U.S. patent application number 17/634873 was filed with the patent office on 2022-08-25 for prefabricated floor panel, construction and method therefor.
The applicant listed for this patent is LWC RESEARCH PTY LTD. Invention is credited to Trevor JONES.
Application Number | 20220268018 17/634873 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-25 |
United States Patent
Application |
20220268018 |
Kind Code |
A1 |
JONES; Trevor |
August 25, 2022 |
PREFABRICATED FLOOR PANEL, CONSTRUCTION AND METHOD THEREFOR
Abstract
There is provided a prefabricated floor panel (101) for use with
a supporting structure (103) including a floor member (105) the
floor member (105) defining a floor surface (107) and being adapted
to engage with an adjacent similar floor panel (101) and at least
one or more strengthening beams (109) configured to engage with the
supporting structure (103) in use to support the prefabricated
floor panel (101).
Inventors: |
JONES; Trevor; (Kingscliff,
AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LWC RESEARCH PTY LTD |
Surfers Paradise, QLD |
|
AU |
|
|
Appl. No.: |
17/634873 |
Filed: |
August 10, 2020 |
PCT Filed: |
August 10, 2020 |
PCT NO: |
PCT/AU2020/050830 |
371 Date: |
February 11, 2022 |
International
Class: |
E04B 5/10 20060101
E04B005/10; E04B 5/04 20060101 E04B005/04; E04C 2/04 20060101
E04C002/04; E04C 2/06 20060101 E04C002/06; E04B 5/02 20060101
E04B005/02 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 13, 2019 |
AU |
2019902927 |
Claims
1-33. (canceled)
34. A flooring system that comprises: a support structure
including: two support beams, each support beam having a supporting
formation; and a prefabricated floor panel, that is moulded from a
settable material, arranged on the support structure and including:
a floor member, the floor member having an upper major face, in the
form of a floor surface, and a lower major face; one or more
strengthening beams disposed on the lower major face of the floor
member; a first overlapping formation that is adapted to engage
with an adjacent floor panel such that the floor member is seated
on top of a strengthening beam of a floor member of the adjacent
floor panel, the floor member being adapted so that the floor
surface is flush with the floor surface of the adjacent floor
panel; and two second overlapping formations at respective opposite
ends of the floor panels, the second overlapping formations being
substantially perpendicular to the one or more strengthening beams
and being supported, respectively, by the supporting formations of
the support beams.
35. The flooring system as claimed in claim 34, which includes
support pillars that are mounted on the support beams to support
further support beams, mounted on the support pillars, and a
prefabricated floor panel supported by the further support
beams.
36. The flooring system as claimed in claim 35, in which the
support pillars include an end plate at at least one end of each
support pillar.
37. The flooring system as claimed in claim 34, in which the one or
more strengthening beams is in the form of a number of
strengthening beams that are substantially parallel to each
other.
38. The flooring system as claimed in claim 34, in which one of the
strengthening beams extends at least partly outside a periphery of
the lower major face to support the first overlapping formation of
the adjacent floor panel in an overlapping manner.
39. The flooring system as claimed in claim 38, in which the one of
the strengthening beams of the floor panel, that extends at least
partly outside the periphery of the lower major face, and the first
overlapping formation of the adjacent floor panel form a lap joint
that is adapted to receive a fireproofing sealant.
40. The flooring system as claimed in claim 34, in which the
supporting formations of the support beams are adapted for
supporting the strengthening beams of the prefabricated floor
panels.
41. The flooring system as claimed in claim 34, in which the
strengthening beams are an integral part of the floor panel.
42. The flooring system as claimed in claim 34, in which the floor
panels are of reinforced, aerated concrete.
43. A prefabricated floor panel for use with a flooring system, the
flooring system including a support structure, which includes two
support beams, each support beam having a supporting formation, the
prefabricated floor panel being moulded from a settable material
and comprising: a floor member, the floor member having an upper
major face, in the form of a floor surface, and a lower major face;
one or more strengthening beams disposed on the lower major face of
the floor member; a first overlapping formation that is adapted to
engage with an adjacent floor panel such that the floor member is
seated on top of a strengthening beam of the adjacent floor member,
the floor member being adapted so that the floor surface is flush
with the floor surface of the adjacent floor panel; and two second
overlapping formations at respective ends of the floor panels, the
overlapping formations being substantially perpendicular to the at
least one or more strengthening beams, and being supported,
respectively, in use, by the supporting formations of the support
beams.
44. The prefabricated floor panel as claimed in claim 43, in which
the one or more strengthening beams is in the form of a number of
strengthening beams that are substantially parallel to each
other.
45. The prefabricated floor panel as claimed in claim 43, in which
one of the strengthening beams extends at least partly outside a
periphery of the lower major face to support the first overlapping
formation of the adjacent floor panel in an overlapping manner.
46. The prefabricated floor panel as claimed in claim 45, in which
the one of the strengthening beams of the floor panel, that extends
at least partly outside a periphery of the lower major face, and
the first overlapping formation are configured to form a lap joint
that is adapted to receive a fireproofing sealant.
47. The prefabricated floor panel as claimed in claim 44, in which
the strengthening beams are an integral part of the floor
panel.
48. The prefabricated floor panel as claimed in claim 44, which is
moulded of reinforced, aerated concrete.
49. A method of constructing a flooring system that comprises a
support structure including two support beams that each have a
supporting formation, and a prefabricated floor panel that is
moulded from a settable material arranged on the support structure,
the floor panel including a floor member that has an upper major
face, in the form of a floor surface, and a lower major face, with
one or more strengthening beams disposed on the lower major face,
the floor panel including a first overlapping formation that is
adapted to engage with an adjacent floor panel such that the floor
member is seated on top of a strengthening beam of a floor member
of the adjacent floor panel, the floor member being adapted so that
the floor surface is flush with the floor surface of the adjacent
floor panel, and including two second overlapping formations at
respective opposite ends of the floor panels, the second
overlapping formations being substantially perpendicular to the at
least one or more strengthening beams and being supported,
respectively, by the supporting formations of the support beams,
the method comprising the step of: supporting a plurality of the
prefabricated floor panels on the supporting formations of the two
support beams so that the floor member of one floor panel is seated
on top of a strengthening beam of the adjacent floor panel.
50. The method as claimed in claim 49, in which the flooring system
includes support pillars, the method including the step of mounting
the support pillars on the support beams, supporting further
support beams on the support pillars, and supporting a further
floor panel on the further support beams.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to concrete floor and/or wall
panels and in particular to a prefabricated floor structure for use
in buildings.
[0002] 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.
BACKGROUND OF THE INVENTION
[0003] 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.
[0004] 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.
[0005] 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.
SUMMARY OF THE INVENTION
[0006] 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.
[0007] According to a first aspect, the present invention may be
said to consist in a prefabricated flooring system comprising:
[0008] a. a plurality of prefabricated floor panels, the plurality
of prefabricated floor panels being adapted to interlock with each
other in use; [0009] b. wherein each one of the plurality of
prefabricated floor panels includes one or more edges adapted to
attach to a support structure in use.
[0010] In one embodiment, the prefabricated floor panels are
created from a settable material.
[0011] In one embodiment, the settable material is concrete.
[0012] In one embodiment, the concrete is reinforced using a
plurality of reinforcing bars embedded within the concrete.
[0013] In one embodiment, the prefabricated floor panels further
include strengthening members.
[0014] In one embodiment, the strengthening members are supporting
beams.
[0015] In one embodiment, the supporting beams include at least one
cavity for the provision of services.
[0016] In one embodiment, the prefabricated floor panels interlock
by way of a lap joint.
[0017] In one embodiment, the lap joint is adapted to receive a
fireproof sealant.
[0018] In one embodiment, the corresponding lap joints are adapted
to be screwed together.
[0019] 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.
[0020] In one embodiment, the support structure is adapted to
attach to at least one support post.
[0021] In one embodiment, the prefabricated flooring panel is about
1.5 m to about 3 m in width.
[0022] In one embodiment, the length is between about 1 m to about
15 m in length.
[0023] 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:
[0024] a. a floor member, the floor member defining a floor surface
and being adapted to engage with an adjacent similar floor panel;
and [0025] b. at least one or more strengthening beams configured
to engage with the supporting structure in use to support the
prefabricated floor panel.
[0026] 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.
[0027] In one embodiment, the prefabricated floor member is adapted
to overlap with an adjacent similar prefabricated floor panel in at
least a vertical direction.
[0028] In one embodiment, the prefabricated floor member is adapted
to be overlapped by an adjacent similar prefabricated floor
panel.
[0029] In one embodiment, the floor panel includes a first
overlapping formation for overlapping with an adjacent similar
prefabricated floor panel.
[0030] In one embodiment, the floor panel includes a second
overlapping formation adapted for overlapping with the supporting
structure in use.
[0031] In one embodiment, the second overlapping formation is
located on opposed sides of the prefabricated flooring panel.
[0032] In one embodiment, the second overlapping formation is
substantially parallel to the supporting structure.
[0033] In one embodiment, the second overlapping formation is
substantially perpendicular to the at least one or more
strengthening beams.
[0034] In one embodiment, the at least one or more strengthening
beams are disposed asymmetrically on the floor member.
[0035] 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.
[0036] In one embodiment, the at least one or more strengthening
beams are disposed on a lower major face of the floor member.
[0037] In one embodiment, the at least one or more strengthening
beams extend in parallel with each other.
[0038] 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.
[0039] In one embodiment, the prefabricated floor panel includes
reinforcing bars.
[0040] In one embodiment, the prefabricated floor panel is
integrally formed.
[0041] In one embodiment, the prefabricated floor panel is made
from conventional concrete.
[0042] In one embodiment, the prefabricated floor panel is made
from aerated concrete.
[0043] According to yet a further aspect, the present invention may
be said to consist in construction comprising: [0044] a. at least
one or more prefabricated floor panels; and [0045] b. at least a
pair of supporting beams, the supporting beams including a
supporting formation adapted for supporting the strengthening beams
of the prefabricated floor panels.
[0046] In one embodiment, the supporting formation is one or more
selected from a lip and a recess.
[0047] 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.
[0048] In one embodiment, the construction includes at least one
support pillar.
[0049] In one embodiment, the support pillars include end plates at
one or either end of the support pillars.
[0050] According to yet a further aspect, the present invention may
be said to consist in method of constructing a construction
comprising steps of: [0051] a. providing a supporting structure;
[0052] b. providing a plurality of prefabricated floor panels, each
floor panel presenting a floor surface; [0053] c. supporting the
prefabricated floor panels on the support structure in a
configuration to at least partly overlap each other.
[0054] In one embodiment, the method further includes the step of
applying a fire retardant compound between the adjacent
prefabricated floor panels.
[0055] 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.
[0056] In one embodiment, the method further comprises the step of
providing at least one or more pillars.
[0057] In one embodiment, the step of providing a support structure
includes the step of providing at least a pair of supporting
beams.
[0058] In one embodiment, the method further comprises the step of
supporting the supporting beams on the at least one or more
pillars.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] In one embodiment, the prefabricated floor panels is a
prefabricated floor panel.
[0063] 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.
[0064] Other aspects of the invention are also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] 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:
[0066] FIG. 1 is a perspective view of the construction in
accordance with a preferred embodiment of the present
invention;
[0067] FIG. 2 is an exploded view of the embodiment of FIG. 1;
[0068] FIG. 3a is a top view of a prefabricated floor panel in
accordance with an embodiment of the present invention;
[0069] FIG. 3b is a bottom view of the prefabricated floor panel of
FIG. 3a;
[0070] FIG. 4a shows two prefabricated floor panels adjoined;
[0071] FIG. 4b shows a side view of the adjoined prefabricated
floor panels of FIG. 4a;
[0072] FIG. 5 shows a side view of the floor panels mounted to a
column; and
[0073] FIG. 6 shows a side view of the floor panels.
DESCRIPTION OF EMBODIMENTS
[0074] It should be noted in the following description that like or
the same reference numerals in different embodiments denote the
same or similar features.
[0075] A prefabricated floor panel and associated construction
according to a first aspect of the invention is generally indicated
by the numeral 1000.
[0076] In one embodiment now described and shown in use in FIG. 1,
there is a prefabricated floor panel 101 which is suitable for use
with a supporting structure 103 as is typically used in the
construction of buildings. The supporting structure 103 will be
described in greater detail later and includes a steel and/or
concrete frame, which is adapted to provide support for the
prefabricated floor panels 101 and wall structures (not shown). The
prefabricated floor panel 101 comprises a floor member 105 which
defines a floor surface 107 (also referred to as an upper major
face).
[0077] As is exemplified in FIGS. 4a and 4b, the floor member 105
is adapted to engage with an adjacent prefabricated floor panel 101
(as is shown at view A of FIGS. 4a & 4b). The prefabricated
floor panels 101 will be typically identical in shape (as in the
embodiments shown in the Figures) however, they need not be
identical for the purposes of the invention. For instance, adjacent
prefabricated floor panels 101 may incorporate cut-outs within the
floor member 105 to allow for the provision of services or
stairwells and the like, furthermore they may be defined by
differing shaped perimeters.
[0078] In FIG. 3b and FIG. 4b, we see the prefabricated floor panel
101 further includes at least one strengthening beam 109 which may
be attached to a lower major face 106 of the prefabricated flooring
panels 101 and are used to provide strength and rigidity to the
prefabricated floor panel 101 and to provide a means of mounting
the prefabricated floor panel 101 to the supporting structure 103
when in use. It will be appreciated by a person skilled in the art,
that the strengthening beams 109 may be an integral part of the
prefabricated floor panel 101 rather than being separately attached
to the prefabricated floor panel 101, allowing for greater strength
and rigidity. It is envisaged that the prefabricated floor panel
101 will be molded as one unit with the strengthening beams 109
being incorporated into the mold, rather than being attached at a
later stage.
[0079] 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.
[0080] 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.
[0081] 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.
[0082] 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.
[0083] 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/m.sup.3 to 2400 kg/m.sup.3. 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.
[0084] It has been found that a density of between 1200 kg/m.sup.3
and 1800 kg/m.sup.3 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/m.sup.3 or higher.
[0085] 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.
[0086] As is shown in FIGS. 4a & 4b in view A, the
prefabricated floor panels 101 are adapted to overlap with adjacent
prefabricated floor panels 101 using a structure such as a lap
joint or similar. It will be appreciated that various other joints
may be suitable in joining the adjacent floor panels 101 together
and are not limited to lap joints. With the embodiment shown, the
panels overlap with each other at the junction where the
strengthening beams 109 are located. In this embodiment, the floor
member 105 sits on top of the strengthening beam 109 providing for
a flush floor surface with the adjacent prefabricated floor panel
101 removing the necessity for any substantive finishing in the
form of applying a layer of concrete or similar in order to provide
a smooth and level fireproof floor surface. Once the floor has been
assembled, it is ready to use with no further preparation
necessary.
[0087] 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.
[0088] 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 FIGS.
4a & 4b view A. The lap joint A may be further adapted to
receive a fire fireproof or fire retardant sealant which may take
the form of intumescent acrylic, an example of such a sealant is
Sika.RTM. Firerate which provides for a 4 hour fire rating in
compliance with current fire regulations such as the Australian
Standard AS1530.4.
[0089] 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.
[0090] 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.
[0091] As can be seen in FIG. 3a, the prefabricated floor panels
101 have about their perimeter, a first overlapping formation 121
and at least two second overlapping formations 122. In the
embodiment shown there is one first overlapping formation 121 which
is adapted to engage with adjacent prefabricated floor panels 101
to provide a flush fireproof interface between adjacent
prefabricated floor panels 101 as is exemplified in view A in FIGS.
4a & 4b.
[0092] 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 FIG. 3a in
particular. The second overlapping formations 122 are adapted to
provide for a means of interfacing with the supporting structure
103 to provide a secure, fireproof attachment to the supporting
structure 103 once located into position. Both the first
overlapping formation 121 and the second overlapping formation 122
are adapted to receive a fireproof sealant such as an intumescent
acrylic as was discussed previously. An example of an appropriate
fireproof sealant is Sika.RTM. Firerate.
[0093] 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.
[0094] 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.
[0095] 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 FIGS. 1 and 2. It is critical that the columns 114
and support beams 113 are precisely located such that they form a
straight line allowing the prefabricated floor panels 101 to be
precisely installed and mounted to the support beams 113 which are
in turn mounted to the columns 114. The accurate location of the
support beams 113 and columns 114 may be aided by the use of laser
guides or similar location aids.
[0096] Returning to FIG. 3b, the strengthening beams 109 have a
depth that is dictated by a number of factors including the
expected loads and the span of the beam with greater loads and/or
spans requiring strengthening beams 109 of greater strength and
hence depth. Further, the strengthening beams contain reinforcing
bar 120 to further improve on the strength of the strengthening
beams 109.
[0097] As is exemplified in FIG. 4b, the strengthening beams 109
are adapted so as to allow the adjacent floor members 105 to bear
on the strengthening beams 109 when in position and to allow the
top of the floor surface 107 (which is typically 75 mm thick) to
half lap onto the strengthening beams 109. The half lap joint
provides a secure fire proof, waterproof and vibration resistant
seal at the junction of the adjacent floor members 105 and allows
for the floor members 105 to be bolted or screwed to the ends of
the strengthening beams 109 once in position with a gap to allow
for expansion and contraction and to enable clearance owing to
manufacturing abnormalities. Panels will have 2-5 mm clearance on
each of its edges to allow for expansion and any tolerance issues
due to fabrication defects.
[0098] In FIG. 5, the positioning of the prefabricated floor panels
101 in relation to the support beams 113 and the columns 114 is
exemplified. It can be seen from FIG. 5, that the prefabricated
floor panels 101 are adapted to mate with the support beams 113
which are positioned on top of the columns 114, typically using
bolts or other suitable attachment means after which the
prefabricated floor panels 101 may be securely attached using an
attachment means such as bolts or screws to ensure the
prefabricated floor panels 101 are securely attached to the support
beams 113 once located in their final positions.
[0099] 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.
[0100] FIG. 6 shows a detailed side view of the prefabricated floor
panels 101, showing the location of the strengthening beams 109 in
relation to the floor surface 107 and the location of the lap
joints A.
[0101] 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.
[0102] 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.times.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.
[0103] 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.
[0104] 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.times.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.
[0105] The installation process involves trucking the precast
elements to site and installing using a tower crane. The process is
as follows: [0106] 1. Mark out the required rows of columns. The
columns will be bolted to the concrete floor for the ground floor
and to the tops of the supporting beams each floor after. There
will be four bolts per top and bottom base. These bolts at the
lower connection point will have adjusting nuts installed prior to
column installation. This will allow the columns to be adjusted in
all directions to ensure the top is in the correct position to take
the supporting beams; [0107] 2. Install and columns followed by the
supporting beams for the first floor; [0108] 3. The supporting
beams are then craned into position and checked using a laser to
ensure correct positioning and length between beams; [0109] 4. The
floor panels are installed so that the half lap that is rebated
into the floor beam is ready to accept the next panel. The layout
position for the panels can be marked on the main supporting beams
prior to installation. The panels also have 5 mm clearance at the
lap to enable adjustment. Each panel must be carefully checked to
ensure it is perfectly in position; [0110] 5. Screw panel joints to
prior laid panel at the lap at 600 mm centres and also to the main
supporting beams; [0111] 6. Grout the base of the columns with the
adjusting nuts with non-shrink high strength grout; and [0112] 7.
Repeat procedure for subsequent floors.
[0113] The method of constructing the construction would comprise
the steps of: [0114] a. providing a supporting structure; [0115] b.
providing a plurality of prefabricated floor panels, each floor
panel presenting a floor surface; [0116] c. supporting the
prefabricated floor panels on the support structure in a
configuration to at least partly overlap each other.
[0117] The above steps may further include applying a fire
retardant compound such as Sika.RTM. Firerate between the adjacent
prefabricated floor panels prior to assembly, in order to provide a
secure fire proof barrier between adjacent floor panels.
Interpretation
Markush Groups
[0118] 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.
Chronological Sequence
[0119] 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.
Embodiments:
[0120] 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.
[0121] 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.
[0122] 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.
Different Instances of Objects
[0123] 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.
Specific Details
[0124] 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.
Terminology
[0125] 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.
[0126] 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.
[0127] As used herein the term "and/or" means "and" or "or", or
both.
[0128] As used herein "(s)" following a noun means the plural
and/or singular forms of the noun.
Comprising and Including
[0129] 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.
[0130] 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.
Scope of Invention
[0131] 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.
[0132] 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.
INDUSTRIAL APPLICABILITY
[0133] It is apparent from the above, that the arrangements
described are applicable to the construction industries.
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