US20200340255A1

US20200340255A1 - Flooring system, a panel and methods of use thereof

Info

Publication number: US20200340255A1
Application number: US16/464,438
Authority: US
Inventors: Warren Weller
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-11-29
Filing date: 2017-11-28
Publication date: 2020-10-29
Also published as: WO2018098526A1

Abstract

The present invention relates to a system and floor panel for use in forming a graded floor, wet area, pathway or decking and to methods of use thereof. The panel has two opposed surfaces including a lower surface and an opposed upper surface. The opposed surfaces are interconnected by opposing edges, including opposed end edges and opposed side edges. The panel tapers in thickness from a first said end edge to an opposed second said end edge with a gradient ranging from about 0.1% to about 2.0%.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of International Application No. PCT/AU2017/051314, filed Nov. 28, 2017, and claiming priority to Australian Application No. 2016904905, filed Nov. 29, 2016, the contents of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a flooring system including a floor panel for use in forming a graded floor or pathway and to methods of use thereof. In particular, the present invention concerns a preformed load bearing panel for use in forming a graded floor or pathway and to methods of use thereof.

BACKGROUND

Proper drainage is critical in any construction project, particularly in the building industry. Improper drainage can quickly lead to deterioration of building elements and costly repairs.
For example, modern building and construction codes generally require that any wet area (e.g., bathrooms, laundries, en-suites and the like) be constructed so that water flows to a floor waste or drainage inlet defined in the wet area floor, without ponding or pooling of water. This is typically achieved by forming a graded wet area floor that permits drainage to the floor waste.
The forming of graded wet area floors generally involves forming a recessed area known as a “step down” in a slab in the location where the wet area is intended to be located. A graded wet area floor is then manually formed atop the step down with a dry mix of concrete. The wet area is formed to fall or taper towards the floor waste defined in the step down. Once formed, the floor is allowed to dry before being typically finished with water proofing and tiling.
Likewise, outdoor entertainment areas, such as, e.g., decks, patios and the like, and outdoor pathways are also usually constructed to be graded to permit drainage of water away from the areas or pathways, again without ponding or pooling.
As with the forming of graded wet area floors, the process typically includes manually forming the area or pathway to fall or taper away from the area or pathway, generally to a side of the area or pathway farthest away from any building structure.
Problems in general with the above processes are that they are time-consuming, tedious and labour-intensive, particularly the defining of a step down in a slab, the manual forming of the graded area, wet area or pathway and the time spent waiting for the area or pathway to set.

SUMMARY OF INVENTION

Embodiments of the present invention provide a preformed load bearing floor panel and methods of use thereof, which may minimise or overcome at least one of the problems mentioned above, or which may provide the public with a useful or commercial choice.
According to a first aspect of the present invention, there is provided a wet area flooring system for forming a graded and waterproofed wet area floor in a room, said system comprising:
a plurality of preformed load bearing floor panels configured to be arranged on a support surface around at least one floor waste in a side edge-to-side edge arrangement so as to form a graded wet area floor in which a gradient of each panel directs water or any other liquid in a direction towards the at least one floor waste, wherein each said panel comprises:

- two opposed surfaces comprising a lower surface and an opposed upper surface, said opposed upper surface configured to have tiling applied thereon, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said panel tapering in thickness from a first of said opposed end edges to a second of said opposed end edges with a gradient ranging from about 0.1% to about 2.0% to thereby direct said water or any other liquid atop the panel from the first of said opposed end edges to the second of said opposed end edges; and

one or more skirting boards configured to be arranged around an outer edge of the room at a junction between an adjacent wall and said first said opposed end edge of an adjacent said panel, wherein each skirting board comprises:

- two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said skirting board extending longitudinally between said opposed end edges,

wherein the plurality of the preformed load bearing floor panels and the one or more skirting boards are each formed from a waterproof material, and
wherein when arranged said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to form the waterproofed wet area floor in the room.
According to a second aspect of the present invention, there is provided a preformed load bearing floor panel for use in forming a graded floor, wet area or pathway, said panel having two opposed surfaces including a lower surface and an opposed upper surface, said opposed surfaces interconnected by opposing edges including opposed end edges and opposed side edges, said panel tapering in thickness from a first of said opposed end edges to a second of said opposed end edges with a gradient ranging from about 0.1% to about 2.0% permitting drainage of water or any other liquid atop the panel from the first of said opposed end edges to the second of said opposed end edges, wherein said panel is configured to be arranged next to at least one further like panel in a side edge to side edge arrangement to form the graded floor or pathway.
According to a third aspect of the present invention, there is provided a preformed load bearing panel for use in forming graded decking, said panel having two opposed surfaces including an upper surface upon which decking is fastened and an opposed lower surface configured to be fastened to a support surface, said opposed surfaces interconnected by opposing edges including opposed end edges and opposed side edges, said panel tapering in thickness from a first of said opposed end edges to a second of said opposed end edges with a gradient ranging from about 0.1% to about 2.0% permitting drainage of water or any other liquid atop the panel from the first of said opposed end edges to the second of said opposed end edges, wherein said panel is configured to be arranged next to at least one further like panel in a side edge to side edge arrangement to form the graded decking.
Advantageously, the flooring system and panel of the present invention enables a graded wet area floor to be readily formed while being fully waterproof. The panel of the present invention also enables a graded floor, pathway, wet area or decking to be readily formed. The above is achieved by simply laying, applying or fastening one or more of the panels atop a support surface in a side edge to side edge arrangement. The floor panels are particularly advantageous in quickly forming graded wet area floors as they obviate the need for a step down to be defined in the slab and the need to manually form a graded floor atop the step down with a dry mix of concrete. Moreover, being preformed load bearing panels, the panels of the present invention obviate the time required to apply formwork, pour concrete and wait for the concrete to cure. As such, a graded wet area floor can now be quickly formed with the panels by removing any delay in waterproofing and tiling the intended wet area while waiting for a manually formed graded floor to set, for example. Indeed, in some embodiments, the present invention obviates the need to waterproof.
As used herein, the term “floor waste” refers to a drain inlet defined in a floor surface. In some embodiments, a floor surface or support surface may include more than one floor waste. For example, the floor or support surface may include a first floor waste for a shower and a second floor waste for a remainder of a room.
As used herein, the term “step down” refers to a recessed area defined in a slab, usually in a location where a wet area is intended to be located. For example, step downs are typically defined in a slab where a bathroom, laundry or en-suite is intended to be located.
As used herein, the term “fall” refers to the gradient of a floor surface or part or portion thereof. Typically, the fall is a negative gradient that is directed in a desired location, such as, e.g., toward a floor waste, a drain or a desired edge.
As used herein, the term “load bearing” refers to the capacity of the preformed floor panel of the present invention to carry or support a load. Generally, the preformed floor panel will in use have a capacity to carry or support both a dead load and a live load. The dead load may include tiling or decking affixed atop the floor panel. The live load may include the weight of furnishings, people and other articles supported atop the floor panel but not permanently affixed to the floor panel.
The floor panel may be of any suitable size, shape and construction and may be formed from any suitable material or materials.
Generally, the floor panel may have a polygonal shape suitable for tiling. Typically, the panel may be substantially rectangular, triangular, hexagonal, heptagonal, octagonal or oblong-shaped, or any variation or combination thereof. Preferably, the panel may be rectangular or square-shaped.
As indicated above, the panel has two opposed surfaces including a lower surface and an opposed upper surface. The opposed surfaces are interconnected by opposing edges including opposed end edges and opposed side edges with the panel tapering in thickness from a first said end edge to an opposed second said end edge with a gradient ranging from about 0.1% to about 2.0% permitting drainage of water or any other liquid atop the panel from the first said end edge to the second of said end edge.
The floor panel may be of any desired length and/or width.
For example, the panel may have a length and/or width of at least 300 mm, at least 350 mm, at least 400 mm, at least 450 mm, at least 500 mm, at least 550 mm, at least 600 mm, at least 650 mm, at least 700 mm, at least 750 mm, at least 800 mm, at least 850 mm, at least 900 mm, at least 950 mm, at least 1,000 mm, at least 1,050 mm, at least 1,100 mm, at least 1,150 mm, at least 1,200 mm, at least 1,250 mm, at least 1,300 mm, at least 1,350 mm, at least 1,400 mm, at least 1,450 mm, at least 1,500 mm, at least 1,550 mm, at least 1,600 mm, at least 1,650 mm, at least 1,700 mm, at least 1,750 mm, at least 1,800 mm, at least 1,850 mm, at least 1,900 mm, at least 1,950 mm, at least 2,000 mm, at least 2,050 mm, at least 2,100 mm, at least 2,150 mm, at least 2,200 mm, at least 2,250 mm, at least 2,300 mm, at least 2,350 mm, at least 2,400 mm, at least 2,450 mm, at least 2,500 mm, at least 2,550 mm, at least 2,600 mm, at least 2,650 mm, at least 2,700 mm, at least 2,750 mm, at least 2,800 mm, at least 2,850 mm, at least 2,900 mm, at least 2,950 mm, at least 3,000 mm, at least 3,050 mm, at least 3,100 mm, at least 3,150 mm, at least 3,200 mm, at least 3,250 mm, at least 3,250 mm, at least 3,300 mm, at least 3,350 mm, at least 3,400 mm, at least 3,450 mm, at least 3,500 mm, at least 3,550 mm, at least 3,600 mm, at least 3,650 mm, at least 3,700 mm, at least 3,750 mm, at least 3,800 mm, at least 3,850 mm, 3,900 mm, at least 3,950 mm or at least 4,000 mm.
In some embodiments, the floor panel may be provided in one or more standard lengths and/or widths. For example, the floor panel may be provided in standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm or 4,000 mm. Likewise, the floor panel may be provided in standard widths of 600 mm, 900 mm, 1,200 mm or 1,350 mm.
In other embodiments, the floor panels may be formed to custom lengths and/or widths.
Likewise, the floor panel may be of any suitable thickness tapering from the first said end edge to the opposed second said end edge with a gradient of at least 0.1%.
For example, the floor panel may have a maximum thickness (as measured at the first said end edge between the opposed surfaces) of at least 5 mm, at least 10 mm, at least 15 mm, at least 20 mm, at least 25 mm, at least 30 mm, at least 35 mm, at least 40 mm, at least 45 mm, at least 50 mm, at least 55 mm, at least 60 mm, at least 65 mm, at least 70 mm, at least 75 mm, at least 80 mm, at least 85 mm, at least 90 mm, at least 95 mm or even at least 100 mm. Typically, the panel may have a maximum thickness of about 10 mm to about 30 mm, preferably about 10 mm.
Typically, the panel may have any suitable gradient that permits the drainage of water atop the panel from the first said end edge to the second said end edge.
For example, in some embodiments, the floor panel may have a gradient of at least 0.2%, at least 0.3%, at least 0.4%, at least 0.5%, at least 0.6%, at least 0.7%, at least 0.8%, at least 0.9%, at least 1.0%, at least 1.1%, at least 1.2%, at least 1.3%, at least 1.4%, at least 1.5%, at least 1.6%, at least 1.7%, at least 1.8%, at least 1.9% or even at least 2.0%.
Generally, the floor panel may taper in thickness from the first said end edge to the opposed second said end edge with a gradient of about 0.1% to 0.5%, preferably about 0.2% to about 0.45%.
Preferably, the gradient may be a negative gradient extending from the first said end edge to the second said end edge.
In some embodiments, the panel may taper in thickness from the first said end edge to the second opposed said end edge with a constant gradient. In other embodiments, the panel may taper in thickness from the first said end edge to the second opposed said end edge with a varying gradient, such as, e.g., an increasing or decreasing gradient.
In some embodiments, the panel may taper in thickness such that the second said end edge forms a single edge (i.e., the opposed surfaces meet). In other embodiments, the second said end edge may form an edge wall extending between the opposed surfaces.
Generally, the floor panel is formed from a durable and load bearing material. For example, the floor panel may be formed from metal, plastic, rubber, glass, fibre, concrete, stone and/or wood material and/or materials, preferably concrete material. In some embodiments, the floor panel may be formed from a mixture of magnesium oxide, at least one binding or filling agent (e.g., carbon fibre, cellulosic fibre, perlite and/or fly ash) and at least one reinforcing mesh positioned between the opposed surfaces.
In some embodiments, the floor panel may be formed from concrete or a cement-polymer composite material. The panel may or may not include at least one reinforcing mesh located between the opposed surfaces.
In other embodiments, the floor panel may be formed from a plastic material or a plastic composite material. For example, the panel may be formed from polyvinyl chloride (“PVC”). In such embodiments, the floor panel may preferably be waterproof. Advantageously, the use of such panels obviates the need for subsequent waterproofing treatments. If formed of plastic, the floor panel may be formed as a plastic extrusion.
In some embodiments, the floor panel may be formed from a plastic material or composite comprising a heat resistant or thermally stable plastic. Advantageously, by having heat resistant or thermally stable properties, the plastic floor panels may be safely used with an under tile heating system.
In some embodiments, at least one of the opposed surfaces of the panel may be textured to at least partially assist in fastening material to the panel, such as, e.g., water proofing, tiling, decking or the like. Preferably both of the opposed surfaces may be textured.
In some embodiments, the floor panel or at least part of the floor panel may be treated with a damp-proof or waterproofing coating, preferably pre-treated.
In some embodiments, at least one of the opposed surfaces of the panel, preferably the upper surface may include one or more markings to assist in arranging materials atop the panel. For example, in one such embodiment, the upper surface of the floor panel may include markings to assist in the placement of tiles atop the panel. In another such embodiment, the upper surface may include markings to assist in the placement and/or spacing of deck boards atop the panel.
Generally, the panel may be laid or applied atop and/or fastened to a support surface with one or more other like panels to form a graded pathway, floor, wet area or decking area. The panels may be arranged in any suitable way.
The support surface may be any suitable surface atop of which the panel may be laid and/or fastened. Typically, the support surface may be a portion or part of a slab, a step down area defined in slab, two or more horizontal support beams, such as, e.g., floor joists, or one or more other underlying floor panels (e.g., Scion™ Secura™ interior flooring panels or HardiePanel™ compressed sheet) supported atop one or more horizontal support beams. In embodiments in which the support surface comprises two or more horizontal support beams, a panel or sheet may be laid atop to cover any gaps between the horizontal support beams prior to the panels being laid and/or fastened. The panel or sheet of sheet may comprise a plywood or block board panel or sheet, for example.
Typically, each panel may be laid or applied atop or fastened to the support surface in a side edge-to-side edge arrangement with other like panels to form a graded surface. In some embodiments, the panels may need to be trimmed and/or mitred along one or both side edges to be suitably arranged. The side edges of adjacently positioned panels may or may not be joined together.
If joined together, the panels may be joined together by any suitable means.
For example, in some embodiments, the side edges may be joined together by one or more fasteners. The one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and/or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).
In other embodiments, each side edge of adjacently positioned panels may be connected together by a connecting mechanism or a part of a connecting mechanism. For example, a portion of a side edge of a first panel may mate with or engage with a portion of a side edge of a second panel.
The connecting mechanism may include mateable male and female portions that couple together, including interference fit (snap-fit) connections, for example. The connecting mechanism may include a male formation associated with a side edge of a first panel configured to be inserted into or coupled with a female formation associated with a female formation associated with a side edge of the second panel.
In some embodiments, a sealing member or sealing agent may be at least partially applied along a side edge of a panel to be joined with a side edge of an adjacently positioned panel.
Any suitable sealing member or agent may be used that may preferably provide a substantially water-tight seal between side edges of adjacently positioned panels.
In some embodiments, the sealing member may be formed from any suitable material or materials, such as, e.g., closed foam, rubber, expanding resin or a like material suitably adapted to form a seal.
In other embodiments, the sealing agent may include a mastic sealant or any other like sealant suitably adapted to form a seal.
In yet other embodiments, the panels may be joined together by waterproof bonding. The waterproof bonding may include any suitable bonding that is able to achieve a water-tight seal or join between side edges of adjacently positioned panels.
In embodiments in which the panels are formed from a plastic or plastic composite material, the waterproof bonding may include plastic welding, preferably hot gas welding. For example, a hot air welder may be used to soften both edges to be joined and a plastic filler rod may be used to apply at least one weld bead along the edges to be joined. Advantageously, the use of plastic welding with plastic panels provides an entirely waterproof solution.
The panels may preferably be arranged or orientated on the support surface such that the fall of each panel is directed in a desired direction.
For example, when forming a graded wet area floor having a floor waste, the panels may typically be arranged or orientated on the support surface such that the gradient or taper of each panel directs water or any other liquid towards the floor waste.
For example, when forming a graded pathway, decking area or floor without a floor waste, the panels may typically be arranged or orientated in a same or similar orientation on the support surface in a side edge-to-side arrangement such that the gradient or taper of each panel directs water or any other liquid in a desired direction, usually away from any adjacent structure. For example, when forming a graded deck, each panel may be orientated to direct water away from an adjacent structure.
The panels may be fastened to the support surface by any suitable means. Typically, each panel may be fastened to the support surface by one or more fasteners, such as, e.g., one or more mechanical fasteners and/or one or more chemical fasteners as described above.
Preferably, the panels may be fastened to the support surface with a chemical adhesive, such as, e.g., a cement-based tile adhesive.
In some embodiments, the panel may be trimmed or shaped to fit around an adjacent structure. For example, the second opposed said end edge of a panel may be trimmed or shaped to snugly fit about a floor waste.
As indicated above, the system of the first aspect further includes one or more skirting boards configured to be arranged around an outer edge of a room at a junction between an adjacent wall and a first opposed end edge of a floor panel for forming a waterproofed wet area floor.
The skirting board may be of any suitable size, shape and construction and may be formed from any suitable waterproof material or materials.
Typically, the skirting board may have a polygonal shape, preferably a rectangular shape for being arranged along the junction. Preferably, each skirting board may have an elongate shape.
As indicated, each skirting board has two opposed surfaces extending substantially parallel to one another and interconnected by opposing edges. The two opposed surfaces include a wall abutting surface configured to be attached or fastened to at least a portion of the wall and an opposed outer surface. The opposing edges include opposed end edges and opposed side edges. The skirting board may preferably extend longitudinally between the opposed end edges.
In some embodiments, the outer surface of each skirting board may be configured to have tiling applied thereon.
In some embodiments, at least the outer surface of the board may be textured to at least partially assist in tiling.
In some embodiments, at least the outer surface of the board may include one or more markings to assist in applying tiles thereon. The markings may preferably assist in the placement of the tiles.
Each skirting board may have a maximum thickness (as measured between the opposed surfaces) of about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, or about 10 mm or more.
Each skirting board may typically have a width (as measured between the opposed side edges) of about 20 mm, about 25 mm, about 30 mm, about 35 mm, about 40 mm, about 45 mm, about 50 mm, about 55 mm, about 60 mm, about 65 mm, about 70 mm, about 75 mm, about 80 mm, about 85 mm, about 90 mm, about 95 mm, about 100 mm, about 105 mm, about 110 mm, about 115 mm, about 120 mm, about 125 mm, about 130 mm, about 135 mm, about 140 mm, about 145 mm, or about 150 mm or more.
The skirting board may be formed from a durable and waterproof material. For example, the board may be formed from metal, plastic, rubber, glass, fibre and/or wood material and/or materials. In some embodiments, the skirting board may be formed from a plastic material or a plastic composite material, such as, e.g., polyvinyl chloride (“PVC”).
Preferably the skirting boards may be formed as plastic extrusions to any desired length for extending along a junction.
Each skirting board may be fastened to at least a lower portion of the wall adjacent the junction by any suitable means.
For example, in some embodiments, each skirting board may be fastened to the lower portion of the wall by one or more fasteners. The one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and/or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).
In preferred embodiments, the wall abutting surface of each skirting board may be adhesively bonded to the lower portion of the wall.
In some embodiments, the system may further include one or more shower wall panels configured to be arranged at a junction between a wall and a first opposed end edge of at least one floor panel at a location in which a shower is to be located in the wet area floor. A person skilled in the art will appreciate that the one or more shower wall panels may also be arranged at a junction between a wall and a first opposed end edge of at least one floor panel at a location in which a bath is to be located.
Each shower wall panel may be of any suitable size, shape and construction and may be formed from any suitable waterproof material or materials.
Generally, the shower wall panel, like the skirting board, may have a polygonal shape, preferably a rectangular or square shape for being arranged along the junction in a shower space. Typically, shower wall panel may be sized and shaped to at least partially span the width and height of a shower cavity wall, preferably entirely span.
Each shower wall panel may have two opposed surfaces extending substantially parallel to one another and interconnected by opposing edges.
The two opposed surfaces may include a wall abutting surface configured to be attached or fastened to at least a lower portion of the wall and an opposed outer surface.
The opposing edges may include opposed end edges and opposed side edges. In some embodiments, the shower wall pane may extend longitudinally in a substantially vertical direction between the opposed end edges.
In some embodiments, the outer surface of each shower wall panel may be configured to have tiling applied thereon.
In some embodiments, at least the outer surface of the panel may be textured to at least partially assist in tiling.
In some embodiments, at least the outer surface of the panel may include one or more markings to assist in applying tiles thereon. The markings may preferably assist in the placement of the tiles.
Each shower wall panel may have a maximum thickness (as measured between the opposed surfaces) of about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, or about 10 mm or more.
Again like the skirting board, the shower wall panel may be formed from a durable and waterproof material. For example, the panel may be formed from metal, plastic, rubber, glass, fibre and/or wood material and/or materials. In some embodiments, the panel may be formed from a plastic material or a plastic composite material, such as, e.g., polyvinyl chloride (“PVC”).
Preferably the shower wall panel may be formed as a plastic extrusion to a desired length and/or width for extending along a junction and at least a lower portion of the wall. Typically, each shower wall panel may be trimmed and/or mitred along one or more edges to suitably fit.
In some embodiments, two or more shower wall panels may be arranged side-by-side to fit a corner of a shower space. The two or more shower wall panels may preferably be waterproof bonded together as described above, preferably in a side-to-side edge arrangement.
In some embodiments, the shower wall panels may also be waterproof bonded to adjacently positioned or arranged floor panels to advantageously provide a waterproof shower space in the wet area floor.
In other embodiments, the shower wall panels may be waterproof bonded to an adjacently positioned preformed shower tray, again to advantageously provide a waterproof shower space in the wet area floor.
Each shower wall panel may be fastened to at least a lower portion of the wall adjacent the junction by any suitable means.
For example, in some embodiments, each shower wall panel may be fastened to the lower portion of the wall by one or more fasteners. The one or more fasteners may include one or more mechanical fasteners (such as, e.g., threaded fasteners) and/or one or more chemical fasteners (such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape).
According to a fourth aspect of the present invention, there is provided a graded floor including a plurality of the panel of the second aspect arranged in a side edge to side edge arrangement and orientated such that the gradient of each panel directs water of any other liquid in a common desired direction.
The graded floor may include one or more characteristics or features of the floor panel as hereinbefore described.
Typically, the common desired direction may be toward a drain or floor waste.
According to a fifth aspect of the present invention, there is provided a graded wet area including: a floor waste; a plurality of the panel of the second aspect arranged around the floor waste in a side edge to side edge arrangement and orientated such that the gradient of each panel directs water of any other liquid towards the floor waste; and waterproofing material and tiling applied atop the plurality of the panel.
The graded wet area may include one or more characteristics or features of the floor panel as hereinbefore described.
According to a sixth aspect of the present invention, there is provided a graded pathway including a plurality of the panel of the second aspect arranged to form the pathway in a side edge to side edge arrangement and orientated such that the gradient of each panel directs water or any other liquid towards a common desired side of the pathway.
The graded pathway may include one or more characteristics or features of the floor panel as hereinbefore described.
According to a seventh aspect of the present invention, there is provided a graded decking including one or more of the panel of the second aspect arranged in a side edge to side edge arrangement atop a supporting surface and orientated such that the gradient of each panel forms a desired fall; and decking fastened atop the plurality of the panel to form the graded decking.
The graded decking may include one or more characteristics or features of the panel as hereinbefore described.
Generally, the graded decking may include more than one panel. Typically, the graded decking may include a plurality of panels. For example, the decking may include at least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine or even at least 10 panels arranged in a side edge to side edge arrangement atop a support surface and orientated such that the gradient of each panel forms a desired fall.
According to an eighth aspect of the present invention, there is provided a method of forming a graded and waterproofed wet rea floor in a room, said method comprising:
arranging a plurality of preformed load bearing floor panels around at least one floor waste in the room in a side edge-to-side edge arrangement so as to form a graded wet area floor in which a gradient of each panel directs water or any other liquid in a direction towards the at least one floor waste, wherein each said panel is formed from a waterproof material and comprises:

- two opposed surfaces comprising a lower surface and an opposed upper surface, said opposed upper surface configured to have tiling applied thereon, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said panel tapering in thickness from a first of said opposed end edges to a second of said opposed end edges with a gradient ranging from about 0.1% to about 2.0% to thereby direct said water or any other liquid atop the panel from the first of said opposed end edges to the second of said opposed end edges;

arranging one or more skirting boards around an outer edge of the room ata junction between an adjacent wall and said first said opposed end edge of an adjacent said panel, wherein each skirting board is formed from a waterproof material and comprises:

- two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said skirting board extending longitudinally between said opposed end edges; and

waterproof bonding said plurality of preformed load bearing floor panels and said one or more skirting boards when arranged to form the waterproofed wet area floor in the room.
The method may include one or more characteristics of the floor panel, the skirting board and the shower wall panel as hereinbefore described.
For example, in some embodiments, the preformed load bearing floor panel may comprise the floor panel as hereinbefore described in the second aspect.
The arranging may include aligning each floor panel relative to one another in a side edge-to-side edge arrangement with each panel orientated such that the gradient or taper of the panel directs water or any other liquid in a desired direction towards the at least one floor waste.
The arranging may also include aligning each skirting board along the junction between an adjacent wall and the first said opposed end edge of an adjacent said floor panel, preferably such that each said skirting board extends longitudinally in a substantially horizontal orientation.
Generally, the arranging may further include fastening the panels and boards to the support surface and wall, respectively. Typically, the panels and boards may be fastened with one or more chemical fasteners, such as, e.g., a wet adhesive, a dry adhesive or a double-sided adhesive tape.
Typically, each panel may be orientated such that the gradient or taper of the panel directs water or any other liquid towards a common side of the graded decking, preferably toward an adjacent drain or away from an adjacent building.
The waterproof bonding may include any suitable bonding in which a waterproof bond is achieved between the panel and/or boards to be bonded. Typically, the bonding may include bonding the plurality of preformed load bearing floor panels and said one or more skirting boards to adjacently arranged floor panels and/or skirting boards, preferably by plastic welding, more preferably by plastic welding applied between adjacent said edges and said side edges to be bonded.
In some embodiments, the method may include, prior to said bonding, arranging one or more shower wall panels at a junction between an adjacent wall and said first said opposed end edge of an adjacent said floor panel at a location in which a shower is to be located.
In such embodiments, the bonding may further include bonding the one or more shower wall panels to adjacently arranged floor panels and/or skirting boards.
Advantageously, in such embodiments, the method may provide a graded and waterproofed wet area with shower space ready for tiling.
According to a ninth aspect of the present invention, there is provided a method of forming a graded floor or pathway, said method including:
applying one or more of the preformed load bearing floor panel of the second aspect atop a support surface such that the gradient of each panel directs water or any other liquid in a desired direction.
The method may include one or more characteristics of the floor panel as hereinbefore described.
The applying may include fastening the one or more floor panels to the support surface with one or more mechanical fasteners or chemical fasteners, typically the latter.
For example, in embodiments in which a graded floor is being formed, each panel may be fastened to the support surface with a chemical adhesive, such as, e.g., a cement-based tile adhesive.
In other embodiments, such as when forming a graded pathway, the applying may include placing or laying each panel atop the support surface.
Typically, the applying may include applying more than one preformed load bearing panel. For example, the applying may include applying a plurality of panels. The applying may include at least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine or even at least 10 panels atop the support surface.
Generally, the applying may include aligning or orientating each panel relative to one another in a side edge-to-side edge arrangement with each panel orientated such that the gradient or taper of the panel directs water or any other liquid in a desired direction.
For example, when forming a graded floor, each panel may be orientated such that the gradient or taper of the panel directs water or any other liquid towards a floor waste or drain inlet defined in the support surface.
When forming a graded pathway, each panel may be orientated in the same or a similar orientation such that the gradient or taper of the panels directs water or any other liquid towards and/or over a common side of the pathway, preferably a common side associated with a drain.
In some embodiments, the placing may further include trimming and/or mitring one or more of the panels along one or both side edges of each panel to enable the panels to be suitably arranged around a structure, such, as, e.g., floor waste or drain inlet.
The method may further include fastening a floor surface atop the one or more floor panels. The floor surface may include decking or tiling, for example.
According to a tenth aspect of the present invention, there is provided a method of forming a graded wet area, said method including:
fastening a plurality of the preformed load bearing panel of the second aspect in a side edge to side edge arrangement atop a support surface and around a floor waste defined in the support surface such that the gradient of each panel forms a desired fall towards the floor waste; and
applying waterproofing material and tiling atop the plurality of the floor panel.
The method may include one or more characteristics of the floor panel as hereinbefore described.
As with the method of the ninth aspect, the fastening may include fastening the panels to the support surface with one or more mechanical fasteners and/or chemical fasteners, preferably a chemical adhesive, such as, e.g., a cement-based tile adhesive.
The fastening may further include aligning each panel relative to one another in a side edge-to-side edge arrangement with each panel orientated such that the gradient or taper of the panel directs water or any other liquid toward the floor waste.
In some embodiments, the fastening may further include trimming and/or mitring one or more of the plurality of panels along one or both side edges to enable the panels to be suitably arranged around the floor waste.
According to an eleventh aspect of the present invention, there is provided a method of forming graded decking, said method including:
fastening one or more of the preformed load bearing floor panel of the second aspect to a support surface such that gradient of each panel forms a desired fall; and
fastening decking atop the one or more of the panel.
The method may include one or more characteristics of the floor panel as hereinbefore described.
As with the methods of the ninth and tenth aspects, the fastening may include fastening the one or more floor panels to the support surface with one or more mechanical fasteners and/or chemical fasteners.
Generally, the fastening may also include aligning each panel relative to one another in a side edge-to-side edge arrangement with each panel orientated such that the gradient or taper of the panel directs water or any other liquid in a desired direction.
Typically, each panel may be orientated such that the gradient or taper of the panel directs water or any other liquid towards a common side of the graded decking, preferably toward an adjacent drain or away from an adjacent building.
The fastening may typically include fastening more than one preformed load bearing panel. For example, the fastening may include fastening a plurality of panels. The fastening may include at least two, at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine or even at least 10 panels to the support surface
The fastening of decking atop the one or more panels may further include locating markings on an upper surface of the one or more panels and aligning each individual deck board relative to the markings prior to fastening the deck board to the upper surface of the one or more panels.
Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.
The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

FIG. 1 is a side view of a floor panel according to an embodiment of the present invention;

FIG. 2 is building floor plan showing wet areas in typical residential dwelling in which a plurality of the floor panel shown in FIG. 1 are installed to form graded wet area floors;

FIG. 3 is a sectional side view showing a plurality of the floor panel shown in FIG. 1 located atop a step down defined in slab for forming a graded wet area floor;

FIG. 4 is another sectional side view also showing a plurality of the floor panel shown in FIG. 1 located directly atop a slab for forming a graded wet area floor; and

FIG. 5 is a sectional upper perspective view of a wet area with a wet area flooring system according to an embodiment of the present invention installed to form a graded and waterproofed wet area floor.

DETAILED DESCRIPTION

FIG. 1 shows a floor panel (100) according to an embodiment of the present invention.
The floor panel (100) has an upper surface (102), an opposed lower surface (104), opposed side edges (105) and opposed end edges, including a first end edge (106) and an opposed second end edge (108). The panel (100) tapers in thickness from the first end edge (106) to the second end edge (108) with a gradient of at least 0.1%. The gradient is a negative gradient configured to direct water or any other liquid towards the second end edge (108).
The floor panel (100) has a rectangular or square shape and is formed from concrete or plastic material and/or materials.
The panel (100) is provided in standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm or 4,000 mm extending between the opposed end edges (106, 108), and standard widths of 600 mm, 900 mm, 1,200 mm, 1,350 mm or 1,500 mm extending between the opposed side edges (105).
Likewise, the panel (100) can have a maximum thickness, as measured at the first end edge (106) between the upper surface (102) and the lower surface (104), of about 25 mm to about 12 mm.
As mentioned, the panel (100) tapers from the first end edge (106) to the second end edge (108) with a negative gradient of at least 0.1%.
Generally, the panel (100) is intended to be laid atop or fastened to a support surface such as, e.g., a concrete slab or one or more floor joists, for forming a graded floor, a graded pathway, a graded wet area floor or a graded decking area.
For panels (100) intended for forming a graded wet area or floor over a slab, the panel (100) has a thickness at the first end edge (106) of about 12 mm and a thickness at the second end edge (108) of about 4 mm. Thus, the panel (100) has a negative gradient of 0.44%, 0.38%, 0.33%, 0.30%, 0.27% and 0.2% at the respective standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm and 4,000 mm.
For panels (100) intended for forming a graded wet area or floor over one or more 12 floor joists, the panel (100) has a thickness at the first end edge (106) of about 22 mm and a thickness at the second end edge (108) of about 15 mm. Thus, the panel (100) has a negative gradient of 0.39%, 0.33%, 0.29%, 0.26%, 0.23% and 0.18% at the respective standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm and 4,000 mm.
For panels (100) intended for forming a graded decking area or pathway, the panel (100) has a thickness at the first end edge (106) of about 25 mm and a thickness at the second end edge (108) of about 10 mm. Thus, the panel (100) has a negative gradient of 0.83%, 0.71%, 0.63%, 0.56%, 0.50% and 0.38% at the respective standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm and 4,000 mm.
The upper and lower surfaces (102, 104) of the panel (100) are textured to at least partially assist in fastening material to the upper surface (102) of the panel (100), such as, e.g., water proofing, tiling, decking or the like, and for fastening the lower surface (104) of the panel (100) to a support surface.
FIG. 2 shows the panel (100) of the present invention being used to form graded wet area surfaces (220) atop a slab (210) in a building (200).
As shown, a plurality of the panel (100) are used to form each wet area surface (220) in the bathroom (230), laundry (240), en-suite (250) and in the showers (260) located in the bathroom (230) and en-suite (250).
To form each wet area surface (220), the panels (100) are fastened atop the slab (210) in a side edge (105) to side edge (105) arrangement with the first end edge (106) of each panel (100) located against an outer perimeter of the wet area surface (220) and the second end edge (108) located adjacent the floor waste (280) defined in each wet surface area (220) such that the gradient or taper of the panel (100) is able to direct water or any other liquid towards the floor waste (280) for drainage.
The side edges (105) of the panels (100) are mitred to allow them to be suitably arranged around the floor waste (280) in each wet area surface (220). Likewise, the second end edge (108) of each panel (100) is trimmed and/or shaped to snugly fit about the floor waste (280).
Each panel (100) is fastened to the slab (210) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.
FIGS. 3 and 4 show sectional side views of a plurality of the panel (100) being respectively fastened atop a slab (210) for forming a graded wet area surface (220).
FIG. 3 shows the panels (100) fastened atop a step down (310) defined in the slab (210) where the wet area is intended to be located.
In contrast, FIG. 4 shows the panels (100) being fastened directly atop the slab (210) without a step down being defined in the slab (210).
A method of forming a graded wet area surface (220) using a plurality of the panel (100) of the present invention is now described in detail with reference to FIG. 2.
The method includes an initial step of preparing the support surface by cleaning the slab (210) where the wet area is intended to be located.
At least four of the panels (100) are then arranged around each floor waste (280) defined in the slab (210) where an intended wet area is to be located. The panels (100) are arranged in a side edge (105) to side edge (105) arrangement and orientated such that the first end edge (106) of each panel (100) is located near or against an outer perimeter of the intended wet area and the opposed second end edge (108) is located near or against the floor waste (280).
The side edges (105) of each panel (100) are mitred to enable the panels (100) to snugly fit side edge (106) to side edge (106) about the floor waste (280). Likewise, the second end edge (108) of each panel (100) is trimmed and shaped, if needed, to snugly fit about the floor waste (280).
Each panel (100) is then fastened to the slab (210) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.
In wet areas including a shower (260), such as, e.g., a bathroom (230) or en-suite (250), one or more panels (100) forming the graded wet area surface (220) of the bathroom (230) or the en-suite (250) are further trimmed to fit about or around the intended wet area for the shower (260).
FIG. 5 shows a wet area flooring system (500) according to an embodiment of the present invention for forming a graded and waterproof wet area surface (220) floor in a room (900).
The system (500) includes a plurality of preformed load bearing floor panels (100) configured to be arranged on a support surface around a floor waste (280) in a side edge (105) to side edge (105) arrangement so as to form a graded wet area surface (220) in the bathroom (230) of the room (900). A preformed shower tray (920) having a gradient to an associated floor waste (280 is arranged in the shower (260). The gradient of each floor panel (100) and shower tray (920) directs water or any other liquid in a direction towards an associated floor waste (280).
As with the embodiment shown in FIG. 1, each floor panel (100) includes an upper surface (102), an opposed lower surface (104), opposed side edges (105) and opposed end edges, including a first end edge (106) and an opposed second end edge (108). The floor panel (100) tapers in thickness from the first end edge (106) to the second end edge (108) with a gradient of at least 0.1%. The gradient is a negative gradient configured to direct water or any other liquid towards the second end edge (108), which is configured to be located adjacent a floor waste (280).
The system (500) includes one or more skirting boards (510) configured to be arranged at least partway around an outer edge of the room (900) at a junction between an adjacent wall (910) and the first end edges (106) of an adjacently arranged floor panels (100).
Each skirting board (510) includes a wall abutting surface (512), an opposed outer surface (514), opposed end edges (516) and opposed longitudinal side edges (518).
The system (500) further includes one or more shower wall panels (520) configured to be arranged at the junction between an adjacent wall (910) and a side edge (922) of the shower tray (920) at a location in which a shower (260) is to be located in the room (900).
Like with the skirting boards (510), each shower wall panel (520) is of a rectangular shape and includes a wall abutting surface (522), an opposed outer surface (524), opposed end edges (526) and opposed longitudinal side edges (528).
In this embodiment, the preformed load bearing floor panels (100), the skirting boards (510) and the shower wall panels (520) are all formed from the waterproof material polyvinyl chloride (“PVC”) as is the shower tray (920). The floor panels (100), the skirting boards (510), the shower wall panels (520) and the shower tray (920) are waterproof bonded to one another by plastic welding to form the waterproofed wet area surface (220) in the room (900). The load bearing floor panels (100), the skirting boards (510) and the shower wall panels (520) are each formed as plastic extrusions.
In this embodiment, each floor panel (100) has a thickness of about 10 mm at the first end edge (106) and a thickness at the second end edge (108) of about 2 mm. Thus, the panel (100) has a negative gradient of 0.88%, 0.66%, 0.59%, 0.44%, 0.38% and 0.33% at the respective standard lengths of 900 mm, 1,200 mm, 1,350 mm, 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm and 4,000 mm.
Each of the upper surface (102) of the floor panels (100) and the outer surfaces (514, 524) of the skirting boards (510) and the shower wall panels (520) are configured to have tiling applied thereon.
The floor panels (100) are fastened to an underlying support surface with a chemical adhesive. Likewise, the wall abutting surfaces (512, 522) of the skirting boards (510) and the shower wall panels (520) are adhesively bonded to a lower portion of the wall (910) with a chemical adhesive.
As indicated, the floor panels (100), the skirting boards (510) and the shower wall panels (520) are waterproof bonded to one another by plastic welding to form the waterproofed wet area surface (220) in the room (900). Specifically, the abutting edges (105, 106, 108) of the floor panels (100) are welded together as well to adjacent objects, such as, e.g., the floor wastes (280), the shower tray (920), a skirting board (510) and/or shower wall panel (520).
Generally, abutting side and end edges (516, 518) of the skirting boards (510) are welded to adjacent objects, such as, e.g., adjacently positioned floor panels (100), skirting boards (510), the shower tray (920) and/or the shower wall panels (520).
Further, abutting side edges and end edges (526, 528) of shower wall panels (520) are welded to adjacent objects, such as, e.g., adjacently positioned floor panels (100), skirting boards (510), the shower tray (920) and/or shower wall panels (520).
In use, each floor panel (100), board (510) and wall panel (520) is trimmed, mitred and/or shaped, prior to being arranged and fastened in place, to fit around, and to, adjacent structures.
A method of forming a graded and waterproofed wet area floor surface (220) using the system (500) is now described in detail.
The method includes an initial step of preparing the support surface by cleaning the underlying support surface where the wet area is intended to be located.
At least four of the floor panels (100) are then arranged around each floor waste (280) defined in the support surface (210) where an intended wet area is to be located. The panels (100) are arranged in a side edge (105) to side edge (105) arrangement and orientated such that the first end edge (106) of each panel (100) is located near or against an outer perimeter of the intended wet area and the opposed second end edge (108) is located near or against the floor waste (280).
The edges (105, 106, 108) of each panel (100) are mitred, trimmed and/or shaped to enable the panels (100) to snugly fit side edge (106) to side edge (106) about the floor wastes (280) and other adjacent structures.
Each floor panel (100) is then fastened to the underlying support surface with a chemical adhesive, such as, e.g., a cement-based tile adhesive.
The preformed shower tray (920) is fastened in place to the underlying support surface with chemical adhesive, such as, e.g., a cement-based tile adhesive, about its associated floor waste (280).
At least two shower wall panels (520) are then arranged side edge (528) to side edge (528) at a junction between a wall (910) and an edge (922) of the shower tray (920) at a location in which a shower (260) is to be located. Each shower wall panel (520) is fastened to the wall (910) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.
Once the shower wall panels (520) are arranged and fastened in place, skirting boards (510) are then arranged around outer edges of the room (900) at the junction between the wall (910) and first end edges (106) of adjacently positioned floor panels (100). Each skirting board (510) extends longitudinally along the junction and is fastened to the wall (910) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.
Once the floor panels (100), the shower tray (920), the shower wall panels (520) and skirting boards (510) are arranged and fastened in place, the respective and abutting edges (105, 106, 108, 922, 516, 518, 526, 528) are waterproof bonded to one another and adjacent structures such as the floor wastes (280). The edges (105, 106, 108, 922, 516, 518, 526, 528) are waterproof bonded by plastic welding to provide the graded and waterproofed wet area floor surface (220).
In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.
Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.
In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1. A wet area flooring system for forming a graded and waterproofed wet area floor in a room, said system comprising:

a plurality of preformed load bearing floor panels configured to be arranged on a support surface around at least one floor waste in a side edge-to-side edge arrangement so as to form a graded wet area floor in which a gradient of each panel directs water or any other liquid in a direction towards the at least one floor waste, wherein each said panel comprises:

two opposed surfaces comprising a lower surface and an opposed upper surface, said opposed upper surface configured to have tiling applied thereon, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said panel tapering in thickness from a first of said opposed end edges to a second of said opposed end edges with a gradient ranging from about 0.1% to about 2.0% to thereby direct said water or any other liquid atop the panel from the first of said opposed end edges to the second of said opposed end edges; and

two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said skirting board extending longitudinally between said opposed end edges,

wherein the plurality of the preformed load bearing floor panels and the one or more skirting boards are each formed from a waterproof material, and

wherein when arranged said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to form the waterproofed wet area floor in the room.

2. The system of claim 1, wherein said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to adjacently arranged floor panels and/or skirting boards.

3. The system of claim 2, wherein said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to adjacently arranged floor panels and/or skirting boards by plastic welding between adjacent said end edges and adjacent said side edges.

4. The system of claim 2, wherein said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to adjacently arranged floor panels and/or skirting boards by application of a sealant between adjacent said end edges and adjacent said side edges.

5. The system of claim 1, wherein said outer surface of each said skirting board is configured to have tiling applied thereon.

6. The system of claim 1, wherein the wall abutting surface of each said skirting board is adhesively bonded to the adjacent wall of the room.

7. The system of claim 1, wherein the lower surface of each preformed load bearing floor panel is adhesively bonded to the support surface.

8. The system of claim 1, wherein the support surface comprises a portion or part of a slab.

9. The system of claim 1, wherein the support surface is comprises two or more horizontal support beams with a panel or sheet laid atop to cover any gaps between the two or more horizontal support beams.

10. The system of claim 1, wherein each said preformed load bearing floor panel tapers from the first of said opposed end edges to the second of said opposed end edges with a gradient ranging from about 0.2% to about 0.45%.

11. The system of claim 1, further comprising one or more shower wall panels configured to be arranged at a junction between an adjacent wall and said first said opposed end edge of an adjacent said floor panel at a location in which a shower is to be located.

12. The system of claim 11, wherein said one or more shower wall panels each comprising two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed edging, and said outer surface configured to have tiling applied thereon.

13. The system of claim 11, wherein the one or more shower wall panels are formed from a waterproof material.

14. The system of claim 13, wherein the one or more shower wall panels are waterproof bonded to adjacently arranged floor panels and/or skirting boards.

15. A method of forming a graded and waterproofed wet area floor in a room, said method comprising:

arranging a plurality of preformed load bearing floor panels around at least one floor waste in the room in a side edge-to-side edge arrangement so as to form a graded wet area floor in which a gradient of each panel directs water or any other liquid in a direction towards the at least one floor waste, wherein each said panel is formed from a waterproof material and comprises:

two opposed surfaces comprising a lower surface and an opposed upper surface, said opposed upper surface configured to have tiling applied thereon, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said panel tapering in thickness from a first of said opposed end edges to a second of said opposed end edges with a gradient ranging from about 0.1% to about 2.0% to thereby direct said water or any other liquid atop the panel from the first of said opposed end edges to the second of said opposed end edges;

arranging one or more skirting boards around an outer edge of the room at a junction between an adjacent wall and said first said opposed end edge of an adjacent said panel, wherein each skirting board is formed from a waterproof material and comprises:

two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said skirting board extending longitudinally between said opposed end edges; and

waterproof bonding said plurality of preformed load bearing floor panels and said one or more skirting boards when arranged to form the waterproofed wet area floor in the room.

16. The method of claim 15, wherein the waterproof bonding comprises bonding said plurality of preformed load bearing floor panels and said one or more skirting boards to adjacently arranged floor panels and/or skirting boards by plastic welding.

17. The method of claim 16, wherein the plastic welding is applied between adjacent said edges and adjacent said side edges.

18. The method of claim 15, further comprising arranging one or more shower wall panels at a junction between an adjacent wall and said first said opposed end edge of an adjacent said floor panel at a location in which a shower is to be located.

19. The method of claim 18, wherein said one or more shower wall panels are formed from a waterproof material and each comprise two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed edging, and said outer surface configured to have tiling applied thereon.

20. The method of claim 19, wherein the waterproof bonding further comprises bonding the one or more shower wall panels to adjacently arranged floor panels and/or skirting boards.