ZA200606541B

ZA200606541B - Composite slabs

Info

Publication number: ZA200606541B
Application number: ZA200606541A
Authority: ZA
Inventors: Botha Andries Hendrik
Original assignee: Void Pro Business Trust
Priority date: 2005-05-07
Filing date: 2006-08-07
Publication date: 2007-07-25

Description

THIS INVENTION relates to composite slabs. It more particularly relates to an element for construction of a composite slab, and to a kit for construction of a composite slab. The invention relates also to a composite slab, and to a building structure including such composite slab.

The invention is expected to be particularly advantageously applicable to suspended slabs and, accordingly, such application should particularly be borne in mind when considering this specification.

In accordance with one aspect of the invention there is provided an element for construction of a composite slab, the element including an elongated body of profiled sheet material, the body being profiled to define one longitudinal ridge, two longitudinal pan portions flanking the ridge, and two longitudinal interlocking formations respectively provided at sides of the pan portions remote from the ridge and projecting operatively upwardly from the pan portions, for locking the element to similar elements provided with complementary interlocking formations.

The element may be of metal construction, i.e. it may be formed from a sheet of metal.

The ridge of the element may comprise a substantially flat crest and two slanted webs respectively extending between the crest and the respective pan portions, the crest having a width which exceeds the combined width of the two pan portions. :

One of the interlocking formations of the element may be in the form of a female formation comprising an interlocking-formation web projecting upwardly from the

S:WHW\Specs\Void former complete 7 August 2006

> .2006/05541 associated pan portion and a generally L-shaped lip projecting laterally from the upper end of the interlocking-formation web in a direction away from the ridge, the other interlocking formation being in the form of a male formation comprising an interlocking-formation web projecting upwardly from the associated pan portion and a flat lip projecting laterally from the upper end of the interlocking-formation web in a direction away from the ridge.

The webs of the ridge may slant downwardly away from the crest of the ridge towards the associated pan portion, the web of each interlocking formation slanting, in the direction of the ridge, upwardly from the associated pan portion towards the associated lip.

The height of the ridge may exceed the height of each interlocking formation.

The crest of the ridge may be provided with at least one longitudinally extending stiffening formation. Each stiffening formation may be in the form of a longitudinally extending groove.

The webs of the ridge may be provided with bonding formations for promoting bonding between the element and a concrete layer covering the element in use. The bonding formations thus serve to resist slip, during expansion and contraction of the composite slab, between the element and the concrete layer. The bonding formations may be in the form of longitudinally spaced dimples which intrude, from operatively outer faces thereof, into the webs.

In some embodiments, the element may include at least one stiffening member fast with the body of the element and located in an operatively downwardly opening channel formed by the ridge. Each stiffening member may be in the form of a metal plate extending, at a substantially right angle relative to the crest and the webs of the ridge, transversely across said channel formed by the ridge, each plate being secured to at least one of the crest and the webs of the ridge. Instead, each stiffening member may be in the form of a wooden board extending transversely across said channel formed by the ridge, each board being secured to at least one of the crest and the webs of the ridge.

S:\JHW\Specs\Void former complete 7 August 2006

In accordance with another aspect of the invention there is provided a kit for forming a composite slab, the kit including two elements as hereinbefore described, ancd a connector for connecting the two elements together, the connector being in the form of an elongated profiled sheet including a longitudinal pan and two connector interlocking formations respectively extending along respective sides of the pan and projectiing operatively upwardly therefrom, the connector interlocking formations complementary to the interlocking formations of each element.

One of the interlocking formations of each element may be in the form oef a female formation comprising an interlocking-formation web projecting upwardly and away from the associated pan portion and a generally L-shaped lip projecting laterally from tthe upper end of the interlocking-formation web in a direction away from the ridge, the othher interlocking formation being in the form of a male formation comprising an interlockimng- formation web projecting upwardly and away from the associated pan portion and a flat: lip projecting laterally from the upper end of the interlocking-formation web in a direction awway from the ridge, one of the connector interlocking formations being in the form of a fem ale formation identical to the female interlocking formation of each of the elements, and —the other connector interlocking formation being in the form of a male formation identical to -the male interlocking formation of each element.

In accordance with a further aspect of the invention there is provided a composite slab which includes: a plurality of elements as hereinbefore described arranged side-by-side such t-hat their ridges face upwardly, with adjacent elements being interlocked by means of their interlocking formations; and a concrete layer covering the elements.

In accordance with a yet further aspect of the invention there is providee a composite slab which includes:

S:\JHW\Specs\Void former complete 7 August 2006 a kit as hereinbefore described, the elements of the kit being arranged side-by-side with and flanking the connector of the kit, with the interlocking formations of the elements and the connector facing upwardly, and with the elements and the connector being interlocked by means of their interlocking formations, such that the pan portions of the 5 elements and the pan portion of the connector form a pan between the ridges of the elements, with the interlocking formations of the elements and the interlocking formations of the connector form two laterally spaced ridges standing proud of the pan; and a concrete layer covering the kit.

The invention, in a still further aspect provides a building structure which includes a composite slab as hereinbefore described.

The composite slab may be a suspended slab.

The invention is now described, by way of non-limiting example, with reference to the accompanying diagrammatic drawings.

In the drawings:

Figure 1 shows, schematically and in part, a three-dimensional view of an element in accordance with the invention for construction of a composite slab;

Figure 2 shows, schematically and in part, a three-dimensional view of a connector which forms part of a kit in accordance with the invention for construction of a composite slab;

Figure 3 shows, schematically and in part, an end elevation of a composite slab in accordance with the invention;

Figure 4 shows, schematically and in part, an end elevation of another embodiment of a composite slab in accordance with the invention; and

Figure 5 shows, schematically and in part, a side elevation of the element shown in

Figure 1.

S\JHW\Specs\Void former complete 7 August 2006

With reference to Figure 1 of the drawings, an element for con: struction of a composite slab is generally designated by reference numeral 10. The elemert 10 includes an elongated body 12 of sheet metal construction. The body 12 is profileed to define a longitudinal ridge 14, two longitudinal pan portions 16, 18 flanking the ridge= 14, and two longitudinal interlocking formations 20, 22 respectively provided at sides of them pan portions 16, 18 remote from the ridge 14. The interlocking formations 20, 22 projeect operatively upwardly from their respective associated pan portions 16, 18. As can be see=n in Figure 1, each of the aforementioned parts defined by the body 12 is generally planar.

The width of the ridge 14, as can be seen in the drawings, is gresater than the width of each pan portion 16, 18.

In use, a plurality of the building elements 10 are interlockeed to form a platform 24 (see Figure 3), which platform 24 is covered by a layer of concrete= 26 to form a composite slab 28 (also Figure 3) in accordance with the invention. Moree particularly, when the elements 10 are interlocked to form the platform 24, they are arra nged side-by- side with their ridges 14 facing upwardly. The elements 10 and, accordinglyw, the platform 24 formed thereby, on the one hand, serve to support, in the fashion of shutte- ring, the layer of concrete 26 whilst it sets and, on the other hand, by virtue of downwaardly opening channels 29 defined by the ridges 14 thereof, provides voids in the composite slab 28, thereby reducing the volume of concrete required to form the composite sslab 28. The elements 10 permanently form part of the composite slab 28, so that they are not removed after the layer of concrete 26 has set. Thus, as will be appreciated, the elerments 10 also serve to reinforce the composite slab 28.

When used in the context of a suspended slab, ends of interlocked elements 10 will rest on or be secured to a building structure, for example the walls of a building.

Depending on the span of a slab to be formed, the elements may be supported between their ends by a beam or the like.

S:\JHW\Specs\Void former complete 7 August 2006

Referring now to Figure 2 of the drawings, a connector forming part of a kit in accordance with the invention for construction of a composite slab is generally designated by reference numeral 30. The connector 30 is used to space two elements 10 laterally apart and to lock them together to form a platform 32 (see Figure 4) for receiving a layer of concrete 34, to form a composite slab 36 (see also Figure 3).

The connector 30 is of sheet metal construction, and is profiled to define a flat planar pan 38, and two connector interlocking-formations 40, 42 respectively provided at sides of the pan 38, and projecting operatively upwardly therefrom.

Referring back to the element 10 shown in Figure 1, the ridge 14 thereof comprises a generally flat crest 44 and two flat webs 46, 48 slanting downwardly and away from the respective side edges of the crest 44 towards the respective pan portions 16, 18.

To provide the element 10 with rigidity, two relatively shallow longitudinal grooves 50, 52 are provided in the crest 44, i.e. the grooves 50, 52 intrude, from an operatively upper or outer face thereof, into the crest 44. Further, the element 10 is provided with bonding formations in the form of dimples 54 provided in the webs 46, 48 for promoting bonding of the layer of concrete 26 to the element 10. More particularly, each of the dimples is generally rectangularly shaped when viewed face-on, with the dimples 54 being longitudinally spaced along the webs 46, 48. The dimples intrude, form operatively outer faces thereof, into the webs 46, 48.

The interlocking formation 20 of the element 10 is in the form of a female interlocking formation, and the interlocking formation 22 of the element 10 is in the form of a male interlocking formation. More particularly, the female interlocking formation 20 includes a flat interlocking-formation web 56 which projects operatively upwardly from one side edge of the pan portion 16 and is slanted towards the ridge 40, and a generally L- shaped lip 58 projecting laterally, away from the ridge 14, from an upper edge of the interlocking-formation web 56. As can be seen in the drawings, the L-shaped lip 58 includes two limbs, the shorter of which projects downwardly. Turning now to the male interlocking formation 22, it includes a flat interlocking-formation web 60 which projects

S:\JHW\Specs\Void former complete 7 August 2006 upwardly from the pan portion 18 and is slanted towards the ridges 14, and a flat lip 62 projecting laterally away from the ridge 14, from an upper edgie of the interlocking- formation web. To effect the aforedescribed interlocking of two adj=acent elements 10, the interlocking formations 20, 22 are complementarily shaped and sizead. Thus, in use, the L- shaped lip 58 of one element 10 is snugly received overt the flat lip 62 of an adjacent element 10, thereby interlocking the two elements 10.

Referring back to the connector 30, its interlocking —formations 40, 42 are complementarily shaped and sized to the interlocking formations 20., 22 of the element 10.

More specifically, the connector interlocking-formation 40 is in #the form of a female interlocking formation, including an interlocking-formation web 64 pr-ojecting upwardly from one side edge of the pan 38 of the connector 30, and an L-shaped ligp 66 projecting from an upper edge of the interlocking-formation web 64. The connector intterlocking-formation 42 of the connector 30, in turn, is in the form of a male interlocking #ormation, including an interlocking-formation web 68 projecting upwardly from the other sicde edge of the pan 38, and a flat lip 70 projecting from an upper edge of the interlocking—formation web 68. As can be seen in the drawings, the two interlocking-formation wetos 64, 68 are slanted towards each other, with their respective lips 66, 70 projecting awaay from each other, i.e. away from the pan 38.

Interlocking or connection of the each element 10 to fhe connector 30 takes place in similar fashion as hereinbefore described with referemnce to interlocking or connecting together of two elements 10.

As can be seen in Figure 4, when a plurality of elemaents 10 are connected together by means of connectors 30, the pan portions 16, 18 of adj acent elements 10 and the pan 38 of the connector 30 form a relatively wide pan, with the interlocking formations 20, 22 of the adjacent elements 10 and the interlocking formations ~40, 42 of the connector standing proud of said relatively wide pan. As will be appreciated, the proud standing 30 interlocking formations 20, 22, 40, 42 form two longitudinal ridgess in the aforedescribed

S:\JHW\Specs\Void former complete 7 August 2006 relatively wide pan, which ridges provide the platform 32 and, accordingly, the composite slab 36, with additional rigidity and strength.

Further, by virtue of the provision of the bonding formations, i.e. the dimples 54, slip, which would typically result from expansion and contraction of a composite slab, between the layer of concrete 26, 34 and the respective platforms 24, 32 is resisted.

Referring now to Figure 5 of the drawings, in certain embodiments, the element 10 may be provided with stiffening members 72. Each of the stiffening members 72 is in the form of a metal plate located in the downwardly opening channel 29 defined by the ridge 14 of the element 10. Each stiffening member 72 extends transversely across the channel 29, and is normal to the crest 44, and to the webs 46, 48. Further, each stiffening member 72, when viewed face-on, has an outline closely corresponding to the end profile of the channel 29 defined by the ridge 14, and is secured to the crest 44 and to the webs 46, 48 of the ridge 14. To permit such securing, the ridge 14 of the element 10 is provided with a plurality of apertures 74 (not shown in Figure 5, but see Figure 1). Also, for clarity, the dimples 54 are omitted from Figure 5. When a plurality of stiffening members 72 form part of the element 10, they are longitudinally spaced from each other along the channel 29. In another embodiment, instead of metal plates, each stiffening member 72 may be of wooden construction, in which case the aforementioned apertures 74 will be particularly advantageous for receiving securing elements, such as screws or nails.

As will be appreciated, the width and the height of the ridge 14 can vary from application to application. Likewise, the heights of the interlocking formations 20, 22 of the element 10 and the interlocking formations 40, 42 of the connector 30 can vary from application to application. Likewise, the length of the element 10 and the length of the connector 10 can vary from application to application.

The invention as described and illustrated thus provides an element for construction of a composite slab, which element is profiled to define a single longitudinal

S:\JHW\Specs\Void former complete 7 August 2006

©.2006/08541 ridge. Furthermore, by virtue of the connector 30, the invention also provides a kit for forming of a platform having pans which can be widened by using tHe connector.

S:\JHW\Specs\Void former complete 7 August 2006

Claims

3 -.2006/065 41, CLAIMS:

1. An element for construction of a composite slab, the element including an elongated body of profiled sheet material, the body being profiled to define one longitudinal ridge, two longitudinal pan portions flanking the ridge, and two longitudinal interlocking formations respectively provided at sides of the pan portions remote from the ridge and projecting operatively upwardly from the pan portions, for locking the element to similar elements provided with complementary interlocking formations.

2. An element as claimed in claim 1, which is of metal construction.

3. An element as claimed in Claim 1 or Claim 2, in which the ridge comprises a substantially flat crest and two slanted webs respectively extending between the crest and the respective pan portions, the crest having a width which exceeds the combined width of the two pan portions.

4. An element as claimed in Claim 3, in which one of the interlocking formations is in the form of a female formation comprising an interlocking-formation web projecting upwardly from the associated pan portion and a generally L-shaped lip projecting laterally from the upper end of the interlocking-formation web in a direction away from the ridge, the other interlocking formation being in the form of a male formation comprising an interlocking-formation web projecting upwardly from the associated pan portion and a flat lip projecting laterally from the upper end of the interfocking-formation web in a direction away from the ridge.

5. An element as claimed in Claim 4, in which the webs of the ridge slant downwardly away from the crest of the ridge towards the associated pan portion, the web of each interlocking formation slanting, in the direction of the ridge, upwardly from the associated pan portion towards the associated lip. S:\JHW\Specs\Void former complete 7 August 2006

6. An element as claimed in Claim 4 or Claim 5, in which the height of the ridge exceeds the height of each interlocking formation.

7. An element as claimed in any one of Claims 4 — 6 inclusive, in which the crest of the ridge is provided with at least one longitudinally extending stiffening formation.

8. An element as claimed in Claim 7, in which each stiffening formation is in the form of a longitudinally extending groove.

9. An element as claimed in any one of Claims 4 — 8 inclusive, in which the webs of the ridge are provided with bonding formations for promoting bonding between the element and a concrete layer covering the element in use.

10. An element as claimed in Claim 9, in which the bonding formations are in the 156 form of longitudinally spaced dimples which intrude, from operatively outer faces thereof, into the webs.

11. An element as claimed in any one of Claims 4 — 10 inclusive, which includes at least one stiffening member fast with the body of the element and located in an operatively downwardly opening channel formed by the ridge.

12. An element as claimed in Claim 11, in which each stiffening member is in the form of a metal plate extending, at a substantially right angle relative to the crest and the webs of the ridge, transversely across said channel formed by the ridge, each plate being secured to at least one of the crest and the webs of the ridge.

13. An element as claimed in Claim 11, in which each stiffening member is in the form of a wooden board extending transversely across said channel formed by the ridge, each board being secured to at least one of the crest and the webs of the ridge. S:\JHW\Specs\Void former complete 7 August 2006

.2006/0 8541

14. A kit for forming a composite slab, the kit including two elements as claimed in any one of the preceding claims, and a connector for connecting the two elements together, the connector being in the form of an elongated profiled sheet including a longitudinal pan and two connector interlocking formations respectively extendi ng along respective sides of the pan and projecting operatively upwardly therefrom, the connector interlocking formations complementary to the interlocking formations of each elemeent.

18. A kit as claimed in Claim 14, in which one of the interlocking fornrmations of each element is in the form of a female formation comprising an interlocking-formaation web projecting upwardly and away from the associated pan portion and a generally L-s haped lip projecting laterally from the upper end of the interlocking-formation web in a directtion away from the ridge, the other interlocking formation being in the form of a male #ormation comprising an interlocking-formation web projecting upwardly and away #from the associated pan portion and a flat lip projecting laterally from the upper en d of the interlocking-formation web in a direction away from the ridge, one of the connector interlocking formations being in the form of a female formation identical to th e female interlocking formation of each of the elements, and the other connector interlocking formation being in the form of a male formation identical to the male interlocking formation of each element.

16. A composite slab which includes: a plurality of elements as claimed in any one of Claims 1 — 13 inclusive arranged side-by-side such that their ridges face upwardly, with adjacent elements being imterlocked by means of their interlocking formations; and a concrete layer covering the elements.

17. A composite slab which includes: a kit as claimed in Claim 14 or Claim 15, the elements of the kit being arran ged side- by-side with and flanking the connector of the kit, with the interlocking formatio=ns of the elements and the connector facing upwardly, and with the elements and the connector being interlocked by means of their interlocking formations, such that the pan p=ortions of S:\JHW\Specs\Void former complete 7 August 2006 the elements and the pan portion of the connector form a pan between the ridges of the elements, with the interlocking formations of the elements and the interlocking formations of the connector form two laterally spaced ridges standing proud of the pan; and a concrete layer covering the kit.

18. A building structure which includes a composite slab as claimed in Claim 16 or Claim 17.

19. A building structure as claimed in Claim 18, in which the composite slab is a suspended slab.

20. An element as claimed in Claim 1, substantially as herein described and illustrated with reference to Figure 1 and 3.

21. A kit as claimed in Claim 14, substantially as herein described and illustrated with reference to Figures 2 and 4.

22. A composite slab as claimed in Claim 16, substantially as herein described and illustrated with reference to Figure 3.

23. A composite slab as claimed in Claim 17, substantially as herein described and illustrated with reference to Figure 4.

23. A building structure as claimed in Claim 18, substantially as herein described. DATED THIS 7TH DAY OF AUGUST 2006 “A SMIT & VAN WYK, INC. APPLICANT'S PATENT ATTORNEYS S:\JHWASpecs\Void former complete 7 August 2006