GB2487265A

GB2487265A - Suspended floor structure and flooring system

Info

Publication number: GB2487265A
Application number: GB201117878A
Authority: GB
Inventors: John R Thornberry
Original assignee: MOULDED FOAMS Ltd
Current assignee: MOULDED FOAMS Ltd
Priority date: 2011-01-17
Filing date: 2011-10-17
Publication date: 2012-07-18
Anticipated expiration: 2031-10-17
Also published as: GB201100648D0; GB2487265B; IE86691B1; IE20110464A1; GB201117878D0

Abstract

The system comprises a number of blocks 110 of insulating material fitting between spaced apart beams 10A, 10B. The blocks have a body portion with two sides, each side including a side portion which rests on a flange 13, 12 on respective beams. On one side of the body portion the block has its own flange 14 which extends underneath a beam. The block further comprises an extending elongate strip 160. The strip and the block are connected together by using complementary formations 20 on the outer edge of the blocks flange which interconnect or engage with formations 21 on the strip Also claimed is a similar floor structure wherein the strip extends underneath a third beam which abuts one of the other beams. The strip preferably has its own formations on its outer side for engagement with additional similar strips and further extends the length of the flange on the block. Also claimed is a method for constructing a suspended floor.

Description

SUSPENDED FLOORING SYSTEM

This invention relates to a suspended flooring system.

It is well known to form suspended floors in buildings by mounting a plurality of horizontal elongate beams, for example of pre-stressed concrete, between opposite side supporting structures of the building. The beams are equally spaced and extend parallel to each other, each beam being of an inverted T-shape in cross-section to define oppositely-extending longitudinal side flanges. Pre-formed blocks of expanded polystyrene material are then laid between the beams, with each block resting on the opposed flanges of adjacent beams.

Each block comprises a lower flanged portion on one side edge thereof, which extends under the bottom surface of one of the side beams, so as to form a continuous planar surface with the blocks of adjacent rows and to thereby form a thermal barrier under the floor.

A screed material is then laid on top of the blocks to form a floor surface. It has been found that the expanded polystyrene material used in combination with pre-stressed concrete beams and a screed provides a good thermally insulated load bearing floor surface.

In order to increase the floor span, it is known to mount two or more such beams side-by-side in rows: the above-mentioned expanded polystyrene blocks are then laid between the opposed beams of adjacent rows to fill the gap therebetween. A disadvantage of this arrangement is that the flanges which extend along the lower side edges of the blocks are not sufficiently wide to cover the bottom surface of the additional beams and hence there is a break in the thermal barrier under the floor.

A first attempted solution to the above-mentioned problem is to cut entire bespoke blocks from unformed blocks of polystyrene material. The blocks can be cut to provide a flange of the necessary width to fully cover and number of side-by-side beams. This procedure is wasteful, messy and time consuming.

A second attempted solution to the above-mentioned problem is to fill the gaps by cutting strips of expanded polystyrene material and then fitting them in-situ under the additional beams by pinning them in place to the know pre-formed blocks. It will be appreciated that it is difficult and messy to cut the strips of expanded polystyrene material. It is also difficult to accurately fit these strips in-situ under the beams. There is also a risk that the strips may become detached over time with the result that a break occurs in the thermal barrier under the floor.

We have now devised a suspended flooring system which alleviates the above-mentioned problems.

In accordance with the present invention, as seen from a first aspect, there is provided a suspended flooring system comprising a plurality of blocks of insulating material for fitting between adjacent spaced-apart beams so as to bridge a gap therebetween, each block comprising a body portion having first and second sides arranged to seat on flanges of respective beams, the second side of the body portion comprising a flange arranged to extend under the beam on which it is seated, the block further comprising an elongate strip portion having a formation on a longitudinal side face thereof for engaging a complementary formation on the outer end face of side flange.

In use, the body and strip portions of the element are inter-engaged to increase the width or the lateral extent of the flange. The complimentary engaging formations serve to securely hold the strip in-situ, such that no further fixing is required and the risk of detachment over time is avoided. Both the strip and body portions are pre-formed and thus the need for cutting and fixing strips of expanded polystyrene material is avoided. The strip serves to cover the bottom surface of a further beam mounted side-by-side with the beam on which the aforementioned second side edge of the body is seated. Advantageously, the strip portion can be engaged with the body portion to form a unitary block prior to fitting the block in-situ.

Preferably the strip portion further comprises an opposite longitudinal side face provided with formations which are complementary to the formations provided on the aforementioned longitudinal side face thereof. These extra formations enable further strips to be successfully mounted face-to-face in order to increase the width or lateral extent of the flange even further. In this manner, a block can simply be assembled to cover the bottom surface of two or more beams and using only two different kinds pre-formed parts.

Preferably the or each strip portion has a width substantially equal to the width of one beam.

Preferably the complementary engaging formations comprise a socket and a projection provided on opposed faces of the respective portions of the block.

Preferably the complementary engaging formations are arranged to resiliently engage each other.

Preferably the complementary formations are arranged to hold the portions of the block in locking engagement with each other.

Also in accordance with the present invention, as seen from a second aspect, there is provided a suspended floor structure comprising a plurality of blocks of insulating material mounted between adjacent spaced-apart beams so as to bridge a gap therebetween, each block comprising a body portion having first and second sides seated on flanges of respective beams, the second side of the body portion comprising a flange which extends under the beam on which it is seated, the block further comprising an elongate strip portion having a formation on a longitudinal side face thereof which is in engagement with a complementary formation on the outer face of side flange.

Also in accordance with the present invention, as seen from a third aspect, there is provided a method of constructing a suspended floor, the method comprising: providing first and second spaced apart parallel beam assemblies, the second beam assembly comprising two side-by-side beams; providing a body of insulating material having first and second sides, the second side comprising a flange having a formation on the outer face thereof; providing a strip of insulating material having a complementary formation on a longitudinal side edge thereof; interengaging the formations to mount the strip along the end face of the flange to form an extended flange; passing the extended flange under the second beam assembly and seating the second side of the body on a portion of the second beam assembly; and seating the first side of the body on a portion of the first beam assembly.

The method may comprise mounting one or more further strips side-by-side to each other in the aforementioned manner, in order to further extend the flange to correspond with the number of beams in the second assembly.

An embodiment of the present invention will now be described by way of an example only, and with reference to the accompanying drawings, in which: Figure 1 is a sectional view through a known suspended floor structure comprising one beam in each row; Figure 2 is a sectional view through a known suspended floor structure comprising two beams in each row; Figure 3 is an isometric view of the body portion of a block of a suspended floor structure in accordance with the present invention; Figure 4 is an isometric view of the strip portion of the block of the suspended floor structure in accordance with the present invention; Figure 5 is an isometric view of the block of the suspended floor structure in accordance with the present invention; Figures 6A and 6B are isometric views of the respective complementary engaging formations of the portions of the block of Figure 5; and Figure 7 is a sectional view through a suspended floor structure in accordance with the present invention comprising two beams in each row; Referring to Figure 1 of the accompanying drawings, there is shown a known suspended floor structure comprising a plurality of rows of horizontal elongate beams 10, for example of pre-stressed concrete, extending between opposite side supporting structures of a building. The beams 10 are equally spaced and extend parallel to each other, each beam 10 being of an inverted T-shape in cross-section to define oppositely-extending longitudinal side flanges.

Blocks 11 of expanded polystyrene material are laid in columns between the rows of beams 10, with each block comprising shoulders 12,13 respectively formed on first and second opposite side faces thereof, the shoulders 12,13 resting on the opposed flanges of respective adjacent beams 10.

Each block 10 further comprises a lower flanged portion 14 extending outwardly from the second side face thereof. The flanged portion 14 extends under the bottom surface of the beam 10 on which the shoulder 13 is seated and into a shoulder 15 formed in the lower portion of the first side face of the block 11 of the next row. It will be appreciated that the assembly of blocks 11 thus form a continuous planar bottom surface to the floor structure and provide a thermal barrier under the beams 10.

A layer of screed or cementitous material 18 is then laid on top of the blocks 11 and covering the beams 10. In this manner the structure provides a good load-bearing floor surface.

Referring to Figure 2 of the accompanying drawings, in order to increase the floor span, it is known to form rows 30,31 of two or more beams IOA, lOB mounted side-by-side: the above-mentioned expanded polystyrene blocks 11 are then laid between the opposed beams of adjacent rows 30,31 to fill the gap therebetween. It will be appreciated that the flanged portions 14 of the blocks 11 are not sufficiently wide to cover the bottom surface of the additional beam lOB. In order to fill the gaps between the blocks 11, it is commonplace to cut strips 16 of expanded polystyrene material, which are then fitted in-situ under the additional beams lOB and held in place by pins 17.

We have found that it is difficult and messy to cut the strips 16 of expanded polystyrene material. It is also difficult to accurately fit the strips 16 in-situ under the beams lOB. There is also a risk that the strips 16 may become detached over time with the result that a break occurs in the thermal barrier under the floor.

Referring to Figure 3 of the accompanying drawings, a suspended floor structure in accordance with the present invention comprises a plurality of block-shaped body portions 110 which are substantially similar to the known blocks 11 of Figures 1 and 2 and like parts are given like reference numerals. The bodies 110 differ in that the outer end face of the flanged portion 14 is castellated to define a row of sockets 20 extending across the face. The similarity of the bodies 110 to the known blocks 10 means that they can be laid in place of the blocks 10 in the kind of floor structure shown in Figure 1.

Referring to Figure 4 of the accompanying drawings, the suspended floor structure in accordance with the present invention further comprises a plurality of elongate strip portions 160 of expanded polystyrene for selectively engaging with the bodies 110 to form blocks. Each strip 160 comprises opposite longitudinal side faces which are castellated and respectively define a row of projections 21 and row of sockets 20.

The sockets 20 are identical to the sockets 20 on the flanged portion 14 of the body and the projections 21 are complementary in shape to the sockets 20 so that they can be interengaged.

Referring to Figure 6A of the accompanying drawings, the sockets 20 extend transversely across the face on which they are disposed such that, in use, they extend vertically of the plane of the floor structure. The upper end of the sockets 20 are formed with cut-outs 22 in their opposed side walls. Channels 25 extend along the opposed side walls of the sockets 20 adjacent their back walls, such that the outwardly-facing mouth of the sockets 20 are narrowed.

Referring to Figure 6B of the accompanying drawings, the projections 21 extend transversely across the face on which they are disposed such that, in use, they extend vertically of the plane of the floor structure. The upper end of the projections 21 are formed with tabs 23 on their oppositely-directed side walls. Ribs 24 extend along the oppositely-directed side walls of the projections 21 adjacent their front walls, such that the outer end of the projections 21 is widened.

Referring to FigureS of the accompanying drawings, a strip 160 can be engaged with the body 110 by positioning the parts relative to each other, so that the projections 21 on the strip 160 are positioned axially over the sockets 20 on the flanged portion 14 of the body 110. The strip 160 is then moved downwardly, transverse the plane of the body 110, to slide the projections 21 fully into the sockets 20 until the tabs 23 thereon seat in the cut-outs 22 of the sockets 20, whereupon further sliding movement is prevented. In this position the top and bottom faces of the strip 160 are disposed in the same plane as the top and bottom surfaces of the flanged potion 14.

Referring to Figure 7 of the accompanying drawings, the assembled block can then be fitted to kind of floor structure shown in Figure 2 by tilting the block out of a horizontal plane and passing the strip 160 and flange 14 under the two beams IOA,IOB. The block is then tilted back to a horizontal plane and moved downwardly to bring the shoulder 15 onto the adjacent row of beams IOA,1OB. It will be appreciated that the co-operation of the cut-outs 22 and tabs 23 serve to prevent the strip 160 from moving downwardly relative to the flange 14. Likewise the co-operation of the ribs 24 and channels 25 serve to prevent the strip 160 from moving outwardly relative to the flange 14. The outer end of the strip 160 is received in the shoulder 15.

The strip 160 extends under the bottom surface of the additional beam I OA and into the shoulder 15 formed in the lower portion of the first side face of the body 110 of the next row. It will be appreciated that the assembly of strips 160 and bodies 110 thus form a continuous planar bottom surface to the floor structure and provide a thermal barrier under the beams IOA,IOB without the need for any cutting or pinning of material.

The sockets 20 on the outer face of the strips 160 enable any number of further strips to be successively mounted to each other to correspond with the width and/or number of the beams in each row.

The strips 160 may have a length which is shorter than the width of the end face of the flange 14: In this arrangement a plurality of strips are then arranged end-to-end to match the desired length.

Claims

CLAI MS1. A suspended flooring system comprising a plurality of blocks of insulating material for fitting between adjacent spaced-apart beams so as to bridge a gap therebetween, each block comprising a body portion having first and second sides arranged to seat on flanges of respective beams, the second side of the body portion comprising a flange arranged to extend under the beam on which it is seated, the block further comprising an elongate strip portion having a formation on a longitudinal side face thereof for engaging a complementary formation on the outer end face of said flange.
2. A suspended flooring system as claimed in claim 1, in which the strip portion has a width substantially equal to the width of one beam.
3. A suspended flooring system as claimed in claims I or 2, in which the strip portion further comprises an opposite longitudinal side face provided with formations which are complementary to the formations provided on the aforementioned longitudinal side face thereof.
4. A suspended flooring system as claimed in claim 3, in which the complementary formations comprise a socket and a projection provided on opposed faces of the respective portions of the block.
5. A suspended flooring system as claimed in claim 4, in which the complementary formations are arranged to resiliently engage each other.
6. A suspended flooring system as claimed in any of claims 3 to 5, in which the complementary formations are arranged to hold the portions of the block in locking engagement with each other.
7. A suspended flooring system substantially as herein described with reference to the accompanying drawings.
8. A suspended floor structure comprising a plurality of blocks of insulating material mounted between adjacent first and second spaced-apart beams so as to bridge a gap therebetween, each block comprising a body portion having first and second sides seated on flanges of respective beams, the second side of the body portion comprising a flange which extends under the second beam on which it is seated, the block further comprising an elongate strip portion having a formation on a longitudinal side face thereof which is in engagement with a complementary formation on the outer face of said flange, the strip portion extending under a third beam mounted adjacent and parallel to said second beam.
9. A suspended flooring structure as claimed in claim 8, in which the strip portion has a width substantially equal to the width of the third beam.
10. A suspended flooring structure as claimed in claims 8 or 9, in which the strip portion further comprises an opposite longitudinal side face provided with formations which are complementary to the formations provided on the aforementioned longitudinal side face thereof.
11.A suspended flooring structure as claimed in claim 10, in which the complementary formations comprise a socket and a projection provided on opposed faces of the respective portions of the block.
12.A suspended flooring structure as claimed in claim 11, in which the complementary formations are arranged to resiliently engage each other.
13. A suspended flooring structure as claimed in any of claims 10 to 12, in which the complementary formations hold the portions of the block in locking engagement with each other under said second and third beams.
14.A suspended flooring structure substantially as herein described with reference to the accompanying drawings.
15. A method of constructing a suspended floor, the method comprising: a. providing first and second spaced apart parallel beam assemblies, the second beam assembly comprising two side-by-side beams; b. providing a body of insulating material having first and second sides, the second side comprising a flange having a formation on the outer face thereof; c. providing a strip of insulating material having a complementary formation on a longitudinal side edge thereof; d. interengaging the formations to mount the strip along the end face of the flange to form an extended flange; e. passing the extended flange under the second beam assembly and seating the second side of the body on a portion of the second beam assembly; and f. seating the first side of the body on a portion of the first beam assembly.
16. A method as claimed in claim 15, comprising mounting a further strip side-by-side with said first strip to further extend the flange to correspond with the number of beams in the second assembly.
17. A method of constructing a suspended floor, the method being substantially as herein described with reference to the accompanying drawings.