WO2021026600A1 - Panneau de plancher préfabriqué, construction et procédé associé - Google Patents

Panneau de plancher préfabriqué, construction et procédé associé Download PDF

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Publication number
WO2021026600A1
WO2021026600A1 PCT/AU2020/050830 AU2020050830W WO2021026600A1 WO 2021026600 A1 WO2021026600 A1 WO 2021026600A1 AU 2020050830 W AU2020050830 W AU 2020050830W WO 2021026600 A1 WO2021026600 A1 WO 2021026600A1
Authority
WO
WIPO (PCT)
Prior art keywords
prefabricated floor
floor panel
prefabricated
supporting
beams
Prior art date
Application number
PCT/AU2020/050830
Other languages
English (en)
Inventor
Trevor Jones
Original Assignee
LWC Research Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2019902927A external-priority patent/AU2019902927A0/en
Application filed by LWC Research Pty Ltd filed Critical LWC Research Pty Ltd
Priority to AU2020281139A priority Critical patent/AU2020281139B2/en
Priority to US17/634,873 priority patent/US20220268018A1/en
Publication of WO2021026600A1 publication Critical patent/WO2021026600A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/10—Load-carrying floor structures formed substantially of prefabricated units with metal beams or girders, e.g. with steel lattice girders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403—Connection details of the elongated load-supporting parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/04—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
    • E04B1/06—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material the elements being prestressed
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6104—Connections for building structures in general of slab-shaped building elements with each other the overlapping ends of the slabs connected together
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • E04B5/046—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement with beams placed with distance from another
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/14—Load-carrying floor structures formed substantially of prefabricated units with beams or girders laid in two directions
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/43—Floor structures of extraordinary design; Features relating to the elastic stability; Floor structures specially designed for resting on columns only, e.g. mushroom floors
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/50—Self-supporting slabs specially adapted for making floors ceilings, or roofs, e.g. able to be loaded
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/02—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance
    • E04C5/04—Mats
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/08—Members specially adapted to be used in prestressed constructions
    • E04C5/085—Tensile members made of fiber reinforced plastics
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/08—Members specially adapted to be used in prestressed constructions
    • E04C5/10—Ducts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/88—Curtain walls
    • E04B2/90—Curtain walls comprising panels directly attached to the structure
    • E04B2/94—Concrete panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403—Connection details of the elongated load-supporting parts
    • E04B2001/2409—Hooks, dovetails or other interlocking connections
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2466—Details of the elongated load-supporting parts
    • E04B2001/2472—Elongated load-supporting part formed from a number of parallel profiles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2484—Details of floor panels or slabs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B2001/6195—Connections for building structures in general of slab-shaped building elements with each other the slabs being connected at an angle, e.g. forming a corner
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2103/00—Material constitution of slabs, sheets or the like
    • E04B2103/02—Material constitution of slabs, sheets or the like of ceramics, concrete or other stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/001—Mechanical features of panels
    • E04C2002/004—Panels with profiled edges, e.g. stepped, serrated

Definitions

  • the present invention relates to concrete floor and/or wall panels and in particular to a prefabricated floor structure for use in buildings.
  • the present invention seeks to provide in particular, a prefabricated flooring system, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.
  • the present invention relates to a prefabricated interlocking flooring system that facilitates the rapid construction of a building in a cost effective manner.
  • the prefabricated interlocking flooring system is adapted such that adjacent prefabricated flooring panels interface with each other to provide for a smooth joint between panels removing the necessity of laying a concrete layer on top of the panels as is commonly done to provide a smooth fire retardant floor surface.
  • the present invention may be said to consist in a prefabricated flooring system comprising: a. a plurality of prefabricated floor panels, the plurality of prefabricated floor panels being adapted to interlock with each other in use; b. wherein each one of the plurality of prefabricated floor panels includes one or more edges adapted to attach to a support structure in use.
  • the prefabricated floor panels are created from a settable material.
  • the settable material is concrete.
  • the concrete is reinforced using a plurality of reinforcing bars embedded within the concrete.
  • the prefabricated floor panels further include strengthening members.
  • the strengthening members are supporting beams.
  • the supporting beams include at least one cavity for the provision of services.
  • the prefabricated floor panels interlock by way of a lap joint.
  • the lap joint is adapted to receive a fireproof sealant.
  • the corresponding lap joints are adapted to be screwed together.
  • the support structure includes a support beam adapted to attach to the at least one or more ends of the prefabricated floor panels when in use.
  • the support structure is adapted to attach to at least one support post.
  • the prefabricated flooring panel is about 1 .5m to about 3m in width.
  • the length is between about 1 m to about 15m in length.
  • the present invention may be said to consist in a prefabricated floor panel for use with a supporting structure, the prefabricated floor panel comprising: a. a floor member, the floor member defining a floor surface and being adapted to engage with an adjacent similar floor panel; and b. at least one or more strengthening beams configured to engage with the supporting structure in use to support the prefabricated floor panel.
  • the prefabricated floor member is further adapted to overlap with an adjacent similar prefabricated floor panel, while presenting a floor surface flush with the adjacent similar prefabricated floor panel.
  • the prefabricated floor member is adapted to overlap with an adjacent similar prefabricated floor panel in at least a vertical direction.
  • the prefabricated floor member is adapted to be overlapped by an adjacent similar prefabricated floor panel.
  • the floor panel includes a first overlapping formation for overlapping with an adjacent similar prefabricated floor panel.
  • the floor panel includes a second overlapping formation adapted for overlapping with the supporting structure in use.
  • the second overlapping formation is located on opposed sides of the prefabricated flooring panel.
  • the second overlapping formation is substantially parallel to the supporting structure.
  • the second overlapping formation is substantially perpendicular to the at least one or more strengthening beams.
  • the at least one or more strengthening beams are disposed asymmetrically on the floor member.
  • the floor member defines an upper major face and a lower major face, and at least one or more minor faces extending about the periphery of the upper major face and the lower major face.
  • the at least one or more strengthening beams are disposed on a lower major face of the floor member.
  • the at least one or more strengthening beams extend in parallel with each other.
  • the at least one or more strengthening beam extends at least partly outside of the periphery of one or more selected from the upper major face and the lower major face.
  • the prefabricated floor panel includes reinforcing bars.
  • the prefabricated floor panel is integrally formed.
  • the prefabricated floor panel is made from conventional concrete.
  • the prefabricated floor panel is made from aerated concrete.
  • the present invention may be said to consist in construction comprising: a. at least one or more prefabricated floor panels; and b. at least a pair of supporting beams, the supporting beams including a supporting formation adapted for supporting the strengthening beams of the prefabricated floor panels.
  • the supporting formation is one or more selected from a lip and a recess.
  • the supporting beams include a receiving formation adapted for receiving at least part of a second overlapping formation of a prefabricated floor panel.
  • the construction includes at least one support pillar.
  • the support pillars include end plates at one or either end of the support pillars.
  • the present invention may be said to consist in method of constructing a construction comprising steps of: a. providing a supporting structure; b. providing a plurality of prefabricated floor panels, each floor panel presenting a floor surface; c. supporting the prefabricated floor panels on the support structure in a configuration to at least partly overlap each other.
  • the method further includes the step of applying a fire retardant compound between the adjacent prefabricated floor panels.
  • the step of supporting the prefabricated floor panels on the support structure in a configuration to at least partly overlap each other includes supporting the prefabricated floor panels on the support structure in a configuration to present a flush floor surface across adjacent floor panels.
  • the method further comprises the step of providing at least one or more pillars.
  • the step of providing a support structure includes the step of providing at least a pair of supporting beams.
  • the method further comprises the step of supporting the supporting beams on the at least one or more pillars.
  • the prefabricated floor panels include at least one or more strengthening beams
  • the step of supporting the prefabricated floor panels on the support structure includes the step of supporting the strengthening beams on a supporting formation on the support beams.
  • the step of supporting the strengthening beams on a supporting formation on the support beams includes the step of locating the prefabricated floor panels to overlap the support beams.
  • the step of locating the prefabricated floor panels to overlap the support beams includes the step of locating a second overlapping formation of the prefabricated floor panels into a receiving formation on the support beams.
  • the prefabricated floor panels is a prefabricated floor panel.
  • This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
  • FIG. 1 is a perspective view of the construction in accordance with a preferred embodiment of the present invention.
  • FIG. 2 is an exploded view of the embodiment of Fig. 1 ;
  • FIG. 3a is a top view of a prefabricated floor panel in accordance with an embodiment of the present invention.
  • Fig. 3b is a bottom view of the prefabricated floor panel of Fig. 3a;
  • Fig. 4a shows two prefabricated floor panels adjoined;
  • Fig. 4b shows a side view of the adjoined prefabricated floor panels of Fig.
  • Fig. 5 shows a side view of the floor panels mounted to a column
  • Fig. 6 shows a side view of the floor panels.
  • a prefabricated floor panel and associated construction according to a first aspect of the invention is generally indicated by the numeral 1000.
  • a prefabricated floor panel 101 which is suitable for use with a supporting structure 103 as is typically used in the construction of buildings.
  • the supporting structure 103 will be described in greater detail later and includes a steel and/or concrete frame, which is adapted to provide support for the prefabricated floor panels 101 and wall structures (not shown).
  • the prefabricated floor panel 101 comprises a floor member 105 which defines a floor surface 107 (also referred to as an upper major face).
  • the floor member 105 is adapted to engage with an adjacent prefabricated floor panel 101 (as is shown at view A of Figures 4a & 4b).
  • the prefabricated floor panels 101 will be typically identical in shape (as in the embodiments shown in the Figures) however, they need not be identical for the purposes of the invention.
  • adjacent prefabricated floor panels 101 may incorporate cut-outs within the floor member 105 to allow for the provision of services or stairwells and the like, furthermore they may be defined by differing shaped perimeters.
  • the prefabricated floor panel 101 further includes at least one strengthening beam 109 which may be attached to a lower major face 106 of the prefabricated flooring panels 101 and are used to provide strength and rigidity to the prefabricated floor panel 101 and to provide a means of mounting the prefabricated floor panel 101 to the supporting structure 103 when in use.
  • the strengthening beams 109 may be an integral part of the prefabricated floor panel 101 rather than being separately attached to the prefabricated floor panel 101, allowing for greater strength and rigidity. It is envisaged that the prefabricated floor panel 101 will be molded as one unit with the strengthening beams 109 being incorporated into the mold, rather than being attached at a later stage.
  • the number of strengthening beams 109 is limited to three per prefabricated floor panel 101. However, it will be appreciated by a person skilled in the art, that more or less strengthening beams 109 may be used depending on the intended load and spans over which the prefabricated floor panel 101 is intended to be used.
  • the strengthening beams 109 may be disposed in either a symmetrical or an asymmetrical fashion on the floor member 105 on its lower major face 106.
  • the prefabricated floor panel 101 may be constructed from concrete and includes conventional reinforcing bar (rebar) 120 to provide strength to the prefabricated floor panels 101.
  • rebar reinforcing bar
  • steel, steel mesh, basalt or fibreglass substitute rebar can be used for the reinforcing bars 120 with basalt being preferred as it provides superior qualities over conventional rebar including resistance to corrosion and aggressive chemical compounds along with light weight and durability.
  • the reinforcing bars 120 apart from being untensioned in a preferred embodiment may be either pre-tensioned or post tensioned.
  • the choice as to whether tensioning is applied to the reinforcing bars 120 will depend on the span over which the prefabricated floor panel 101 is to span and more generally, the amount of strength required for each floor panel 101 which would typically be dependent on the likely load that each of the floor panels 101 is likely to be subjected to when in use.
  • the concrete used can take a number of forms from conventional concrete to lightweight varieties. Lightweight concrete is to be preferred as it substantially reduces the weight of the completed building structure reducing the demand on the buildings foundations. Furthermore, the use of lightweight concrete aids with the transport and handling of the prefabricated floor panels 101 during the construction phase.
  • a propriety additive is added to the concrete mix that aerates the concrete to a selected density.
  • the density is dictated by the amount of additive added.
  • the additive can adjust the concrete density from 300kg/m 3 to 2400kg/m 3 . It will be appreciated by a person skilled in the art, that as the density of the concrete is reduced, the compressive strength will be reduced with the advantage being a lighter weight structure. On the other hand, the higher the density of the concrete the higher the compressive strength of the concrete will be at the cost of higher weight of the prefabricated floor panels 101.
  • non-structural members can be constructed of less dense concrete while structural members would need to be constructed of a higher density concrete in the range of 1800kg/m 3 or higher.
  • fibre is added to the concrete to improve strength and flexibility.
  • the fibres themselves may be made of basalt or polypropylene depending on whether compressive strength or flexibility is the priority. Basalt improves the compressive strength of the concrete whereas polypropylene provides for greater flexibility. A combination of both materials is desirable.
  • the prefabricated floor panels 101 are adapted to overlap with adjacent prefabricated floor panels 101 using a structure such as a lap joint or similar. It will be appreciated that various other joints may be suitable in joining the adjacent floor panels 101 together and are not limited to lap joints. With the embodiment shown, the panels overlap with each other at the junction where the strengthening beams 109 are located. In this embodiment, the floor member 105 sits on top of the strengthening beam 109 providing for a flush floor surface with the adjacent prefabricated floor panel 101 removing the necessity for any substantive finishing in the form of applying a layer of concrete or similar in order to provide a smooth and level fireproof floor surface. Once the floor has been assembled, it is ready to use with no further preparation necessary.
  • fasteners such as screws or potentially bolts or other appropriate fasteners (not shown) may be used to securely attach the floor member 105 to each other via the strengthening beams 109 and the supporting structure 103 in general, after they have been located into their final position.
  • the prefabricated floor panels 101 are adapted to join with the adjacent prefabricated floor panels 101 by overlapping each other using a lap joint as shown in Figures 4a & 4b view A.
  • the lap joint A may be further adapted to receive a fire fireproof or fire retardant sealant which may take the form of intumescent acrylic, an example of such a sealant is Sika® Firerate which provides for a 4 hour fire rating in compliance with current fire regulations such as the Australian Standard AS1530.4.
  • the ability of the lap joint A to receive the fire retardant sealant is important in achieving the object of providing a structure that satisfies current fire safety standards and has the ability to contain fires from spreading to adjacent levels in the building which is critical especially in multi-level constructions where fires need to be contained between levels.
  • the floor member 105 may be adapted to interface with adjacent floor members 105 using a variety of different joining means, ranging from overlapping joints to rabbet or rebate joints. It is important that each of the joints used provide for a smooth surface at the junction of the floor members 105, to achieve the object of providing a smooth flush floor surface without the need for additional finishing whilst providing a fireproof joint.
  • the prefabricated floor panels 101 have about their perimeter, a first overlapping formation 121 and at least two second overlapping formations 122.
  • first overlapping formation 121 which is adapted to engage with adjacent prefabricated floor panels 101 to provide a flush fireproof interface between adjacent prefabricated floor panels 101 as is exemplified in view A in Figures 4a & 4b.
  • first overlapping formation 121 and the second overlapping formation 122 are adapted to receive a fireproof sealant such as an intumescent acrylic as was discussed previously.
  • a fireproof sealant such as an intumescent acrylic as was discussed previously.
  • An example of an appropriate fireproof sealant is Sika® Firerate.
  • the prefabricated floor panels 101 can be constructed using molds made of plywood, fibreglass or steel with steel being preferable for repeated use.
  • the molds would typically be 12m long and 2.5m wide, the lengths of which have been chosen so they can fit a standard semi-trailer for transport to the building site. It will be appreciated that the aforementioned dimensions may be varied depending on application.
  • the depth of the prefabricated floor panels 101 may be up to 600mm. Depending on the loading, the depth of the prefabricated floor panels 101 may be reduced by inserting tapered block outs along the bottom of the mold for the strengthening beams 109 in a lengthwise sense.
  • the block outs may be made of polystyrene with a 4mm form ply glued to the top enabling the molds to produce panels of varying depths from 300mm to 600mm. This will allow each mold to be readily modified to suit the length and the depth required of the prefabricated floor panels 101.
  • the molds will have a predefined camber to allow the prefabricated floor panel 101 to be level once they have been installed and loaded with the specified load for the building. Further, the edges of the mold will be 50-100mm higher than the underside of the floor enabling the prefabricated floor panels 101 to be readily screeded to an exact height so that each panel laps onto the next prefabricated floor panels 101 perfectly providing for a flat, finished fireproof floor structure.
  • the supporting structure 103 includes support beams 113 and columns which may be made from steel or concrete depending on the application, with concrete beams being preferable when compressive forces are applied such as with the columns 114 and steel being preferred when tensile loads are applied such as with the support beams 113.
  • the support beams 113 are supported by the columns 114 as is shown in Figures 1 and 2. It is critical that the columns 114 and support beams 113 are precisely located such that they form a straight line allowing the prefabricated floor panels 101 to be precisely installed and mounted to the support beams 113 which are in turn mounted to the columns 114.
  • the accurate location of the support beams 113 and columns 114 may be aided by the use of laser guides or similar location aids.
  • the strengthening beams 109 have a depth that is dictated by a number of factors including the expected loads and the span of the beam with greater loads and/or spans requiring strengthening beams 109 of greater strength and hence depth. Further, the strengthening beams contain reinforcing bar 120 to further improve on the strength of the strengthening beams 109.
  • the strengthening beams 109 are adapted so as to allow the adjacent floor members 105 to bear on the strengthening beams 109 when in position and to allow the top of the floor surface 107 (which is typically 75mm thick) to half lap onto the strengthening beams 109.
  • the half lap joint provides a secure fire proof, waterproof and vibration resistant seal at the junction of the adjacent floor members 105 and allows for the floor members 105 to be bolted or screwed to the ends of the strengthening beams 109 once in position with a gap to allow for expansion and contraction and to enable clearance owing to manufacturing abnormalities.
  • Panels will have 2-5mm clearance on each of its edges to allow for expansion and any tolerance issues due to fabrication defects.
  • Figure 6 shows a detailed side view of the prefabricated floor panels 101 , showing the location of the strengthening beams 109 in relation to the floor surface 107 and the location of the lap joints A.
  • a walling system (not shown) may be constructed for attachment to the supporting structure 103.
  • the wall panels (not shown) may be fabricated on tilting steel beds in one embodiment being 9m by 3m however they may be varied in size to suit requirements.
  • the walls may be made on tilting steel casting beds.
  • the beds would ideally be 9m by 3m, but can be varied to suit requirements. They can be made in a similar fashion to a stud wall out of 150mm x 50mm RHS.
  • the length of the beams are 3m and they are welded to 9m long top and bottom plates at 450mm centres. 3mm flat plate is glued to these frames to produce the wall bottom.
  • Steel RHS borders of the required wall thickness are attached to the external perimeter of the mold. This use of steel molds produces perfectly flat, square and true panels.
  • the beds have four pivot points along the bottom of the panel.
  • the walls have either steel mesh or basalt mesh as reinforcement and also basalt or polypropylene fibres as required.
  • the panels have 3m long x 12mm or 16mm threaded rod or rebar with connector nuts top and bottom to allow the panels to be lifted and also to have rod joined to the underside of the panel when installing them.
  • the floor or floor panels have corresponding oversize holes drilled in them which are filled with high strength grout when installing. This has the same effect of using starter bars in block wall construction.
  • the installation process involves trucking the precast elements to site and installing using a tower crane.
  • the process is as follows:
  • the supporting beams are then craned into position and checked using a laser to ensure correct positioning and length between beams;
  • the floor panels are installed so that the half lap that is rebated into the floor beam is ready to accept the next panel.
  • the layout position for the panels can be marked on the main supporting beams prior to installation.
  • the panels also have 5mm clearance at the lap to enable adjustment. Each panel must be carefully checked to ensure it is perfectly in position;
  • the method of constructing the construction would comprise the steps of: a. providing a supporting structure; b. providing a plurality of prefabricated floor panels, each floor panel presenting a floor surface; c. supporting the prefabricated floor panels on the support structure in a configuration to at least partly overlap each other.
  • the above steps may further include applying a fire retardant compound such as Sika® Firerate between the adjacent prefabricated floor panels prior to assembly, in order to provide a secure fire proof barrier between adjacent floor panels.
  • a fire retardant compound such as Sika® Firerate
  • plastic shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer.

Abstract

L'invention concerne un panneau de plancher préfabriqué (101) destiné à être utilisé avec une structure de support (103) comprenant un élément de plancher (105) l'élément de plancher (105) définissant une surface de plancher (107) et étant conçu pour venir en prise avec un panneau de plancher similaire adjacent (101) et au moins une ou plusieurs poutres de renfort (109) configurées pour venir en prise avec la structure de support (103) lors de son utilisation pour supporter le panneau de plancher préfabriqué (101).
PCT/AU2020/050830 2019-08-13 2020-08-10 Panneau de plancher préfabriqué, construction et procédé associé WO2021026600A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU2020281139A AU2020281139B2 (en) 2019-08-13 2020-08-10 Prefabricated floor panel, construction and method therefor
US17/634,873 US20220268018A1 (en) 2019-08-13 2020-08-10 Prefabricated floor panel, construction and method therefor

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2019902927A AU2019902927A0 (en) 2019-08-13 Prefabricated floor panel, construction and method therefor
AU2019902927 2019-08-13

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WO2021026600A1 true WO2021026600A1 (fr) 2021-02-18

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US (1) US20220268018A1 (fr)
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WO (1) WO2021026600A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT202100029342A1 (it) * 2021-11-19 2023-05-19 Spatti Ingegneria S R L Struttura prefabbricata, trave prefabbricata e tegolo prefabbricato
IT202100029348A1 (it) * 2021-11-19 2023-05-19 Spatti Ingegneria S R L Struttura prefabbricata, modulo prefabbricato

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US1867615A (en) * 1931-04-07 1932-07-19 Structural Gypsum Corp Slab and building construction
WO2001040592A1 (fr) * 1999-11-29 2001-06-07 Bahra Harambasic Structure de construction faisant appel a des elements de construction modulaires
US20060059835A1 (en) * 2004-09-22 2006-03-23 Richard Werner Precast composite floor panel with integrated joist and method of manufacturing same
US20060144005A1 (en) * 2004-12-30 2006-07-06 United States Gypsum Company Non-combustible reinforced cementitious lightweight panels and metal frame system for flooring
WO2011005970A1 (fr) * 2009-07-08 2011-01-13 Diversakore Llc Structure de construction
WO2011153916A1 (fr) * 2010-06-09 2011-12-15 Hong Kong Mei Li Sheng Flooring Co., Limited Ensemble planche de plancher
GB2504720A (en) * 2012-08-07 2014-02-12 Laing O Rourke Plc Reinforced joints between precast concrete elements
US20150240502A1 (en) * 2012-10-17 2015-08-27 Grc Environments Pty Ltd Floor assembly

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WO1992014886A1 (fr) * 1991-02-22 1992-09-03 Fearn Richard N Fondations de batiment et ensemble de formation de plancher
JPH08184121A (ja) * 1994-12-28 1996-07-16 Maeda Corp プレキャスト床板接合部構造
JP4372922B2 (ja) * 1999-11-02 2009-11-25 有限会社Ｏｍｎｉ ｈｏｕｓｅ．ｅｔ スラブ用埋込材
US8850770B2 (en) * 2001-06-21 2014-10-07 Roger C. Roen Structurally integrated accessible floor system
ITTO20060091U1 (it) * 2006-06-16 2007-12-17 Andrea Bonelli Pannello prefabbricato per la realizzazione di solai e tetti
GB2569607B (en) * 2017-12-21 2020-03-04 Laing Orourke Plc Demountable floor construction

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Publication number Priority date Publication date Assignee Title
US1867615A (en) * 1931-04-07 1932-07-19 Structural Gypsum Corp Slab and building construction
WO2001040592A1 (fr) * 1999-11-29 2001-06-07 Bahra Harambasic Structure de construction faisant appel a des elements de construction modulaires
US20060059835A1 (en) * 2004-09-22 2006-03-23 Richard Werner Precast composite floor panel with integrated joist and method of manufacturing same
US20060144005A1 (en) * 2004-12-30 2006-07-06 United States Gypsum Company Non-combustible reinforced cementitious lightweight panels and metal frame system for flooring
WO2011005970A1 (fr) * 2009-07-08 2011-01-13 Diversakore Llc Structure de construction
WO2011153916A1 (fr) * 2010-06-09 2011-12-15 Hong Kong Mei Li Sheng Flooring Co., Limited Ensemble planche de plancher
GB2504720A (en) * 2012-08-07 2014-02-12 Laing O Rourke Plc Reinforced joints between precast concrete elements
US20150240502A1 (en) * 2012-10-17 2015-08-27 Grc Environments Pty Ltd Floor assembly

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US20220268018A1 (en) 2022-08-25
AU2020281139B2 (en) 2021-03-25

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