U.S. patent application number 10/116148 was filed with the patent office on 2002-10-24 for flooring.
Invention is credited to Smith, Roger.
Application Number | 20020152712 10/116148 |
Document ID | / |
Family ID | 26245994 |
Filed Date | 2002-10-24 |
United States Patent
Application |
20020152712 |
Kind Code |
A1 |
Smith, Roger |
October 24, 2002 |
Flooring
Abstract
A building component is described comprising a molding adapted
to be secured to the top surface of flooring joists either along
the length thereof or transversely thereacross, having a rebate
along its length to provide a ledge on which a floorboard edge can
rest. The depth of the rebate accommodates at least the thickness
of the floorboard, and the thickness of the molding below the ledge
creates a services void between the floorboard and the upper
surface of the joists. The molding may also include a second
parallel rebate leaving a ridge therebetween. The two floorboards
are spaced apart by the ridge. A further rebate can be provided to
accommodate at least part of another member. Where a floor covering
is laid over the floorboards the rebate(s) is/are sufficient to
accommodate both boards and covering. A floor panel including such
moldings comprises a plurality of spaced apart joists secured at
their ends to rim boards, elongate moldings secured to the joists,
flooring boards located on the rebates and secured to the moldings,
to create a void between the floorboards and the tops of the
joists. A services supporting platform is formed by flat panels
between and supported on the lower flanges of parallel I-beam
joists.
Inventors: |
Smith, Roger; (Bury St
Edmunds, GB) |
Correspondence
Address: |
William M. Lee, Jr.
Lee, Mann, Smith, McWilliams, Sweeney & Ohlson
P.O. Box 2786
Chicago
IL
60690-2786
US
|
Family ID: |
26245994 |
Appl. No.: |
10/116148 |
Filed: |
April 4, 2002 |
Current U.S.
Class: |
52/650.3 ;
52/143; 52/220.8; 52/648.1 |
Current CPC
Class: |
E04B 5/12 20130101; E04F
15/02452 20130101; E04C 2003/026 20130101; E04F 15/02447 20130101;
E04B 5/48 20130101; E04C 3/02 20130101 |
Class at
Publication: |
52/650.3 ;
52/143; 52/220.8; 52/648.1 |
International
Class: |
E04H 012/00; E04H
001/12; E04B 001/34 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 21, 2001 |
GB |
0109854.0 |
Jan 15, 2002 |
GB |
0200788.8 |
Claims
1. A building component comprising a moulding adapted to be secured
to the top surface of flooring joists either along the length
thereof or transversely thereacross, having a rebate along the
length of the moulding to provide a ledge on which the edge of a
floorboard can rest, wherein: 1) the depth of the rebate is such as
to accommodate at least the thickness of the floorboard, and 2) the
thickness of the moulding between the upper surface of the
floorboard-receiving rebate and its underside is such as to create
a void between the underside of the floorboard and the upper
surface of the joists sufficient to accommodate services such as
pipes and/or cables and/or ducting therein.
2. A building component according to claim 1 wherein the moulding
includes a second rebate similar to and formed parallel to the
first leaving a ridge along the length of the moulding
therebetween, so that the parallel edges of two floorboards can be
rested on, and be secured to, the moulding, spaced apart by the
ridge between the two rebates
3. A building component according to claim 2 which includes at
least one further rebate in the cross-section of the moulding to
accommodate at least part of another wall or floor member
4. A building component according to claim 1 when incorporated in a
floor formed by floorboards carried by the component in which the
floorboards are covered by a floor covering, wherein the rebate is
sufficient to accommodate the combined thickness of the boards and
floor covering.
5. A building component according to claim 1 when incorporated in a
floor formed by floorboards carried by the component in which the
rebate equals the thickness of the floorboards, and the latter are
covered by a floor covering, and a strip of material of the same
thickness as the covering is planted on the exposed surface of the
moulding, to provide a coplanar surface, adjacent or between
floorboards carrying the said floor covering.
6. A method of creating a void below floorboards and above joists
over which the floorboards extend, comprising the steps of securing
to the upper face of each of the joists at positions corresponding
to the edges of the boards, lengths of building component moulding
each of which is rebated to receive an edge of a floorboard, and
positioning floorboards so that their edges rest on the rebates,
wherein the depth of the rebate is selected to be at least
commensurate with the thickness of the floorboards, so that when
secured in place the upper surface of the boards and the exposed
faces of the building component mouldings present a substantially
flat surface.
7. A method according to claim 6 further comprising a floor
covering over the floorboards and the depth of the rebate is such
as to accommodate the combined thickness of the boards and the
floor covering thereon.
8. A method according to claim 6 further comprising a floor
covering over the floorboards and a strip of material of the same
thickness as the floor covering is secured to the exposed face of
each of the lengths of building component moulding.
9. A floor panel which includes provision for the laying of
services below the floor surface thereof after the panel has been
installed in a building during construction, and which is
constructed off-site, comprising: a) a plurality of parallel spaced
apart I-beam joists, b) transversely extending rim boards secured
to the ends of the joists, c) elongate building component mouldings
secured to the upper surfaces of the joists, each building
component moulding having at least one rebated edge, into which
edges of flooring boards can fit, and d) flooring boards located on
the rebates and secured to the building component mouldings,
whereby an elongate void exists between the undersides of the
floorboards and the tops of the joists within which cables or pipes
or ducting can be run to form a services run, without the need for
notching the upper surfaces of the joists along a run which extends
transversely to the joists.
10. A floor panel according to claim 9 wherein the depth of the
rebate is such that the upper surface of the floorboards is flush
with the exposed faces of the mouldings.
11. A floor panel according to claim 9 wherein at least some of the
floorboards are secured to the building component mouldings by
removable securing means, whereby the boards can be removed after
the panel is in situ, to enable pipes and cables and ducting to be
laid located below the boards, before the boards are secured in
place, and to allow subsequent access to the pipes, cables and
ducting.
12. A floor panel according to claim 11 wherein one or more service
runs are provided in the overall panel by floorboard panels or
traps, running parallel to the edges of the overall panel, each
floorboard panel or trap having a reduced width and being supported
by, and removably secured to, parallel and appropriately spaced
apart building component mouldings, at least one of which is
adapted by means of a second rebate to accommodate the edges of
adjoining floorboards, the latter being secured to the building
component mouldings during manufacture of the overall panel, and
the reduced width panels or traps are supplied with the main floor
panel.
13. A floor panel according to claim 9 wherein a floor covering is
laid over the boards and the depth of the rebate is such as to
accommodate the thickness of the floorboards together with the
thickness of the covering.
14. A floor panel according to claim 13 wherein at least some of
the floorboards are secured to the building component mouldings by
removable securing means, whereby the boards can be removed after
the panel is in situ, to enable pipes and cables and ducting to be
laid located below the boards, before the boards are secured in
place, and to allow subsequent access to the pipes, cables and
ducting.
15. A floor panel according to claim 14 wherein one or more service
runs are provided in the overall panel by floorboard panels or
traps, running parallel to the edges of the overall panel, each
floorboard panel or trap having a reduced width and being supported
by, and removably secured to, parallel and appropriately spaced
apart building component mouldings, at least one of which is
adapted by means of a second rebate to accommodate the edges of
adjoining floorboards, the latter being secured to the building
component mouldings during manufacture of the overall panel, and
the reduced width panels or traps are supplied with the main floor
panel.
16. A rectilinear prefabricated floor panel bounded by rim boards
and spanned by a parallel array of timber I-beams, to form
floorboard supporting joists to which floorboards are attached,
with building component mouldings according to claim 1 located
between the joists and the undersides of the floorboards to provide
a services void above the joists, wherein a plurality of parallel
spaced apart shorter timber I-beams are secured transversely
between two of the rim boards and the first and last of the
parallel array of main I-beams, the main joists and shorter joists
providing transversely extending joists within the prefabricated
structure for bearing on load supporting walls therebelow, adjacent
each of the four edges of the panel.
17 A floor panel according to claim 9 wherein a services run is
parallel to and extends between an adjoining pair of I-beam joists
and a cable and pipe supporting platform is provided at the bottom
of the services run, formed by locating one or more flat panels so
as to rest on the lower rails of the two adjoining parallel timber
I-beam joists.
18. A floor panel according to claim 17 wherein ducting is carried
by the panels to contain the services.
19. A floor panel according to claim 9 wherein holes are formed in
the web of the I-beam joists, through which services can be
threaded, to enable services runs to extend transversely to
parallel spaced apart timber I-beam joists.
20. A floor panel according to claim 19 wherein all said holes are
located at similar positions along the length of the web of each
I-beam, so that when assembled, the holes are in substantial
alignment transverse to the rims of the beams when the I-beams are
arranged in the parallel spaced array within the panel.
21. A building having load bearing walls on which prefabricated
floor panels constructed according to claim 9 having an accessible
services void below floorboards secured to and forming an integral
part of the panels, are located on the load bearing walls.
22. A timber framed building in which prefabricated timber wall
panels comprise load bearing walls thereof and a flooring panel
constructed according to claim 9 having an accessible services void
below floorboards secured to and forming an integral part of the
panel, is sandwiched along at least one edge region thereof,
between timber framed wall panels above and below the floor panel.
Description
FIELD OF INVENTION
[0001] This invention concerns flooring and in particular the
provision of services such as electrical wiring, telecommunications
and data cabling and pipes for water supplies and heating, below a
floor in a building. The invention is of particular relevance where
flooring is to be constructed from prefabricated panels, but is not
restricted to prefabrication and can be employed in on-site
construction of floors and may be incorporated into buildings
having timber framed or masonry walls.
BACKGROUND TO THE INVENTION
[0002] Traditionally flooring for first and higher floors in a
building has been constructed by laying timber joists in a parallel
spaced array between pairs of load-bearing walls or other
load-bearing devices such as transverse joists or steel beams
themselves carried by load-bearing walls. Floorboards having
tongued and grooved edges have then been laid transversely to the
run of the floor joists and nailed or screwed to the joists. Whilst
relatively narrow boards were favoured in the past, larger area
boards formed from woodchip have been used in more recent years and
are now the norm especially in domestic property.
[0003] The installation of services below the floorboards has
usually been carried out during the construction of the building
before the boards are screwed to the joists. Where possible pipes
and cables have been run parallel to the joists, in the gaps
between the joists, and have been secured by proprietary clips to
the sides of the joists. Where a pipe or cable run has to run
transversely to the run of the joists the latter have been notched
in their upper surface to allow pipes or cables or ducting to run
just below the floorboards in alignment with the desired pipe,
cable or ducting run so as to extend transversely to the joists
just below the floorboards.
[0004] In general joists have comprised lengths of solid sawn
timber of rectangular cross-section. However an alternative to
solid timber joists is now available in the form of timber I-beams
such as those supplied by TJM Europe SPRL under the TJI trademark.
These beams are constructed from upper and lower rails (chords)
which may be of solid timber or laminated veneer lumber, which are
routed to accommodate OSB web material to which they are secured by
adhesive, to form an I-section timber beam. The widths of the rails
are similar to the thickness of the solid timbers used for flooring
joists hitherto, and substituting these timber I-beams during
construction, for solid timber, has allowed floorboards to be
secured thereto in the usual way using nails or screws as desired.
The I-beams tend to have equally good load-bearing characteristics
as solid timber joists, and also tend to be more stable and less
likely to shrink or bow or twist as can happen with solid timber,
resulting in squeaks and dips characteristic of conventionally
constructed floors using solid timber joists.
[0005] The use of timber I-beams as floor joists does however
create a problem in relation to the location of pipes, cables and
ducting below the floorboards laid thereover, in that the
structural integrity of the I-beam is severely affected if any
notch is formed in the rails (chords). Indeed the design of such
beams is such that any cutting away of material from either rail
would probably cause the beam to fail under load. Thus although it
is still possible to run pipes, cables and ducting parallel to the
I-bean joists, it is not possible to notch them to permit
transverse runs as has hitherto been the case with solid timber
joists.
[0006] With the trend towards prefabrication of building
components, such as flooring panels and wall panels, off site,
there is a benefit to be gained in terms of the reduced weight of
such components, if timber I-beam joists of the type described, can
be used wherever possible in place of heavier solid timber. However
there remains the problem of installing services below the
floorboards used to clad such joists.
[0007] It is one object of the present invention to provide a
flooring member for use in conjunction with joists and floorboards,
to enable services to run transversely to the run of the joists
without the need to notch the latter.
[0008] It is a further object of the invention to provide a form of
construction for a prefabricated flooring panel which can be
transported to site and simply lifted into place by crane, which
allows the use of timber I-beam joists yet still allows services to
be installed below the level of the floorboards cladding the panel,
after the latter has been positioned on the load-bearing walls of
the building of which it is to form a part.
SUMMARY OF THE INVENTION
[0009] According to one aspect of the invention a building
component is provided in the form of a moulding adapted to be
secured to the top surface of flooring joists either along the
length thereof or transversely thereacross, and by virtue of a
rebate along the length of the moulding to provide a ledge on which
the edge of a floorboard can rest, the depth of the rebate being
such as to accommodate at least the thickness of the board, so that
the upper surface of the moulding will be flush with the upper
surface of a floorboard when positioned thereon (or with a floor
covering if the boards are covered or to be covered therewith), and
wherein the thickness of the moulding between the upper surface of
the board-receiving rebate and its underside is such as to create a
void between the underside of the boards and the upper surface of
the joists sufficient to accommodate services such as pipes and/or
cables and/or ducting therein.
[0010] This aspect of the invention is applicable to any type of
flooring joist and can be used in combination with solid timber
joists or timber I-beam joists or steel beams, since there is no
requirement to notch the joists to accommodate transverse services
runs of pipes or cables or ducting. This aspect of the invention is
also of particular advantage where the joists are timber I-beams of
the type described and where a flooring panel is to be constructed
off-site, using such I-beam joists as the supports for floorboards.
However it is to be understood that the invention (and this aspect
in particular) is not limited to prefabricated panel construction
but can equally be employed in on-site floor construction in any
form of building whether having timber framed or masonry walls,
although in the latter case no rim beams will normally be
required.
[0011] The moulding may be formed from timber or metal or plastics
or a composite material such as GRP and may be formed by extrusion
or moulding or machining as appropriate.
[0012] The moulding may be secured to the upper surface of the
joist for example by nails, screws, bolts, adhesive, nail plates,
or clips.
[0013] Where the moulding is to be situated between two
floorboards, a second rebate may be formed parallel to the first,
so that the parallel edges of the two floorboards can be rested on,
and be secured to, the moulding, spaced apart by a ridge in the
upper surface of the moulding left between the two rebates. By
making the depth of each rebate equal to the thickness of the
floorboard the edge of which is to be accommodated thereon, so the
upper surface of the floorboards and the upper surface of the ridge
will present a smooth flat floor surface.
[0014] If a floor covering is to be planted on the floorboards the
depth of the rebate may be increased to accommodate the combined
thickness of board and covering, or a strip of material of
appropriate thickness may be planted on the exposed surface of the
moulding, to provide a coplanar surface.
[0015] Where the moulding is to co-operate with other floor or wall
members, one or more further rebates may be formed in the
cross-section of the moulding to accommodate the other member or
members.
[0016] According to a second aspect of the invention a method of
creating a void below floorboards and above the joists over which
the boards extend comprises the steps of securing to the upper face
of the joists at positions corresponding to the edges of the
boards, lengths of moulding which are rebated to receive the
floorboard edge, positioning floorboards so that their edges rest
on the rebates in the mouldings, wherein the depth of the rebate in
the moulding is commensurate with the thickness of the floorboards,
so that when secured in place the upper surface of the boards and
the exposed faces of the mouldings are co-planar to present a
substantially flat floor surface.
[0017] The joists may be of solid timber or metal or may be timber
I-beams of the type described and the step of securing the
mouldings to the joists may for example involve nailing, screwing,
bolting, or adhesively joining the two.
[0018] According to a further aspect of the invention a floor panel
which includes provision for the laying of services below the floor
surface thereof after the panel has been installed in a building
during construction, and which can be constructed off-site and
delivered thereto for craning into position, comprises:
[0019] (a) a plurality of parallel spaced apart joists,
[0020] (b) a plurality of transversely extending rim boards secured
to the ends of the joists,
[0021] (c) mouldings as aforesaid secured to the upper surfaces of
the joists to define rebated openings into which flooring boards
can be fitted with the edges of the boards resting in the rebates
in the mouldings,
[0022] (d) flooring boards located in the said openings and secured
to the mouldings, with the upper surface of the boards flush with
the exposed faces of the mouldings, whereby a void exists between
the undersides of the floorboards and the tops of the joists within
which cables or pipes or ducting can be run, without the need of
notching the upper surfaces of the joists.
[0023] The floorboards are typically sheets of chipboard or the
like, typically of standard size such as 600 mm by 2400 mm by 22 mm
thick.
[0024] Securing the boards to the joists to form a prefabricated
floor panel, creates a stable panel which has little tendency to
distort as by twisting or bending or moving out of square, when
being stored or transported or lifted into position using a crane
or the like.
[0025] If at least some of the floorboards are secured to the
mouldings by removable securing means, such as screws or bolts, the
boards can be removed after the panel is in situ, to allow access
to the services void, to enable pipes and/or cables and/or ducting
to be laid over the joists, before the boards are finally secured
in place.
[0026] One or more service runs may be provided in the main panel
by floorboard panels or traps, running parallel to the edges of the
main panel, and having a reduced width of the order of 250-300 mm,
supported by and secured to parallel and appropriately spaced apart
mouldings, at least one of which is adapted by means of a second
rebate to accommodate the edge of a full size floorboard, the
latter being secured to the mouldings during manufacture of the
main panel, and the reduced width panels being removably secured to
the main floor panel during manufacture or simply supplied loose
therewith for securing thereto after the main floor panel has been
installed in the building of which it is to form a part.
[0027] In a rectilinear prefabricated floor panel bounded by rim
boards and spanned between the rim boards by timber I-beams of the
type described, to form floorboard supporting joists, with
mouldings between the joists and the undersides of the floorboards
to provide a services void above the joists, a first additional
timber I-beam is secured at corners thereof between the rim board
and the first of the array of I-beam joists parallel to the rim
board, spaced from the rim board by a distance commensurate with
the width of the load-bearing wall on which the edge of the
prefabricated floor panel is to rest, so as to form with the rim
board, and upper and lower elongate closure plates, a box section,
for transmitting the load of walling above the edge of the floor
panel to walling therebelow, and a second additional timber I-beam
is secured perpendicular to the first additional I-beam, and
located between the other rim board forming the corner of the
prefabricated structure and the part of a plurality of transversely
extending timber I-beams secured between the first mentioned rim
board and the said first of the parallel array of I-beams parallel
thereto, to provide transversely extending joists within the
prefabricated structure for bearing on the load supporting wall,
and the second additional I-beam serves as a support for mouldings
laid in line therewith and transversely thereto, for supporting the
inner edges of panels overlying the services void created by these
mouldings and the first mentioned mouldings.
[0028] Preferably a tray provides a cable platform at the bottom of
each services run, formed by locating one or more flat panels
resting on and optionally secured to the lower rails of parallel
timber I-beam joists situated on either side of the services run.
Typically cabling is laid directly on the platform so formed.
Alternatively or in addition dusting is laid thereon to contain at
least some of the cables.
[0029] Where a services run is to extend transversely to parallel
spaced apart timber I-beam joists, holes are preferably formed in
the OSB web of the I-beam joists, through which cables or pipes,
especially plastics pipes, can be threaded.
[0030] Since small openings in the web of an I-beam, albeit clear
of the ends thereof, do not significantly affect the load carrying
capabilities of such a beam, when used as a joist, each I-beam to
be employed as a joist in a prefabricated flooring panel is
preferably formed with a plurality of such holes in its web,
typically as by drilling, before assembly of the I-beams to form
the joists in the panel.
[0031] Preferably all said pre-formed holes are located at similar
positions along the length of each I-beam, so that when assembled,
the holes are in substantial alignment when the I-beams are
arranged in a parallel spaced array, and are viewed in a direction
transverse to the run of the I-beams.
[0032] Where the services run extends transversely to parallel
spaced apart I-beams, the upper rails of the I-beams provide a
support for pipes, cables or ducting extending along the run just
below the floorboards. However no such support exists along the
length of a services run which extends parallel to an array of
I-beam joists, and according to a preferred feature of the
invention, struts are provided which extend transversely below the
mouldings defining the services run, the struts being spaced apart
along the length of the run in the form of the rungs of a
ladder.
[0033] The struts may be secured as for example by adhesive or
clips or friction fit joints or fir-tree connectors, to the
mouldings.
[0034] Alternatively and preferably each strut includes a central
region adapted to span the gap between the upper rails of the two
I-beam joists on either side of the services run, and is stepped at
each end to extend over the upper rails of the I-beam joists to
support the central region below the mouldings.
[0035] In a preferred embodiment each stepped end which is to
overlie an I-beam joist has a thickness commensurate with the
height of the floorboard supporting ledges of the mouldings.
Preferably each extends over an I-beam by not more than the width
of each upper rail.
[0036] Each strut may be formed from metal or plastics or a
composite material such as GRP, or from three lengths of timber, a
first longer length no longer than the spacing between the rails of
the two I-beam joists, and two shorter lengths secured to the upper
surface of the strut one at each end, so as to extend beyond the
ends of the longer length to fit over the tops of the two
rails.
[0037] Where the strut is formed from timber, as aforesaid, the two
shorter lengths may be joined to the longer length for example by
adhesive, or nails, or screws, or nail-plates, or bolts, or any
combination thereof.
[0038] Alternatively the struts may be formed from an elongate
element carried at each end by miniature joist hangers which clip
over or are secured to the upper rails of the I-beam joists and
receive the ends of the elongate element. The latter may be formed
from timber or plastics or a composite material such as GRP, or
metal.
[0039] According to a preferred feature pipe and/or cable retailing
clips may be provided in each strut and where at least the central
section spanning the gap between the two I-beam joists is moulded
from plastics material, the clips may be moulded integrally with
the strut.
[0040] Where the thickness of the parts of each strut which extend
over rails of the I-beam joists is commensurate with the thickness
of the mouldings below the floorboard supporting ledges thereof,
the parts of the strut which extend over the I-beam rails provide
additional support for the floorboards.
[0041] Where mouldings are to extend parallel to and between I-beam
joists, the central span of each transverse strut not only provides
support for pipes, cables and the like, but also for the
mouldings.
[0042] The invention also lies in a services supporting strut
adapted to fit between a pair of Ibeam joists having end regions
which extend beyond and above the ends of a main section of the
strut for support on the upper rails of the two I-beams.
[0043] A similar services supporting platform (especially for
cables or plastics pipes), may be provided between I-beam joists
which extend transversely to a services void by locating flat
panels between the webs of the I-beam joists, with their ends
supported on (and optionally secured to) the lower rails of the
I-beam joists, and the invention also lies in a method of creating
such a platform by fitting flat panels between the webs as
aforesaid, and in flat panels adapted to be so fitted.
[0044] The invention also lies in a building having load bearing
walls on which prefabricated floor panels as aforesaid having an
accessible services void below floorboards secured thereto, is
located on the load bearing walls.
[0045] The invention also lies in a timber framed building in which
prefabricated timber wall panels comprise load bearing walls
thereof and a flooring panel as aforesaid having an accessible
services void below floorboards secured thereto, is sandwiched
along at least one edge region thereof, between timber wall panels
above and below the floor panel.
[0046] Where a load-bearing wall is to be supported above an edge
region of the flooring panel, the latter is preferably reinforced
in the said edge region thereof, to enable the weight of the wall
above the panel to be reliably transferred to the wall
therebelow.
[0047] It is to be understood that except where inappropriate to
the context, all of the foregoing underfloor construction
techniques, construction of services runs and supports for cabling
and pipework can be employed in flooring supported by timber framed
or masonry walls or any combination thereof, and may be employed
during on-site floor construction or in prefabrication of flooring
panels.
[0048] The invention will now be described by way of example with
reference to the accompanying drawings, in which:
[0049] FIG. 1 is a schematic plan view of a flooring deck
constructed from two flooring panels each constructed in accordance
with the invention,
[0050] FIG. 2 is a section AA of FIG. 1,
[0051] FIG. 3 is a section BB of FIG. 1,
[0052] FIG. 4 shows the sole plate layout for the flooring deck of
FIG. 1,
[0053] FIG. 5 shows how wall panels can be mounted on the
peripheral regions of the flooring deck of FIG. 1,
[0054] FIG. 6 is a cross-section to an enlarged scale through the
lower RH corner of the structure of FIG. 2,
[0055] FIGS. 7 and 8 are plan views of the two panels which can be
joined to form the deck of FIG. 1, showing the run of the mouldings
defining the edge of the service void,
[0056] FIG. 9 is a scrap section on DD in FIG. 8 to an enlarged
scale, showing how these different mouldings may be employed,
[0057] FIGS. 10, 11 and 12 are sectional views of the three
mouldings employed in FIGS. 7-9,
[0058] FIGS. 13 and 14 are plan views if the rim-board and I-beam
joist layouts in the panels of FIGS. 7 and 8,
[0059] FIGS. 15, 16 and 17 are side elevations of different I-beam
joists employed in the panels of FIGS. 13 and 14,
[0060] FIG. 18 is a section through a part of the services void
provided in accordance with the invention in the panel of FIG.
1,
[0061] FIG. 19 is a perspective view of a part of a services void
between two parallel spaced I-beam joists showing how transverse
struts can fit over and between the I-beams, and
[0062] FIG. 20 is a section through a flooring arrangement where a
floor covering is applied to the floorboards and to the services
cover.
DETAILED DESCRIPTION OF THE DRAWINGS
[0063] FIG. 1 illustrates in plan view a flooring deck constructed
by joining two pre-fabricated floor panels P1 and P2 along two
longer edges each made up of a timber I-beam joist 10, 12. The two
joists can be secured by screws or bolts or any other convenient
means, side by side as shown. Rimboards 14, 16 define the parallel
edges of the two panels P1 and P2 and similar but shorter rimboards
18, 20 define the other two sides of PI and rimboards 22, 24 define
the other two sides of P2.
[0064] Each panel is formed by one or more timber I-beam major
joists 26, 28 in the case of P1, and 30 in the case of P2 with
shorter lengths of similar I-beam forming cross joists spanning the
gaps between joist 26 and rimboard 14 (identified by 32-42) and
between joist 30 and rimboard 16 (identified by 44-54). Additional
I-beam joists are provided at each corner, denoted 56, 58, 60 and
62 respectively.
[0065] The spacing (measured perpendicular to the joists) between
the shorter cross joists, such as 46, 48 is substantially the same
as the spacing between the major joists, such as 26, 28, and the
purpose of the cross joists will become apparent as later Figures
are described. This spacing is selected to correspond to the width
of standard floorboards such as are currently manufactured from
chipboard and the like, namely 600 mm.
[0066] The major joists and the cross joists are secured to the
rimboards and the cross joists to the major joists, using the
joining techniques described in our corresponding Patent
applications filed under case references C1335/M and C1336/M.
[0067] FIGS. 2 and 3 show how pre-fabricated wall panels 64, 66 and
68, 70 can be located on the peripheral regions of the floor panel,
with the timber I-beams transferring the weight of the walls (and
any structures carried by them) to the footings or the walls of the
floor below.
[0068] FIG. 4 shows how the sole plate, (made up of four lengths of
38 m.times.89 mm timber 72,74,76 and 78) can be constructed for
fitting below the floor panels P1, P2 as denoted in FIGS. 2 and
3.
[0069] FIG. 5 is a plan view showing the four wall panels 64, 66,
68, 70 in situ.
[0070] In accordance with the invention services void is created by
laying the flooring boards (generally designated by 80 in FIGS.
2-3) over mouldings (illustrated in more detail in later Figures),
so as to permit pipes an/or cables and/or ducting to be located
between the underside of the boards 80 and the upper surfaces of
the major joists (such as 10, 12) and the cross joists (such as 32,
34).
[0071] In general this is sufficient to support pipes at 600 mm
intervals, and by running any pipes parallel to any one of the four
sides of the deck made up of P1 and P2, close to the edge of the
deck (at least within 600 mm from the edge) it will be seen that
this degree of support is readily obtained.
[0072] FIG. 6 shows the floor construction to an enlarged scale.
The I-beam joist 28 includes a web 82 and upper and lower rails 84,
86 respectively, routed to receive the upper and lower edges of the
web. The wall panel 66 is spaced from the upper surface of the
I-beam 28 and rimboard 20 by a length of 22 mm chipboard 88 and the
sole plate 76 is shown engaging the underside of the I-beam 82 and
rimboard 20.
[0073] The web is formed with two 38 mm diameter holes 90, 92 and
the 22 mm chipboard flooring boards 80 are carried on mouldings
laid over and secured to the I-beam joists. One of the mouldings is
shown in cross-section in FIG. 6 and is denoted by reference
numeral 94. It will be seen that the 22 mm chipboard spacer 88
extends beyond the inside face of the wall panel 66, and to this
end the moulding 94 is undercut to accommodate the protruding 22 mm
thickness in much the same way as the upper surface of the moulding
in the diametrically opposite corner of the section, is rebated to
accommodate the 22 mm thickness of the flooring board 80.
[0074] FIGS. 7 and 8 show panels P1 and P2 to a larger scale and
show overlaid thereon mouldings and flooring boards, and FIGS. 9-12
show the three different mouldings 94 (as already illustrated and
described with reference to FIG. 6), (see FIG. 10), 96 in FIGS. 11
and 98 in FIG. 12. FIG. 9 shows how each of the three mouldings is
used.
[0075] Thus 94 is located around the periphery of the deck formed
by P1 and P2, and provides a ledge 100 to receive an edge of a
services cover board 102; 96 provides two such ledges 104, 106, the
first to support the other parallel edge of the services cover
boards 102 and the other (106) to support an edge of a flooring
board 108 which is cut to extend halfway across the width of the
moulding 98. The edge of the next board 112 abuts the edge of board
108 and is supported by the other half of the width of the moulding
98 (as shown in FIG. 9).
[0076] An upstand 114 extends along the length of the moulding 96
between the two ledges 106, 106, the height of the upstand being
equal to the 22 mm thickness of the flooring boards such as
generally designated at 80 in FIG. 6.
[0077] The line of abutment of the edges of the boards 108, 112 is
denoted by 116, also visible in FIG. 9.
[0078] The remaining boards are outlined in FIG. 8 and are denoted
by reference numerals 118 to 124, while services cover boards are
denoted by 102 (already described), 126 and 128.
[0079] In a similar way the boards are outlined in FIG. 7 and
denoted by reference numerals 130-140, and the three services cover
boards are denoted by reference numerals 142, 144 and 146.
[0080] The mouldings shown in FIGS. 7 and 8 are denoted by the same
reference numerals as employed in FIG. 9, but where they do not
correspond to the actual mouldings identified in FIG. 9, they
include a suffix, such as 94a to 94e, 114a to 114e, and the
abutment lines over the mouldings corresponding to moulding 98 in
FIG. 9 are denoted by 116a-116i.
[0081] FIGS. 13 and 14 illustrate the way in which the different
component parts of the panels are joined. Each joint is labelled
with an identifier the code for which is indicated in the drawing.
I-beam to rimboard joints are denoted by an asterisk and the joints
are of the type described in our corresponding Application
reference C1335/M, and each joint is formed by:
[0082] 1) forming two holes a short distance from the end of the
I-beam to be butt-jointed to the rim-joist, one in each of the
upper and lower rails (or flanges) of the I-beam section, the two
holes being coaxial and generally aligned with and parallel to the
web of the I-beam section,
[0083] 2) locating the rim-joist in place and forming two further
holes through the rim-joist and into the ends of the upper and
lower rails (flanges) of the I-beam joist, generally perpendicular
to and intersecting the first two holes,
[0084] 3) inserting two cross-dowels into the two first holes, each
having a transverse threaded opening, and aligning the openings
with the holes which intersect the holes containing the
cross-dowels,
[0085] 4) inserting threaded bolts into the intersecting holes to
engage in the threaded openings in the cross-dowels, and tightening
the bolts so as to draw the rim-joist towards the abutting end of
the I-beam joist, and thereby clamp the rim-joist thereto.
[0086] The cross-dowels may be formed from metal, or from a rigid
plastics material or from a composite material.
[0087] The bolts are typically formed from metal or a rigid
plastics material.
[0088] A load spreading washer may be located between the head of
each bolt and the rim-joist, or each bolt head may include an
integral load spreading flange for increasing the area of the bolt
head which is to make contact with the rim-joist.
[0089] The ends of the holes through the rim-joist through which
the bolts pass into the rim-joist may be enlarged to accommodate
the heads of the bolts, so that the latter are wholly contained
within the rim-joist.
[0090] Where the upper and lower rails (flanges) of the I-beam
joist are laminated, the holes which are to receive the
cross-dowels preferably extend generally perpendicular to the
laminations.
[0091] I-beam to I-beam joints are denoted by the superimposed
circle and cross symbol and are of the type described on our
corresponding Application reference C1336/M, and each joint is
formed by:
[0092] 1) fitting the end of the web of the first I-beam between
the two side cheeks of a rigid channel member,
[0093] 2) securing the web to the channel member by means of
through fastenings such as bolts, the bridging section of the
channel member having at least one stud protruding therefrom in
line with the web of the first I-beam for securing to the web of
the second transverse I-beam,
[0094] 3) forming a hole in the web of the second I-beam through
which the or each stud can pass, and
[0095] 4) screwing the two beams together by fitting a closure
member to the protruding end of the stud and tightening
thereover.
[0096] Preferably the stud is formed with a screw thread and the
closure is a nut which may be a locking nut, with a washer
sandwiched between it and the web of the second beam, if desired,
and the joint is formed by screwing the nut onto the stud, until
the web is tightly sandwiched between the nut (and washer if
fitted) and the rear of the channel member attached to the web of
the first beam.
[0097] The load bearing capacity of a joint formed in accordance
with the invention can be increased to advantage by enlarging the
opening in the web of the second beam which is to receive the stud,
and fitting into the enlarged opening a dished shear ring so as to
be a tight fit therein, the shear ring having a small central
opening through which the stud protrudes and the engagement of the
closure device on the stud serves to clamp the shear ring to the
web of the second beam and to the rear of the channel member
attached to the web of the first beam.
[0098] The closure member may be formed from metal or a rigid
plastics material or from a metal reinforced plastics combination,
or a composite such as GRP.
[0099] The stud or studs and the closures are typically formed from
metal but may be formed from a rigid plastics material or a metal
reinforced plastics combination.
[0100] The shear ring if fitted may be formed from rigid plastics
or metal or GRP or a metal reinforced plastics configuration.
[0101] In order to improve the fit between the end of the first
beam and the side of the second beam, the upper and lower rails (or
flanges) of the first beam may to advantage be cut back by an
amount commensurate with the overhang of the corresponding rails
(flanges) on the second beam relative to the web of the latter less
the thickness of the bridging bar of the channel member, so that
the web of the first beam extends beyond the end faces of the upper
and lower rails (flanges) thereof.
[0102] Preferably the side cheeks of the channel member extend over
substantially the whole height of the web of the first beam so that
the channel member is a snug fit between the upper and lower rails
(flanges) of the first beam.
[0103] Preferably the side cheeks of the channel member are formed
with pairs of aligned holes and similar holes are formed in the web
of the first I-beam, to allow bolts to be pushed through the hole
in the end of the web and the two aligned holes on either side of
the side cheeks of the channel member.
[0104] The panels P1 and P2 (as shown in FIGS. 7 and 8) are made
using three different lengths of timber I-beam joists, labelled
type A, B and C.
[0105] The type A joist is shown in FIG. 16, the type B in FIG. 15
and the type C in FIG. 17.
[0106] It will be seen that pairs of 38 mm diameter holes are
formed in the web 148 of joist C, adjacent each end thereof, as
denoted by 150, 152 and 154, 156. By locating these holes at the
same distance from each end, in all the C-type joists, cables or
pipes, especially flexible pipes) or ducting can be threaded
through these holes from one joist to the next, either during or
after assembly.
[0107] Similar pairs of holes are provided in the web 158 of joist
type A at 160, 162 and in the web 164 of joist type B at 166, 168.
Again by carefully locating the holes relative to the ends of these
shorter joists the holes will be generally aligned when the joists
are in position, to permit services such as cables or pipes
(especially flexible pipes) or ducting to be threaded therethrough
so as to extend from and through one joist to the next.
[0108] FIG. 18 illustrates how underfloor supports can be formed
for supporting services, and where necessary, mouldings which run
parallel to the run of the joists so that the latter cannot
themselves be used for support.
[0109] Two supports are shown, an upper one generally designated
170 and a lower one 172. Support 170 comprises an elongate timber
strut 174 which extends between the side faces of the upper rails
of two parallel spaced apart I-beam joists generally designated
176, 178 and two shorter lengths of timber 180, 182 overlying the
ends of strut 174 and protruding a short distance therebeyond to
form overhangs which will rest on the upper faces of the rails 184,
186 of the I-beam joists 176, 178 respectively. As shown these
overhanging items 180, 182 are secured to the ends of the strut 174
by nail plates two of which are shown at 188, 190. Similar nail
plates (not shown) are driven into the timbers on the opposite side
of the overhang.
[0110] The strut 174 provides support for mouldings such as 192,
194 having rebates on which panels of 22 mm floor grade chipboard
196, 198, 200 are received. The thickness of the overhangs 180, 182
must not exceed the thickness of the floor panels 196 etc., and to
advantage is made the same as that thickness so as to further
support the flooring panels 196 etc.
[0111] A lower support is provided by a panel 172 dimensioned to
fit between the webs 202, 204 of the I-beam joists 176, 178 and
rest on the inner ledges 206, 208 of the lower rails 210, 212 of
the I-beam joists. The support may be continuous (by providing long
lengths of panel 172) or more preferably, discontinuous by locating
short length panels at regular intervals along the length of the
joists 176, 178. Cables or pipes or ducting can be laid between the
joists to rest on the panels, which may be secured at their ends to
the rails 210, 212 by means of nails, screws, clips or
adhesive.
[0112] Although preferably formed from timber or OSB, the panels
172 and struts 170 may be formed from plastics or metal or a
composite material such as GRP, or any combination thereof.
[0113] Although not shown in FIG. 18 pipe or cable clips may be
provided in the upper edge of the strut 170 or upper face of the
lower panel 172. Where these are moulded from plastics the clips
may be integrally formed with the primary device during the
moulding process.
[0114] FIG. 19 is an exploded perspective view of a region of a
floor panel showing a pair of parallel I-beam joists 214, 216
having secured to their upper rails lengths of moulding 218, 220,
222, 224 which leave gaps 226, 228 into which the overhanging ends
230, 232 can fit so as to rest on the rails 234, 236 with the
bridging section 238 spanning the gap between the rails 234, 236.
Intermediate type B mouldings 240, 242 running parallel to and
between the rails 234, 236 rest on, and can be secured to the
bridging section 238 and pipe or cable clips 244, 246 are secured
to or formed integrally with the section 238.
[0115] The gap between the upstands 248, 250 of two B-type
mouldings 240, 242 is bridged by a services cover panel (or series
of such panels) an example of which is denoted by reference numeral
252, while similar floorboards 254, 256 rest on the other rebates
of the B-type mouldings 240, 242 and extend over, or partially over
the flat topped type C mouldings 218, 222, 220, 224.
[0116] Although not shown clips may be secured to or formed
integrally with the lower support panel(s).
[0117] In the flooring example shown in FIGS. 9-12 the flooring
boards 108 and services cover board 102 are shown as standard 22 mm
chipboard. In this event the height of the upstand 114 of moulding
96 and the corresponding edge support in moulding 94 need only be
22 mm, to just accommodate the 22 mm chipboard thickness. If
however it is desired to cover the chipboard with a floor covering
such as thin timber flooring, floor tiles or vinyl, which is to be
secured to the chipboard by an adhesive, it is important that the
floor covering does not extend in a continuous manner over the
removable services cover board such as 102 in FIG. 9.
[0118] To this end the mouldings 94, 96 may be modified as shown in
FIG. 20 so that the upstand 96 and edge support region of 94 are of
increased height to accommodate the thickness of the floor
covering.
[0119] As shown in FIG. 20 this can be achieved by simply
increasing the overall height of each of the mouldings, in which
event the top surface of the upstand 114 (of 96) and the edge
support region of 94 will be visible, but will be coplanar with the
surface of the floor covering sheet material 117, 119.
[0120] By colouring the mouldings (or at least the upper surface
which will be visible) so the upper surface of the mouldings can be
made either to appear as a contrasting feature in the floor, or to
blend in colour and texture with the floor covering material.
[0121] Alternatively mouldings having upstands and edge support
heights just sufficient to accommodate the floor boarding may be
employed, as shown in FIGS. 9-12, and a narrow strip of material
may be planted on the upper exposed surface of the mouldings, so as
to produce the desired visual effect (i.e. either a contrast or to
blend with the floor covering material). The strip material should
have a similar thickness to the floor covering material, so that
the upper surfaces are coplanar, and may be secured in place by
means of an adhesive and may to advantage be self-adhesive with a
peel-off backing strip, to facilitate installation.
* * * * *