Patent Application
20220268018
The present invention relates to concrete floor and/or wall panels and in particular to a prefabricated floor structure for use in buildings.
The invention has been developed primarily for use in building structures and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.
Presently, building structures such as unit blocks and high rise apartments have their floor structures created from poured concrete which substantially increases the amount of time, labour and cost that goes into providing the flooring in the structure. In particular, the flooring must be given enough time to set which can substantially delay the progress of construction.
The present invention seeks to provide in particular, a prefabricated flooring system, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.
It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.
The present invention relates to a prefabricated interlocking flooring system that facilitates the rapid construction of a building in a cost effective manner. In accordance with the invention, the prefabricated interlocking flooring system is adapted such that adjacent prefabricated flooring panels interface with each other to provide for a smooth joint between panels removing the necessity of laying a concrete layer on top of the panels as is commonly done to provide a smooth fire retardant floor surface.
According to a first aspect, the present invention may be said to consist in a prefabricated flooring system comprising:
In one embodiment, the prefabricated floor panels are created from a settable material.
In one embodiment, the settable material is concrete.
In one embodiment, the concrete is reinforced using a plurality of reinforcing bars embedded within the concrete.
In one embodiment, the prefabricated floor panels further include strengthening members.
In one embodiment, the strengthening members are supporting beams.
In one embodiment, the supporting beams include at least one cavity for the provision of services.
In one embodiment, the prefabricated floor panels interlock by way of a lap joint.
In one embodiment, the lap joint is adapted to receive a fireproof sealant.
In one embodiment, the corresponding lap joints are adapted to be screwed together.
In one embodiment, the support structure includes a support beam adapted to attach to the at least one or more ends of the prefabricated floor panels when in use.
In one embodiment, the support structure is adapted to attach to at least one support post.
In one embodiment, the prefabricated flooring panel is about 1.5 m to about 3 m in width.
In one embodiment, the length is between about 1 m to about 15 m in length.
According to a further aspect, the present invention may be said to consist in a prefabricated floor panel for use with a supporting structure, the prefabricated floor panel comprising:
In one embodiment, the prefabricated floor member is further adapted to overlap with an adjacent similar prefabricated floor panel, while presenting a floor surface flush with the adjacent similar prefabricated floor panel.
In one embodiment, the prefabricated floor member is adapted to overlap with an adjacent similar prefabricated floor panel in at least a vertical direction.
In one embodiment, the prefabricated floor member is adapted to be overlapped by an adjacent similar prefabricated floor panel.
In one embodiment, the floor panel includes a first overlapping formation for overlapping with an adjacent similar prefabricated floor panel.
In one embodiment, the floor panel includes a second overlapping formation adapted for overlapping with the supporting structure in use.
In one embodiment, the second overlapping formation is located on opposed sides of the prefabricated flooring panel.
In one embodiment, the second overlapping formation is substantially parallel to the supporting structure.
In one embodiment, the second overlapping formation is substantially perpendicular to the at least one or more strengthening beams.
In one embodiment, the at least one or more strengthening beams are disposed asymmetrically on the floor member.
In one embodiment, the floor member defines an upper major face and a lower major face, and at least one or more minor faces extending about the periphery of the upper major face and the lower major face.
In one embodiment, the at least one or more strengthening beams are disposed on a lower major face of the floor member.
In one embodiment, the at least one or more strengthening beams extend in parallel with each other.
In one embodiment, the at least one or more strengthening beam extends at least partly outside of the periphery of one or more selected from the upper major face and the lower major face.
In one embodiment, the prefabricated floor panel includes reinforcing bars.
In one embodiment, the prefabricated floor panel is integrally formed.
In one embodiment, the prefabricated floor panel is made from conventional concrete.
In one embodiment, the prefabricated floor panel is made from aerated concrete.
According to yet a further aspect, the present invention may be said to consist in construction comprising:
In one embodiment, the supporting formation is one or more selected from a lip and a recess.
In one embodiment, the supporting beams include a receiving formation adapted for receiving at least part of a second overlapping formation of a prefabricated floor panel.
In one embodiment, the construction includes at least one support pillar.
In one embodiment, the support pillars include end plates at one or either end of the support pillars.
According to yet a further aspect, the present invention may be said to consist in method of constructing a construction comprising steps of:
In one embodiment, the method further includes the step of applying a fire retardant compound between the adjacent prefabricated floor panels.
In one embodiment, the step of supporting the prefabricated floor panels on the support structure in a configuration to at least partly overlap each other includes supporting the prefabricated floor panels on the support structure in a configuration to present a flush floor surface across adjacent floor panels.
In one embodiment, the method further comprises the step of providing at least one or more pillars.
In one embodiment, the step of providing a support structure includes the step of providing at least a pair of supporting beams.
In one embodiment, the method further comprises the step of supporting the supporting beams on the at least one or more pillars.
In one embodiment, the prefabricated floor panels include at least one or more strengthening beams, and the step of supporting the prefabricated floor panels on the support structure includes the step of supporting the strengthening beams on a supporting formation on the support beams.
In one embodiment, the step of supporting the strengthening beams on a supporting formation on the support beams includes the step of locating the prefabricated floor panels to overlap the support beams.
In one embodiment, the step of locating the prefabricated floor panels to overlap the support beams includes the step of locating a second overlapping formation of the prefabricated floor panels into a receiving formation on the support beams.
In one embodiment, the prefabricated floor panels is a prefabricated floor panel.
This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
Other aspects of the invention are also disclosed.
Notwithstanding any other forms which may fall within the scope of the present invention, a preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.
A prefabricated floor panel and associated construction according to a first aspect of the invention is generally indicated by the numeral 1000.
In one embodiment now described and shown in use in
As is exemplified in
In
In the embodiment shown in the figures, the number of strengthening beams 109 is limited to three per prefabricated floor panel 101. However, it will be appreciated by a person skilled in the art, that more or less strengthening beams 109 may be used depending on the intended load and spans over which the prefabricated floor panel 101 is intended to be used. The strengthening beams 109 may be disposed in either a symmetrical or an asymmetrical fashion on the floor member 105 on its lower major face 106.
The prefabricated floor panel 101 may be constructed from concrete and includes conventional reinforcing bar (rebar) 120 to provide strength to the prefabricated floor panels 101. In the embodiment shown, it is envisaged that steel, steel mesh, basalt or fibreglass substitute rebar can be used for the reinforcing bars 120 with basalt being preferred as it provides superior qualities over conventional rebar including resistance to corrosion and aggressive chemical compounds along with light weight and durability.
The reinforcing bars 120, apart from being untensioned in a preferred embodiment may be either pre-tensioned or post tensioned. The choice as to whether tensioning is applied to the reinforcing bars 120 will depend on the span over which the prefabricated floor panel 101 is to span and more generally, the amount of strength required for each floor panel 101 which would typically be dependent on the likely load that each of the floor panels 101 is likely to be subjected to when in use.
The concrete used can take a number of forms from conventional concrete to lightweight varieties. Lightweight concrete is to be preferred as it substantially reduces the weight of the completed building structure reducing the demand on the buildings foundations. Furthermore, the use of lightweight concrete aids with the transport and handling of the prefabricated floor panels 101 during the construction phase.
To reduce the weight of the concrete, a propriety additive is added to the concrete mix that aerates the concrete to a selected density. The density is dictated by the amount of additive added. For instance, the additive can adjust the concrete density from 300 kg/m3 to 2400 kg/m3. It will be appreciated by a person skilled in the art, that as the density of the concrete is reduced, the compressive strength will be reduced with the advantage being a lighter weight structure. On the other hand, the higher the density of the concrete the higher the compressive strength of the concrete will be at the cost of higher weight of the prefabricated floor panels 101.
It has been found that a density of between 1200 kg/m3 and 1800 kg/m3 provides for a good compromise between weight and strength. Clearly, non-structural members can be constructed of less dense concrete while structural members would need to be constructed of a higher density concrete in the range of 1800 kg/m3 or higher.
In addition to the use of a propriety additive to adjust the density of the concrete, and apart from the aforementioned rebar, fibre is added to the concrete to improve strength and flexibility. The fibres themselves may be made of basalt or polypropylene depending on whether compressive strength or flexibility is the priority. Basalt improves the compressive strength of the concrete whereas polypropylene provides for greater flexibility. A combination of both materials is desirable.
As is shown in
It is envisaged that fasteners such as screws or potentially bolts or other appropriate fasteners (not shown) may be used to securely attach the floor member 105 to each other via the strengthening beams 109 and the supporting structure 103 in general, after they have been located into their final position.
As mentioned previously, the prefabricated floor panels 101 are adapted to join with the adjacent prefabricated floor panels 101 by overlapping each other using a lap joint as shown in
The ability of the lap joint A to receive the fire retardant sealant is important in achieving the object of providing a structure that satisfies current fire safety standards and has the ability to contain fires from spreading to adjacent levels in the building which is critical especially in multi-level constructions where fires need to be contained between levels.
In other embodiments, the floor member 105 may be adapted to interface with adjacent floor members 105 using a variety of different joining means, ranging from overlapping joints to rabbet or rebate joints. It is important that each of the joints used provide for a smooth surface at the junction of the floor members 105, to achieve the object of providing a smooth flush floor surface without the need for additional finishing whilst providing a fireproof joint.
As can be seen in
In the embodiment shown in the figures, there are two second overlapping formations 122 which are situated at each end of the prefabricated floor panels 101 as is exemplified in
The prefabricated floor panels 101 can be constructed using molds made of plywood, fibreglass or steel with steel being preferable for repeated use. The molds would typically be 12 m long and 2.5 m wide, the lengths of which have been chosen so they can fit a standard semi-trailer for transport to the building site. It will be appreciated that the aforementioned dimensions may be varied depending on application. The depth of the prefabricated floor panels 101 may be up to 600 mm. Depending on the loading, the depth of the prefabricated floor panels 101 may be reduced by inserting tapered block outs along the bottom of the mold for the strengthening beams 109 in a lengthwise sense. The block outs (not shown) may be made of polystyrene with a 4 mm form ply glued to the top enabling the molds to produce panels of varying depths from 300 mm to 600 mm. This will allow each mold to be readily modified to suit the length and the depth required of the prefabricated floor panels 101.
The molds will have a predefined camber to allow the prefabricated floor panel 101 to be level once they have been installed and loaded with the specified load for the building. Further, the edges of the mold will be 50-100 mm higher than the underside of the floor enabling the prefabricated floor panels 101 to be readily screeded to an exact height so that each panel laps onto the next prefabricated floor panels 101 perfectly providing for a flat, finished fireproof floor structure.
The supporting structure 103 includes support beams 113 and columns which may be made from steel or concrete depending on the application, with concrete beams being preferable when compressive forces are applied such as with the columns 114 and steel being preferred when tensile loads are applied such as with the support beams 113. The support beams 113 are supported by the columns 114 as is shown in
Returning to
As is exemplified in
In
The addition of fire fireproof or fire retardant sealant to the junction between the support beams 113 and the prefabricated floor panels 101 may be added at this point.
It is envisaged that a walling system (not shown) may be constructed for attachment to the supporting structure 103. The wall panels (not shown) may be fabricated on tilting steel beds in one embodiment being 9 m by 3 m however they may be varied in size to suit requirements.
The walls may be made on tilting steel casting beds. The beds would ideally be 9 m by 3 m, but can be varied to suit requirements. They can be made in a similar fashion to a stud wall out of 150 mm×50 mm RHS. The length of the beams are 3 m and they are welded to 9 m long top and bottom plates at 450 mm centres. 3 mm flat plate is glued to these frames to produce the wall bottom. Steel RHS borders of the required wall thickness are attached to the external perimeter of the mold. This use of steel molds produces perfectly flat, square and true panels. The beds have four pivot points along the bottom of the panel.
These are attached to a concrete floor or bored concrete piers if manufacturing onsite. The tilting beds allow the panels to be picked up 24 hours after pouring, which greatly increases production output.
The walls have either steel mesh or basalt mesh as reinforcement and also basalt or polypropylene fibres as required. The panels have 3 m long×12 mm or 16 mm threaded rod or rebar with connector nuts top and bottom to allow the panels to be lifted and also to have rod joined to the underside of the panel when installing them. The floor or floor panels have corresponding oversize holes drilled in them which are filled with high strength grout when installing. This has the same effect of using starter bars in block wall construction.
The installation process involves trucking the precast elements to site and installing using a tower crane. The process is as follows:
The method of constructing the construction would comprise the steps of:
The above steps may further include applying a fire retardant compound such as Sika® Firerate between the adjacent prefabricated floor panels prior to assembly, in order to provide a secure fire proof barrier between adjacent floor panels.
In addition, where features or aspects of the invention are described in terms of Markush groups, those skilled in the art will recognise that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group.
For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be carried out in chronological order in that sequence, unless there is no other logical manner of interpreting the sequence.
Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.
Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.
Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.
As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.
In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.
In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “forward”, “rearward”, “radially”, “peripherally”, “upwardly”, “downwardly”, and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.
For the purposes of this specification, the term “plastic” shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer.
As used herein the term “and/or” means “and” or “or”, or both.
As used herein “(s)” following a noun means the plural and/or singular forms of the noun.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.
Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.
Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.
It is apparent from the above, that the arrangements described are applicable to the construction industries.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019902927 | Aug 2019 | AU | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/AU2020/050830 | 8/10/2020 | WO |
