GB2391562A

GB2391562A - Structural Flooring Element

Info

Publication number: GB2391562A
Application number: GB0317772A
Authority: GB
Inventors: Christopher Williams Whapples
Original assignee: VOLLAR STEPHEN ROBERT
Current assignee: VOLLAR STEPHEN ROBERT
Priority date: 2002-08-09
Filing date: 2003-07-30
Publication date: 2004-02-11
Anticipated expiration: 2023-07-30
Also published as: GB2391562B; GB0317772D0; GB0218530D0

Abstract

A structural flooring element 10A is arranged in an initial engagement position whereby the abutment means 26 abuts against the abutment means 26 of a second structural flooring element 10B. Lowering of the first element 10A into the engagement position causes rotation about the abutment means 26 such that the coupling means 22 of element 10A engages the coupling means 32 of element 10B. The elements may be constructed from concrete and may include reinforcement.

Description

239 1 562

Structural Flooring Kit The present invention relates in general to a 5 structural flooring kit, a flooring element for use in a structural flooring kit, and method of arranging flooring elements to construct a structural floor.

Buildings such as structured car parks are constructed lo from a system of load bearing beams and columns. Panels or other load bearing flooring elements are provided to span the beams and form floors.

Typically, known reinforced concrete floor panels of 15 the type used in car park structures are heavy and are difficult to align. Further, wet concrete is used to form a joint between the panels, which adds to construction costs. Furthermore, additional construction time is required while the joint concrete hardens, before the 20 structure can be used. If thin or lightweight reinforced concrete panels are used, they normally require a structural topping of wet concrete. Before such structural topping can be applied, temporary supports for the lightweight panels must be installed. The temporary 2s supports must remain in place until the structural topping has hardened. Again, these steps increase construction costs and require additional construction time.

An aim of the present invention is to reduce the use 30 of wet concrete in the assembly of reinforced concrete floors. Also, it is desired to provide flooring elements that are easily manufactured. Further, it is desired to provide flooring elements for a structural flooring kit,

whose assembly into a floor is easily performed on site.

Preferred embodiments of the structural flooring kit aim to allow easy alignment and positioning of flooring elements in close contact with each other within a floor.

According to a first aspect of the invention there is provided a structural flooring kit comprising: a first flooring element comprising a first abutment means and a first coupling means; and a second flooring element lo comprising a second abutment means and a second coupling means; the first and second flooring elements being arrangeable in an initial position with the first flooring element angled relative to the second flooring element at an introduction angle, and being arrangeable in an

15 engagement position with the first coupling means engaging the second coupling means, wherein in use the first abutment means abuts the second abutment means in the initial position, and the first flooring element being lowerable relative to the second flooring element to cause 20 relative rotation of the first flooring element toward the engagement position.

Preferably, the first and second flooring elements are relatively rotatable about an interface between the first 2s and second abutment means. Preferably, the first and second flooring elements are relatively rotatable substantially about the interface at a lower portion of the first and second abutment means. Preferably, the first and second flooring elements are relatively 30 rotatable due to the first and second abutment means bearing on one another, and the weight of the first flooring element.

Preferably, the first and second coupling means comprise a pair of complementary surfaces.

Preferably, the first and second coupling means 5 comprise a projection and a recess respectively, or vice versa. Preferably, the projection and the recess in cross section each comprise an arcuate profile. Preferably, the lo projection and the recess in cross section each comprise an arc of a circle.

Preferably, the projection and the recess each extend substantially along the length of an end surface of the 5 first or second flooring element respectively.

Preferably, the first and second abutment means each comprise a substantially planar abutment surface.

Preferably, the abutment surfaces of the first and second 20 flooring elements are each angled relative to an upper surface of the first and second flooring element respectively. Preferably the first abutment surface connects an 25 upper surface of the first flooring element to the projection or recess. Preferably, the second abutment surface connects the projection or recess to the upper surface of the second flooring element.

30 Preferably, each abutment surface is angled to provide a portion of the introduction angle. Preferably, the

abutment surfaces of the first and second flooring elements are each angled to bisect the introduction angle.

The introduction angle may comprise any suitable angle

between 0 and 90. Preferably, the introduction angle is

approximately 20.

5 Suitably, the first and second flooring elements comprise a concrete material. Preferably, the first and second flooring elements comprise a reinforced concrete material. Preferably, the first and second flooring elements are load bearing elements. Preferably, the first lo and second flooring elements are a spanning load bearing panels for use in a building structure, such as a structured car park.

Preferably, the flooring elements have a required 15 surface finish applied at the time of manufacture.

The structural flooring kit of any may further comprise: a third flooring element comprising a third abutment means and a third coupling means, wherein the 20 first flooring element comprises further abutment means and further coupling means such that the third flooring element is arrangeable relative to the first flooring element as the first flooring element is arrageable relative to the second.

In a particularly preferred embodiment, the first and second flooring elements each include a first end portion comprising a first abutment means and a projection, and a second end portion comprising a second abutment means and 30 a recess, and, a deck portion arranged between the first and second end portions. Preferably the depth of the deck portion is less than that of the end portions.

Preferably, the first and second flooring elements

comprise a solid construction, substantially without internal voids. Preferably, the first and second flooring elements comprise a ribbed construction. Preferably, the first and second flooring elements comprise ribs extending 5 from the deck portion at the lower surface of the flooring element. Preferably, the ribs are arranged to strengthen the deck portion.

Preferably, the first and second flooring elements are TO substantially identical, each comprising a first end surface comprising a projection and an abutment means, and further comprising a second end surface comprising a recess and an abutment means.

5 According to a second aspect of the invention, there is provided a flooring element for use in a structural flooring kit according to the first aspect of the invention. 20 According to a third aspect of the invention there is provided a flooring element, comprising: coupling means and abutment means, the flooring element arrangeable in an initial non-coplanar position relative to a neighbouring flooring element such that the abutment means abuts an 25 abutment means of the neighbouring flooring element, and, arrangeable in an engagement position in which the flooring element and the neighbouring flooring element are substantially coplanar, and with the coupling means engaging a coupling means of the second flooring element.

According to a fourth aspect of the invention there is provided a method of arranging a first flooring element with a second flooring element, the method comprising

steps of: (a) arranging the first flooring element relative to the second flooring element at an introduction

angle such that a first abutment means of the first flooring element abuts a second abutment means of the 5 second flooring element; and (b) lowering the first flooring element relative to the second flooring element to cause relative rotation of the first flooring element toward an engagement position in which a first coupling means of the first flooring element engages a second lo coupling means of the second flooring element.

Preferably, the relative rotation of step (b) is caused by the weight of the first flooring element, such that the first coupling means is forced into engagement 15 with the second coupling means. Preferably, the relative rotation of step (b) occurs substantially about an interface between the first and second abutment means.

Preferably, the step (a) comprises the sub-steps of 20 (al) angling the first and second flooring elements relative to one another at an introduction angle; and (a2)

lowering the first abutment means of the first flooring element against the second abutment means of the second flooring element.

Preferably, the step (a) is performed with the first flooring element hanging from support means. Suitably, the support means comprise chains, straps or ropes.

30 For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

Figure 1 is a side sectional view of an example flooring element; 5 Figure 2 shows a side view of a first example flooring element being positioned relative to a second example flooring element; Figure 3 is a top view of the example flooring element lo of Figure 1; Figure 4 is a sectional view of the example flooring element along line B-B of Figure 3 in the direction of the arrows; Figure 5 is a sectional view of the example flooring element along line A-A of Figure 3 in the direction of the arrows; and 20 Figure 6 is a sectional view of the example flooring element along line C-C of Figure 3 in the direction of the arrows. Figure 1 shows a side sectional view of a flooring 25 element according to a preferred embodiment of the present invention. The flooring element 10 comprises an upper surface 12, a lower surface 14, a first end surface 20, a second end surface 30, and first and second side surfaces.

The first end surface 20 comprises a projection 22, and a 30 first abutment means comprising a first abutment surface 26. In cross section the projection 22 comprises an arc of a circle. In three dimensions the projection 22 comprises a convex section of the curved surface of a

cylinder, arranged with its axis generally along the length of the first end surface 20. The second end surface 30 comprises a corresponding recess 32, which is likewise arranged with its axis generally along the length 5 of the second end surface 30, and further comprises a second abutment means comprising a second abutment surface 26. The projection 22 and recess 32 comprise sections of substantially equal radius of curvature. The described profile of projection 22 and recess 32 are preferred to 3 lo other arcuate or mating surface profiles, due to simplicity of manufacture.

Figure 2 shows first flooring elements lOA being arranged on site. The second flooring element lOB in 15 already in position, with its first side surface on a support beam 50. The second flooring element lOB is also supported by a beam at its second side surface. The first flooring element lOA is lifted on two sets of chains, long chains 60 and short 62. The arrangement of the long 20 chains 60 on the first flooring element lOA proximate to the projection 22 and short chains 62 proximate to the recess 32 supports the first flooring element lOA at an angle to the horizontal, with the projection 22 at its lower end. This angle comprises the introduction angle.

25 To position the projection 22 within the recess 32 the following procedure is carried out: Firstly, a first abutment surface 26 of the first flooring element lOA is positioned against a second 30 abutment surface 26 of the second flooring element lOB.

In this initial position the first and second flooring elements lOA,lOB comprise neighbouring flooring elements, and are arranged in a noncoplanar position.

The first flooring element lOA is lowered so that the long chains 60 become slack. The weight of the first flooring element lOA is supported by the short chains 62 5 and the contact of the first abutment surface 26 of the first flooring element lOA and the second abutment surface 26 of the second flooring element lOB.

The first flooring element lOA is lowered further.

lo The weight of the first flooring element lOA causes it to rotate against the second flooring element lOB into position with the projection 22 within the recess 32.

Rotation occurs substantially about a line of contact between the first and second abutment surfaces 26, along 5 an edge where the first abutment surface 26 joins the upper edge of the projection 22 and the second abutment surface 26 joins the upper edge of the recess 32.

Lowering continues until the projection 22 is located 20 within the recess 32, and the first end surface 20 of the first flooring element lOA comes into direct contact with the second end surface 30 of the second flooring element lOB. 25 The upper surfaces 12 of the first and second flooring elements lOA,lOB form a floor. The neighbouring first and second flooring elements loA,lOB are now substantially coplanar. The projection 22 engages with the recess 32, forming a dry joint between the first and second flooring 30 elements lOA,lOB. The dry joint is capable of transmitting shear load between the first and second flooring elements lOA,lOB. A complete floor can be built up from a plurality of flooring elements 10 laid end to

end as described in relation to the first and second flooring elements lOA,lOB. The flooring elements lOA,lOB may be substantially identical to one another, and to third flooring elements lOC that are to be assembled into 5 a floor. The size and weight of the flooring elements lOA,lOB serves to resist separation. To further resist separation, and to secure the flooring elements lOA,lOB to the supporting beams, a stitch joint is used, as will be described later.

Figure 3 shows a top view of the example flooring element 10 of Figure 1. The first end surface 20 shown in Figure 3 comprises the projection 22 along a central region. End regions 24 comprise portions of the first end 15 surface 20 from which the projection 22 does not extend, and corresponding portions of the second end surface 30 in which the recess 32 is not present. The recess 32 is shown with a dashed line to indicate hidden detail.

20 Figure 4 shows the projection 22 of a first flooring element lOA in engagement with the recess 32 of the second flooring element lOB. Also shown in Figure 4 are steel reinforcements 40.

25 Figure 5 shows an end region 24 of a first flooring element lOA in abutment with an end region 24 of a second flooring element lOB. The first and second end surfaces 20,30 further comprise abutment surfaces 26 and lower angled sections 28. The abutment surfaces 26 comprise 30 substantially planar portions of the first and second end surfaces 20,30 between the upper surface 12 and the projection 22 and recess 32 respectively. The abutment surfaces 26 are arranged at an angle of approximately 80.

to the upper surface 12, although any suitable acute angle can be used. The lower angled sections 28 serve to round off the corner where the lower surface 14 meets the first and second end surfaces 20,30. The lower angled sections 5 28 preferably comprise substantially planar surfaces arranged at 45 to the lower surface 14.

As shown in Figures 4 and 5, when first and second flooring elements lOA, lOB are positioned with respective lo end regions 24 in engagement with one another and the projection 22 in engagement with the recess 32, the abutment surfaces 26 form a substantially V-shaped notch.

The V-shaped notch can be filled with a sealant to assist in rendering the joint between the first and second 15 flooring elements lOA,lOB substantially watertight.

Figure 6 shows a flooring element 10 resting on a support beam 50. The support beam 50 can comprise steel, concrete or any other suitable material, and preferably 20 comprises a projection 52 or series of projections 52 along its length. The flooring element 10 comprises a ledge 54 which rests on the support beam. The steel reinforcement 40 extends from within the flooring element 10 over the support beam 50 and the projection(s) 52 into 25 the region 60. To secure the flooring element 10 to the support beam 50, the region 60 is filled with wet concrete. In this way, the concrete ties the beam 50 to the flooring element 10 through the projection 52 and protruding steel reinforcement 40, forming an in situ 30 stitch joint. This joint also serves to prevent the first and second flooring elements lOA,lOB from moving apart.

This joint is the only wet trade needed on site to complete the floor. The ledge 54 enables the flooring

elements to be constructed into a floor at reduced height from the top of the beams which support the flooring elements 10. Reducing the floor height in this way is advantageous when flooring elements at different levels 5 are to be connected by ramps, for example as in a structured car park, as the ramps can be of reduced gradient. Alternative embodiments of the flooring element 10 may omit the ledge 54, so that the lower surface 14 of the flooring element rests directly on support beams. The lo ledge 54 becomes more desirable as the depth of the flooring element 10 to be used increases, in particular if the depth of the flooring element is over approximately 225mm. 15 If desired, additional mechanical fixing elements, e.g. bolts, dowels or keys, are used to maintain adjacent elements in close contact.

The lower angled sections 28 help to reduce any damage 20 that might be caused by collision of the flooring elements with each other or any other fixed structures during construction by eliminating the sharp corner at the junction of the end surfaces 20,30 and the lower surface 14. In particular, the recess 32 is protected against 25 damage by impact of the first end surface 22.

Using ribbed solid flooring elements 10, i.e. ribbed panels without internal hollows or cores, the system described does not collect water internally. This offers 30 increased durability over hollow or cored systems. The dimensions, materials and reinforcement of the flooring elements can be varied to suit the required floor area, and loads. In typical applications such as car park, the

use of ribbed panels with the edges and in situ stitch joint described allows a deck of reduced thickness to be used as it forms a composite load bearing section with the supporting beam. Using a deck of reduced thickness 5 reduces costs. Furthermore, the flooring elements 10 can be cast with a desired surface finish, eliminating the need for an additional screed to be applied once the structure of the floor has been completed.

lo The embodiment described uses gravity to force the flooring elements 10 together, thus ensuring the flooring elements 10 tightly abut one another, and can easily be positioned to a high degree of accuracy. This improves the mechanical strength of the joint between the flooring 15 elements, and enables vertical shear forces to be transferred between flooring elements lo. By placing the flooring elements in close contact, the tolerance to which the complete floor can be constructed is increased.

Furthermore, rotating the flooring elements 10 into place 20 avoids sliding them over the support beams 50. Such sliding would require large forces to overcome friction, and could potentially damage the sliding surfaces.

Thus there has been provided a structural flooring 25 kit, a flooring element for use in a structural flooring kit, and method of arranging flooring elements to construct structural a floor that reduces the use of wet concrete in the assembly of reinforced concrete floors.

Preferred embodiments comprise easily manufactured 30 components that are easy to install on site, reducing costs and construction time.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and

which are open to public inspection with this s specification, and the contents of all such papers and

documents are incorporated herein by reference.

All of the features disclosed in this specification

(including any accompanying claims, abstract and lo drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

15 Each feature disclosed in this specification

(including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, 20 each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any 25 novel one, or any novel combination, of the features disclosed in this specification (including any

accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

Claims

1. A structural flooring kit comprising: 5 a first flooring element comprising a first abutment means and a first coupling means; and a second flooring element comprising a second abutment means and a second coupling means; the first and second flooring elements being arrangeable in an initial position with the first flooring element angled relative to the second flooring element at an introduction angle, and being arrangeable in an

15 engagement position with the first coupling means engaging the second coupling means, wherein in use the first abutment means abuts the second abutment means in the initial position, and the 20 first flooring element being lowerable relative to the second flooring element to cause relative rotation of the first flooring element toward the engagement position.

2. The structural flooring kit of claim 1, wherein the 25 first and second flooring elements are relatively rotatable about an interface between the first and second abutment means.

3. The structural flooring kit of claim of claim 1 or 2, 30 wherein the first and second flooring elements are relatively rotatable substantially about the interface at a lower portion of the first and second abutment means.

4. The structural flooring kit of any one of claims 1, 2 or 3, wherein the first and second flooring elements are relatively rotatable due to the first and second abutment means bearing on one another, and the weight of the first 5 flooring element.

5. The structural flooring kit of any preceding claim, wherein the first and second coupling means comprise a pair of complementary surfaces.

6. The structural flooring kit of any preceding claim, wherein the first and second coupling means comprise a projection and a recess respectively, or vice versa.

5 7. The structural flooring kit of claim 6, wherein the projection and the recess in cross section each comprise an arcuate profile.

8. The structural flooring kit of claim 6 or 7, wherein 20 the projection and the recess in cross section each comprise an arc of a circle.

9. The structural flooring kit of any one of claims 6, 7, or 8, wherein the projection and the recess each extend 25 substantially along the length of an end surface of the first or second flooring element respectively.

10. The structural flooring kit of any preceding claim, wherein the first and second abutment means each comprise 30 a substantially planar abutment surface.

11. The structural flooring kit of claim 10, wherein the abutment surfaces of the first and second flooring

elements are each angled relative to an upper surface of the first and second flooring element respectively.

12. The structural flooring kit of claim 10 or 11, wherein 5 the first abutment surface connects an upper surface of the first flooring element to the projection or recess.

13. The structural flooring kit of claim 12, wherein the second abutment surface connects the projection or recess to the upper surface of the second flooring element.

14. The structural flooring kit of any one of claims 10 to 13, wherein each abutment surface is angled to provide a portion of the introduction angle.

5 15. The structural flooring kit of claim 14, wherein the abutment surfaces of the first and second flooring elements are each angled to bisect the introduction angle.

16. The structural flooring kit of claim 14 or 15, wherein 20 the introduction angle comprises any suitable angle

between 0. and 90.

17. The structural flooring kit of claim 14 or IS, wherein the introduction angle is approximately 206.

18. The structural flooring kit of any preceding claim, wherein the first and second flooring elements comprise a concrete material.

30 19. The structural flooring kit of claim 18, wherein the first and second flooring elements comprise a reinforced concrete material.

20. The structural flooring kit of any preceding claim, wherein the first and second flooring elements are load bearing elements.

5 21. The structural flooring kit of any preceding claim wherein the first and second flooring elements are spanning load bearing panels for use in a building structure. lo 22. The structural flooring kit of claim 21, wherein the first and second flooring elements are spanning load bearing panels for use in a structured car park.

23. The structural flooring kit of any preceding claim, 5 wherein the first and second flooring elements have a required surface finish applied at the time of manufacture. 24. The structural flooring kit of any preceding claim 20 further comprising: a third flooring element comprising a third abutment means and a third coupling means, and, 25 wherein the first flooring element comprises further abutment means and further coupling means such that the third flooring element is arrangeable relative to the first flooring element as the first flooring element is arrageable relative to the second.

25. The structural flooring kit of any preceding claim, wherein the first and second flooring elements each include a first end portion comprising a first abutment

means and a projection, and a second end portion comprising a second abutment means and a recess, and, a deck portion arranged between the first and second end portions. 26. The structural flooring kit of claim 25, wherein the depth of the deck portion is less than that of the end portions. lo 27. The structural flooring kit of any preceding claim, wherein the first and second flooring elements comprise a solid construction, substantially without internal voids.

28. The structural flooring kit of any preceding claim, 15 wherein the first and second flooring elements comprise a ribbed construction.

29. The structural flooring kit of any preceding claim as dependent on claim 25, wherein the first and second 20 flooring elements comprise ribs extending from the deck portion at the lower surface of the flooring element.

30. The structural flooring kit of claim 29, wherein the ribs are arranged to strengthen the deck portion.

31. The structural flooring kit of any preceding claim, wherein the first and second flooring elements are substantially identical, each comprising a first end surface comprising a projection and an abutment means, and 30 further comprising a second end surface comprising a recess and an abutment means.

32. A flooring element for use in the structural flooring kit of any preceding claim.

33. A flooring element, comprising: coupling means and 5 abutment means, the flooring element arrangeable in an initial non-

coplanar position relative to a neighbouring flooring element such that the abutment means abuts an abutment 10 means of the neighbouring flooring element, and, arrangeable in an engagement position in which the flooring element and the neighbouring flooring element are substantially coplanar, and with the coupling means 15 engaging a coupling means of the second flooring element.

34. A method of arranging a first flooring element with a second flooring element, the method comprising steps of: 20 (a) arranging the first flooring element relative to the second flooring element at an introduction angle such

that a first abutment means of the first flooring element abuts a second abutment means of the second flooring element; and 2s (b) lowering the first flooring element relative to the second flooring element to cause relative rotation of the first flooring element toward an engagement position in which a first coupling means of the first flooring 30 element engages a second coupling means of the second flooring element.

35. The method of claim 34, wherein the relative rotation of step (b) is caused by the weight of the first flooring element, such that the first coupling means is forced into engagement with the second coupling means.

36. The method of claim 34 or 35, wherein the relative rotation of step (b) occurs substantially about an interface between the first and second abutment means.

lo 37. The method of any one of claims 34, 35 or 36, wherein the step (a) comprises the sub-steps of: (al) angling the first and second flooring elements relative to one another at an introduction angle; and

(a2) lowering the first abutment means of the first flooring element against the second abutment means of the second flooring element.

20 38. The method of any one of claims 34 to 37, wherein the step (a) is performed with the first flooring element hanging from support means.

39. The method of claim 38, wherein the support means 25 comprises chains, straps or ropes.

40. A structural flooring kit substantially as herein described, with particular reference to the Figures 1 to 6. 41. A flooring element substantially as herein described, with particular reference to Figures 1 to 6.

42. A method of arranging a first flooring element with a second flooring element, substantially as herein described, with particular reference to Figure 2.