GB2550292B

GB2550292B - Suspended flooring system

Info

Publication number: GB2550292B
Application number: GB1708480.7A
Authority: GB
Inventors: R Thornberry John
Original assignee: MOULDED FOAMS Ltd
Current assignee: MOULDED FOAMS Ltd
Priority date: 2015-12-14
Filing date: 2015-12-14
Publication date: 2019-10-09
Anticipated expiration: 2035-12-14
Also published as: GB2550292A; GB2535599A; GB201522000D0; GB2535599B; GB201708480D0; IE86886B1; IE20160269A1; IE20170131A1

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. A plurality of blocks of insulating material are fitted between adjacent spaced-apart beams so as to bridge the gap therebetween. Each block comprises first and second sides arranged to seat on flanges of respective beams, the second side comprising a flange arranged to extend under the beam on which it is seated, so as to form a continuous thermal barrier which extends under the beam. 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 problem of this arrangement is that the flanges which extend along the second side 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.

Our UK Patent GB 2,487,265 B discloses a solution to this problem in the form of blocks of the above-mentioned type, which are characterised in an elongate strip portion is also provided, the strip having a formation on a longitudinal side face thereof for engaging a complementary formation provided on the outer end face of the block flange which extends under the beam.

In use, the strip and block 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 on the block, such that no further fixing is required and the risk of detachment over time is avoided. Both the strip and block 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. Further such strips can be fitted to further increase the width or the lateral extent of the flange if more than two beams are mounted side-by-side.

Whilst the arrangement disclosed in GB 2,487,265 B works well, it can be difficult to fit the blocks on site and it is also necessary to excavate the ground under the beams sufficiently for the blocks to be fitted. Also, because the layer of insulating material extends under the beams, it can be difficult to ensure that the layer is continuous and that cold spots will not exist. This may occur, for example, if a strip is inadvertently omitted.

It is also known that flat sheets may be laid to provide two horizontal layers, which one extending between the beams and one extending over the beams. Such layers can be used to provide an insulated deck on which to pour a screed for a floor. The upper sheet is generally of a higher density loading duty to support the floor. In this case the top layer has a uniform load bearing capability when it only needs a localised load bearing capability above the beam. In addition such arrangements suffer from the same problems as the previously mentioned arrangement, in that it can be difficult to ensure that cold spots will not exist from omitted and I or badly fitted parts.

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

In accordance with the present invention there is provided a suspended flooring system comprising a plurality of block members of insulating material for fitting between adjacent spaced-apart beams so as to bridge a gap therebetween and a plurality of capping members of insulating material for fitting onto the beams, each capping member being channel-shaped in section and comprising a central portion arranged to extend over the beam and opposite side portions which extend down respective opposite sides of the beam, wherein the central portion of each capping member comprises a series of recesses or apertures along its length.

In use, the capping members are fitted end-to-end along each beam and the blocks are then fitted side-by-side between the beams so as to close the gap between opposite capping members and thereby form a continuous layer of insulating material which extends over the beams and which provides a substantially flat surface onto which a screed material can be laid to form a floor surface.

Because the continuous layer of insulation material extends over rather than under the beam, it is possible to fit the all of the system from above, therefore allowing the least movement of beams in the process. In addition when fitted, all insulation parts contributing to the system are visible from above making validation that all parts are included and therefore reduces the risks of cold spots.

The channel shape of the capping members means that they easily and perfectly centre themselves onto the beam and prevent building errors by misplacement of the parts.

The capping members may be formed of a different colour material than the block members, so that it is easy to determine if any have been omitted or if any have been fitted incorrectly.

There may be a requirement to build an internal wall or to place another heavy structure on the floor surface which has been laid on top of the layer of insulating material. It is desirable for the weight of such structures to be borne by the beams since their weight may compress the insulating layer and provide undue forces on the unsupported areas between the beams. Accordingly, the central portion of each capping member comprises a series of recesses or apertures along its length which can be filled with a material which is less compressive than the insulating material and which help to apply loads onto the beam. The recesses are preferably formed in the surface of the central portion that faces upwardly in use. The bottom of the recesses may comprise a layer of the or another insulating material which prevents direct contact between the filler material and the beam but which is sufficiently thin that it will not unduly compress under load.

The filler material may be a liquidous material that can be applied into the apertures or recess and allowed to set, or it may be solid blocks or plugs which are inserted into the apertures or recess prior to laying the screed material.

In one embodiment, each block member comprises first and second ends arranged such that said first and second ends may be seated on flanges of the respective opposite beams.

In another embodiment, the opposite side portions of each capping members are arranged to abut flanges on respective opposite sides of the beam to which they may be fitted. In this way, loads applied to the capping members are applied directly to the beams. The insulating material of the capping members may be denser and less compressive than the insulating material of the block members, thereby ensuring that the suitable density material is always positioned over the load bearing area.

Opposite ends of the block members may comprise formations for engaging complementary formations on the capping members, the formations serving to support the blocks members between the capping members. Alternatively or additionally the block members may be adhered to the capping members.

The complementary engaging formations may comprise a socket and a projection provided on opposed faces of the respective members.

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

Preferably the complementary formations are arranged to hold the members in locking engagement and planar alignment with each other.

Preferably the opposite side portions of the capping members comprise outer faces which lie in parallel planes, thereby ensuring that the capping members fit closely side-by-side when fitted to side-by-side beams.

Also in accordance with the present invention, there is provided a suspended floor structure comprising adjacent spaced-apart beams and both the plurality of block members and the plurality of capping members as hereinbefore described.

The beams may be of an inverted T-section shape, and may comprise an i-shaped stem portion having oppositely directed flanges at its lower end. The capping members may be fitted onto the top of the stem, such that the opposite side portions extend down respective opposite sides of the stem. The opposite side portions may extend partially of fully down respective opposite sides ofthe stem: in the latter case, the lower ends of the opposite side portions may abut respective flanges. The capping members may have a width which is substantially equal to the width of the beams.

Also in accordance with the present invention there is provided a method of constructing the suspended floor structure hereinbefore described, the method comprising: providing first and second spaced apart parallel beams; fitting the plurality of channel-section capping members of insulating material onto each beam such that a central portion of each member extends over the beam and such that opposite side portions extend down respective opposite sides of the beam; and fitting the plurality of block members of insulating material between adjacent spaced-apart beams so as to bridge a gap therebetween.

The capping member may be fitted prior to fitting the block members or vice-versa.

The capping members may be fitted end-to-end along the entire length of each beam.

Apertures or recesses in the central portion of one or more capping members may be filled with a material. A screed or other cementitious layer may be laid onto a surface provided by said capping and block members.

Embodiments 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 plan view of an embodiment of suspended floor structure in accordance with the present invention;

Figure 2 is a side view of a block member of the structure of Figure 1;

Figure 3 is a bottom view of the structure of Figure 1;

Figure 4 is an end view of the structure of Figure 1;

Figure 5 is an isometric view of the structure of Figure 1;

Figure 6 is an isometric and part-sectional view of the structure of Figure 1;

Figure 7 is a sectional view of a second embodiment of suspended floor structure in accordance with the present invention.

Referring to Figures 1 to 6 of the accompanying drawings, there is shown a 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 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 10F.

Block members 11 of expanded polystyrene material are laid side-by-side in columns between the rows of beams 10, with each block comprising a pair of ribs 12 respectively formed on first and second opposite side faces thereof, the ribs 12 resting on the opposed flanges of respective adjacent beams 10. A plurality of capping members 13 of insulating material are fitted end-to-end along the beams 10. Each capping member 13 is channel-shaped in section and comprises central portion 14 which extends over the beam and opposite side portions 15 which extend downwardly and embrace respective opposite sides of the beam above the flanges 10A thereof. The capping members 13 have a width which is substantially equal to the width of the beams 10. The lower ends of the opposite side portions 15 abut against the upper side face of the lips 12 of the block members 11.

The upper surfaces of the capping and block members 13,11 form a continuous planar surface layer onto which a screed material can be laid. It will be appreciated that the screed layer is therefore entirely insulated from the beams 10 and any underlying void by the insulating material of the members 13,11. Thus, the overall floor structure will have a very good heat transfer coefficient (u-value) and will not suffer from cold spots.

There may be a requirement to build an internal wall or to place another heavy structure on the floor surface which has been laid on top of the screed. Hence, the central portion 14 of each capping member comprises a series of recesses 16 along its length which can be selectively filled with a cementitious material which is less compressive than the insulating material and which help to apply any overlying loads onto the beam 10. The bottom of the recesses 16 comprise a layer of the insulating material which prevents direct contact between the filler material and the beam 10 but which is sufficiently thin that it will not unduly compress under load.

Referring to particularly to Figure 6 of the accompanying drawings, one end face of each block member 11 is castellated above the rib 12 to define a row of dovetailed projections 17 for engaging with complementary recesses 18 on one side face of the capping member 13 at the upper end thereof. The other side face of the capping member 13 is flat and lies in a plane which extends parallel to the plane of the recessed side face. In use, once the block members 11 have been fitted in-situ, the capping members 13 are fitted by aligning their recesses 18 with the projections 17 of the block members 11 and pushing them into engagement. This helps to form a unitary and stable structure onto which the screed can be laid.

At least one block and capping member 11, 13 may alternatively be fitted together prior to installing them in-situ

Referring to Figure 7 of the accompanying drawings, in order to increase the floor span, it is known to form rows of two or more beams 10A, 10B mounted side-by-side: the above-mentioned block members 11 are then laid between the opposed pairs of beams of adjacent rows to fill the gap therebetween. A capping member 13 is then fitted to each beam 10A, 10B in the same manner. The recesses 18 on the left-hand capping member 10A are not used but, the fact that they are recesses allows the side face of the capping member 10A to lie flat against the opposing face of the righthand capping member 10B.

Claims

1. A suspended flooring system comprising a plurality of block members of insulating material for fitting between adjacent spaced-apart beams so as to bridge a gap therebetween and a plurality of capping members of insulating material for fitting onto the beams, each capping member being channelshaped in section and comprising a central portion arranged to extend over the beam and opposite side portions which extend down respective opposite sides of the beam, wherein the central portion of each capping member comprises a series of recesses or apertures along its length.

2. A suspended flooring system as claimed in claim 1, in which the capping members are formed of a different colour material than the block members.

3. A suspended flooring system as claimed in any one preceding claim, in which the recesses are formed in the surface of the central portion that faces upwardly in use.

4. A suspended flooring system as claimed in claim 3, in which the bottom of the recesses comprises a layer of insulating material.

5. A suspended flooring system as claimed in any preceding claim, in which each block member comprises first and second ends arranged such that said first and second ends may be seated on flanges of the respective opposite beams.

6. A suspended flooring system as claimed in any of claims 1 to 4, in which the opposite side portions of each capping member are arranged to abut flanges on respective opposite sides of the beam to which they may be fitted.

7. A suspended flooring system as claimed in any preceding claim, in which the insulating material of the capping members is denser and less compressive than the insulating material of the block members.

8. A suspended flooring system as claimed in any preceding claim, in which opposite ends of the block members comprise formations for engaging complementary formations on the capping members, the formations serving to support the blocks members between the capping members.

9. A suspended flooring system as claimed in claim 8, in which the complementary engaging formations comprise a socket and a projection provided on opposed faces of the respective members.

10. A suspended flooring system as claimed in claim 8 or 9, in which the complementary engaging formations are arranged to resiliently engage each other.

11. A suspended flooring system as claimed in any of claim 8 to 10, in which the complementary formations are arranged to hold the members in locking engagement and planar alignment with each other.

12. A suspended flooring system as claimed in any preceding claim, in which opposite side portions of the capping members comprise outer faces which lie in parallel planes.

13. A suspended floor structure comprising adjacent spaced-apart beams and both the plurality of block members and the plurality of capping members described in any one of claims 1 to 12.

14. A method of constructing the suspended floor structure of claim 13, the method comprising: providing first and second spaced apart parallel beams; fitting the plurality of channel-section capping members of insulating material onto each beam such that a central portion of each member extends over the beam and such that opposite side portions extend down respective opposite sides of the beam; and fitting the plurality of block members of insulating material between adjacent spaced-apart beams so as to bridge a gap therebetween.