EP2580403B1

EP2580403B1 - Building or part thereof, prefab floor part and method for forming a building or a floor part

Info

Publication number: EP2580403B1
Application number: EP11726226.1A
Authority: EP
Inventors: Gerardus Cornelis Maria Van Der Zanden
Original assignee: Kanaalbreedplaat Holding BV
Current assignee: Kanaalbreedplaat Holding Bv
Priority date: 2010-06-09
Filing date: 2011-06-09
Publication date: 2018-11-28
Anticipated expiration: 2031-06-09
Also published as: NL2004863C2; EP2580403A1; WO2011155840A1

Description

The invention relates to a building or part thereof, comprising at least a wall part and a prefab floor part, supported at least by said wall part. The invention further relates to a prefab floor part or floor element. The invention further relates to a method for forming such building or such floor part or floor element.
In modern building use is often made of prefab building elements, such as elements for walls, floors or roofs. These elements are commonly solid concrete elements, which can be provided with isolating material to one side thereof and can be provided with openings for doors or windows. For floor elements openings can be provided in solid concrete elements for elements like stairs or creep hatches. These elements have the disadvantage that they are heavy and are difficult to provide utility lines through, such as but not limited to plumbing, data and electricity cables.
For floor elements channel plates can be used. These exist mainly of an upper and lower plate or slab, connected to each other by a large series of standing separating walls, separating channels from each other. Cross bores can be provided for feeding lines through in a direction across the channels. These channel plates have the disadvantage that openings for for example stairs or hatches have to be provided for in the work, during placing, by means of a saw or the like, or that the length of the plates have to be shortened and lentils have to be used to support the shorter plate, borne by two neighbouring plates. This is time consuming and costly, and prone to mistakes. Moreover, this requires a lot of finishing work to get a proper finish of the building.
WO2008051923 discloses a pre-tensioned, concrete floor element, comprising a slab with beams on a top side thereof, wherein between the beams a filling foam material is provided, used as part of the casting mould. The top side of the beams is level with the top side of the filling material, such that the space between the beams is fully filled with the filling material. A top floor is cast on top of the beams and the filling material. In each of the beams three pre-tensioned steel rods are provided, two at the level of the slab and one near a widened top of the beam. In a floor formed with such elements, as shown in fig. 3, openings can be provided for a stair case or elevator, by providing one or more elements with a cross beam spaced apart from an end of the element. The elements forming the opening are asymmetrical. The elements are provided with a groove along an outer longitudinal side, such that between two adjacent elements a channel is formed, in which a connecting rod is mounted, for keeping the elements level, allowing the top floor to be formed over the elements. The elements are provided at their short ends by notches extending from the relevant cross beam, which can be inserted into slots in a wall element such as a bar. Moreover, the sides of any opening formed in the floor have to be provided with a labour intensive finish. The elements are relatively expensive, provide a large amount of waste, due to the filling material, and need special adaptations to the supporting structure. Moreover, the top floor is an integral part of the floor and does prevent access to the space between the beams and makes the production of a floor relatively labour intensive.
The present invention has as an object to provide an alternative for a building or part thereof comprising an integrated opening for stairs. Another object of the present invention is to provide an alternative for a prefab floor element. Still another object of the present invention is to provide an alternative method for forming a prefab floor element and/or a building or part thereof.
The invention shall further be elucidated by the following description, with reference to the drawings. The embodiments disclosed and discussed therein are used by way of example only and should by no means be considered as limiting the scope of the invention. In the drawings shows:

Fig. 1 in top view a prefab floor element;
Fig. 2 in partial cross section part of a building;
Fig. 3 in partial cross section and top view a floor element, in a first embodiment of the invention;
Fig. 4 in partial cross section and top view a prefab floor element, in a second embodiment of the invention; and
Fig. 5 in top view part of a prefab floor element, with different profiles of stairs in the opening thereof.

In the following description different embodiments are disclosed, showing aspects of the present invention. These are only shown by way of example. In this description in different embodiments the same or similar elements have the same or similar reference signs. Combinations of all elements of the different embodiments are possible within the disclosure.
In this description floor elements are disclosed, made of concrete, wherein reinforcement can be provided, especially in support beams and/or cross beams. Reinforcements can be made of iron rods, wrought iron, netting or similar systems known in the art. The reinforcements are not shown in the drawings. Any reinforcement in the floor elements, especially in any beam intermediate to longitudinal sides of the elements, are preferably not pre tensioned. In the embodiments shown support beams and cross beams are shown which are substantially straight. Where desired however at least some of these beams can be curved in part or over their entire length. In the embodiments shown an opening is provided for placement of stairs. In embodiments not according to the invention, other means for movement between floors can be provided, in the opening, such as but not limited to lift, elevator or lifting platform. An opening has to be understood at least as an opening extending through the element, from a top side of the element to an opposite lower side of the element, preferably enclosed at all sides, framing the opening.
In fig. 1 in top view a general construction of a floor element 1 is shown, for forming a floor part 2 of a building 3, with a cover element partly cut away. In the embodiment shown the floor part 2 is a storey floor of a building 3, but similarly it can for example be a ground floor part 2. The floor part 2, also referred to as floor element 2 or prefab floor element 2, comprises a slab 4, a first outer support beam 5, a second outer support beam 6, a first cross beam 7. a second cross beam 8, a fourth cross beam 9 and two further support beams 10, 11. The slab 4 and the beams 5 - 11 have been made integrally, preferably of concrete, in a mould, such as but not limited to a carousel mould.
The floor element 1 is in this embodiment, which is not according to the invention substantially rectangular, having a length L and a width W. Without limiting the scope of the description or invention, the width can for example be about 2.4 or 3.0 meter, the length can for example be between 3 and 6 meters, for example about 5 to 5.5 meter. In a preferred embodiment the width W is about 3.5 meter. As can be seen in the drawings the slab 4 has a length L₁ which is smaller than the length L of the element 1. The slab 4 has a first end 12 and an opposite second end 13. The first and second outer support beams 5, 6 extend along two opposite longitudinal sides of the slab 4, from near the second end 13 to beyond the first end 12. Between the first ends 14 of the outer support beams 5, 6 the first cross beam 7 is provided and between the second ends 15 the fourth cross beam 9. A second cross beam 8 extends substantially parallel to the first and fourth cross beams 7, 9, along the first end 13 of the slab 4, and is connected to both outer support beams 5, 6. The further support beams 10, 11 extend between the second and fourth cross beams 8, 9, on an upper surface 16 of the slab 4. They are spaced preferably at a regular spacing W_int from both each other and the adjacent first and second outer support beams 5, 6 respectively. It should be clear that a different number of support beams can be provided on the slab 4, depending for example on the width W of the floor element 1, the load to be carried by the element, the width and height of the beams and thickness of the slab, the materials used and other obvious criteria to be used in designing an element 1.
Since the outer support beams 5, 6 extend beyond the first end 12 of the slab 4, there is an opening 17 formed between the first and second cross beams 7, 8 and the parts 18, 19 of the outer support means 5, 6 extending beyond said first end 12. This opening 17 is, in this embodiment, substantially rectangular, having an internal width W_opening and an internal length L_opening. The internal width W_opening is for example about 3.2 meter for an element width W of 3.5 meter, whereas the internal length L_opening can for example be 1.2 meter. The opening 17 is intended for receiving elevating means such as a stair or staircase or a lift. In an opening of 3.2 * 1.2 meters most sizes of standard stairs can be fitted, as is schematically shown in fig. 5.
The thickness t of the slab 4 is preferably relatively small, compared to the total thickness T of the floor element 1, such that pockets 20 are formed between adjacent support beams 5, 6, 10, 11. In these pockets installation elements can be provided, such as but not limited to drainage pipes, sewage pipes, electricity, data or cable wires, plumbing and the like. The top surfaces 22 of the beams 5, 6, 8, 9, 10, 11 are preferably within one plane. The top surface 22 of the first cross beam can be in the same plane or can be in a different plane. This can be chosen for example on the bases of constructional considerations, weight to be supported, mould flow paths and the like. Cover elements 21 can be placed on top surfaces 22 of the beams 5, 6, 8, 9, 10, 11, for closing off the pockets 20 and forming part of a floor surface 23. In order to acoustically isolate the cover elements 21 from the beams 5, 6, 8, 9, 10, 11, strips 24 of acoustically isolating material such as but not limited to rubber, elastomeric material, felt or the like can be provided on top surfaces of the beams. In this description top and bottom have to be understood in relation to the position of use of the elements 1, in which the slab 4 is at the underside or bottom of the element, the pockets 20 are at the top or upper side of the slab 4. The strips 24 on the top surfaces 22 of the beams 5, 6, 8, 9, 10, 11 extend only on the parts thereof that support the at least one cover element 21. For example the top surfaces 22 of the parts 18, 19 of the support beams 5, 6 are free from said strips 21, whereas of the fourth cross beam 9 only a part of the top surface 22 adjacent the side facing the second cross beam is provided with such strip, such that the other side of said surface 22 can be used to support for example a wall 25, as schematically indicated in fig. 1 by the striped line 25. As can be seen in fig. 1 the wall 25 is preferable free from the cover element or elements 21, in order to again acoustically isolate the cover elements 21 from the further building structure.
As can be seen in fig. 2 a floor element 1 can be supported by a wall 26, by the first cross beam 7 supported on an upper side of a wall part 27 of a lower floor or storey 28, directly below said cross beam 7. A wall part 29 for an upper floor or storey 30 can be supported on the top surface 22 of the first cross beam 7. The wall 26 is in this embodiment a hollow wall or cavity wall, including an inner wall 26A, an outer wall 26B and a cavity 26C in between, which can be filled with insulation, such as but not limited to rock or glass wool elements 35. The first cross beam 7 rests on the inner wall 26A. The wall 26 has at the side of the floor element 1 a face 31. Especially the wall part 27 below the cross beam 7 and the wall part 28 on top of the cross beam 7 have parallel faces 31, which are coplanar at the side facing the opening 17. The cross beam 7 has a face 32 set back over a short distance d relative to the faces 31, into the wall 26. Preferably the inner wall 26A has a thickness T_w which is about equal to the thickness T_b of the cross beam, augmented with the distance d (T_w = T_b + d), such that a surface 33 of the cross beam 7 facing away from the opening 17 can be flush with the inner face 34 of the inner wall 26A and can rest against the insulating material 35. This ensures easy building and especially easy positioning of the element 1 and the wall parts 27, 28 in the right relative positions.
As can be seen in fig. 2 at the side of the opening 17 of the first cross beam 7 a space 36 is formed, forming a niche, with a depth d. This has the advantage a finish can easily be applied to the wall 26, by filling the space or niche 36, for example but not limited to filling by plaster or filler. The filling can be made flush with the face 31 of the wall parts 27, 28, and thus with the face 31 of the wall 26. This means that only a relative very small part of the wall 26 has to be plastered in order to get a flat or at least smooth wall face 31 in the area of the opening 17, in stead of the entire wall within the space in which the opening is provided, both above and below the element 1 and across the space 36. A further advantage of the space 36 can be that slight misalignments, differences in thickness of wall elements above and below and/or or to the sides of the opening and/or tolerances in positioning of walls and floor elements can easily be compensated by the filling of the space.
In embodiments the further support beams 10, 11 can have a width W_{10, 11} larger than the width W_{5, 6} of the outer support beams 5, 6. The width W_{10, 11} can be about twice the width W_{5, 6}, whereby the outer support beams 5, 6 can be fixed to similar outer support beams of adjacent floor elements 1 not having an opening 17 but further having the same or a similar construction. These elements are for example described in NL1035068 , herein incorporated by reference. To this end the outer support beams 5, 6 can be provided with through bores or channels 38 through which bolts 39 can be inserted, through similar bores or channels in the adjacent beam of an adjacent floor element 1A, to bolt them together in a known manner, e.g. as disclosed in NL1035068 . In fig. 1 schematically such floor element is disclosed schematically to either side of the floor element 1. The combined outer beams of the element 1 and 1A then have a strength comparable to that of the further support beams 10, 11. Near to or preferably substantially flush with the upper surface of the slab 4 between the support beams 5, 10, 11, 6 openings 50 can be provided, extending through the support beams 5, 10, 11, 6, preferably in straight lines, such that tubes or lines, wires and the like can be fed through one or a series of such openings 50, from one pocket to a next and/or from one element 1 to a next 1A. This allows easy feeding of these provisions for e.g. water, sewage, data, electricity and the like to different parts of the building. Openings can be provided in the cover elements 21 for bringing these to the different spaces above the floor elements 1.
In elements of WO2008051923 the pretension bars will prevent the forming of openings 50, as will the filling bars between the elements.
It will be clear that the fourth cross beam can be supported on a wall part in a way similar to the way the first cross beam 7 is supported by the wall part 27. However, other support means can be used too, such as for example but not limited to columns.
By way of example only, and without wanting to be limited to any of these sizes or positions, a floor element according to this description could have the following dimensions. The length of the elements 1 can for example be up to about 6.2 to 6.5 metres, although other lengths would be possible, depending on inter alia the number and sizes of the beams and the thickness of the slab, as well as the reinforcements used. The width of the elements can be chosen basically as desired. In the present invention it is preferred that the width W of the elements 1 is such that the opening 30 is wide enough to receive stairs or the like. The width can for example be about 3 to 3.5 metres. The width preferably is such that the elements can be transported in one piece over public roads. To that end it is preferred that the elements can be placed substantially vertically or horizontally on a road vehicle, without needing special permission to transport. This can differ for different countries. Generally the width will be preferred to be up to about 3.5 to 4 metres maximally.
In an embodiment of fig. 3 according to the invention the slab 4 has an extension 40 into the opening 17. This extension has a width W_e which is smaller than the width W_opening of the opening 17 and extends from the second cross beam 8 over a distance s into the opening 17. The width W_e and distance s can be chosen on the basis of the stairs or other elevation means to be placed in said opening, as schematically shown in fig. 5. The extension 40 can be a bases for a finish of the opening to fit the stairs 41. In the embodiment of fig. 3 a cover element 21 is provided, extending over the second cross beam 9 to the same extend into the opening 17 as the extension 40. A finishing profile 42 having a substantially U-shaped cross section is provided against the side of the extension 40 and cover element 21, the legs 43 of the profile 42 lying on the cover element 21 and under the extension 40 respectively. The profile 42 can for example be made of metal, plastic, concrete, wood or any other suitable material. It can for example be clicked, glued, stapled, screwed, bolted or otherwise be fixed in position. The cover element 21 can be provided with a groove or indentation 44 along its edge 43 near the opening 17, for receiving the leg of the profile 42, flush with the top side of the cover element 21. Similarly the slab 4 can be provided with such groove or indentation 44 for fitting the other leg of the profile 42.
The underside of a slab 4 can be a ceiling forming side. This can be ready for for example painting, spachtelputsch, plaster or other finishing layer. In an alternative embodiment the underside 45 of the slab 4 can be provided with an integral finishing.
In fig. 4 an embodiment according to the invention of a part of a building, especially an element 1 is shown similar to the embodiment of fig 3, having a third cross beam 46 extending along the free edge of the extension 40, substantially parallel to the first and second cross beams 7, 8. A connecting beam 47 can extend along the free edge of the extension 40 between an end of the third cross beam 46 and the second cross beam. The third cross beam 46 and the connecting beam preferably are provided with a stepped top surface at the side facing away from the opening 17. Preferably such that an edge portion of the cover element or cover elements 21 can rest on such stepped profile, with the top side of the cover element 21 substantially flush with the higher side of the stepped top surface. In this embodiment no finishing profile is necessary along the side of the opening 17. This even further limits costs for finishing work on the staircase, and moreover allows easily for a similar finish layer as the ceiling.
In fig. 5 part of a floor part or element 1 is shown according to the invention, in top view, showing the extension 40 in one embodiment. In the opening 17 next to the extension three different stair profiles are shown, in separate hatchings, as indicated in the legend. By amending the extension during prefabrication of the elements 1 the profile of the opening 17 can easily be amended in accordance with the stairs to be fitted.
A prefab floor element 1 can be cast in one go, by forming a mould cavity according to the desired shape and size, including the opening and, if desired, the extension 40 with the third cross beam 46 and the connecting beam 47. This has the advantage that the element can be ready for use directly out of the mould. This however means that a different mould will be necessary for each type of element, especially each type of stairs, and different moulds for for example left and right hand stairs. In an alternative embodiment the element 1 is formed in a mould in a standard configuration, without an extension, as shown in fig. 1, after which a formwork can be fitted in the opening, suitable for the desired extension 40 and, if desired, third cross beam 46 and/or connecting beam 47, after which concrete or another type of settable material is poured into the formwork to connect to the slab 4, second cross beam 8 and one of the outer support beams 5, 6. In such embodiment two pouring steps are necessary, but only different formworks have to be used for different elements 1. Obviously the extension can also be provided for in any other suitable way, like for example but not limited to by carpentry.
In an embodiment a building can be designed wherein first a position is chosen for the stairs, defining the position for the first prefab floor element 1, according to the invention. Then further prefab elements 1A, for example according to NL1035068 can be fitted to either side of the element 1, for forming the entire floor for the storey. At one or both ends of the floor filling floor elements 1B can be fitted, which can have a different width then the further elements 1, 1A. This allows greater freedom in building design.
The invention is by no means limited to the embodiments described in this disclosure, by way of example only. Many variations are possible within the scope if the claimed invention. For example the opening can be provided for more central in the elements, a slab 4 and cover elements 21 being provided on both sides of the opening. In the embodiments shown in the drawings the opening is designed such that the stairs to be fitted will have a main ascending/descending direction which is substantially parallel to the width direction of the opening 17 and element 1. However, the opening can also be designed to fit stairs having a main direction of ascending/descending which has a different direction, for example substantially parallel to the length direction of the support beams.

Claims

Building or part thereof, comprising at least a wall part (26) and a prefab floor part (1), the floor part (1) supported at least by the wall part (26), wherein the floor part (1) comprises a slab (4) forming a ceiling part and at least two outer support beams (5, 6) extending substantially parallel to each other, at two opposite sides of the slab (4), at or on an upper side thereof, and at least a first and a second cross beam (7, 8), connecting the support beams (5, 6), and extending substantially parallel to each other, wherein an opening (17) is provided extending between the two cross beams (7, 8) and the two support beams (5, 6), for fitting a staircase extending through said opening (17), whereas at least one floor cover element (21) can be provided on the support beams (5, 6), beside said opening (1 7), and wherein the first cross beam (7) is supported by or in said wall part (26), characterised in that the slab (4) has an extension (40) extending into an area defined by the support beams (5, 6) and the two cross beams (7, 8), which extension has a width (W_e) which is smaller than the width (W_opening) of the opening (17) and extends from the second cross beam (8) over a distance (s) into said area.
Building or part thereof according to claim 1, wherein the wall (26) has a face (31) facing the opening (17), wherein the first cross beam (7) has a face (32) facing the opening (17), wherein the face (32) of the first cross beam (32) is set back relative to the face (31) of the wall (26), into the wall (26).
Building or part thereof according to any one of the previous claims, wherein a third cross beam (46) is provided, extending between the first and second cross beam (7, 8), preferably having a length parallel to the first and second cross beams (7, 8) which is smaller than the perpendicular distance between the said two support beams (5, 6).
Building or part thereof according to claim 3, wherein the third cross beam (46) extends from one of the outer support beams (5, 6) in the direction of the opposite outer support beam (6, 5), and is connected with the second cross beam (8) by a connecting beam (47), wherein preferably the first and second cross beam (7, 8) have the same height, measured between an upper and lower side of the floor part, and the third cross beam (46) preferably has a larger height, such that at least part of a top surface (22) thereof lies substantially flush with an upper surface of a cover element (21) provided on at least the second cross beam (8).
Building or part thereof according to claim 2, 3 or 4, wherein the extension of the slab (4) extending into the area and/or the third cross beam (46) are made integral with at least the slab (4), the first and second cross beam (7, 8) and the support beams (5, 6).
Building or part thereof according to any one of the previous claims, wherein at least one further support beam (10, 11) extends between the two support beams (5, 6), substantially parallel, which support beam (10, 11) extends from the second cross beam (8) in a direction away from the first cross beam (7), wherein preferably the or each further support beam (10, 11) has a width (W₁₀, W₁₁), measured substantially parallel to a length direction of the cross beams (7, 8), which is wider than the width (W₅, W₆) of the outer support beams (5, 6), more preferably about twice the width, and the same height above the slab (4).
Building or part thereof according to any one of the previous claims, wherein at least the support beams (5, 6; 10, 11) and the second cross beam (8) have an upper surface (22), provided with isolating strips (24), on the support beams (5, 6; 10, 11) extending from the second support beam (8) to an end of the floor part remote from the first cross beam (7), wherein preferably at said end a further cross beam (9) is provided extending between the outer support beams (5, 6), supported in or on another wall or wall part (25) and provided on a part of an upper surface (22) with said isolating strip (24), wherein the or each floor cover (21) can be born by the isolating strips (24), isolated from the or each wall (25, 26) supporting the or supported on the first and further cross beam (7, 8, 9, 46), wherein preferably a wall (25) is supported on the top surface (22) of the said further cross beam (9) next to the isolating strip (24) provided thereon.
Prefab floor part, made of concrete, comprising a slab (4) and at least two outer support beams (5, 6) extending substantially parallel to each other, at two opposite sides of the slab (4), at or on an upper side thereof, and at least a first and second cross beam (7, 8), connecting the support beams (5, 6), and extending substantially parallel to each other, wherein an opening (17) is provided extending between the two cross beams (7, 8) and the two support beams (5, 6) said opening (17) extending through the slab (4) from one side of the floor part to the opposite side thereof, wherein the opening (17) is provided for fitting a stair case, wherein between the two cross beams (7, 8) and the two support beams (5, 6) an area is defined in which said opening (17) is provided, characterised in that the slab (4) has an extension (40) extending into said area, which extension has a width (W_e) which is smaller than the width (W_opening) of the opening (17) and extends from the second cross beam (8) over a distance (s) into said area.
Prefab floor part according to claim 8, wherein the said area is substantially rectangular, wherein the distance (W_opening) between the outer support beams (5, 6) is larger than the distance (L_opening) between the first and second cross beams (7, 8), and wherein at the side of the second cross beam (8) the extension (40) is provided extending inside the area, which preferably has an lower surface flush with underside of the slab (4), and more preferably a side surface facing the first cross beam (7) which is closed by a third cross beam (46), wherein the extension (40) is connected to one of the outer support beams (5, 6) and spaced apart from the opposite outer support beam (6, 5).
Prefab floor part according to claim 9, wherein at least one cover element (21) is provided, carried on at least support beams (5, 6) and cross beams (7, 8), where the at least one cover part (21) extends over the extension (40).
Prefab floor part according to claim 9 or 10, wherein at least three cross beams (7, 8, 9) are provided, and wherein the opening (17) is at least partly defined by two of said cross beams (7, 8).
Method for forming a prefab floor part according to any one of claims 8- 11, using a mould, wherein in a first mould part elements are provided for forming the support beams (5, 6; 10, 11) and a filling element for forming the opening (17) and the first and second cross beams (7, 8), wherein a second mould part is closed against the first mould part for forming the beams and opening in cooperation with the first mould part and the said elements, where after concrete is poured into the mould and allowed to set.
Method according to claim 12, wherein after at least partly setting of the floor part the mould is opened and at least part of the filling element is removed from the opening (17), where after a filling part (40) is formed by pouring concrete into a filling part forming moulding element set inside the opening (17), against at least one outer support beam (5, 6) and a second cross beam (8), and allowing to set.
Method for forming a floor of a building, wherein a building part is assembled according to any one of claims 1 - 8, where after prefab elements are positioned to either side of the floor part (1), forming a floor of the building, and wherein a wall part (29) is set up on the first cross beam (7), where after a finishing layer is provided over the side (32) of the first cross beam (7) facing the second cross beam (8), such that a face is provided flush with faces of the wall parts (26, 29) below and above said first beam (7), wherein the finishing layer is preferably made using at least plaster or filler.