WO2007040412A2 - Suspended concrete floor - Google Patents
Suspended concrete floor Download PDFInfo
- Publication number
- WO2007040412A2 WO2007040412A2 PCT/NZ2006/000256 NZ2006000256W WO2007040412A2 WO 2007040412 A2 WO2007040412 A2 WO 2007040412A2 NZ 2006000256 W NZ2006000256 W NZ 2006000256W WO 2007040412 A2 WO2007040412 A2 WO 2007040412A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- floor
- manufacturing
- bottom layer
- sheets
- concrete floor
- Prior art date
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
- E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
- E04B5/17—Floor structures partly formed in situ
- E04B5/18—Floor structures partly formed in situ with stiffening ribs or other beam-like formations wholly cast between filling members
Definitions
- the present invention relates to a suspended concrete floor and to a method for making such a floor on-site.
- Suspended concrete floors are often pre-fabricated off-site, then transported to the building site and put in place. This usually requires the use of a crane on-site to position the floor, as well means to transport a floor panel from the place it is made to the building site. Handling a pre-fabricated concrete floor can be dangerous, and the provision of the necessary equipment is very expensive. There can be additional problems in remote or difficult building sites, where access for the machinery may be an issue. It is therefore preferable to manufacture the floor on-site.
- on-site suspended concrete floors generally are manufactured from a pre- made concrete or steel panel which is secured in place and then provided with a further cladding layer of concrete. This method is relatively labour-intensive and the resulting floor does not have particularly good heat or sound insulating properties.
- US Application 2005/0055926 describes alternative mouldings for a concrete floor to be cast in situ.
- the mouldings define troughs, which allow beams to be integrally poured with the main part of the floor.
- the space between adjacent beams is predominantly air, with spacer plates maintaining the shape of the moulding under load. This does not achieve good heat or sound insulating properties in the finished floor.
- US 6,098,359 describes a complicated way of supporting moulding for beams which are formed integrally with a suspended concrete floor poured in situ. Some of the moulding may be removed after the pour, which is labour intensive. No thermal or sound insulation is disclosed.
- EP 1 ,690,991 describes a pre-fabricated slab, which includes surface-exposed steel profiles, to which insulating panels can be welded. However, this has the disadvantages of pre-fabricated slabs which are discussed above.
- US 5,526,629 describes a composite building panel, manufactured away from its installation location, which includes a concrete slab with frame members half embedded therein. An insulating or other surface may be attached to the free end of the frame members, but it does not form an integral part of the finished product.
- US 6,101 ,779 addresses the issue of insulation by providing a pre-fabricated concrete slab, with beams and purlins extending downwardly from the bottom of the slab, poured integral with the slab, and polystyrene foam insulating material filling the voids between the beams and purlins.
- this invention does not provide insulation for the entire floor, and does not address any of the problems associated with prefabricated panels.
- EP 1 ,536,077 describes a method of making a building, including suspended floors which are made by placing interconnecting light weight, heat insulating floor elements, supporting them if necessary, and pouring structural fill-material, such as concrete or the like, onto the floor elements to form the floor.
- This in situ manufacture is an improvement over the use of pre-fabricated panels, and the floor elements are described as being made of polystyrene, which has good thermal and sound insulating properties.
- the floor elements are specially contoured to provide moulds for integrally formed beams.
- the floor elements meet at the bottom of each trough, and are interconnected with a special steel connector to reduce leakage of the un-cured concrete.
- Each floor element is specially adapted to mate closely with the connector. This system therefore requires special manufacture of the floor elements and connectors, and relatively complicated installation of the floor elements to form a mould.
- An object of the present invention is the provision of a suspended concrete floor and a method for making such a floor which overcomes at least some of the problems identified in the prior art, reduces the labour necessary for making the floor and which provides a floor which has good heat and sound insulating properties.
- the present invention provides:- a suspended concrete floor comprising a layer of concrete formed integrally with a plurality of spaced parallel beams, the beams being separated by panels of insulating material, and the floor further including a bottom layer forming a lower surface of the floor.
- the bottom layer is made of insulating material, most preferably a high- density insulating material.
- the bottom layer may be comprised of sheets of plywood or fibre-cement.
- the floor may also include reinforcing in the concrete layer and/or the beams.
- the present invention further provides a method of manufacturing a concrete floor as described above, wherein sheets of material are supported at the desired floor level upon scaffolding or other support means to form a bottom layer of the floor, panels of insulating material are placed on the bottom layer, with the panels spaced apart to form the sides of moulds for the floor beams, boxing is erected to form the sides of the floor, and concrete is poured over the panels of insulating material to form the concrete floor panel and integrally formed floor beams.
- the panels may be secured to the sheets of material which will form the bottom layer prior to installation; the steps of supporting the sheets, erecting boxing and pouring concrete then follow as described above.
- the method may include further steps selected (either independently or in combination) from the list: butting together the sheets comprising the bottom layer; fastening together the sheets comprising the bottom layer using fastening means selected from: glue, staples, adhesive tape and tongue-and-groove fitting; securing the panels to the bottom layer; providing reinforcing; and removing the support means and/or boxing.
- Figure 1 is a flow chart showing the steps of the method of the present invention.
- Figure 2 is a section through a floor in accordance with the present invention, under construction. Best Method of Carrying Out the Invention
- a floor 2 consist of an upper layer of concrete 3 formed integrally with a plurality of parallel spaced beams 4 which are separated by panels 5 of insulating material (e.g. polystyrene foam), resting on a bottom layer 6 of high-density insulating material (e.g. high-density insulating foam).
- insulating material e.g. polystyrene foam
- the resulting floor is strong, and has good sound and heat insulating properties because of the incorporated insulation.
- the concrete layer 3 is reinforced, (e.g. with mesh) and the beams 4 also are reinforced using any suitable reinforcing method.
- the flow chart of Figure 1 shows the steps for making the above described floor:- in step 1 supporting scaffolding is erected to the height of the underside of the finished floor, with scaffolding poles 10 and support plates or scaffolding planks 11 spaced along the length of each of the beams 4 of the floor.
- sheets of high-density insulating material 6 are supported across the plates 11 , with adjacent sheets of material 6 butted and glued together to form a continuous surface.
- the sheets 6 may be made of a standard insulating material (i.e. not high-density).
- the bottom layer 6 is comprised of sheets of plywood or fibre-cement instead of high-density insulating foam.
- This alternative embodiment is particularly useful where the area of the floor is large. Because commercially plywood sheets are generally larger than commercial high-density insulating foam sheets, and each sheet of material used requires support during construction, less scaffolding is required when plywood is used. The plywood sheets are butted and glued together to form a continuous surface.
- step 3 the panels 5 of insulating material are glued in position on top of the material 6, with adjacent panels 5 spaced apart to form the sides of the moulds for the beams 4.
- step 3 precedes at least step 2, in that the panels 5 of insulating material are glued on to the material 6 before the bottom layer 6 is placed on the scaffolding plates.
- This may be either be carried out on-site, or the panels may be glued into position off-site, and the sheets with pre-fitted panels transported to the site for quicker installation.
- step 4 the outer edge of the floor is defined using either conventional or polystyrene boxing.
- step 5 reinforcing for the concrete layer 3 and the beams 4 is supported upon the insulating layers 5,6 in known manner.
- step 6 concrete is poured over the reinforcing to form the concrete layer 3 and the beams 4. Once the concrete has cured, the boxing and the scaffolding both are removed.
- the concrete layer 3 forms the upper surface of the floor, and the bottom layer 6 can be used to form the ceiling of the room below; paint can be applied directly to the bottom layer if required, or other finishes can be used.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)
- Panels For Use In Building Construction (AREA)
- Floor Finish (AREA)
Abstract
A suspended concrete floor comprising a layer of concrete formed integrally with a plurality of spaced parallel beams, the beams being separated by panels of insulating material, and the floor further including a bottom layer forming a lower surface of the floor, and a method of manufacturing the same.
Description
SUSPENDED CONCRETE FLOOR Technical Field
The present invention relates to a suspended concrete floor and to a method for making such a floor on-site.
Background Art
Suspended concrete floors are often pre-fabricated off-site, then transported to the building site and put in place. This usually requires the use of a crane on-site to position the floor, as well means to transport a floor panel from the place it is made to the building site. Handling a pre-fabricated concrete floor can be dangerous, and the provision of the necessary equipment is very expensive. There can be additional problems in remote or difficult building sites, where access for the machinery may be an issue. It is therefore preferable to manufacture the floor on-site.
At present, on-site suspended concrete floors generally are manufactured from a pre- made concrete or steel panel which is secured in place and then provided with a further cladding layer of concrete. This method is relatively labour-intensive and the resulting floor does not have particularly good heat or sound insulating properties.
An example of such a method is described in US 6,755,001 , which discloses the use of sheets to form a mould onto which the concrete slab of a suspended floor may be poured. In a preferred embodiment, the sheets are described as being corrugated sheets of fibre cement. This has the disadvantages described above.
US Application 2005/0055926 describes alternative mouldings for a concrete floor to be cast in situ. The mouldings define troughs, which allow beams to be integrally poured with the main part of the floor. However, the space between adjacent beams is predominantly air, with spacer plates maintaining the shape of the moulding under load. This does not achieve good heat or sound insulating properties in the finished floor.
US 6,098,359 describes a complicated way of supporting moulding for beams which are formed integrally with a suspended concrete floor poured in situ. Some of the moulding may be removed after the pour, which is labour intensive. No thermal or sound insulation is disclosed.
EP 1 ,690,991 describes a pre-fabricated slab, which includes surface-exposed steel profiles, to which insulating panels can be welded. However, this has the disadvantages of pre-fabricated slabs which are discussed above. Similarly, US 5,526,629 describes a composite building panel, manufactured away from its installation location, which includes a concrete slab with frame members half embedded therein. An insulating or other surface may be attached to the free end of the frame members, but it does not form an integral part of the finished product.
US 6,101 ,779 addresses the issue of insulation by providing a pre-fabricated concrete slab, with beams and purlins extending downwardly from the bottom of the slab, poured integral with the slab, and polystyrene foam insulating material filling the voids between the beams and purlins. However, this invention does not provide insulation for the entire floor, and does not address any of the problems associated with prefabricated panels.
EP 1 ,536,077 describes a method of making a building, including suspended floors which are made by placing interconnecting light weight, heat insulating floor elements, supporting them if necessary, and pouring structural fill-material, such as concrete or the like, onto the floor elements to form the floor. This in situ manufacture is an improvement over the use of pre-fabricated panels, and the floor elements are described as being made of polystyrene, which has good thermal and sound insulating properties. The floor elements are specially contoured to provide moulds for integrally formed beams. The floor elements meet at the bottom of each trough, and are interconnected with a special steel connector to reduce leakage of the un-cured concrete. Each floor element is specially adapted to mate closely with the connector. This system therefore requires special manufacture of the floor elements and connectors, and relatively complicated installation of the floor elements to form a mould.
Disclosure of Invention An object of the present invention is the provision of a suspended concrete floor and a method for making such a floor which overcomes at least some of the problems identified in the prior art, reduces the labour necessary for making the floor and which provides a floor which has good heat and sound insulating properties.
The present invention provides:- a suspended concrete floor comprising a layer of concrete formed integrally with a plurality of spaced parallel beams, the beams being
separated by panels of insulating material, and the floor further including a bottom layer forming a lower surface of the floor.
Preferably, the bottom layer is made of insulating material, most preferably a high- density insulating material. In an alternative embodiment the bottom layer may be comprised of sheets of plywood or fibre-cement. The floor may also include reinforcing in the concrete layer and/or the beams.
The present invention further provides a method of manufacturing a concrete floor as described above, wherein sheets of material are supported at the desired floor level upon scaffolding or other support means to form a bottom layer of the floor, panels of insulating material are placed on the bottom layer, with the panels spaced apart to form the sides of moulds for the floor beams, boxing is erected to form the sides of the floor, and concrete is poured over the panels of insulating material to form the concrete floor panel and integrally formed floor beams.
Alternatively, the panels may be secured to the sheets of material which will form the bottom layer prior to installation; the steps of supporting the sheets, erecting boxing and pouring concrete then follow as described above.
The method (in either embodiment) may include further steps selected (either independently or in combination) from the list: butting together the sheets comprising the bottom layer; fastening together the sheets comprising the bottom layer using fastening means selected from: glue, staples, adhesive tape and tongue-and-groove fitting; securing the panels to the bottom layer; providing reinforcing; and removing the support means and/or boxing.
Description of the Drawings
By way of example only, a preferred embodiment of the present invention is described in detail, with reference to the accompanying drawings in which:-
Figure 1 is a flow chart showing the steps of the method of the present invention; and
Figure 2 is a section through a floor in accordance with the present invention, under construction.
Best Method of Carrying Out the Invention
Referring to the drawings, in a preferred embodiment a floor 2 consist of an upper layer of concrete 3 formed integrally with a plurality of parallel spaced beams 4 which are separated by panels 5 of insulating material (e.g. polystyrene foam), resting on a bottom layer 6 of high-density insulating material (e.g. high-density insulating foam).
The resulting floor is strong, and has good sound and heat insulating properties because of the incorporated insulation.
The concrete layer 3 is reinforced, (e.g. with mesh) and the beams 4 also are reinforced using any suitable reinforcing method.
The flow chart of Figure 1 shows the steps for making the above described floor:- in step 1 supporting scaffolding is erected to the height of the underside of the finished floor, with scaffolding poles 10 and support plates or scaffolding planks 11 spaced along the length of each of the beams 4 of the floor.
In step 2, sheets of high-density insulating material 6 are supported across the plates 11 , with adjacent sheets of material 6 butted and glued together to form a continuous surface. Alternatively, the sheets 6 may be made of a standard insulating material (i.e. not high-density).
In an alternative embodiment, the bottom layer 6 is comprised of sheets of plywood or fibre-cement instead of high-density insulating foam. This alternative embodiment is particularly useful where the area of the floor is large. Because commercially plywood sheets are generally larger than commercial high-density insulating foam sheets, and each sheet of material used requires support during construction, less scaffolding is required when plywood is used. The plywood sheets are butted and glued together to form a continuous surface.
In step 3, the panels 5 of insulating material are glued in position on top of the material 6, with adjacent panels 5 spaced apart to form the sides of the moulds for the beams 4.
In an alternative method, step 3 precedes at least step 2, in that the panels 5 of insulating material are glued on to the material 6 before the bottom layer 6 is placed on
the scaffolding plates. This may be either be carried out on-site, or the panels may be glued into position off-site, and the sheets with pre-fitted panels transported to the site for quicker installation.
In step 4, the outer edge of the floor is defined using either conventional or polystyrene boxing. In step 5, reinforcing for the concrete layer 3 and the beams 4 is supported upon the insulating layers 5,6 in known manner. In step 6, concrete is poured over the reinforcing to form the concrete layer 3 and the beams 4. Once the concrete has cured, the boxing and the scaffolding both are removed.
The concrete layer 3 forms the upper surface of the floor, and the bottom layer 6 can be used to form the ceiling of the room below; paint can be applied directly to the bottom layer if required, or other finishes can be used.
Claims
1. A suspended concrete floor comprising a layer of concrete formed integrally with a plurality of spaced parallel beams, the beams being separated by panels of insulating material, and the floor further including a bottom layer forming a lower surface of the floor.
2. A suspended concrete floor according to claim 1 , wherein the bottom layer is made of insulating material.
3. A suspended concrete floor according to claim 2, wherein the bottom layer is made of high-density insulating material.
4. A suspended concrete floor according to any one of the preceding claims, wherein at least one of the layer of concrete and the beams includes reinforcing.
5. A suspended concrete floor according to claim 1 , wherein the bottom layer consists of sheets of material selected from: plywood and fibre-cement.
6. A suspended concrete floor according to claim 5, wherein at least one of the layer of concrete and the beams includes reinforcing.
7. A method of manufacturing a suspended concrete floor in situ, including the steps of: supporting sheets of material at the desired floor level to form a bottom layer of the floor, placing panels of insulating material on the bottom layer, with the panels spaced apart to form the sides of moulds for floor beams, erecting boxing to form the sides of the floor, and pouring concrete over the panels to form a concrete floor panel and integrally formed floor beams.
8. A method of manufacturing a suspended concrete floor in situ, including the steps of: securing panels of insulating material to sheets of base material, supporting the sheets of the base material at the desired floor level to form a bottom layer of the floor, such that the panels of insulating material are spaced apart to form the sides of moulds for floor beams, erecting boxing to form the sides of the floor, and pouring concrete over the panels to form a concrete floor panel and integrally formed floor beams.
9. A method of manufacturing a suspended concrete floor in situ according to either of claims 7 or 8, wherein the sheets of material used to form the bottom layer are sheets of insulating material.
10. A method of manufacturing a suspended concrete floor in situ according to claim 9, wherein the sheets of material used to form the bottom layer are sheets of high-density insulating material.
11. A method of manufacturing a suspended concrete floor in situ according to any one of claims 7 to 10, wherein the sheets of material forming the bottom layer are supported by scaffolding.
12. A method of manufacturing a suspended concrete floor in situ according to claim 11 , further including the step of removing the scaffolding once the concrete has cured sufficiently to be self-supporting.
13. A method of manufacturing a suspended concrete floor in situ according to any one of claims 7 to 12, further including the step of providing reinforcing for at least one of the floor panel and the floor beams.
14. A method of manufacturing a suspended concrete floor in situ according to any one of claims 7 to 13, further including the step of butting together the sheets forming the bottom layer.
15. A method of manufacturing a suspended concrete floor in situ according to any one of claims 7 to 14, further including the step of fastening together the sheets comprising the bottom layer using fastening means selected from: glue, staples, adhesive tape and tongue-and-groove fitting.
16. A method of manufacturing a suspended concrete floor in situ according to any one of claims 7 to 15, further including the step of securing the panels to the bottom layer.
17. A method of manufacturing a suspended concrete floor in situ according to any one of claims 7 to 16, further including the step of removing the boxing after the concrete has cured sufficiently to be self-supporting.
18. A method of manufacturing a suspended concrete floor in situ according to either of claims 7 or 8, wherein the sheets of material used to form the bottom layer are sheets of material selected from: plywood and fibre-cement.
19. A method of manufacturing a suspended concrete floor in situ according to claim 18, wherein the sheets of material forming the bottom layer are supported by scaffolding.
20. A method of manufacturing a suspended concrete floor in situ according to claim 19, further including the step of removing the scaffolding once the concrete has cured sufficiently to be self-supporting.
21. A method of manufacturing a suspended concrete floor in situ according to any one of claims 18 to 20, further including the step of providing reinforcing for at least one of the floor panel and the floor beams.
22. A method of manufacturing a suspended concrete floor in situ according to any one of claims 18 to 21, further including the step of butting together the sheets forming the bottom layer.
23. A method of manufacturing a suspended concrete floor in situ according to any one of claims 18 to 22, further including the step of fastening together the sheets comprising the bottom layer using fastening means selected from: glue, staples, adhesive tape and tongue-and-groove fitting.
24. A method of manufacturing a suspended concrete floor in situ according to any one of claims 18 to 23, further including the step of securing the panels to the bottom layer.
25. A method of manufacturing a suspended concrete floor in situ according to any one of claims 18 to 24, further including the step of removing the boxing after the concrete has cured sufficiently to be self-supporting.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| NZ542842 | 2005-10-05 | ||
| NZ54284205A NZ542842A (en) | 2005-10-05 | 2005-10-05 | Suspended insulated concrete floor with integral cast in beams |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2007040412A2 true WO2007040412A2 (en) | 2007-04-12 |
| WO2007040412A3 WO2007040412A3 (en) | 2007-11-08 |
Family
ID=37906576
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/NZ2006/000256 WO2007040412A2 (en) | 2005-10-05 | 2006-10-05 | Suspended concrete floor |
Country Status (2)
| Country | Link |
|---|---|
| NZ (1) | NZ542842A (en) |
| WO (1) | WO2007040412A2 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9593487B2 (en) | 2014-09-05 | 2017-03-14 | James F. Harvey | Modular building system |
| AU2021103539B4 (en) * | 2021-06-22 | 2022-02-17 | SHAPE Australia Pty Limited | A flooring panel, system and method for constructing a fire-rated suspended floor |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103437558B (en) * | 2013-08-26 | 2015-09-30 | 国家电网公司 | A kind of construction method preventing resonance damage |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1389404A (en) * | 1918-06-18 | 1921-08-30 | White Barclay | Reinforced concrete construction |
| US3382637A (en) * | 1965-04-15 | 1968-05-14 | Longinotti Enrico | Ribbed barrier with lapped, edgejoined facing panels |
| US4573303A (en) * | 1982-01-29 | 1986-03-04 | Figari Andres G | Method of casting floors and ceilings of buildings and a panel for use therein |
| US5930965A (en) * | 1997-09-23 | 1999-08-03 | Carver; Tommy Lee | Insulated deck structure |
| US5934036A (en) * | 1996-11-01 | 1999-08-10 | Gallagher, Jr.; Daniel P. | Insulated concrete slab assembly |
| US20040154240A1 (en) * | 2003-02-06 | 2004-08-12 | Hiroaki Hiraguri | Sound insulating floor structure |
-
2005
- 2005-10-05 NZ NZ54284205A patent/NZ542842A/en unknown
-
2006
- 2006-10-05 WO PCT/NZ2006/000256 patent/WO2007040412A2/en active Application Filing
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1389404A (en) * | 1918-06-18 | 1921-08-30 | White Barclay | Reinforced concrete construction |
| US3382637A (en) * | 1965-04-15 | 1968-05-14 | Longinotti Enrico | Ribbed barrier with lapped, edgejoined facing panels |
| US4573303A (en) * | 1982-01-29 | 1986-03-04 | Figari Andres G | Method of casting floors and ceilings of buildings and a panel for use therein |
| US5934036A (en) * | 1996-11-01 | 1999-08-10 | Gallagher, Jr.; Daniel P. | Insulated concrete slab assembly |
| US5930965A (en) * | 1997-09-23 | 1999-08-03 | Carver; Tommy Lee | Insulated deck structure |
| US20040154240A1 (en) * | 2003-02-06 | 2004-08-12 | Hiroaki Hiraguri | Sound insulating floor structure |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9593487B2 (en) | 2014-09-05 | 2017-03-14 | James F. Harvey | Modular building system |
| US10156073B2 (en) | 2014-09-05 | 2018-12-18 | James F. Harvey | Modular building system |
| AU2021103539B4 (en) * | 2021-06-22 | 2022-02-17 | SHAPE Australia Pty Limited | A flooring panel, system and method for constructing a fire-rated suspended floor |
| AU2021103539C4 (en) * | 2021-06-22 | 2022-12-15 | SHAPE Australia Pty Limited | A flooring panel, system and method for constructing a fire-rated suspended floor |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2007040412A3 (en) | 2007-11-08 |
| NZ542842A (en) | 2008-10-31 |
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