55 for forming the internal beams 205; Step 12 - steel reinforcement bars 20 are placed in a grid pattern over the entire top 10 surface of the first insulation layer modules 55; Step 13 - all the steel reinforcement 20 of slab 201 is fully inspected and certified after which uncured concrete 23 is poured to create insulated concrete thermal mass suspended slab 201; Step 14 - various services such as electrical, data, plumbing, air conditioning etc are 15 placed in the services cavity 69 formed between the under slab steel support beams 65; Step 15 - a ceiling lining layer 13 is attached to the bottom of the steel beams 65. It will be appreciated that the illustrated insulated concrete thermal mass slab systems disclosed herein enhance energy efficiency by utilising the properties of thermal mass to naturally keep building interiors comfortable across changing seasons. 20 The illustrated systems allow the concrete thermal mass slabs 101, 201, 201' to directly interact with the interiors of a building, by virtue of the slabs not having any insulation on their top surface, which enables the interiors of the building to derive benefits from the energy storage properties of the bottom insulated thermal mass concrete slab. In other words, because there is no insulation provided on the top surface of the concrete slab, 25 thermal energy transfer is facilitated on this side of the slab. The illustrated insulated concrete thermal mass ground slab system 11 is a very advanced system that combines outer slab edge insulation 12, outer under beam insulation 19 and inner under slab insulation 18 and interlocks all of them in a seamless contiguous layer of insulation to create in-situ integral perimeter ring beams 103 and integral under 30 slab grid beams 105 that together provide exceptional strength to the ground slab 101 and also reduce the overall quantities of the concrete and reinforcement steel required. The ground slab system 11 also has an integral slab set-down forming channel 27 that enables the concrete walls 100 to be set-down within the concrete ground slab 101 to help prevent water ingress around the perimeter of the concrete ground slab 101. The 35 system 11 also has an outer protective casing channel 25 that encapsulates the outer slab edge insulation layer 12 and provides it with additional protection from pests, termites, 3148371_.doc 29 vegetation etc and also provides a rigid surface for soil backfilling as well as a textured base surface for application of tiles, renders and other external finishes. The illustrated insulated concrete thermal mass suspended slab system 51 is a very advanced system that combines the reinforcing layer modules 54 and the insulation layer 5 modules 55, 55' and provides them with sufficient strength and rigidity to span across the steel support beams 65 and hold the weight of the concrete slab 201, 201' until it is cured sufficiently to support its own weight. Further, the insulation layer modules 55, 55' fully encapsulate the bottom of the concrete suspended slab 201, 201' in a seamless contiguous layer of insulation and also form internal concrete beams 205 that provide exceptional 10 strength and rigidity and enable the concrete slab 201, 201' to bridge or cantilever over large spans whilst reducing the overall quantities of the concrete and reinforcement steel required. The space between the under slab steel support beams 65 also acts as a full services cavity 67 for the installation of electrical, plumbing, air conditioning, data and other services under the bottom of the suspended slab 201, 201'. 15 The insulated concrete thermal mass slab systems disclosed herein are thus energy efficient and facilitate construction of strong, well engineered concrete slabs quickly and cost effectively compared to traditional methods, thus saving overall cost, time and effort for the builder. It will be appreciated that the insulated concrete thermal mass suspended slabs 201 20 and 201' may also be used for forming flat roofs of buildings by covering the top concrete layer with a suitable waterproofing plastic membrane along with a layer of protective tiles or pavers. The insulated concrete thermal mass suspended slabs 201 and 201' may also be used for forming inclined or sloped roofs of buildings simply by setting up, propping and shoring the under slab steel support beams 65 at the desired roof angle, followed by setting 25 and placing of the end beam insulation inserts 67, reinforcement layer modules 54, first insulation layer modules 55, 55', reinforcement bars 20 and concrete 23, all at the desired roof angle, and then covering the top concrete layer with a suitable waterproofing plastic membrane along with a layer of protective tiles. The insulated concrete thermal mass suspended slabs 201, 201' may also be used for forming flat "green" roofs by covering the 30 top concrete layer with suitable waterproofing plastic membrane along with plastic drainage cell modules, water retention and drainage trays, geotextile filter fabric, light weight growing media and the like, followed by plants and shrubs. The illustrated systems are also easy to use and facilitate significant savings in site labour as well as overall production costs. 35 The illustrated systems also facilitate placement, inspection and certification of steel reinforcement bars prior to pouring of concrete to form the slabs. 3148371_.doc 30 It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not 5 restrictive. Examples of possible variations and/or modifications include, but are not limited to: * the system 11, 51 for forming an insulated concrete thermal mass slab as described above may be pre-assembled in a factory, or can be assembled on-site by either a builder or a do-it-yourself owner-builder; 10 * the connection between the spacers 16c and the outer and/or inner studs 16a, 16b may be a mechanical connection (eg., the studs 16a, 16b may be pre-fabricated with connecting formations at predetermined intervals for engagement by corresponding connecting formations on the spacers 16c to mechanically interconnect the spacers and studs); 15 * the outer slab edge insulation layer 12 may be formed from pre-meshed and pre rendered insulation panels for facilitating rendered finishes for the exteriors of a building, with associated significant savings in site costs and works; * depending on the typical climate for a particular site, the insulation layer under the main part of the ground slab 101 may be partly or completely omitted and replaced 20 with concrete or conventional stay in place formwork to provide for earth coupling along the full area of the underside of the underside of the slab; * the slots 16c3 in the outer frame member 16 and inner frame member 16' may be of different depths to facilitate a tailored arrangement of the steel reinforcement 23 in the ring beams and grid beams; and/or 25 * the outer slab edge insulation layer 12 may be formed from insulated panels that are pre-laminated with fibre cement sheets, magnesium oxide sheets and/or other mineral-based sheets for providing additional physical protection, as well as fire resistance, to the exteriors of a building, with associated significant savings in site costs and works. 30 3148371_.doc

Claims (16)

1. A system for forming an insulated concrete thermal mass ground slab, said system comprising: a first insulation layer for insulating an outer edge of the slab; 5 a second insulation layer, spaced apart from the first insulation layer, for insulating an underside of the slab; and first frame members extending between the first and second insulation layers and engageable with each of the first and second insulation layers to interlock the first and second insulation layers together so as to maintain the space therebetween for 10 receiving uncured concrete to form an outer perimeter ring beam of the slab, wherein the first and second insulation layers, and the engagement therebetween via the frame members, have sufficient strength to support the forces applied by the uncured concrete.

2. A system according to claim 1, wherein the second insulation layer forms part of 15 an inner under slab insulation module comprising one or more of: a third insulation layer for insulating an inner side of the peripheral ring beam; and a fourth insulation layer for insulating at least part of a base of the peripheral ring beam. 20

3. A system according to claim 2, wherein the inner under slab insulation module comprises a planar top surface and peripheral sidewalls extending generally perpendicularly from the top surface.

4. A system according to claim 3, including a said fourth insulation layer that comprises a peripheral flange extending outwardly from the sidewalls at an end of the 25 sidewalls opposite the top surface.

5. A system according to any one of claims 2 to 4, comprising a plurality of the inner under slab insulation modules connected together to insulate an entire underside area of the slab.

6. A system according to claim 4, comprising a plurality of the inner under slab 30 insulation modules connected together to insulate an entire underside area of the slab, and wherein channels are defined by the sidewalls and peripheral flanges of adjoining inner under slab insulation modules, the channels being configured to form inner grid beams of the slab.

7. A system according to claim 5 or claim 6, comprising second frame members 35 extending between adjoining inner under slab insulation modules and engaging each of 3148371_.doc 32 the adjoining inner under slab insulation modules to interlock the adjoining inner under slab insulation modules together so as to maintain a space there between for receiving uncured concrete to form the slab, wherein the inner under slab insulation modules, and the engagement therebetween via the second frame members, have sufficient strength 5 to support the forces applied by the uncured concrete.

8. A system according to any one of claims 2 to 7, comprising a fifth insulation layer for insulating at least part of a base of a peripheral ring beam of the slab.

9. A system according to claim 8, wherein the fifth insulation layer is engageable with the inner under slab insulation module.

10 10. A system according to any one of claims 2 to 9, wherein the or each said inner under slab insulation module comprises slots for slidably receiving correspondingly shaped anchors of the frame members to engage the inner under slab insulation module to the frame members.

11. A system according to any one of the preceding claims, comprising a slab set 15 down forming flange connectable to and extending substantially vertically from the first frame members at a position intermediate the first and second insulation layers, a top end of the slab set-down forming flange being positioned above the height of the first and second insulation layers so as to create a set-down or rebate around a perimeter edge of the slab. 20

12. A system according to claim 11, comprising corner reinforcement brackets engageable with the slab set down forming flange to reinforce mitred joints of external and internal corners of the slab set-down forming flange.

13. A system according to any one of the preceding claims, comprising a protective casing at least partially encapsulating the first insulation layer. 25

14. A system according to claim 13, wherein an outer surface of the casing is adapted for application of tiles, renders and other external finishes thereto.

15. A system according to any one of the preceding claims, wherein the first insulation layer comprises slots for slidably receiving correspondingly shaped first anchors of the first frame members to engage the first insulation layer to the first frame 30 members.

16. A system according to any one of the preceding claims, wherein each of the first and second frame members comprises a pair of elongate, spaced apart, substantially parallel, studs and a plurality of spacers interconnecting the pair of studs, the studs comprising outer and inner studs for connection to the adjacent insulation layers. 3148371_.doc