WO2003027410A1

WO2003027410A1 - Floor comprising pre-formed elements and method of construction of said floor

Info

Publication number: WO2003027410A1
Application number: PCT/IB2002/003879
Authority: WO
Inventors: Jacques André BABEN; Goffredo Mugnaioni
Original assignee: Baben Jacques Andre
Priority date: 2001-09-21
Filing date: 2002-09-20
Publication date: 2003-04-03

Abstract

The invention relates to an on-site constructional slab which includes a continuous generally planar horizontal layer of pre-formed panels (10), each panel having an upwardly opening receiving cavity (16). A layer (18) of set cementitious material overlies the layer and projects downwardly into the cavities. The layer of panels is incorporated into the layer of cementitious material by cementitious bonding of the cementitious material to the panels, the layer of panels forming shuttering (11) for the cementitious material. The invention extends to a kit for providing shuttering for use in forming the slab and including pre-formed panels, each panel having an outwardly opening receiving cavity and being shaped for abutment with similar panels to form a continuous generally planar horizontal layer with the receiving cavities of the panels directed upwardly; to a building which incorporates the slab; and to a method of forming the slab on-site.

Description

FLOOR COMPRISING PRE-FORMED ELEMENTS AND METHOD OF CONSTRUCTION OF SAID FLOOR

THIS INVENTION relates to construction. In particular, the invention

relates to an on-site constructional slab, and to a building incorporating the slab. The

invention extends to a kit for providing shuttering for use in the forming of an on-site

constructional slab, and to a method of forming a constructional slab on-site.

The invention provides an on-site constructional slab which includes:

a continuous generally planar horizontal layer comprising a plurality of pre¬

formed panels, each panel having an upwardly opening receiving cavity; and

a layer of set cementitious material overlying the layer of panels and projecting

downwardly into the cavities, the layer of panels being incorporated into the layer of

cementitious material by cementitious bonding of the cementitious material to the

panels, and the layer of panels forming shuttering for the cementitious material.

Typically, each panel is a pre-cast cementitious element, for instance

being a pre-cast concrete element, and the cementitious material received in the shuttering formed by the panels may be concrete. Incorporation of the layer of panels

into the cementitious material is such that the slab is a monolithic or unitary structure.

The panels may be interlocked together by interlocking formations provided on the panels, each panel being provided with at least one such interlocking

formation.

In a preferred embodiment, each panel is roughly trough-shaped, being

elongated and having open ends, with its receiving cavity being defined between a pair

of opposed more or less parallel side walls thereof, the side walls extending

longitudinally between the ends of the panel. In such case, the layer of panels will

typically be formed by a plurality of rows of the panels, the rows being arranged side-

by-side, each row comprising plurality of the panels which are aligned end-to-end, so

that a common longitudinally extending receiving cavity is formed by each row of

panels. In a variation of the invention, each panel has a pair of opposed side walls and

a pair of opposed end walls. Interlocking formations may in such a case be provided

on side walls of the panels as well as on end walls of the panels.

The slab may include a plurality of metal reinforcing rods which are

located so that at least one reinforcing rod extends lengthwise along the common

cavity of at least one of the rows of panels, the reinforcing rods being embedded in

the set cementitious material. Typically, the slab also includes transverse reinforcing

rods which extend transversely to the rows and are located above the panels, being

embedded in the set cementitious material.

At least one of the rows of panels consists of aligned reinforcing panels, the reinforcing panels having a depth greater than that of the remaining panels, the

reinforcing panels projecting downwardly below the remaining panels, at least one

reinforcing rod being located to extend lengthwise along the common cavity of each

row of reinforcing panels. Each row of reinforcing panels thus provides an integrally

formed reinforcing beam for the slab.

The layer of panels may be supported on a plurality of columns, each of

which is located at a position below a row of reinforcing panels, which row rests

thereon. Each column may have a plurality of tie rods projecting upwardly from an

upper end thereof, the reinforcing panel which rests on the upper end of said column

having an opening in a floor of its cavity through which opening the tie rods pass, the reinforcing panel being supported on said column with the upper end of the column

closing off the opening, to inhibit or prevent leaking of the cementitious material

through the opening in the floor of the cavity during forming of the slab. It will be

appreciated that the slab will typically be supported on columns in this manner when

the slab is located at an elevated level.

The interlocking formations may interlock together adjacent panels

extending alongside each other. In one embodiment of the invention, the interlocking

formations comprise complementary tongue-and-groove formations. In such case,

each panel may have a groove in which a complementary tongue of a like adjacent

panel is received, each panel also having a tongue which is received in a complementary groove on another like adjacent panel. Typically, the tongue and

groove are respectively provided in opposite longitudinally extending side edges of

each panel. Instead, each panel may be provided on its respective side edges with

tongues or with grooves, the layer consisting of alternating rows of tongued panels

and grooved panels respectively.

Each panel may be provided with at least one keying formation which

keys the panel to the set cementitious material. In a particular embodiment, each

keying formation is provided by an overhang on an inner surface of a wall of the

receiving cavity of the panel.

The invention extends to a building which includes a slab as described

above, the slab being built into the building.

The slab may, for instance, provide a floor of the building at ground level,

or it may provide a floor or ceiling which is elevated and supported at a number of

points by supporting walls or columns.

The invention further provides a kit for providing shuttering for use in

forming an one-site constructional slab of cementitious material, which kit includes

a plurality of pre-formed panels, each panel having an outwardly opening receiving

cavity and each panel being shaped for abutment with a plurality of similar panels to form a continuous generally planar horizontal layer of pre-formed panels with the

receiving cavities of the panels directed upwardly to form shuttering for receiving

downward projections from an overlying layer of settable cementitious material, for

incorporation of the panels into the layer of cementitious material upon setting of the

cementitious material, to form the slab.

Typically, each panel is a pre-cast cementitious element, for instance

being a pre-cast concrete element.

Each panel may have at least one interlocking formation for engagement

with a complementary interlocking formation on another of the panels, to interlock the

panels together when the panels are arranged in the layer of panels. The interlocking

formations on each panel may, for instance, comprise a groove in one side of said

panel for receiving a complementary tongue on one side of another of the panels, and

a tongue which projects from the opposite side of said panel for reception in a

complementary groove on one side of another of the panels.

Each panel may be roughly trough-shaped, being elongated and having

open ends, the receiving cavity being defined between a pair of opposed more or less

parallel side walls of the panel extending longitudinally between the ends of the panel.

In such case, the tongue may project laterally from one side wall of the panel,

extending longitudinally along the panel, the groove being provided in the other side wall of the panel, extending longitudinally along the panel.

Each panel may be provided with at least one keying formation for keying

the panel to set cementitious material, in use, received in the receiving cavity of the

panel. Each keying formation may, for instance, be provided by an overhang on an

inner surface of a wall of the receiving cavity.

The kit may include a plurality of reinforcing panels, the reinforcing panels

having a depth greater than that of the remaining panels, the reinforcing panels

optionally being provided with openings in floors of their cavities for receiving tie rods.

The invention also provides a method of forming a constructional slab on-

site, which method includes:

forming a continuous generally planar horizontal layer comprising a plurality of

pre-formed panels, each panel having an upwardly opening receiving cavity, to provide

shuttering for receiving cementitious filler material;

receiving settable cementitious filler material in the shuttering; and

allowing the cementitious filler material to set, so that a slab, incorporating the

layer of panels, is formed by cementitious bonding of the set cementitious material to

the shuttering.

Forming the layer of panels may include interlocking the panels together

by engagement of interlocking formations forming part of each panel. Typically, forming the layer of panels comprises arranging the panels in

a plurality of rows of the panels, the rows being arranged side-by-side and the

receiving cavities of the panels in each row of the panels being aligned end-to-end and

in communication to form a common receiving cavity extending along the row, with

at least some of the rows being formed by reinforcing panels which project

downwardly below the remainder of the layer of panels, the method including

supporting at least some of the reinforcing panels on upper ends of columns located

below the layer of panels.

The method may include connecting a reinforcing metal framework

located at least partially in the receiving cavities of the panels to tie rods which project

from the upper ends of the supporting columns, the tie rods projecting through

openings in the floors of the reinforcing panels resting on the columns, and into the

receiving cavities of said reinforcing panels.

The invention will now be further described and illustrated, by way of

example, with reference to the accompanying diagrammatic drawings, in which:

Figure 1 is a schematic plan view of a panel forming part of a kit for providing

the shuttering for an on-site constructional slab in accordance with the invention;

Figure 2 is a schematic sectional end view of the panel of Figure 1 , taken at line

H-ll in Figure 1 ;

Figure 3 is a schematic plan view of a portion of shuttering formed by means of the kit; and

Figure 4 is a schematic sectional end view of a slab formed by means of the

shuttering of Figure 3.

In the drawings reference numeral 1 0 generally indicates a panel which forms

part of a modular kit for providing the on-site shuttering 1 1 for a constructional slab

1 2, in accordance with the invention. The panel 10 is a pre-formed concrete element

and has an upper face 1 4 which defines an upwardly opening receiving cavity 1 6 for

receiving cementitious material, in this example concrete 1 8 (shown in Figure 4 of the

drawings) .

The panel 1 0 is roughly trough-shaped, being elongated and having open

ends 20. The receiving cavity 1 6 is defined between a pair of opposed side walls 22

which extend longitudinally between the ends 20 of the panel 1 0. As can best be

seen in Figure 2 (in which, for clarity of illustration, the panel 1 0 is shown without

cross-hatching), the inner surface of each side wall 22 has an overhang, the overhangs

of the side walls 22 serving as keying formations for keying the concrete 1 8 to the

panel 10.

The panel 10 is provided with interlocking formations in the form of a

tongue 24 which extends longitudinally along one side 26 of the panel 10, and a

complementary groove 28 which extends longitudinally along the other side 30 of the panel 10.

In use, a modular kit which includes a plurality of the panels 1 0 is used

to form the shuttering 1 1 for a concrete slab 12. The slab 1 2 forms part of a larger

concrete structure or building (not shown), in this case being elevated and extending between two parallel spaced apart walls (not shown). At a number of positions

between the walls, the shuttering 1 1 is supported by supporting columns 32.

The shuttering 1 1 is formed by interlocking a plurality of the panels 10

to form a continuous generally planar horizontal layer 34 of the panels 10 (shown in

Figure 3), the receiving cavities 1 6 opening upwardly. The layer 34 comprises a

number of rows 36 of panels 1 0, which rows 36 are arranged side-by-side, with the

panels 10 of each row 36 being aligned end-to-end, so that the receiving cavities 1 6

of the panels 10 in each row 36 are joined to form a common receiving cavity which

extends longitudinally along the full length of each row 36. It will be appreciated that Figure 3 shows only the repeating pattern of a central portion of the shuttering 1 1 .

The panels 10 are interlocked by receiving the tongue 24 of each panel

10 in the groove 28 of an adjacent panel 10 which extends alongside said panel 10

and forms part of an adjacent row 34. The rows 37 of panels 10 which are supported

by the columns 32, consist of longitudinally aligned reinforcing panels 38 which form

troughs that are deeper than those of the other panels 1 0. The rows 37 of reinforcing panels 38 project downwardly below the rest of the lower surface 40 of the slab 12.

The respective reinforcing panels 38 which are supported by the columns 32 each

have an opening 46 in the floor 42 of its trough. A number of tie rods 44 project from

the upper end of each column 32, passing through the opening 46 and extending into

the cavity 1 6 defined by the reinforcing panel 38.

Eight longitudinally extending reinforcing rods 48 are positioned

lengthwise in each of the cavities 1 6 of the rows 37 of reinforcing panels 38, the rods

48 being arranged in a square configuration, when viewed in end view (Figure 4), and

are tied together at spaced intervals by peripherally extending rods 50. The slab 1 2

also includes transversely extending reinforcing rods 52 (one of which is shown) which

are positioned in the concrete 1 8 above the layer 34 of panels 10. For clarity of

illustration, the reinforcing rods 48, 50, 52 respectively, are shown in chain-dotted

lines in Figure 3. The tie rods 44 are tied to some of the longitudinally extending

reinforcing rods 48, and, although not shown, the transverse reinforcing rods 52 are

tied to the longitudinal reinforcing rods 48. An interconnected mesh or grid of

reinforcing rods 48, 52 is thus formed.

Concrete 1 8 is received in the cavities 1 6 of the shuttering 1 1 such that it overflows the cavities 1 6, to form a continuous layer of concrete 18 overlying the

panels 10 and projecting downwardly into the receiving cavities 1 6 of the panels 10,

38. A level upper surface 54 of the slab 1 2 is thus formed by the upper surface of the concrete 1 8, the reinforcing rods 48, 50 and 52 respectively being embedded in

the concrete 18. Although not shown, provision is made for the containment of the

concrete 18 in the shuttering 1 1 , allowing the concrete level to rise above the pre¬

formed panels 1 0, by end-panels which border the shuttering 1 1 and project above the layer 34 of panels 1 0.

The engagement of the lower surface of each reinforcing panel 38 with

the upper surface of the associated column 32 is such that the opening 46 is closed

off by the panel 38, inhibiting leaking of the concrete 1 8 through the openings 46.

As can be seen in Figure 4 of the drawings, in which the layer of concrete

1 8 is shown without cross-hatching or shading for ease of illustration, the concrete

18 is allowed to set, so that the panels 10 are incorporated in the layer of concrete

1 8 by cementitious bonding of the concrete 1 8 to the panels 10, to form the slab 1 2

which has a monolithic or unitary structure.

The concrete 1 8 which is received in each row 37 of reinforcing panels

38 effectively forms, together with the reinforcing panels 38 of that row 37, an

integrally formed beam, due to the greater relative depth of the reinforcing panels 38,

which causes the row 37 to have a greater resistance to bending than the other rows

36. It is an advantage of the invention as illustrated with reference to the

accompanying drawings that a constructional slab 1 2 can be formed on-site without

providing temporary shuttering for the slab which has to be removed after the concrete 18 has set. The pre-cast concrete panels 10 are less expensive than

conventional steel shuttering which has a limited life and can be used only a few

times.

This method is less labour intensive than conventional methods of

forming such slabs, and is consequently more cost effective. The amount of skill

required by a person in order successfully to construct the slab 1 2 is also reduced.

Furthermore, the lower surface 40, or soffit, of the slab 1 2 is formed by

the lower surfaces of the floors 43 of the panels 10, and is thus relatively smooth and

clean. Not only is it possible to form the panels 10 such that the soffit 40 presents

a decorative or aesthetically pleasing pattern, but the need for plastering and/or

cleaning the soffit 40 after forming of the slab 1 2 can be obviated, again leading to

a reduction in construction costs.

Claims

CLAIMS:

1 . An on-site constructional slab which includes:

a continuous generally planar horizontal layer comprising a plurality of pre¬

formed panels, each panel having an upwardly opening receiving cavity; and

2. A slab as claimed in claim 1 , in which each panel is a pre-cast

cementitious element.

3. A slab as claimed in claim 1 or claim 2, in which the cementitious material

received in the shuttering formed by the panels is concrete.

4. A slab as claimed in any one of the preceding claims, in which the panels

are interlocked together by interlocking formations provided on the panels, each panel

being provided with at least one such interlocking formation.

5. A slab as claimed in claim 4, in which each panel is roughly trough- shaped, being elongated and having open ends, with its receiving cavity being defined

between a pair of opposed more or less parallel side walls thereof, the side walls

extending longitudinally between the ends of the panel.

6. A slab as claimed in claim 5, in which the layer of panels is formed by a

plurality of rows of the panels, the rows being arranged side-by-side, each row

comprising plurality of the panels which are aligned end-to-end, so that a common

longitudinally extending receiving cavity is formed by each row of panels.

7. A slab as claimed in claim 6, which includes a plurality of metal

reinforcing rods which are located so that at least one reinforcing rod extends

lengthwise along the common cavity of at least one of the rows of panels, the

reinforcing rods being embedded in the set cementitious material.

8. A slab as claimed in claim 6 or claim 7, in which at least one of the rows

of panels consists of aligned reinforcing panels, the reinforcing panels having a depth

greater than that of the remaining panels, the reinforcing panels projecting downwardly

below the remaining panels, at least one reinforcing rod being located to extend

lengthwise along the common cavity of each row of reinforcing panels.

9. A slab as claimed in claim 8, in which the layer of panels is supported by

a plurality of columns, each of which is located at a position below a row of reinforcing panels, which row rests thereon.

10. A slab as claimed in claim 9, in which each column has a plurality of tie rods projecting upwardly from an upper end thereof, the reinforcing panel which rests

on the upper end of said column having an opening in a floor of its cavity through which opening the tie rods pass, the reinforcing panel being supported on said column

with the upper end of the column closing off the opening.

1 1 . A slab as claimed in any one of claims 4 to 10 inclusive , in which the

interlocking formations interlock together adjacent panels extending alongside each

other.

12. A slab as claimed in any one of claims 4 to 1 1 inclusive, in which the

interlocking formations comprise complementary tongue-and-groove formations.

1 3. A slab as claimed in claim 1 2, in which each panel has a groove in which

a complementary tongue of a like adjacent panel is received, and each panel also has

a tongue which is received in a complementary groove on another like adjacent panel.

14. A slab as claimed in any one of the preceding claims, in which each panel

is provided with at least one keying formation which keys the panel to the set

cementitious material.

1 5. A slab as claimed in claim 14, in which each keying formation is provided

by an overhang on an inner surface of a wall of the receiving cavity of the panel.

1 6. A building which includes a slab as claimed in any one of claims 1 to 1 6

inclusive, the slab being built into the building.

17. A kit for providing shuttering for use in forming an on-site constructional

slab of cementitious material, which kit includes a plurality of pre-formed panels, each

panel having an outwardly opening receiving cavity and each panel being shaped for

abutment with a plurality of similar panels to form a continuous generally planar

horizontal layer of pre-formed panels with the receiving cavities of the panels directed

upwardly to form shuttering for receiving downward projections from an overlying

layer of settable cementitious material, for incorporation of the panels into the layer

of cementitious material upon setting of the cementitious material, to form the slab.

18. A kit as claimed in claim 1 7, in which each panel is a pre-cast

cementitious element.

1 9. A kit as claimed in claim 1 7 or claim 1 8, in which the each panel has at

least one interlocking formation for engagement with a complementary interlocking

formation on another of the panels, to interlock the panels together when the panels

are arranged in the layer of panels.

20. A kit as claimed in claim 19, in which the interlocking formations on each

panel comprise a groove in one side of said panel for receiving a complementary

tongue on one side of another of the panels, and a tongue which projects from the

opposite side of said panel for reception in a complementary groove on one side of

another of the panels.

21 . A kit as claimed in any one of claims 1 7 to 1 9 inclusive, in which each

panel is roughly trough-shaped, being elongated and having open ends, the receiving

cavity being defined between a pair of opposed more or less parallel side walls of the

panel extending longitudinally between the ends of the panel.

22. A kit as claimed in any one of claims 1 7 to 21 inclusive, in which each

panel is provided with at least one keying formation for keying the panel to set cementitious material received in the receiving cavity of the panel.

23. A kit as claimed in claim 22, in which each keying formation is provided

by an overhang on an inner surface of a wall of the receiving cavity.

24. A kit as claimed in any one of claims 1 7 to 23 inclusive, which includes

a plurality of reinforcing panels, the reinforcing panels having a depth greater than that

of the remaining panels.

25. A kit as claimed in claim 24, in which the reinforcing panels are provided with openings in floors of their cavities for receiving tie rods.

26. A method of forming a constructional slab on-site, which method

includes: forming a continuous generally planar horizontal layer comprising a plurality of

shuttering for receiving cementitious filler material;

receiving settable cementitious filler material in the shuttering; and

the shuttering.

27. A method as claimed in claim 26, in which forming the layer of panels

includes interlocking the panels together by engagement of interlocking formations

forming part of each panel.

28. A method as claimed in claim 26 or claim 27, in which forming the layer

of panels comprises arranging the panels in a plurality of rows of the panels, the rows

being arranged side-by-side and the receiving cavities of the panels in each row of the

panels being aligned end-to-end and in communication to form a common receiving

cavity extending along the row, with at least some of the rows being formed by reinforcing panels which project downwardly below the remainder of the layer of

panels, the method including supporting at least some of the reinforcing panels on

upper ends of columns located below the layer of panels.

29. A method as claimed in claim 28, which includes connecting a reinforcing

metal framework located at least partially in the receiving cavities of the panels to tie

rods which project from the upper ends of the supporting columns, the tie rods

projecting through openings in the floors of the reinforcing panels resting on the

columns, and into the receiving cavities of said reinforcing panels.