WO2021023990A1

WO2021023990A1 - Flooring assembly

Info

Publication number: WO2021023990A1
Application number: PCT/GB2020/051873
Authority: WO
Inventors: Stephen Joseph HORN
Original assignee: Euro Polymers Consult Limited
Priority date: 2019-08-06
Filing date: 2020-08-05
Publication date: 2021-02-11
Also published as: GB2587789B; GB2587789A; GB201911236D0

Abstract

A flooring assembly suitable for use on balconies, terraces and other external or internal surfaces of a building. The flooring assembly comprises a frame, legs provided at the frame and a plurality of covering panels, each comprising a substrate and a tray to support the substrate. The flooring assembly is constructed exclusively from non-combustible materials.

Description

Flooring Assembly

Field of invention

The present invention relates to a flooring assembly and in particular to a flooring assembly for external use such as in or on a balcony, decking, terrace or roof assembly. Background art

Balcony, decking or terrace assemblies typically have a floor surface supported above a base surface by a frame on legs. Particularly where the base surface is the external surface of a building, the cavity underneath the raised floor provides space for thermal insulation materials and waterproofing layers. Adjustable legs are often used to accommodate uneven building surfaces so as to provide a horizontal, stable balcony or terrace.

Existing assemblies primarily use wooden planking as the floor surface, as this achieves a high-quality finish. Conventional wooden terraces are typically constructed by bolting, screwing or nailing wooden planks to a plastic, metal, plastic coated metal or wooden frame. This assembly process is time consuming as each plank needs to be attached in several places. Removal of planks for access or for replacement when rotten or broken or is not straightforward and in some cases not possible without destroying the plank. Wooden balcony assemblies require regular treatment and planks may require replacement every few years.

Alternatives to wooden planks include plastic or polymer boards. However these may be susceptible to warping or cracking with the variations in temperatures commonly experienced on external building surfaces. Plastic may discolour and become more brittle upon exposure to sunlight which reduces the lifetime of the balcony assembly. Composite materials containing a mixture of wood fibre and plastics have been shown to improve weathering and temperature resistance.

The use of wood and plastic for external building assemblies has become less desirable owing to the combustibility of these materials. Wood/plastic composites are also combustible. The use of such materials in new balcony assemblies is undesirable as it affects the overall fire performance of the assembly. In some jurisdictions such materials may no longer meet regulations for new construction projects.

A common non-combustible material used in balcony assemblies is aluminium.

Aluminium has good corrosion resistance and is lightweight and non-combustible. However aluminium or other metal flooring may be unpleasantly hot or cold depending on the weather. Current assemblies often address this by applying an insulating plastic layer to the aluminium. As the plastic layer is combustible this affects the overall fire performance of the assembly. Exposed aluminium balconies are often perceived as low quality and are undesirable.

Summary of the Invention

The present invention seeks to provide a flooring assembly with a high quality, durable and non-combustible floor surface. In particular, the floor of the assembly (where “floor” means the exposed upper surface of the assembly) comprises a substrate made from a high quality material such as ceramic, porcelain, quarry tile, natural stone, structural glass or glass reinforced concrete. Viewed from a first aspect the present invention provides a flooring assembly comprising: a frame; a plurality of legs provided at or mountable to the frame to support the frame; a plurality of covering panels each having a tray and a substrate, the tray having a mounting region intended to face towards the frame such that the panels are attachable at the frame via the mounting region, and a support region intended to face away from the frame, wherein the substrate is mountable or mounted in contact with and supported by the tray via the support region; wherein the covering panels comprise exclusively non-combustible materials.

By providing a flooring assembly constructed exclusively from non-combustible materials, the flooring assembly of the invention is able advantageously to meet fire safety regulations.

The tray provides support to the substrate. Where a brittle substrate such as ceramic or porcelain is used, this support prevents the substrate cracking or breaking when pressure is applied (such as when the panel is stood on). With the support provided by the tray the thickness of the substrate can be reduced. Where expensive materials such as ceramic or porcelain materials are used for the substrate, this can reduce the overall cost of the assembly. A lower substrate thickness also reduces the weight of the covering panels. Weight management and balancing are critical in certain balcony assemblies.

In the context of this invention the term “non-combustible ” should be interpreted as a material which fulfils the requirements of the Euroclass A1 rating as outlined in Official Journal of the European Communities L 050, 23/02/2000 P. 0014 - 0018. To meet the Euroclass A1 rating, when a cylindrical test specimen of the material is inserted into a vertical tube furnace at a temperature of around 750 °C (as specified by EN ISO 1182) the temperature change in the furnace should be equal to or less than 30 °C, the mass change of the sample during the test should be less than or equal to 50 % and no sustained flaming of the sample should be observed during the test. In addition to this the gross calorific potential of the material should be less than or equal to 2.0 MJ kg ¹ or 1.4 MJ m ² when measured in accordance with the EN ISO 1716 test procedure. A main body of the frame may comprise longitudinal and transverse beams connected to form a grid. Alternatively the main body of the frame may comprise only transverse beams or only longitudinal beams. The beams may be tubular with a rectangular or circular cross- section. Alternatively the beams may be I- or H-shaped. Preferably each beam has a planar upper face, the upper faces together defining a planar surface. The beams may be connected together by bolts, linking plates or welding. Where only transverse or longitudinal beams are used there may be no direct connection between adjacent beams.

In a preferred embodiment, the frame, legs and tray are composed of a first material and the substrate is composed of a second material being different to the first material. A light weight, low cost, durable material may be used on the non-exposed frame, legs and tray, with a higher quality, heavier material for the exposed substrate. The thickness of the substrate may be reduced given the extra support provided to the substrate by the tray. This keeps the weights of the covering panels and assembly within acceptable ranges.

Preferably the frame and legs are composed of a metal or a metal alloy. Preferably the tray is composed of the same or a different metal or metal alloy. The metal or metal alloy may be any metal or alloy suitable for structural use such as iron, steel, aluminium or an aluminium alloy. Particularly preferably the metal is aluminium or an aluminium containing alloy. Aluminium and its alloys have several advantages including a high strength to weight ratio, excellent corrosion resistance and a resistance to temperature change. Aluminium components can also be formed by extrusion, which reduces manufacturing costs compared to conventional casting methods. Using aluminium keeps the overall weight of the assembly comparable with conventional assemblies despite heavier substrate materials such as ceramic and porcelain being used. By confining aluminium to non-exposed parts of the assembly, the high-quality appearance of the assembly is maintained.

Preferably the substrate is composed of a material selected from a group consisting of a ceramic, a porcelain, a quarry tile, a natural stone, a structural glass or a glass reinforced concrete. Particularly preferably the substrate is composed of a porcelain. Porcelain is advantageous due to its high wear resistance and durability, low maintenance, luxury appearance and moisture resistance.

The substrate may be coloured and/or textured to resemble wood or a stone material. An exposed surface of the substrate may have indentations such as grooves or dimples to improve grip (for example when the surface is wet). The substrate may have a thickness of up to 20 mm. Preferably the thickness of the substrate is between 5 mm and 15 mm, particularly preferably the thickness is approximately 10 mm.

The support region of the tray may have a surface. The surface is preferably an interior surface which extends between two or more side walls of the tray. Preferably the surface has a plurality of grooves. The grooves may have a semi-circular, a rectangular or a trapezoidal cross-section. The purpose of the grooves is to receive an adhesive substance to bind the tray to the substrate.

The covering panels may further comprise end pieces attachable to each end of the tray. The end pieces may be intended to be permanently attached to the end of the tray and would fit mechanically into place. The end piece may have a projection which can be sandwiched between the tray and the substrate to hold the end piece in place. The end piece protects the substrate and tray from damage during transportation and installation. The end pieces may be composed of the same material as the tray and are preferably aluminium or an aluminium containing alloy.

Preferably an adhesive is applied between the tray and the substrate. Alternatively or additionally the substrate may be held in the tray in a tight press fit between the side walls, or held in place under one or more protrusions from the side walls of the tray. The substrate may have one or more tapered or angled edges which are received under corresponding angled protrusions on the tray to hold the substrate in place. Preferably the adhesive is a cementitious mortar. Cementitious mortar is advantageous compared to polymer or epoxy-based adhesives as it is non-combustible and therefore does not affect the fire performance of the assembly. The tray may comprise a first part of an attachment means to mate with a second part of the attachment means provided at or about the frame. Preferably the first and second parts of the attachment means are releasably mateable. Preferably the first part of the attachment means is located at the mounting region of the tray.

The first and second parts of the attachment means may comprise a combination of at least one barb mateable with at least one shoulder, lip, flange or groove. Preferably the at least one barb is provided at the second part of the attachment means and the at least one shoulder, lip, flange or groove is provided at the first part of the attachment means. The barbs and shoulders, lips, flanges or grooves may have smoothed edges to allow them to be slid easily into a mating position. The covering panels can in this way easily be clipped into position on the frame.

Alternatively the first and second parts of the attachment means may comprise one or more slide nuts which are slidably received within one or more slots. Preferably the slide nuts are provided at the second part of the attachment means and the slots are provided at the first part of the attachment means.

In a preferred embodiment, the frame further comprises a sub-frame for supporting the covering panels. The sub-frame may be mounted to the main body of the frame at the mounting plane. Preferably the sub-frame comprises a plurality of sub-frame elements. Each sub-frame element may be connected directly to the main body. Alternatively each sub-frame element may be connected to at least one other sub-frame element and at least one sub-frame element may be connected to the main body. The sub-frame is preferably composed of a metal or a metal alloy. Particularly preferably, the sub-frame is composed of aluminium or an aluminium containing alloy. The sub-frame offers additional support to the covering panels and the substrate, as well as providing a surface for easy attachment/detachment of the covering panels. In certain embodiments, the sub-frame may be used to support additional services such as cables for lighting, sound or heating systems, or pipes to carry water for taps or heating. The legs may comprise a support plate, a threaded portion and a foot plate. The support plate may have a substantially planar upper surface intended for contacting and supporting the sub-frame. The support plate may have one or more attachment points to allow insertion of an attachment means such as a bolt to attach the leg to the sub-frame. The threaded portion allows the overall height of the leg to be adjusted to account advantageously for an uneven or sloped base surface. The foot plate may have one or more fixing holes to allow the leg and flooring assembly to be fastened to a building.

The sub-frame may comprise the second part of the attachment means. Preferably each sub-frame element comprises at least a pair of walls, wherein at least one barb is provided at each of the walls. The walls may extend from opposite edges of each sub-frame element or may extend from the same face. An interior base surface may extend between the pair of walls. The interior base surface and walls may define a socket suitable for receiving at least one covering panel.

The tray may have at least a pair of flanges projecting from a main structure, wherein each flange has a shoulder mateable with at least one barb. The flange is mateable with a corresponding wall on the frame or sub-frame through the interlocking of the barb and the shoulder. Preferably each flange is resiliently deformable and is biased against its corresponding wall when in a mated position. This ensures a tight fit and enables removal of the covering panels from frames by deforming the flange to release the barb from the shoulder. This release may be achieved with the aid of a suitable tool. This allows the flooring assembly to be easily disassembled for maintenance, replacement or access.

The panels and sub-frame elements may be elongate, having a length greater than a width. The substrate may be elongate in order to more closely resemble a wooden plank. The tray may have substantially the same cross-section across an entirety of its length. Similarly each sub-frame element may have substantially the same cross-section across an entirety of its length. This makes it simpler to manufacture these components by extrusion.

The tray may further comprise at least one support foot at the mounting region for contacting the frame or sub-frame element when the covering panels are mounted to the frame. Each support foot may extend in a longitudinal direction and may extend substantially the entire length of the tray. Each support foot offers additional support to the tray and substrate. This prevents flexing of the tray when pressure is applied which could damage the brittle substrate.

Alternatively the mounting region of the tray may comprise one or more elongate tunnels extending in a longitudinal direction, and at least one mounting slot adjacent the at least one tunnel. The mounting slot may be defined by a first protrusion extending from a side wall of the tray and a second protrusion extending from an external wall of the elongate tunnel. The mounting slots are suitable to slideably receive one or more slide nuts positioned at or attached to the frame to attach the covering panel to the frame.

The interior base surface of each sub-frame element may have at least one channel extending in a longitudinal direction. Such channels improve the structural rigidity of the sub-frame element and can also be used to carry pipes for heating or water supply, or electrical cables for lighting or sound systems. The channels may also be used to attach bolts, screws or other fixing means to the sub-frame element for attachment to the main body of the frame. Each sub-frame element may have at least one elongate foot to support the sub-frame element in contact with the main body of the frame. The elongate foot preferably has a C-shaped cross-section and may be used to receive bolts or slide nuts for attachment of the sub-frame element to the main body of the frame.

Where the panels are elongate, the plurality of grooves on the support surface of the tray may run substantially parallel to each other in a longitudinal direction. The grooves may extend substantially the entire length of the tray.

The first part of the attachment means may extend along substantially the entire length of the panels and the second part of the attachment means may extend along substantially the entire length of each sub-frame element. This ensures that the panel is securely attached to and supported by a sub-frame element along its entire length. The panels may have a length substantially equal to the length of the sub-frame element. Alternatively the panels may have a length less than the length of the sub-frame element. The assembly may comprise multiple panels of the same or different lengths containing the same or different substrate materials.

Viewed from a further aspect the present invention provides a covering panel as hereinbefore defined.

Preferably the covering panel has a tray and a substrate, the tray having a mounting region intended to face towards a frame such that the panel is attachable at the frame via the mounting region, and a support region intended to face away from the frame, the substrate mountable in contact with and supported by the tray via the support region; wherein the covering panel comprises exclusively non-combustible materials.

Brief description of drawings

Specific implementations of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which:

Figure 1 shows a partially constructed flooring assembly according to a first embodiment. Figure 2 is an expanded view of the partially constructed flooring assembly of Figure 1. Figure 3 shows the tray of Figure 1 when deconstructed.

Figure 4 shows the tray of Figure 3 when constructed.

Figure 5 is a cross-sectional view of one sub-frame element and one covering panel of Figure 1 when assembled.

Figure 6 is a cross-sectional view of a tray of Figure 1.

Figure 7 is a cross-sectional view of the sub-frame element of Figure 5.

Figure 8 is an end view of the partially constructed assembly of Figure 1.

Figure 9 shows a partially constructed flooring assembly according to a second embodiment.

Figure 10 is an expanded view of the partially constructed assembly of Figure 9.

Figure 11 shows a partially constructed flooring assembly according to a third embodiment. Figure 12 is an expanded view of the partially constructed flooring assembly of Figure 11. Figure 13 shows a leg according to the embodiment of Figure 9.

Embodiment 1

Referring initially to Figures 1 and 8, a first embodiment of a flooring assembly 1 for a terrace or balcony is shown. The flooring assembly 1 comprises a frame 10 which has a main body consisting of longitudinal beams 14 and transverse beams 12 bolted together to form a grid. In this particular embodiment, box beams with a rectangular cross-section are used. The upper faces of each beam 12, 14 define a planar surface. A sub-frame 16 is bolted to the beams 12, 14 at the planar surface.

The frame 10 is supported by legs 20. An upper portion 22 of each leg 20 has a shoe 23 which receives and supports part of a transverse beam 12. The upper portion 22 is connected to a first end of a main leg portion 24. The main leg portion 24 is connected at a second end to a foot portion 26 which is intended to contact the ground or an external surface of a building via a foot plate 27. The connections between the main leg portion 24 and the upper and foot portions 22, 26 are threaded. The length of the threaded connection is long enough to allow the overall height of each leg 20 to be adjusted by turning one or more of the leg portions 22, 24, 26. The legs 20, beams 12, 14 and sub-frame 16 are made from aluminium. Aluminium is usefully lightweight compared to other metals such as steel and is also more resistant to corrosion. Unlike plastic materials used in existing assemblies, aluminium is non-combustible.

As shown in Figure 1, the upper portions 22 of the legs 20 are positioned on the transverse beams 12 at or near each longitudinal beam 14. Every other transverse beam 12 is directly supported by legs 20. The number and spacing of the legs 20 can be adjusted as required to ensure adequate support for the flooring assembly.

As shown best in Figure 2, the sub-frame 16 comprises multiple sub-frame elements 40. Each sub-frame element 40 is elongate and is mounted to the beams 12, 14 such that the length of the sub-frame element 40 runs substantially parallel to the longitudinal beams 14 and substantially perpendicular to the transverse beams 12. The sub-frame elements 40 are adjacent to and contact each other at side faces 46. There is no direct connection between adjacent sub-frame elements 40. The sub-frame elements 40 are composed of aluminium.

Figure 7 shows a cross-sectional profile of the sub-frame element 40. A second part of an attachment means is provided at each sub-frame element 40 and comprises two walls 41 extending in a longitudinal direction from a base surface 42. Along a distal end of each wall 41 is a barb 45. The walls 41 are resiliently deformable. Each sub-frame element 40 contacts the main body of the frame 10 via two elongate feet 44. There are two channels 43 which run longitudinally along the entire length of base surface 42. The channels 43 and the elongate feet 44 improve the structural rigidity of the sub-frame element 40. Each sub- frame element 40 is attached to the main body of the frame 10 with bolts 47 applied through the channels 43 as illustrated in Figure 5.

Referring to Figures 3 and 4, each covering panel 30 has a tray 32 and an elongate substrate 31. The tray 32 is elongate with two side walls to define a support region 38 to receive the elongate substrate 31. The elongate substrate 31 is formed of a porcelain and has a pattern of longitudinal peaks and troughs on an upward facing surface. This is to improve traction on the exposed surface and also improve the look and feel of the assembly. The substrate 31 is around 10 mm thick.

With reference to Figure 3 and Figure 6, the tray 32 has a series of grooves 37 in support region 38. The grooves 37 are parallel and extend in a longitudinal direction the entire length of tray 32. The tray 32 and the substrate 31 are bonded together using a cementitious mortar between the grooves 37, the support region 38 and an underside face of substrate 31. A cementitious mortar is preferable over other types of adhesive as it is non-combustible.

An end plate 33 is attached at each longitudinal end of the tray 32 and the substrate 31. A lip 35 of the end plate 33 is inserted between the support region 38 and the substrate 31 to hold the end plate 33 in place. The tray 32 and the end plate 33 are made from aluminium. The tray 32 has two flanges 34 extending from a mounting region. The flanges 34 are elongate and extend the length of the tray 32. Each flange 34 has a shoulder 36 which is suitable for mating with the barb 45 on the sub-frame element 40. Each flange 34 is resiliently deformable. This allows the barb 45 to interlock with the shoulder 36 when the covering panel 30 is pushed into place on the sub-frame element 40.

The tray 32 has three support feet 35. The support feet 35 are elongate and extend the entire length of the tray 32. Each support foot 35 consists of a cylindrical rod with a flat shoe intended to contact the base surface 42 of the sub-frame element 40. The end plate 33 is shaped to cover the end of the support feet 35. The support feet 35 provide extra support when pressure is applied to the covering panel 30. This prevents excessive flexing of the tray 32 which may crack the substrate 31. As shown in Figures 3 and 4, a distal end of each flange 34 is also shaped to contact the base surface 42 thereby providing additional support.

Figure 5 shows how the covering panel 30 interfaces with the sub-frame element 40. The covering panel 30 is held at the sub-frame element 40 by the interlocking of the barb 45 with the shoulder 36. A distal end of the flange 34 as well as the support feet 35 contact the base surface 42 of the sub-frame element 40 thereby providing five additional support regions spaced across the width of the panel 30.

Both the sub-frame element 40 and the tray 32 have cross-sections as shown in Figure 7 and Figure 6 respectively which are substantially the same along their entire length. As both components are aluminium, this allows the sub-frame elements 40 and the trays 32 to be manufactured by an extrusion process rather than by a slower and more labour-intensive casting process. This reduces manufacturing costs. The use of aluminium also reduces the weight of the flooring assembly.

The flooring assembly 1 of this particular embodiment can be assembled by fixing the legs 20 to the transverse beams 12 via the shoe 23 and adjusting each leg 20 by turning the threaded connections between the different leg portions 22, 24, 26 to ensure that each foot plate 27 contacts the ground or external building surface. The grid of beams 12, 14 forming the main body of the frame 10 may be assembled in situ or prefabricated to save time at the construction site.

Once the legs 20 and main body of the frame 10 are in place, sub-frame elements 40 are attached to the beams 12, 14 with bolts 47 in the channels 43. Each sub-frame element 40 is aligned in a longitudinal direction ( i.e . parallel to longitudinal beams 14). The sub-frame elements 40 are aligned by bringing the side faces 46 of adjacent sub-frame elements 40 into contact with each other.

The covering panels 30 are pre-fabricated before transportation to the assembly site. A cementitious mortar is applied to the support surface of the tray 32 and/or the underside surface of the substrate 31 and the substrate 31 is placed in the tray 32. The end plate 33 is attached by sandwiching the lip 39 between the substrate 31 and the tray 32.

Each covering panel 30 is fixed into place at the sub-frame element 40 by aligning the flanges 34 with the walls 41 and pushing the panel 30 downwards towards the sub-frame element 40. This causes the walls 41 to resiliently deform outwards (towards each side of the sub-frame element 40) allowing the flange 34 to slide down into contact with the base surface 42. The barb 45 then holds the covering panel 30 in place at the shoulder 36. The covering panels 30 can be removed from the sub-frame element 40 by inserting a special tool between adjacent panels 30 to pull each wall 41 outwards and release the barbs 45 from the shoulders 36.

Embodiment 2

Referring to Figures 9 and 10, an alternative embodiment of the flooring assembly 101 is shown. In this embodiment, the main body of the frame has only transverse beams 112.

The transverse beams 112 are composed of aluminium and define a planar surface onto which a sub-frame 116 is mounted. The transverse beams 112 are substantially parallel to each other. Each transverse beam 112 is coupled to the sub-frame 116. Therefore each transverse beam 112 is only connected to other transverse beams 112 via sub-frame 116. There is no direct connection between the beams 112. As best illustrated by Figure 13, the legs 120 of this embodiment have a planar support plate 121 at the first end of a shaft 122. The shaft 122 threadably connects at a second end to a threaded portion 125 connected to a foot plate 127. By rotating the shaft 122, the overall length (the distance between the foot plate 127 and the support plate 121) of the leg 120 can be adjusted. Individual legs 120 can be easily adjusted in this manner to accommodate uneven building or ground surfaces. The support plate 121 has attachment points 123 for attaching to the sub-frame 116. Fixing holes 128 are also provided at the foot plate 127 to enable the assembly 101 to be secured to the external surface of a building or the ground.

The planar support plate 121 contacts and supports the sub-frame 116. In this embodiment the sub-frame 116 consists of multiple sub-frame elements 140 composed of aluminium. Each sub-frame element 140 is connected to the transverse beams 112. There is no direct connection between adjacent sub-frame elements 140, the sub-frame 116 is therefore held together via the transverse beams 112.

Unlike other embodiments, the legs 120 are not connected to the main body of the frame but are connected directly to the sub-frame 116. In this manner the legs 120 support the sub-frame elements 140 via the support plate 121. The sub-frame elements 140 collectively support the transverse beams 112 which are not load bearing. This arrangement is advantageous as it enables the frame (consisting of the transverse beams 112 and sub- frame elements 140) to be at least partially pre-assembled before delivery to the construction site. Final assembly then involves positioning the legs 120, bolting the sub- frame elements 140 to the support plates 121, then clipping the covering panels 130 into place on each sub-frame element 140.

The sub-frame elements 140 are substantially the same as sub-frame elements 40, and have elongate channels 143 and two walls 141 each with a barb 145. The walls 141 are resiliently deformable. In this embodiment the sub-frame elements 140 are connected to the support plate 121 via fixing bolts 47 through channels 143 as illustrated in Figure 5, and attachment points 123. The flooring assembly 101 comprises covering panels 130 which are similar to covering panels 30. The covering panels 130 consist of a substrate 131 supported in a tray 132. The substrate 131 is held in place with a cementitious mortar applied in grooves 137 in the tray 132. A mounting region of the tray 132 has two elongate flanges 134 each with a shoulder 136 for contacting the respective barb 145 on one of the walls 141. The mounting region also has three elongate support feet 135 to provide further support to the tray 132 and the substrate 131.

The substrate 131 is a 10 mm thick porcelain tile. An upper exposed surface of the substrate 131 has longitudinal grooves to improve appearance and traction on the flooring surface. The covering panel 130 does not have end plates. Omitting the end plates enables adjacent panels 130 to be installed so that there is minimal gap between adjacent longitudinal ends of each substrate 131.

The overall length of the covering panel 130 is less than the length of each sub-frame element 140. Multiple covering panels 130 are therefore installed in each sub-frame element 140. The covering panels 130 are installed by aligning the walls 141 with the flanges 134 and pushing the covering panel 130 into contact with the sub-frame element 140. This causes the walls 141 and the flanges 134 to resiliently deform, thereby allowing the barbs 145 to interlock with the shoulders 136. The panels 130 can be removed by using a tool to deform the walls 141 to release the barbs 145 from the shoulder 136, thereby allowing the panel 130 to be lifted.

Embodiment 3

Figures 11 and 12 show a flooring assembly 201 according to a third embodiment. In this embodiment, the frame comprises longitudinal and transverse beams 214, 212 which are welded together to form a grid. The beams 212, 214 are made from aluminium. Upper surfaces of each beam 212, 214 define a mounting plane. The beams 212, 214 are box shaped with a hollow interior.

The transverse beams 212 have a series of bore holes through the upper surface, with corresponding bore holes through the lower surface. A series of threaded rods 244 are disposed vertically within the bore holes. Each threaded rod 244 passes through a bore hole on the upper surface and the corresponding bore hole on the lower surface. The bore holes and rods 244 are arranged in pairs. The threaded rods 244 are each held in place by two securing nuts 245 on either side of and in contact with the transverse beam 212.

Unlike flooring assemblies 1 and 101 described above, the frame of flooring assembly 201 does not have a sub-frame. Covering panels 230 are mounted to the transverse beams 212 via the threaded rods 244. At an uppermost end of each threaded rod is a nut 243, a washer 242 and a slide nut 241. The slide nut 241 has a diamond shape. By altering the position of the securing nuts 245 on the threaded rods 244, the height of the slide nut 241 and the mounted covering panel 230 can be adjusted.

The covering panel 230 has a similar configuration to the covering panels 30 and 130.

Each covering panel consists of a substrate 231 mounted in and supported by a tray 232. The substrate 231 is a glass reinforced concrete with a thickness of around 10 mm. The substrate 231 is secured into the tray 232 with a cementitious mortar. The tray 232 is composed of aluminium.

A support region of the tray 232 designed to receive the substrate 231 has longitudinal grooves 237. These grooves receive the cementitious mortar used to hold substrate 231 in place within the tray 232.

A mounting region of tray 232 is different to the mounting regions of trays 132 and 32 described above. As best shown in Figure 12, each tray has two box-shaped tunnels 233 at the mounting region. On either side of the tunnels is a C-shaped slot 238 defined by a side wall 235 extending from the side end of the tray 232 with a first protrusion 236 at a distal end. A second protrusion 234 similar to the first protrusion 236 extends from an external surface of a tunnel 233.

The covering panels 230 are secured to the frame by sliding slide nuts 241 into slots 238. The diamond shaped slide nuts 241 are then rotated by approximately 45 degrees, thereby causing the corners of the slide nuts 241 to contact the internal edges of the slots 238. Each nut 243 can then be tightened to bring the washers 242 into contact with the first and second protrusions 236, 234 to secure the covering panel 230 in place.

Claims

1. A flooring assembly comprising: a frame; a plurality of legs provided at or mountable to the frame to support the frame; a plurality of covering panels each having a tray and a substrate, the tray having a mounting region intended to face towards the frame such that the panels are attachable at the frame via the mounting region, and a support region intended to face away from the frame, wherein the substrate is mountable or mounted in contact with and supported by the tray via the support region; wherein the covering panels comprise exclusively non-combustible materials.

2. The flooring assembly of claim 1, wherein the frame, legs and tray are composed of a first material and the substrate is composed of a second material being different to the first material.

3. The flooring assembly of claim 1 or 2, wherein the frame and the legs are composed of a metal or a metal alloy.

4. The flooring assembly of any preceding claim, wherein the tray is composed of a metal or a metal alloy.

5. The flooring assembly of claim 3 or 4, wherein the metal is aluminium or an aluminium containing alloy.

5. The flooring assembly of any preceding claim, wherein the substrate is composed of a material selected from a group consisting of a ceramic, a porcelain, a quarry tile, a natural stone, a structural glass or a glassfibre reinforced concrete.

6. The flooring assembly of any preceding claim, wherein the support region has a surface with a plurality of grooves.

7. The flooring assembly of any preceding claim, wherein the covering panels further comprise end pieces attachable to each end of the tray.

8. The flooring assembly of claim 7, wherein the end pieces comprise the same material as the tray.

9. The flooring assembly of any preceding claim, further comprising a cementitious mortar between the tray and the substrate.

10. The flooring assembly of any preceding claim, wherein the tray comprises a first part of an attachment means to mate with a second part of the attachment means provided at or about the frame.

11. The flooring assembly of claim 10, wherein the first and second parts of the attachment means comprises at least one barb mateable with at least one shoulder, lip, flange or groove.

12. The flooring assembly of claim 11, wherein the at least one barb is provided at the second part of the attachment means and the at least one shoulder, lip, flange or groove is provided at the first part of the attachment means.

13. The flooring assembly of any previous claim, wherein the frame further comprises a sub-frame for supporting the covering panels.

14. The flooring assembly of claim 13, wherein the legs comprise a support plate, a threaded portion and a foot plate, wherein the support plate is intended for contacting and supporting the sub-frame.

15. The flooring assembly of claim 13 or 14, wherein the sub-frame comprises a plurality of sub-frame elements.

16. The flooring assembly of claims 13 to 15 when dependent on claim 10, wherein the sub-frame comprises the second part of the attachment means.

17. The flooring assembly of claim 16, wherein the second part of the attachment means comprises at least a pair of walls, wherein at least one barb is provided at each of the walls.

18. The flooring assembly of claim 17, wherein the tray has at least a pair of flanges projecting from a main structure, wherein each flange has a shoulder mateable with at least one barb.

19. The flooring assembly of claim 18, wherein each flange is resiliently deformable.

20. The flooring assembly of claim 17, wherein the sub-frame has an interior base surface extending between the pair of walls.

21. The flooring assembly of claims 15 to 20, wherein the covering panels and sub- frame elements are elongate and have a length greater than a width.

22. The flooring assembly of any preceding claim, wherein the tray further comprises at least one support foot at the mounting region for contacting the frame when the covering panels are mounted to the frame.

23. The flooring assembly of claim 22, wherein the support foot extends in a longitudinal direction.

24. The flooring assembly of claim 20, wherein the interior base surface has at least one channel extending in a longitudinal direction.

25. The flooring assembly of claim 21, wherein the first part of the attachment means extends along substantially the entire length of the covering panels and the second part of the attachment means extends along substantially the entire length of each sub-frame element.

26. A covering panel for a flooring assembly as defined in any preceding claim.