GB2538781A

GB2538781A - A beam

Info

Publication number: GB2538781A
Application number: GB1509201.8A
Authority: GB
Inventors: Kanwaljit Gill Singh
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-05-28
Filing date: 2015-05-28
Publication date: 2016-11-30
Anticipated expiration: 2035-05-28
Also published as: GB2538781B; GB201509201D0

Abstract

The beam 10 comprises a plastic body 12 defining a cavity 18, and a retention arrangement 24 for retaining insulation 22 within the cavity. The retention arrangement may be projections 24a, 24b which extends into the insulation. The beam may be reinforced along its entire length by a high tensile wire 28, metal banding, or a lattice 26. The reinforcements may be steel and have a non-linear cross section. The beam may have attachment arrangements on opposing sides of the body for attaching the beam to another like beam. The attachment arrangement may comprise hooks, or apertures for receiving an insert. Also claimed is a beam comprising a plastic body and a reinforcement member extending along the bodys longitudinal axis. Also claimed is a beam having a plastic body having a surface for receiving flooring, the surface having an arrangement for connecting the flooring to the beam.

Description

A beam The present invention relates to a beam for use in construction.

It is known to provide support for a layer of flooring material when constructing buildings such as houses. The "beam and block" construction method is commonly used, involving a series of blocks, usually concrete, supported by beams. Insulation material is laid over the blocks, followed by flooring material. Pipes and cables required to be installed in the flooring are usually laid beneath the insulation material.

There are downsides to such construction methods. The use of concrete blocks is inefficient, as the blocks are heavy and unwieldy so are difficult and time consuming to install and transport. A crane or other machinery is usually required for installation. Blocks must he of the required size for a particular foundation, and are difficult to re-size. Foundations deep enough to receive the beams and blocks must be dug, which again is time consuming.

Separate insulation material must be used, as the concrete blocks do not comply with insulation standards. A separate damp-proof membrane is also required. Installation of pipes and cables must take place whilst the flooring is being laid.

The present invention seeks to overcome, or at least mitigate, the problems of the prior art.

According to the present invention there is provided a beam for use in construction, the beam having a plastic body. The body defines a cavity configured to receive insulation material. The beam comprises a retention arrangement configured to retain insulation material within the cavity.

Advantageously, insulation material can be fitted to the beam prior to installation and/or transportation of the beam for quick and easy installation and/or transportation. The beam being of plastic makes it light arid thus easy to manipulate in transportation or installation.

The retention arrangement may comprise at least one projection. The projection may be configured in use to extend into insulation material retained within the cavity.

This provides a simple and effective means of retaining insulation material within the beam.

The body may comprise a wall at least partially defining the cavity, wherein the projection extends from the wall into the cavity.

The beam may further comprise at least one elongate reinforcement member extending within the body substantially parallel to a longitudinal axis of the body.

The reinforcement member provides additional support to the body, improving the strength of the beam, in particular the tensile strength.

The reinforcement member may extend substantially the full length of the body.

The reinforcement member may be of high tensile wire.

The reinforcement member may be of metal banding. The banding may define at least one aperture configured to receive a projection of the body for securement of the banding in relation to the body.

The reinforcement member may he of lattice, preferably metal lattice.

The reinforcement member may have a non-linear cross-section. For example, the 30 reinforcement member may have an L-shaped, U-shaped, C-shaped or X-shaped cross-section. This improves adhesion between the reinforcement member and the body.

The reinforcement member may be of steel.

The beam may comprise an attachment arrangement configured for attachment of the beam to another, like, beam.

Two or more beams can thus be easily attached to one another to create a flooring assembly.

The attachment arrangement may comprise a female part at a first side of the body and a I 0 corresponding male part at a second side of the body.

The attachment arrangement may comprise a push-fit arrangement.

The attachment arrangement may comprise corresponding first and second hooks at opposing sides of the body configured for attachment to one another.

The attachment arrangement may comprise first and second apertures defined by first and second opposing sides of the body respectively, and an insert, wherein the insert is configured to be received and retained by the first aperture of the beam and by the second aperture of another, like, beam.

The body may have a uniform cross-section.

A uniform cross-section allows the body to be produced by extrusion.

The body may define a surface configured to receive flooring material, and the surface may comprise a connection arrangement configured to provide a connection between the beam and said flooring material.

The connection arrangement may comprise at least one recess. The recess may define a neck at an end distal the remainder of the body. The recess may define opposing sides tapered towards the neck.

The recess may extend substantially along the length of the beam. The connection arrangement may comprise a series of substantially parallel recesses.

The body may be of recycled plastic.

I 0 The beam may comprise insulation material configured for attachment to the beam.

The insulation material may he foamed polystyrene.

There is further provided a beam for use in construction comprising a plastic body and at least one elongate reinforcement member extending substantially parallel to a longitudinal axis of the body.

The reinforcement member may be of high tensile wire.

Alternatively, the reinforcement member may be of metal banding.

The banding may define at least one aperture configured to receive a projection of the body for securement of the banding in relation to the body.

Alternatively, the reinforcement member may be of lattice, preferably metal lattice.

There is yet further provided a beam for use in construction, the beam having a plastic body, and the body defining a surface configured to receive flooring material. The surface 10 comprises a connection arrangement configured to provide a connection between the beam and said flooring material.

There is further provided a method of manufacturing a beam as described above comprising the steps of: a) providing at least one elongate reinforcement member for a beam; and b) extruding the plastic body about the reinforcement member.

The method may, where the reinforcement member is of banding, further comprise the step of, between steps a) and b): c) creating at least one aperture in the handing.

A beam will now he described in detail by way of example and with reference to the 30 accompanying drawings in which: Figure 1 is a cross-sectional view through a beam according to a first embodiment of the invention; Figure 2 is a side view of a reinforcement member of the embodiment of Figure 1; Figure 3 is a cross-sectional detail view through a beam according to a second embodiment of the invention; Figure 4 is a cross-sectional detail view through a beam according to a third embodiment of I 0 the invention; Figure 5a is a cross-sectional view through a beam according to a fourth embodiment of the invention; Figure 5b is a partial cross-sectional view through the beam of Figure 5a connected to a further beam; Figure 6a is a cross-sectional view through a beam according to a fifth embodiment of the invention; Figure 6b is a partial cross-sectional view through the beam of Figure 6a connected to a further beam; Figure 7 is a cross-sectional view through a beam according to a sixth embodiment of the invention; Figure 8 is a cross-sectional view through a flooring assembly according to the embodiment of Figure 7; Figure 9 is a cross-sectional view through a beam according to a seventh embodiment of the invention; Figure 10 is a cross-sectional view through a beam according to an eighth embodiment of the invention; Figure 11 is a cross-sectional view through a beam according to a ninth embodiment of the invention; Figure 12 is a cross-sectional view through a beam according to a tenth embodiment of the invention; Figure 13 is a series of cross-sectional views through beams according to an eleventh embodiment of the invention; Figure 14a is a series of cross-sectional views through beams according to a twelfth embodiment of the invention; Figure 14b is a partial cross-sectional view through a beam of Figure 14a; Figure 15 is a series of cross-sectional views through a flooring assembly according to the 20 embodiment of Figure 14a; Figure 16 is a perspective cross-sectional view through a beam according to a thirteenth embodiment of the invention; Figure 17 is a cross-sectional view through a beam according to a fourteenth embodiment of the invention; Figure 18a is a cross-sectional view through a beam according to a fifteenth embodiment of the invention; Figure 18b is a partial cross-sectional view through the beam of Figure 19a connected to a further beam; Figure 19 is a cross-sectional view through a beam according to a sixteenth embodiment of the invention; Figure 20 is a cross-sectional view through a flooring assembly according to the embodiment of Figure 19; Figure 21 is a cross-sectional view through a wall component according to the embodiment of Figures 19 and 20; Figure 22a is a cross-sectional view through a beam according to a seventeenth embodiment of the invention; Figure 22b is a cross-sectional view through a variation of the beam of Figure 22a; Figure 23a is a cross-sectional view through a beam according to an eighteenth embodiment of the invention; and Figure 23b is a cross-sectional view through a variation of the beam of Figure 23a.

Referring to Figures 1 and 2, a beam for use in construction is indicated generally at 10. The beam 10 is intended for use as part of a flooring assembly, i.e. the beam 10 is intended to be laid alongside multiple like beams 10 to provide support for a layer of flooring material.

The beam 10 comprises an elongate body 12 defining a longitudinal axis (not shown). The body 12 is of an inverted U-shape, having two substantially parallel side walls 14 connected by a top 16.

In this embodiment, the walls 14 and top 16 have a thickness of substantially 4 to 5mm, though in alternative embodiments other suitable thicknesses may be used. The body 12 of this embodiment has a height x (see Figure 1) of substantially 250mm to 350mm, though in alternative embodiments other suitable heights may be used.

A cavity 18 is defined by the sides 14 and the top 16. In alternative embodiments, three or more sides 14 defining multiple cavities 18 may be connected by a single top 16, in order to save material.

An upper face 20 of the top 16 provides a surface upon which a layer of flooring material can be laid. The upper face 20 is in this embodiment roughened e.g. by scouring, to inhibit slip on the surface.

The body 12 is in this embodiment of recycled plastic. ln this embodiment, the body 12 is of recycled polyvinylchloride (PVC). PVC has the advantage of being inherently fireproof, so that the body 12 is advantageously fireproof In alternative embodiments, the body 12 may be of recycled high-density polyethylene or polyethylene terephthalate, or some other suitable material, recycled or otherwise.

Pulverised fuel ash or calcium carbonate may be used as a filler.

The body 12 is in this embodiment produced by extrusion and cut to a required length. The body 12 has a uniform cross-section, so is suitable for this form of manufacture. The body 12, and therefore the beam 10, can thus be produced at any suitable length. There is in this embodiment a fillet radius 15 where the sides 14 meet the top 16, for ease of extrusion.

The beam 10 further comprises insulation material 22. The insulation material 22 is in this embodiment fully received by the cavity 18, and substantially fills the cavity 18. In alternative embodiments, the insulation material 22 may extend beyond the cavity 18, and/or may only partially fill the cavity 18. In this embodiment, the insulation material 22 extends substantially the full length of the beam 10, though in other embodiments the insulation material 22 may extend only part of the length of the beam 10.

In use, the insulation material 22 may be fitted to the body 12 prior to transportation, or on site. In this embodiment the projections 24 are located at an end 14a of the sides 14 distal the top 16, though in alternative embodiments the projections 24 may be located elsewhere on the sides 14. The body 12 may include more than one projection on each side 14.

In this embodiment, the insulation material 22 is fitted into the cavity 18 along the longitudinal axis of the body 12, though in alternative embodiments the insulation material 22 may be fitted into the cavity 18 by some other suitable method.

In this embodiment, the insulation material 22 is of foamed polystyrene, although other suitable insulation materials, for example foamed polyurethane or wool-based insulation, 15 may be used.

A retention arrangement 24 is used to retain the insulation material 22 within the cavity 18. In this embodiment, the retention arrangement 24 is integral to the body 12, though in alternative embodiments a separate retention arrangement may be used. The retention arrangement 24 is in this embodiment in the form of a projection 24 extending from each side 14 into the cavity 18. The projections 24 are configured to extend into the insulation material 22, thus retaining the insulation material 22 within the cavity 18.

The projections 24 are in this embodiment substantially triangular in shape. As shown in Figure 1, each projection 24 comprises a first, sloped, side 24a and a second side 24b, substantially perpendicular to the sides 14. The projections 24 bite into the foamed polystyrene insulation material 22 to retain it within the cavity 18, with the perpendicular second sides 24b in particular inhibiting movement of the insulation material out of the cavity 18. The projections 24 extend the full length of the body 12, and are in this embodiment extruded with the remainder of the body 12. The projections 24 of this embodiment extend substantially 1.5mm into the cavity 18, though in alternative embodiments the projections 24 may be of some other suitable size. The size of the projections 24 may depend upon the insulation material 22 used.

The insulation material 22 is in this embodiment further secured to the body 12 with a suitable adhesive, such as rubber adhesive or some other suitable adhesive.

The beam 10 includes in this embodiment an elongate reinforcement member 26, 28 extending within each side 14 substantially parallel to the longitudinal axis of the body 12. The reinforcement members 26, 28 increase the strength of the beam 10. The reinforcement I 0 members 26, 28 have high tensile strength, so increase the tensile strength of the beam 10.

The reinforcement members 26, 28 extend substantially the full length of the body 12, though in alternative embodiments they may extend through only part of the length of the body 12.

In this embodiment, two alternative reinforcement members 26, 28 are shown. The first of these is indicated at 26 in Figure 1, and is shown in Figure 2. The reinforcement member 26 is steel lattice having top and bottom steel wires 27 and an intermediate steel wire 29 extending between and welded to the wires 27 to form a repeating V-shaped pattern. In this embodiment, the intermediate wire 27 has a diameter less than that of the top and bottom wires 29.

The lattice 26 is flexible and can be coiled, so is relatively easy to transport.

The reinforcement member 28 is high tensile wire, in this embodiment steel wire. The wire 28 of this embodiment has a diameter of substantially 5nam, though in alternative embodiments other suitable diameters may be used. The wire 28 is in this embodiment located towards the end I4a of the sides 14 distal the top 16, although in alternative embodiments the wire 28 may be elsewhere in the sides 14.

The different types of reinforcement member 26, 28 are shown in a single beam 10 as an example only. The beam 10 will usually have a reinforcement member 26, 28 of the same type extruded within each of the sides 14, rather than different types of reinforcement member 26, 28, though different types of reinforcement member 26, 28 may be included in a single beam 10.

In alternative embodiments, the beam 10 may include more than two reinforcement members (e.g. as described with respect to further embodiments, below), or may include a single reinforcement member 26, 28 only.

As stated above, the plastic body 12 is formed by extrusion. The body 12 is extruded about 10 the reinforcement members 26, 28, such that the reinforcement members 26, 28 are embedded within the body 12. In the case of the lattice 26, the body 12 is moulded around and through the lattice 26. The lattice 26 is thus securely embedded within the body 12.

The beam 10 further includes end plates (not shown) configured for attachment to one or both ends of the body 12. The end plates secure the insulation material 22 within the body 12.

The beam 10 also includes a damp-proof membrane (not shown), embedded within the body 12 or alternatively attached to the exterior of the body 12.

A second embodiment of the invention is shown in Figure 3. This embodiment is similar to the first embodiment, except in that the beam 10 includes an alternative reinforcement member 30. The reinforcement member of this embodiment is metal banding strip or strapping, in this embodiment high carbon steel banding strip 30. The banding 30 has substantially parallel sides 32. The banding 30 is in this embodiment orientated such that the sides 32 are substantially parallel to the body sides 14.

The banding 30 defines a series of apertures 34 along its length. The banding 30 is passed through a shaping device (not shown) before the body 12 is moulded about the banding 30. 30 The apertures 34 allow plastic to mould through the banding 30 upon extrusion of the body 12 about the banding 30, forming projections, so that the banding 30 is securely embedded within the body 12. The apertures 34 are small enough to avoid a substantial adverse effect on the shear and tensile strength of the banding 30.

As with the previously described reinforcement members 26, 28, the banding 30 has high tensile strength, so increases the strength of the beam 10. The banding 30 has relatively high shear strength due to the depth of the strip, so also increases the shear strength of the beam 10. The banding 30 is in this embodiment located towards the end I 4a of the sides 14 distal the top 16, although in alternative embodiments the banding 30 may be elsewhere in the sides I 4.

The banding 30 is flexible, and can he coiled for ease of transportation.

A third embodiment of the invention is shown in Figure 4. This embodiment is similar to the first and second embodiments, except in that the beam 10 inchdes an alternative reinforcement member 36. The reinforcement member 36 of this embodiment is substantially U-shaped in cross-section, and is formed of steel banding or some other suitable material crimped or otherwise formed into a U-shape. The U-shaped cross-section of the member 36 provides an improved adhesive connection between the member 36 and the body 12, improving securement of the member 36 within the body 12.

A fourth embodiment of the invention is shown in Figures 5a and 5b. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "1". Only features that differ from those of the first embodiment are discussed in more depth.

As shown in Figures 5a and 5b, the beam 110 of this embodiment includes an attachment arrangement 140, 142. The attachment arrangement 140, 142 is configured to allow attachment of the beam 110 to another, like, beam, such that a flooring assembly configured to support a layer of flooring material can be created.

In this embodiment, the attachment arrangement includes two first hooks 140 extending upwardly (i.e. towards the top 116 of the body 112) from one of the sides 114, and two second hooks 142 extending downwardly (i.e. away from the top 116 of the body 112) from the other of the sides 114. In this embodiment, there is an upper first hook 140 and an upper second hook 142 adjacent the top 116, and a lower first hook 140 and a lower second hook 142 adjacent the respective ends 114a of the sides 114. A recess 141 is defined in the side 114 adjacent the open end of each first hook 140.

In alternative embodiments, the attachment arrangement may include only one set of hooks 140, 142, or may include three or more sets of hooks 140, 142. The hooks 140, 142 can be located elsewhere on the sides 114.

The first hooks 140 are configured to receive the second hooks 142 of a second beam 110, so that the beams 110 are connected to one another and retained with respect to one another in a horizontal direction, as shown in Figure 5b. The second hooks 142 are received into the recesses 141, so that the beams 110 are adjacent one another and the tops 116 form a substantially continuous surface. A further beam 110 is then connected via its first hooks 140 to the second hooks 142 of the beam 110, and so on until multiple beams 110 are connected and a floor assembly is created.

In this embodiment, the hooks 140, 142 extend the full length of the body 112, so that there is a connection along the full length of the beam 110. The body 112 thus has a uniform cross-section, so can be simply produced by extrusion.

The connection formed between adjacent beams 110 is substantially gas-tight and so inhibits the movement of harmful gases such as radon into a building. Adhesive can be used between the beams 110 to further improve the connection.

The body 112 of this embodiment further includes first and second apertures 145, 147 of 30 different example types configured to allow pipes and/or cables (not shown) to run along the length of the beam 110. Both apertures 145, 147 are defined by walls 144, 146 extending within the cavity 118 between one of the sides 114 and the top 116. The wall 144 of the first aperture 145 approximately defines two sides of square, with a radius between the sides. The wall 146 of the second aperture 147 defines two sides of a square with a right angle between the sides. The walls 144, 146 provide structural support in addition to defining the apertures 145, 147.

The cable apertures 145, 147 allow cables to be easily and quickly fitted to or through the floor assembly even after it has been installed, and after a layer of flooring material has been laid on the beams 110. The cables are protected by the walls 144, 146.

Figures 6a and 6b show a beam 110 according to a fifth embodiment of the invention, the beam 110 having an alternative attachment arrangement 148, 150. Each side 114 defines an aperture 148 extending partway into the exterior of the side 114 and extending along the full length of the body 112. The apertures 148 have inclined sides and increase in width as they extend into the sides 114, such that the opening of each aperture 148 is narrower than the body of the aperture 148.

An insert 150 (see Figure 6b), having a V-notch at each end, is configured for insertion into one of the apertures 148 of the beam 110, and into an aperture 148 of a second beam 110, such that half of the insert 150 extends into and is retained by each aperture 148. The beams are thus connected to one another, e.g. as shown in Figure 6b. A second insert 150 is fitted to the aperture 148 on the other side 114 of the beam 110, so that a third beam 110 can be connected thereto, and so on.

The insert 150 of this embodiment extends substantially the full length of the body 112. In alternative embodiments, the insert 150 extends only partway along the body 112, and multiple inserts 150 may be used to connect two beams 110. The insert 150 is of extruded plastic, although other suitable materials and/or production methods may be used.

The attachment arrangement 148, 150 allows a simple connection between multiple beams 110. The insert 150 can be fitted to the beam 110 prior to transportation, for ease and speed of installation on site.

In this embodiment, the apertures 148 are located substantially midway up the sides 114, although in alternative embodiments the apertures 148 are located elsewhere on the sides 114. In alternative embodiments, the sides 114 define more than one aperture 148 such that more than one insert 150 can be used to connect two beams 110.

As the apertures 148 extend along the full length of the body 112, the body has a uniform cross-section, so is suitable for production by extrusion.

A further advantage of this arrangement is that the sides 114 of the beams are identical to one another, so the beams can be connected to one another from either side.

In alternative embodiments the beam 110 may include an alternative attachment arrangement. For example, the attachment arrangement may include a male part (not shown) on one side 114 configured to push-fit into a corresponding female part (not shown) on the other side 114 of a second beam 110, or a clip arrangement may be used. The attachment arrangements shown in the fourth and fifth embodiments can be used with the other embodiments described herein.

A sixth embodiment of the invention is shown in Figures 7 and 8. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "2". Only features that differ from those of the previous embodiments are discussed in more depth.

As shown in Figure 7, the body 212 of this embodiment is T-shaped in cross-section, having an arm 217 configured to be substantially upright on installation, and a perpendicular cross-bar 219. The body 212 is configured to be installed in an inverted T-shape, i.e. such that the cross-bar 219 supports the insulation material 222 from below, e.g. as shown in Figures 7 and 8. The body 212 is configured for arrangement alongside a further body 212, such that the longitudinal axes of the bodies 212 are substantially parallel to one another. The cavity 218 is defined between the bodies 212. Each body 212 is configured to define part of two adjacent cavities 218, i.e. such that the arm 217 abuts two portions of insulation material 222, saving material.

The cross-bar 219 includes projections 224 at each end, providing a retention arrangement. The projections 224 extend upwardly from the cross-bar 219 when the beam 210 is installed. locating the insulation material 222 within the cavity 218.

Two alternative bodies 212a, 212b are shown in Figure 7, the bodies 2I2a, 212b having different reinforcement members 228, 230. The first body 2 I 2a has reinforcement members in the form of high tensile wire 228. The body 212a has high tensile wire 228 towards a free end 217a of the arm 217, distal the cross-bar 219, and at three substantially equidistant points along the cross-bar 219, including the point where the arm 217 meets the cross-bar 219.

The second body 21213 has reinforcement members in the form of steel banding strip 230. The body 212b has a strip of banding 230 towards the free end 217a of the arm 217, orientated such that the sides 232 are substantially parallel to the arm 217. The body 212b has three further strips of banding 230 at substantially equidistant points along the cross-bar 219, including the point where the arm 217 meets the cross-bar 219, orientated such that the sides 232 are substantially parallel to the cross-bar 219.

In alternative embodiments, the body 212 may include a combination of different types of reinforcement member 228, 230, and/or a lattice or U-shaped reinforcement member 26, 36 as described above. The body 212 may include fewer than or more than four reinforcement members 228, 230, and the reinforcement members 228, 230 may be arranged in some other configuration.

As shown in Figure 8, a layer of flooring material 252 is laid over the installed beams 210.

In Figure 8, a layer of concrete 252a and a layer of boarding 252h (such as silicon magnesium boarding) are shown by way of example. In alternative embodiments, other types of flooring material such as tiles may be used.

As shown in Figure 8, for example, the arms 217 extend into flooring material such as concrete 252a, to secure the flooring material 252 with respect to the beams 210.

Alternatively, the arms 217 abut the flooring material such as boarding 252b, e.g. as shown in Figure 8. In alternative embodiments, the arms 217 may not extend into flooring material such as concrete, or may extend into flooring material such as hoarding.

A seventh embodiment of the invention is shown in Figure 9. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "3". Only features that differ from those of the previous embodiments are discussed in more depth.

The body 312 of this embodiment is substantially 1-shaped in cross-section, with an arm 317 extending between two cross-bars 319. The cross-bars 319 form the top and bottom of the body 312 when the beam 310 is installed. Again, the body 312 is configured for arrangement alongside a further body 312, such that the longitudinal axes of the bodies 312 are substantially parallel to one another. The cavity 318 is defined between the bodies 312, and between the opposing cross-bars 319. Each body 312 is configured to define part of two adjacent cavities 318, i.e. such that the arm 317 abuts two portions of insulation material 322, saving material.

The cross-bars 319 each have a projection 324 located towards each end, the projections 324 extending into the cavity 318 to form the retention arrangement 324.

As in the sixth embodiment, two alternative bodies 312a, 3! 2h are shown in Figure 9, the bodies 312a, 3!2b having alternative reinforcement members 328, 330. The first body 312a has reinforcement members in the form of high tensile wire 328. The body 3 12a has high tensile wire 328 at three substantially equidistant points along each cross-bar 319, including the point where the arm 317 meets the cross-bars 319.

The second body 3126 has reinforcement members in the form of steel banding strip 330. The body 3126 has three strips of banding 330 at substantially equidistant points along each cross-bar 319, including the point where the arm 317 meets the cross-bars 319, orientated such that the sides 332 are substantially parallel to the cross-bar 319.

Again, in alternative embodiments, the body 312 may include a combination of different types of reinforcement member 328, 330, and/or a lattice or U-shaped reinforcement member 26, 36 as described above. The body 312 may include fewer than or more than six reinforcement members 328, 330, and the reinforcement members 328, 330 may be arranged in some other configuration.

An eighth embodiment of the invention is shown in Figure 10. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "4". Only features that differ from those of the previous embodiments are discussed in more depth.

The body 412 of this embodiment is substantially C-shaped in cross-section, having an arm 417 extending between substantially perpendicular arms 419. The arms 419 form the top and bottom of the body 412 when the beam 410 is installed. Each beam 410 has two bodies 412 arranged opposite to one another with reflective symmetry, so that the cavity 418 is defined between the bodies 412, and between the opposing arms 419.

The arms 419 each have two projections 424 extending into the cavity 418 to form the retention arrangement 424. In alternative embodiments, the arms 419 may each have one projection 424, or three or more projections 424, or one or other of the arms 419 may not have any projections.

As in the sixth embodiment, two alternative bodies 4! 2a, 412b are shown in Figure 10, the 30 bodies 412a, 412b having different reinforcement members 428, 430. The first body 412a has reinforcement members in the form of high tensile wire 428. The body 4I2a has high tensile wire 428 at each end of the arms 419, including the point where the arm 417 meets the arms 419.

The second body 41213 has reinforcement members in the form of steel banding strip 430.

The body 412b has a strip of banding 430 at each free end 419a of the arms 419, orientated such that the sides 432 are substantially parallel to the arms 419. The body 412h also has a strip of banding 430 at each end of the arm 417, i.e. at the point where the arm 417 meets the perpendicular arms 419, orientated such that the sides 432 are substantially parallel to the arm 417.

Again, in alternative embodiments, the body 412 may include a combination of different types of reinforcement member 428, 430, and/or a lattice or U-shaped reinforcement member 26, 36 as described above. The body 412 may include fewer than or more than four reinforcement members 428, 430, and the reinforcement members 428, 430 may be arranged in some other configuration.

A ninth embodiment of the invention is shown in Figure 11. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "5". Only features that differ from those of the previous 20 embodiments are discussed in more depth.

The body 512 is configured to enclose insulation material 522. The body 512 has a square outer wall 554 and two perpendicular inner walls 556 arranged to form a cross shape within the outer wall 554. Four cavities 518 are thus defined by the body 512.

In this embodiment, the retention arrangement is provided by the walls 554, 556, which enclose the insulation material 522.

The body 512 of this embodiment provides protection for the insulation material 522 during transportation and installation, as the insulation material 522 is enclosed within the body 512.

In alternative embodiments, the outer wall 554 may be of some other shape, and/or the inner walls 556 may form an alternative shape within the outer wall 554. For example, the outer wall 554 may form a rectangle. The body 512 may have only one inner wall 556, or may not have any inner walls, so that the cavity 518 is defined by the outer wall 554.

A tenth embodiment of the invention is shown in Figure 12. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "6". Only features that differ from those of the previous embodiments are discussed in more depth.

The body 612 of this embodiment includes a top 616 and detachable sides 614. The sides 614 are configured to extend substantially perpendicular to the top 616. Each top 616 is configured to retain three sides 614 via connection points 658, 660. Each connection point 658, 660 includes a pair of arms 658 extending downwardly from the top 616 and defining a substantially mushroom-shaped aperture 660 having a neck 659.

Each side 614 has a connection end 662 configured for insertion and retention in a connection point 658, 660. The connection end 662 is substantially mushroom-shaped, corresponding to the shape of the aperture 660, having a taper to a maximum width point 663. The arms 658 are resilient, so allow expansion of the neck 659 of the aperture 660 about the maximum width point 663 of the connection end 662 upon insertion. When the connection end 662 is fully inserted into the aperture 660, the arms 658 return to their original position. The arms 658 retain the side 614 in position against the top 616 via the maximum width point 663.

The top 616 has a connection arrangement 664, 666 at its ends configured to allow connection of one body 612 to another, like, body 612. The top 616 defines a male part 664 at a first end 616a, and a female part 666 at a second end 616b. The male part 664 is configured for insertion and retention in the female part of a second body 512, such that a series of bodies 612 can be connected together to form a flooring assembly upon which a flooring material can be laid.

Advantageously, one side 614 is configured to abut two portions of insulation material 622, saving material.

Projections (not shown) similar to those of the previous embodiments may be included in the body 612 to provide a retention arrangement Each side 614 includes a reinforcement member in the form of banding 630 at an end 614a distal the connection end 662. In alternative embodiments, other types of reinforcement 10 member, e.g. one of those described above, may be used.

An eleventh embodiment of the invention is shown in Figure 13. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "7". Only features that differ from those of the previous embodiments are discussed in more depth.

Figure 13 shows different types of enclosed beams 710 similar to the enclosed beam 510 of the ninth embodiment, i.e. a beam 710 with a body 712 having an outer wall 754 and a series of inner walls 756 dividing the interior into cavities 718. The inner walls 756 are parallel to one another and extend substantially vertically when the beam 710 is installed, such that the cavities 718 are rectangular. Each of the beams 710 is configured to define a different number of cavities 618.

A twelfth embodiment of the invention is shown in Figures 14a, 14b and 15. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "8". Only features that differ from those of the previous embodiments are discussed in more depth.

Figure 14a shows beams 810 with multiple sides 814 connected to a shared top 816.

Substantially triangular cable apertures 845 are defined by walls 844 extending within the cavity 818 between one of the sides 814 and the top 816. An interior side 814a has a retention arrangement 824 on either side, extending into both cavities 818.

As shown in Figure 14b, the sides 814 incorporate a reinforcement member 30.

Figure 15 shows the beams 810 of Figure I4a incorporated in a flooring assembly 884, with a layer of flooring material 852 laid over the installed beams 810. The sides 814 of this embodiment extend into a foundation layer 853 of, for example, concrete, for additional securement. However, in alternative embodiments the foundation layer 853 is not required.

A thirteenth embodiment of the invention is shown in Figure 16. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "9". Only features that differ from those of the previous embodiments are discussed in more depth.

The beam 910 of this embodiment is again of the enclosed type, having an outer wall 954 and a series of inner walls 956. The inner walls 956 are arranged in X-shapes to define triangular cavities 918.

A fourteenth embodiment of the invention is shown in Figure 17. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "10". Only features that differ from those of the previous embodiments are discussed in more depth.

The beam 1010 of this embodiment is once again of the enclosed type, having an outer wall 1054 and a series of inner walls 1056. The inner walls 1056 are arranged in V-shapes to define triangular cavities 1018.

A fifteenth embodiment of the invention is shown in Figures 18a and 18b. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "11". Only features that differ from those of the previous embodiments are discussed in more depth.

The beam 1110 of this embodiment is similar to that of Figures 5a and 5b. However, the beam 1110 has three sides 1114 extending from a shared top 1116. Substantially triangular cable apertures 1145 are defined by walls 1144 extending within the cavity 1118 between one of the sides 1114 and the top 11 I 6. An interior side II I 4a has a retention arrangement 1124 on either side, extending into both cavities 11 I 8.

As shown in Figure 18a, the beam 1110 includes reinforcement members 1128, I I 30.

The beam I 110 has a surface 1185 configured to receive flooring material such as concrete or boarding (not shown), moulded to fit the surface or boarding shaped to fit the surface. The surface 1185 has a connection arrangement 1186. The connection arrangement 1186 provides means for a connection between the beam 1110 and the flooring material.

In this embodiment, the connection arrangement is in the form of a series of recesses 1186. The recesses 1186 of this embodiment are elongate, and extend along the length of the beam 1110. The recesses 1186 of this embodiment are substantially parallel to one another and to a longitudinal axis of the beam 1110, though in alternative embodiments the recesses 1186 may be otherwise positioned.

Each recess 1186 has opposing sides 1187 that are tapered towards one another in a direction away from the body of the beam 1110, so that the recess 1186 forms a dovetail shape, and has a neck 1188 at an end of the recess 1186 distal the remainder of the body of the beam.

The neck 1188 is configured to secure flooring material within the recess 1186. For 30 example, concrete flooring material may be laid on top of the surface 1185, and may mould into the recess 1186. Alternatively, boarding shaped to correspond to the recesses 1186 may be fitted to the beam 1110, for example by sliding the boarding along the beam 1110 substantially parallel to the longitudinal axis of the beam 1110. The neck 1188 inhibits movement of the flooring material away from the beam 1110 in a direction substantially transverse to the longitudinal axis of the beam 1110. Advantageously, therefore, flooring material can be mechanically connected to the beam 1110, as well as by e.g. adhesion.

The connection arrangement 1186 may be provided on any of the beams described herein.

A sixteenth embodiment of the invention is shown in Figures 19, 20 and 21. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "12". Only features that differ from those of the previous embodiments are discussed in more depth.

The beam 1210 of this embodiment has a series of sides 1214 connected to a shared underside 1216, rather than a shared top as in previous embodiments. The sides 1214 define cavities 1218 configured to receive and retain insulation material 1222, as in previous embodiments. However, the cavities 1218 of this embodiment are also configured to receive part of a wall feature 1289. As shown in Figure 20, a layer 1290 of wall material such as concrete is supported in a cavity 1218 adjacent an inner layer 1291 of insulation material.

The wall material 1290 is intended to support building material such as bricks (not shown).

A wall component 1292 is supported in the cavity 1218 adjacent and outside the wall material 1290. In this embodiment the wall component 1292 is of suitable plastics material, e.g. PVC, although in alternative embodiments other suitable materials may be used. In an alternative embodiment, the wall component 1292 may include a foam-filled cavity. The wall component 1292 is intended to provide a surface to which a decorative facade (e.g. stone, brick, wood or some other suitable material) can he attached. As shown in Figure 21, the wall component 1292 includes a connection arrangement 1286 on each side. The connection arrangement, in the form of recesses 1286, allows secure attachment of the wall component 1292 to the wall material 1290, and the secure attachment of a facade to the wall component 1292.

A seventeenth embodiment of the invention is shown in Figures 22a and 22b. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "13". Only features that differ from those of the previous embodiments are discussed in more depth.

Figures 22a and 22b show a beam 1370 intended for use where additional support is required from the flooring assembly. The beam 1370 has a substantially arrowhead-shaped body 1312, with a rectangular upper part 1378 extending from a lower part 1380. The lower part 1380 is in this embodiment in the shape of a downwardly pointing truncated triangle, i.e. a triangle where all three corners have been removed, and extends either side of the upper part 1378. In use, the beam 1370 is intended for positioning under a cavity wall (not shown). Bricks or blocks forming the wall can be supported on the upper part 1378, and the lower part 1380 can support beams 10 or insulation material either side of the upper part 1378.

As shown in Figure 22a, the body 1312 includes an outer wall 1372, and a number of inner walls 1374 dividing the interior into cavities 1376. The inner walls 1374 define a number of rectangular cavities 1376 with substantially vertical and horizontal walls 1374, most of which are further divided into triangular cavities 1376 by diagonal walls 1374. As with the previous embodiments, the cavities 1376 are configured to receive and retain insulation material 1322. The walls 1372, 1374 provide a retention arrangement. In alternative embodiments, a projection as described above may be included as part of the retention arrangements.

An alternative body 1312 is shown in Figure 22b. Here, the body 1312 includes the outer wall 1372 only, defining a single cavity 1376. The cavity 1376 is filled with concrete 1382, to provide further support for a wall.

A fourteenth embodiment of the invention is shown in Figures 23a and 23b. Features corresponding to those of the previous embodiment have been given corresponding reference numbers with the additional prefix "14". Only features that differ from those of the previous embodiments are discussed in more depth.

The beam 1410 of this embodiment has a body 1412 similar to those of the previous embodiment, except in the overall shape. The body 1412 is substantially half-arrowhead shaped, with a rectangular upper part 1478 extending from a lower part 1480, the lower part 1480 forming substantially half the truncated triangle of die thirteenth embodiment such that the lower part 1480 extends only one side of the upper part 1478. Again, in use, the beam 1470 is intended for positioning under a cavity wall (not shown). Bricks or blocks forming the wall can be supported on the upper part 1478, and the lower part 1480 can support beams 10 and/or insulation material either side of the upper part 1478.

As shown in Figure 16a, the body 1412 includes an outer wall 1472, and a number of inner walls 1474 dividing the interior into cavities 1476. The inner walls 1474 define a number of rectangular cavities 1476 with substantially vertical and horizontal walls 1474, most of which are further divided into triangular cavities 1476 by diagonal walls 1474. As with the previous embodiments, the cavities 1476 are configured to receive and retain insulation material 1422. The walls 1472, 1474 provide a retention arrangement. In alternative embodiments, a projection as described above may be included as part of the retention arrangements.

An alternative body 1412 is shown in Figure 16b. Here, the body 1412 includes the outer wall 1472 only, defining a single cavity 1476. The cavity 1476 is filled with concrete 1482, to provide suitable support for a wall.

The beams 10, 210, 310, 410, 510, 610, 710, 810, 910, 1010, 1110, 1210, 1310, 1410 can be produced in varying sizes. The beam bodies can be produced in a range of standard widths, and/or can be produced at a particular width for a specific application. The beam body is uniform in cross-section, so is suitable for production by extrusion. As the beam bodies are manufactured via extrusion, they can be produced at any required length. Again, a range of standard lengths may be produced, and/or a particular length may be produced for a specific application, so that material and part management is advantageously simple.

In alternative embodiments, the beam bodies may each have multiple projections forming the retention arrangement, e.g. two or more projections, and/or some parts that are described as having projections may not include projections.

In alternative embodiments (not shown), the reinforcement members may he of some suitable 10 material other than steel. The reinforcement members may be L-shaped, C-shaped or X-shaped in cross-section, or may have some other suitable non-linear cross-section.

The beam may include an attachment arrangement for a vacuum insulated panel, for further insulation.

In alternative embodiments, the beam includes an adjustable internal diaphragm configured for positioning beneath an internal wall, in order to provide additional support.

The beam described above provides a number of advantages over existing flooring assemblies. The plastic body and the insulation material are light, and the beam is thus easy to transport and install. An ordinary road vehicle can be used for transportation. In addition, the light nature of the beam inhibits damage that can be caused e.g. in an earthquake or by tremors.

The beam can easily be assembled (i.e. thaw-the insulation material 22 to the body 12) prior to transportation, or on site. Either method leads to increased efficiency of installation in comparison to the "beam and block" method. Speed of installation is increased by the lightness of the beam, which can be installed by hand, and the simplicity of the beam. The beams can be connected to one another without the need for fasteners, as described above.

Beams can support weight as soon as they are installed, so can advantageously be used to support e.g. a construction worker during construction.

Several beams can be stacked to provide suitable support over longer spans where required.

Although described here as for use in flooring, the beam can also be used in the construction of walls and roofing. The PVC of the body is fire retardant. Fire-proof boarding such as silicon magnesium boarding may he laid on the beams to provide additional fire-proofing, particularly in embodiments where the insulation material is exposed at the top of the beam (e.g. as shown in Figures 7, 9 and 10), or if the beams are to he used in roofing, in which cases an alternative insulation material to polystyrene may be used for reasons of fire-proofing.

The beam provides a high level of insulation due to the materials used. With a body height x of 250mm to 350mm, an overall heat transfer coefficient (i.e. U value) of 0.1 can be reached. Using the beam, a dwelling having a level of at least 5 in the energy emissions category can be constructed. Thermal bridging is limited due to the materials used. Passive housing standards can advantageously be reached.

The fireproof, self-extinguishing nature of the PVC material used improves safety, and can reduce insurance costs.

Recycled waste plastic is used to produce the body, which is relatively inexpensive and environmentally friendly.

The body of the beam can be formed by extrusion, so can be any suitable length. The reinforcement members used in the beam are inexpensive and easily transportable, and provide suitable tensile strength.

The upper face of the beam may itself form flooring material, removing the need for additional floor hoards or tiles. Carpet can be laid directly on the upper face of the beam.

Claims

Claims 1. A beam for use in construction, the beam having a plastic body; the body defining a cavity configured to receive insulation material; wherein the beam comprises a retention arrangement configured to retain insulation material within the cavity.
2. A beam according to claim I wherein the retention arrangement comprises at least one projection. I 0
3. A beam according to claim 2 wherein the projection is configured in use to extend into insulation material retained within the cavity.
4. A beam according to claim 2 or claim 3 wherein the body comprises a wall at least partially defining the cavity, and wherein the projection extends from the wall into the cavity.
5. A beam according to any preceding claim further comprising at least one elongate reinforcement member extending within the body substantially parallel to a longitudinal axis of the body.
6. A beam according to claim 5 wherein the reinforcement member extends substantially the full length of the body.
7. A beam according to claim 5 or claim 6 wherein the reinforcement member is of high tensile wire.
8. A beam according to claim 5 or claim 6 wherein the reinforcement member is of metal banding.
9. A beam according to claim 8 wherein the banding defines at least one aperture configured to receive a projection of the body for securement of the banding in relation to the body.
10. A beam according to claim 5 or claim 6 wherein the reinforcement member is of lattice.
A beam according to any one of claims 5 to 10 wherein the reinforcement member has a non-linear cross-section.
12. A beam according to any one of claims 5 to 1 I wherein the reinforcement member is of steel.
13. A beam according to any preceding claim comprising an attachment arrangement configured for attachment of the beam to another, like, beam.
14. A beam according to claim 13 wherein the attachment arrangement comprises a female part at a first side of the body and a corresponding male part at a second side of the body.
15. A beam according to claim 13 or claim 14 wherein the attachment arrangement comprises a push-fit arrangement.
16. A beam according to any one of claims 13 to 15 wherein the attachment arrangement comprises corresponding first and second hooks at opposing sides of the body configured for attachment to one another.
17. A beam according to any one of claims 13 to 16 wherein the attachment arrangement comprises first and second apertures defined by first and second opposing sides of the body respectively, and an insert, wherein the insert is configured to be received and retained by the first aperture of the beam and by the second aperture of another, like, beam.
18. A beam according to any preceding claim wherein the body has a uniform cross-section.
19. A beam according to any preceding claim wherein the body defines a surface configured to receive flooring material, and wherein the surface comprises a connection arrangement configured to provide a connection between the beam and said flooring material.

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20. A beam according to claim 19 wherein the connection arrangement comprises at least one recess.
21. A beam according to claim 20 wherein the recess defines a neck at an end distal the remainder of the body.
22. A beam according to claim 21 wherein the recess defines opposing sides tapered towards the neck.
23. A beam according to any one of claims 20 to 22 wherein the recess extends substantially along the length of the beam.
24. A beam according to any one of claims 19 to 23 wherein the connection arrangement comprises a series of substantially parallel recesses.
25. A beam according to any preceding claim wherein the body is of recycled plastic.
26. A beam according to any preceding claim and insulation material configured for attachment to the beam.
27. A beam according to claim 26 wherein the insulation material is foamed polystyrene.
28. A beam for use in construction comprising: a plastic body; and at least one elongate reinforcement member extending substantially parallel to a longitudinal axis of the body.
29. A beam according to claim 28 wherein the reinforcement member is of high tensile wire.
30. A beam according to claim 28 wherein the reinforcement member is of metal banding.
31. A beam according to claim 30 wherein the banding defines at least one aperture configured to receive a projection of the body for securement of the banding in relation to the body.
32. A beam according to claim 28 wherein the reinforcement member is of lattice.
33. A beam according to any one of claims 28 to 32 wherein the body defines a surface configured to receive flooring material, and wherein the surface comprises a connection 20 arrangement configured to provide a connection between the beam and said flooring material.
34. A beam according to claim 33 wherein the connection arrangement comprises at least one recess.
35. A beam according to claim 34 wherein the recess defines a neck at an end distal the remainder of the body.
36. A beam according to claim 35 wherein the recess defines opposing sides tapered towards the neck.
37. A beam according to any one of claims 34 to 36 wherein the recess extends substantially along the length of the beam.
38. A beam according to any one of claims 33 to 37 wherein the connection arrangement comprises a series of substantially parallel recesses.
39. A beam for use in construction, the beam having a plastic body; the body defining a surface configured to receive flooring material; wherein the surface comprises a connection arrangement configured to provide a connection between the beam and said flooring material.
40. A beam according to claim 39 wherein the connection arrangement comprises at least one recess.
41. A beam according to claim 40 wherein the recess defines a neck at an end distal the remainder of the body.
42. A beam according to claim 41 wherein the recess defines opposing sides tapered towards the neck.
43. A beam according to any one of claims 40 to 42 wherein the recess extends substantially along the length of the beam.
44. A beam according to any one of claims 39 to 43 wherein the connection arrangement comprises a series of substantially parallel recesses.
45. A method of manufacturing a beam according to any one of claims 5 to 12 or 28 to 38 comprising the steps of: a) providing at least one elongate reinforcement member for a beam; and b) extruding the plastic body about the reinforcement member.
46. A method according to claim 45 when dependent upon claim 9 or claim 31, further comprising the step of, between steps a) and b): c) creating at least one aperture in the banding.
47. A beam substantially as described herein, and/or with reference to the accompanying drawings. I 0