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WO2018152589A1 - Panneau préfabriqué pour un système de revêtement de plancher, procédé de formation d'un tel panneau préfabriqué, et système de revêtement de plancher - Google Patents

Panneau préfabriqué pour un système de revêtement de plancher, procédé de formation d'un tel panneau préfabriqué, et système de revêtement de plancher Download PDF

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Publication number
WO2018152589A1
WO2018152589A1 PCT/AU2018/050163 AU2018050163W WO2018152589A1 WO 2018152589 A1 WO2018152589 A1 WO 2018152589A1 AU 2018050163 W AU2018050163 W AU 2018050163W WO 2018152589 A1 WO2018152589 A1 WO 2018152589A1
Authority
WO
WIPO (PCT)
Prior art keywords
floor panel
board
boards
panel according
floor
Prior art date
Application number
PCT/AU2018/050163
Other languages
English (en)
Inventor
Danny BORZILLO
Grant Bruce JOHNSON
Jason Andrew WYLIE
Original Assignee
JBW Designs 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 AU2017900629A external-priority patent/AU2017900629A0/en
Application filed by JBW Designs Pty Ltd filed Critical JBW Designs Pty Ltd
Publication of WO2018152589A1 publication Critical patent/WO2018152589A1/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
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/01—Flat foundations
    • E02D27/02—Flat foundations without substantial excavation
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E—FIXED CONSTRUCTIONS
    • E03—WATER SUPPLY; SEWERAGE
    • E03C—DOMESTIC PLUMBING INSTALLATIONS FOR FRESH WATER OR WASTE WATER; SINKS
    • E03C1/00—Domestic plumbing installations for fresh water or waste water; Sinks
    • E03C1/12—Plumbing installations for waste water; Basins or fountains connected thereto; Sinks
    • 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
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2002/3488—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by frame like structures

Definitions

  • PREFABRICATED PANEL FOR A FLOORING SYSTEM METHOD OF FORMING SUCH A PREFABRICATED PANEL, AND A FLOORING SYSTEM
  • the present invention relates to a prefabricated floor panel for a flooring system, a flooring system incorporating such a prefabricated floor panel, a method of forming a prefabricated floor panel and a flooring system with the prefabricated floor panel.
  • the present invention seeks to overcome one or more of the disadvantages in the existing systems or at least to provide the public with a useful choice.
  • the present invention broadly consists in a prefabricated floor panel adapted for use in a floor system, the prefabricated panel including: a first board, a second board, and a spacing element for spacing the first board apart from the second board to form a load bearing floor panel.
  • the spacing element may comprise at least one structural reinforcement connected to the first and second panels.
  • the structural reinforcement may comprise a timber or steel support frame.
  • the structural reinforcement may alternatively comprise a fibre reinforced polymer or a reinforced MgO board section.
  • the structural reinforcement spaces the first and second boards from each other.
  • the floor panel may include a plurality of structural reinforcements, which are spaced apart from each other.
  • the plurality of structural reinforcements are spaced apart from each other, along a width of the first and second boards, by a distance of about 400mm to 900mm, preferably about 600mm.
  • the structural reinforcement, or at least one of the plurality of structural reinforcements may have an l-shape in cross section.
  • the structural reinforcement, or at least one of the plurality of structural reinforcements may have a C-shape in cross section.
  • the structural reinforcement, or at least one of the plurality of structural reinforcements may have a rectangular cross-section, such as a rectangular solid.
  • the structural reinforcement may for example be an I- joist, or a C-joist.
  • the structural reinforcement may include a diagonal structure.
  • the structural reinforcement is an open web truss system extending along a length of the first and second boards.
  • One such open web truss system is sold under the registered trade mark Posi-STRUT® which is owned by Mitek Holdings, Inc.
  • the floor panel may include an insulating material disposed between the first and second boards.
  • the spacing element may comprise an insulating material extending between the first and second boards.
  • the insulating material may completely fill the space between the first and second boards. In this case, a structural reinforcement may not be required, provided the floor panel comprising the combination of the first and second boards and the insulating material has sufficient load bearing capacity for normal use.
  • the insulating material may include any one or more of the following: expanded polystyrene (EPS), extruded polystyrene (XPS), glass, glass wool, rockwool, polyester, fibreglass, foil, or paper.
  • EPS expanded polystyrene
  • XPS extruded polystyrene
  • At least one of the first and second boards may comprise a concrete- based or cement-based board, such as autoclaved aerated concrete or fibre cement.
  • At least one of the first and second boards includes magnesium oxide (MgO).
  • MgO magnesium oxide
  • MgO magnesium oxide board
  • Magnesium oxide boards have previously been used as structurally insulated wall panels, though they have generally not been regarded as suitable for load bearing floor panels. We have found that structurally insulated floor panels in accordance with the invention are effective for use as load bearing floor panels having spans of up to about 3 metres.
  • the first board and/or the second board may comprise a wood-based board board, such as plywood or particle board.
  • at least one of the first and second boards is an oriented strand board (OSB). Oriented strand boards are similar to particle board, and are formed by adding adhesives and compressing layers of wood stands or flakes in particular orientations.
  • OSB oriented strand board
  • each of the first and second boards has a thickness of greater than 3mm.
  • the thickness of each board is between about 3mm to 40mm.
  • the thickness of the first board is different from the thickness of the second board.
  • the first board is preferably a top board and the second board is preferably a bottom board.
  • the thickness of the top board is preferably greater than the thickness of the bottom board.
  • the thickness of the top board is between about 18mm and 24mm.
  • the thickness of the bottom board is between about 4mm and 12mm.
  • the thickness of the first board may be the same as the thickness of the second board.
  • the insulating material includes expanded polystyrene (EPS).
  • the insulating material may additionally, or alternatively, include extruded polystyrene (XPS).
  • XPS extruded polystyrene
  • the insulating material may additionally, or alternatively, include glass insulation.
  • the insulating material may additionally, or alternatively, include glass wool, rockwool, polyester, or fibreglass material.
  • the insulating material may additionally, or alternatively, include recycled paper or a foil. In the case where the insulating material may additionally or alternatively include air.
  • the first and second boards may be spaced apart from each other by a distance from about 100 to about 450mm.
  • the distance between the boards is from about 150mm to about 400mm.
  • the distance between the boards is preferably from about 200mm to about 400mm and more preferably the distance between the boards is from about 240mm to about 300mm.
  • the distance between the boards is preferably from about 100mm to about 300mm and more preferably the distance between the boards is from about 150mm to about 200mm.
  • the first board includes an inlet aperture for to allow for access into a space between the first and second boards.
  • the second board may include an outlet aperture, wherein the inlet aperture is in fluid communication with the outlet aperture in a space between the first and second boards.
  • a channel or conduit is provided between the inlet aperture and outlet aperture to provide the fluid communication between the inlet aperture and outlet aperture.
  • the inlet aperture, the outlet aperture, and the channel or conduit provides internal plumbing for the prefabricated panel.
  • the present invention provides a method of forming a prefabricated floor panel, the method comprising: providing a first board, providing a second board spaced apart from the first board; and providing a spacing element between the first board and the second board to form a load bearing floor panel.
  • the method may include connecting at least one structural reinforcement to the first and second boards to form the spacing element between the first and second boards.
  • the method may include providing an insulating material between the first and second boards.
  • the insulating material may be injected into a space between the two boards. Alternatively, the insulating material may be glued to the first and/or second boards. Alternatively, the insulating material may be sprayed into the space between the two boards.
  • the present invention provides a prefabricated floor panel when formed by the method of the second aspect described above.
  • the present invention provides a floor system incorporating a prefabricated floor panel according to the first aspect or the third aspect described above.
  • the floor system may include at least one beam to which the prefabricated floor panel is secured.
  • the at least one beam may be a precast beam, a prestressed concrete precast beam, a T-beam, or an I-beam.
  • the prefabricated floor panel may include a hanger connection for attachment to the beam.
  • the floor system includes a screw pile or a bored pier for securing the beam to the ground.
  • the screw pile may be a 'twin fin' type screw pile, such as the KatanaTM Pile made by Katana Foundations Australia.
  • Katana is a registered trade mark owned by Patented Foundations Pty Ltd.
  • FIGURE 1 shows an elevation view of a first embodiment of a floor panel
  • FIGURE 2 shows a front view of a panel shown in Figure 1 ;
  • FIGURE 3 shows a perspective view of the floor panel of Figure 1 ;
  • FIGURES 4A to 4D show different front views of the floor panel of Figure 1 with different insulating material
  • FIGURES 5A and 5B show schematic sectional views of a floor panel similar to Figure 1 incorporating a drain;
  • FIGURE 6A and 6B show a top perspective view and a side view respectively of parts of the drain of Figure 5;
  • FIGURES 7A to 7C show schematic sectional views of the floor panel of Figure 1 in example panel-to-wall assemblies with a precast beam;
  • FIGURE 8A to 8C show schematic sectional views of the floor panel of Figure 1 in example panel-to-wall assemblies with a T-beam;
  • FIGURE 9 shows a perspective view of a T-beam used in the panel-to- wall assemblies of Figures 8A to 8C;
  • FIGURES 10A to 10C show schematic sectional views of the floor panel of Figure 1 in example panel-to-wall assemblies with a prestressed concrete precast beam;
  • FIGURES 1 1 A to 1 1 C show schematic sectional views of the floor panel of Figure 1 in example panel-to-panel assemblies with a precast beam;
  • FIGURES 12A to 12C show schematic sectional views of the floor panel of Figure 1 in example panel-to-panel assemblies with a T-beam;
  • FIGURES 13A to 13C show sectional side views of the floor panel of
  • Figure 1 in example panel-to-panel assemblies with a prestressed concrete precast beam
  • FIGURE 14 shows an elevation view of a second embodiment of a floor panel
  • FIGURE 15 shows a front view of the floor panel shown in Figure 14;
  • FIGURE 16 shows a perspective view of the floor panel of Figure 14
  • FIGURES 17A and 17B show schematic sectional views of the floor panel of Figure 14 in example panel-to-wall assemblies with a precast beam;
  • FIGURES 18A and 18B show schematic sectional views of the floor panel of Figure 1 in example panel-to-wall assemblies with a T-beam;
  • FIGURE 19 shows a perspective view of a T-beam used in the panel- to-wall assemblies of Figures 18A and 18B;
  • FIGURES 20A and 20B show schematic sectional views of the floor panel of Figure 14 in example panel-to-wall assemblies with a prestressed concrete precast beam;
  • FIGURES 21 A and 21 B show schematic sectional views of the floor panel of Figure 14 in example panel-to-panel assemblies
  • the boards 120, 140 may be formed from a concrete-based or cement-based material, and in one embodiment are magnesium oxide (MgO) boards.
  • the boards 120, 140 may alternatively comprise fibre cement or autoclaved aerated concrete.
  • each board 120, 140 is preferably an Oriented Strand Board (OSB), though other wood-based materials may be used, such as plywood or particle board.
  • OSB Oriented Strand Board
  • Each board 120, 140 preferably has a thickness from about 3mm to about 40mm.
  • the top board 120 may be thicker than the bottom board 140.
  • the boards may have the same thickness, or In one embodiment, the top board 120 has a thickness of about 32mm, while the bottom board 140 has a thickness has a thickness between 4mm and 8mm, and preferably about 4mm. In other embodiments, the thickness of the first, top board may be the same as the thickness of the second, bottom board, or the bottom board 140 may be thicker than the top board 120.
  • the first and second boards 120, 140 may be spaced apart from each other by a distance from about 150mm to about 450mm. In one embodiment, the boards are spaced apart from each other by a distance of about 248mm.
  • a spacing element in the form of a structural reinforcement 160.
  • the structural reinforcement 160 is connected to the top and bottom boards 120, 140 and may comprise an open web truss system of the type sold under the registered trade mark Posi-STRUT® which is owned by Mitek Holdings, Inc.
  • the reinforcing structure may include any timber or steel support frame, for example having an l-shape cross-sectional area or a C-shape cross- sectional area.
  • the structural reinforcement may be any timber or steel support frame, for example having an l-shape cross-sectional area or a C-shape cross- sectional area.
  • other diagonally arranged structures may be used as the structural reinforcement.
  • the panel 100 includes a plurality of reinforcing structures 160 extending substantially along the length of the boards 120, 140.
  • the reinforcing structures 160 are preferably spaced from each other by a distance from about 450mm to about 900mm. In one embodiment, the reinforcing structures are spaced from each other by a distance of about 555mm.
  • the reinforcing structure 160 may have a hanger connection 162 along at least one side as shown in Figure 3 for allowing connection of the panel 100 to a wall or to an adjacent panel. In other embodiments of the panel, the hanger connection may not be provided.
  • the panel may be provided with an insulating material 180 in the space 130 between the two boards 120, 140.
  • the insulating material 180 may comprise expanded polystyrene (EPS).
  • the insulating material may additionally or alternatively include extruded polystyrene (XPS).
  • the insulating material is preferably injected into a space between the two boards.
  • the insulating material can additionally or alternatively include glass insulation, fibreglass material.
  • the space 130 between the boards 120, 140 and the reinforcing structures 160 may simply be filled with air.
  • Figures 4A to 4D illustrate different insulating materials that can be provided in the space 130.
  • the space 130 between the two boards 120, 140 is filled by glass wool insulation 182.
  • the space between the two boards 120, 140 may be filled by a rockwool insulation or polyester insulation.
  • an insulating foil 184 is provided in the space between the two boards 120, 140.
  • the foil 184 is attached to the top board 120.
  • the space between the two boards 120, 140 is at least partially filled with an expanded polystyrene insulating material 186.
  • the expanded polystyrene is held in place in the space between neighbouring reinforcing structures 160.
  • the space 130 between the two boards 120, 140 is filled with a foam insulating material 188, which is sprayed or injected into the space between the two boards 120, 140.
  • the floor panel 100 is provided with an inlet aperture 1 10 in the top board 120 and an outlet aperture 1 15 in the bottom board 140.
  • a drain 1 1 1 is mounted in the inlet aperture 1 10 and is in fluid communication with the outlet aperture 1 15.
  • piping 1 50 is provided in the space 130 between the first and second boards 120, 140, to connect the inlet aperture 1 10 and drain 1 1 1 to the outlet aperture 130.
  • the piping 150 forms a conduit or channel between the inlet aperture 1 10 and outlet aperture 1 15 to provide the fluid communication between the inlet aperture 1 10 and outlet aperture 130.
  • the inlet aperture 1 10, the drain 1 1 1 , the outlet aperture 130, and the piping 150 provide internal plumbing for the prefabricated floor panel 100.
  • the piping 150 can extends beyond the outlet aperture 1 15 to a suitable drainage point as shown in Figure 5A.
  • the inlet aperture 1 10, outlet aperture 120 and/or space 180 between the first and second boards 120, 140 could be used for any type of piping or cabling.
  • other purposes include electronic cabling or optical fibre cabling.
  • FIGs 6A and 6B show different views of the drain 1 1 1 , which is mounted in the inlet aperture 1 10.
  • the drain 1 1 1 has a hollow body 1 12 with an entry opening 1 14 on one side of the hollow body 1 12, and an exit opening 1 16 (shown in Figure 6B) on an opposite side of the hollow body 1 12.
  • the hollow body 1 12 is provided with a lip 1 18 surrounding the entry opening 1 14, which is adapted to sit substantially flush with the top board of the prefabricated panel when the drain is positioned in the inlet aperture 1 10 in the floor panel.
  • the entry opening 1 14 is larger than the exit opening 1 16.
  • the panel 100 rests against a precast beam 400, with the hanger connection 162 of the reinforcing structure engaging the precast beam 400.
  • a timber packer 440 is provided in the space between the precast beam 400 and the hanger connection 162 of the panel 100 to provide support for the hanger connection 162 on the precast beam 400.
  • the panel 100 is secured to a side face of the precast beam 400 via a bolt 460, such as a DynaboltTM.
  • the precast beam 400 supports a wall 300.
  • the precast beam 400 supporting the wall 300 can be secured to the ground in one of a variety of configurations.
  • the precast beam 400 can be secured to the ground using a screw pile.
  • the screw pile may be a 'twin fin' type screw pile 520, such as a KatanaTM Pile made by Katana Foundations Australia as shown in Figure 7A.
  • a pile 540 having a plurality of steel tubes, such as a SurefootTM pile may be used as shown in Figure 7B.
  • a thick galvanized steel cap plate 510 is provided to secure the screw pile to a side face and the lower face of the precast beam 400.
  • the precast beam 400 can be secured to the ground using a bored pier 560 as shown in Figure 7C.
  • a dowel 530 is provided for securing the precast beam 400 and the bored pier 560 through the hanger connection of the panel 100.
  • the wall 300 is a brick veneer wall having inner and outer wall sections 310 and 320, with space 330 between the inner and outer wall sections 310, 320.
  • the wall 300 shown in Figures 7 A to 7C is an exterior wall of a building, with compacted backfill 350 shown adjacent the exterior surfaces of the wall 300 and the upper ends of the respective piles 520, 540 or bored pier 560.
  • the precast beam 400 of Figure 7A to 7C may be replaced by a steel T-beam 600 as shown in Figures 8A to 8C and Figure 9, or by a prestressed concrete pre-cast beam 700 as shown in Figures 10A to 10C. Similar to the embodiments described with reference to Figures 7A to 7C, the steel T-beam plate 600 and the prestressed concrete pre-cast beam 700 can be secured to the ground using a screw piles, such as the KatanaTM screw pile 520 or the SurefootTM pile 540, or using a bored pier 560.
  • a screw piles such as the KatanaTM screw pile 520 or the SurefootTM pile 540
  • the T-beam is formed by an orthogonal arrangement of two plates 610 and 630, as shown in Figure 9.
  • the plates 610, 630 are preferably made of a metal, more preferably steel, but may be made of other materials, such as MgO.
  • the two plates 610 and 630 may be secured together or formed such that the arrangement forms a T-shape in cross-section by any convenient method. In the case of steel or other metal plates, the plates may be secured together by welding. Plates made of MgO may be laminated together. In other embodiments, the MgO plates can be arranged to form a cross-section having an l-shape, C-shape, or box shape.
  • a floor panel 100' is shown connected to a steel T-beam 600. Similar to the panel 100 shown in Figures 1 to 3, the panel 100' of this embodiment has a top board 120 spaced apart from the bottom board 140, with a reinforcing structure 160 provided between the boards 120, 140. However, unlike the panel 100 of Figures 1 to 3, the reinforcing structure 160 of the panel 100' of this embodiment does not have a hanger connection. When the panel 100' engages the T-beam, 600, the panel rests substantially flush against a face of the T-beam 600.
  • the T-beam 600 is provided with slots 620 in a section of the T-beam that is configured to engage the screw pile or bore pier.
  • Fastening means such as a screw or a bolt, secures the T-beam 600 to the screw- pile or bore pier through the slots 620.
  • the slots 620 allow the T-beam to be horizontally adjusted in a direction 640 along the length of the T-beam during assembly.
  • FIG. 10A to 10C The example assemblies shown in Figures 10A to 10C are similar to the example assemblies disclosed with reference to Figures 7A to 7C and like reference numerals indicate like parts.
  • the example assemblies of Figures 10A to 10C instead of a precast beam 400 as disclosed with reference to Figures 7A to 7C, the example assemblies of Figures 10A to 10C use a prestressed concrete pre-cast beam 700. While the embodiments with the prestressed concrete precast beam 700 are generally similar to the embodiments with the precast beam 400, for the embodiment of Figure 10C where a bored pier 560 is used, a dowel is not provided unlike for when the bored pier 560 is used for a precast beam.
  • FIG. 1 1 A to 1 1 C, 12A to 12C and 13A to 13C respectively show example panel-to-panel assemblies in accordance with embodiments of the present inventions.
  • like reference numerals as those used in Figures 7A to 10C parts indicate like parts.
  • the adjacent panels 100 can be connected to form a floor system using the precast beam 400.
  • the precast beam 400 can be secured to ground using a screw pile, such as a KatanaTM screw pile 520, or a SurefootTM pile 540, or a bored pier 560.
  • a screw pile such as a KatanaTM screw pile 520, or a SurefootTM pile 540, or a bored pier 560.
  • a bolt such as a DynaboltTM may be used to secure each respective panel 100 to a side face of the precast beam 400.
  • a dowel can be provided through the hanger connection of the respective panel 100 and through the precast beam 400 into the bored pier 560 to secure the respective panel 100 to the bored pier 560.
  • the hanger connection of each panel 100 and the precast beam 400 are dimensioned such that, when hanger connections of adjacent panels 100 are positioned on a precast beam 400, the reinforcing structures of each panel are substantially adjacent to a side face of the precast beam 400, and hanger portions of adjacent panels 100 form a substantially continuous surface on the precast beam 400.
  • adjacent panels 100' of the embodiment without hanger connections can be connected to form a ground slab using a T-beam 600.
  • the T-beam 600 can be secured to ground using a screw pile, such as the KatanaTM screw pile 520, or a SurefootTM pile 540, or a bored pier 560.
  • adjacent panels 100 can be connected to form a floor system using a prestressed concrete precast beam 700.
  • the example assemblies of these embodiments are generally the same as the example assemblies described with reference to Figures 1 1 A to 1 1 C. However, for the embodiment of Figure 1 1 C where a bored pier 560 is used, a dowel is not provided unlike for when the bored pier 560 is used for a precast beam.
  • FIG. 14 to 16 another embodiment of a prefabricated floor panel 800 adapted for use in a flooring system is shown.
  • the floor panel 800 comprises a first, top board 820 and a second, bottom board 840 that are spaced apart from each other.
  • the floor panel 800 differs from the embodiment of Figures 1 to 3 in that the space 830 between the first and second boards 820, 840 is completely filled with insulating material 860, and there is no additional structural reinforcement.
  • the floor panel 800 can withstand loads of up to 7kN/m 2 .
  • loads of up to 7kN/m 2 For most residential purposes, it is typically sufficient for the floor panels to withstand loads of up to about 3kN/m 2 .
  • the first and second boards 820, 840 are preferably magnesium oxide (MgO) boards, though they may be formed from other concrete-based or cement-based materials, such as fibre cement or autoclaved aerated concrete.
  • each board 820, 840 is preferably an Oriented Strand Board (OSB), though other wood-based materials may be used, such as plywood or particle board.
  • OSB Oriented Strand Board
  • Each board 820, 840 preferably has a thickness from about 3mm to about 40mm.
  • the top board 820 may be thicker than the bottom board 840, or alternatively, the boards may have the same thickness.
  • the top board 820 has a thickness of between about 18mm and 24mm, while the bottom board 840 has a thickness has a thickness between about 4mm and 12mm.
  • the thickness of the first, top board may be the same as the thickness of the second, bottom board, or the bottom board 840 may be thicker than the top board 820.
  • the insulating material 860 in the space 830 between the first and second boards 820, 840 may have a thickness from about 100mm to about 300mm. In one embodiment, the boards are spaced apart from each other by a distance of between 150mm and about 200mm.
  • the insulating material 860 in the space 830 between the two boards 820, 840 preferably comprises polystyrene, either in the form of expanded polystyrene (EPS) or extruded polystyrene (XPS), or another foam insulating material.
  • the insulating material 860 may be injected, or sprayed into the space 830 between the two boards 820, 840.
  • the insulating material can additionally, or alternatively, include glass insulation, such as glass wool insulation, fibreglass material, rockwool insulation, or polyester insulation.
  • the floor panel 800 may also be provided with a connecting structure 862 on at least one side edge to assist in connecting the floor panel 800 to a wall, or to another floor panel.
  • the connecting structure 862 may be a hanger connection similar to the hanger connection of the embodiment of Figures 1 to 3, or another element, such as a concrete beam or steel plate which can be bolted or other secured to a beam of a wall or a similar beam of steel plate on an adjacent floor panel.
  • Figure 17A shows the floor panel 800 secured to a precast beam 400 of a wall structure 300 by a bolt 920, such as a DynaboltTM or ChemsetTM bolt which extends through the connecting structure 862 and the precast beam 400.
  • the precast beam 400 can be secured to the ground in one of a variety of configurations.
  • the precast beam 400 can be secured to the ground using a screw pile.
  • the screw pile may be a 'twin fin' type screw pile 520, such as a KatanaTM Pile made by Katana Foundations Australia as shown in Figure 17A.
  • a pile having a plurality of steel tubes, such as a SurefootTM pile may be used in similar manner to that shown in Figure 7B.
  • the precast beam 400 can be secured to the ground using a bored pier 560 in similar manner to that shown in Figure 7C.
  • Figure 17B shows the floor panel 800 secured to the upper end of a bored pier 560 on which a wall structure 300 is supported.
  • the floor panel 800 may be secured to the bored pier by bolts 980 which extend completely through the first and second boards 820, 840 and the insulating material 860 of the panel into the upper end of the bored pier 560.
  • the precast beam 400 of Figure 17A and 17B may be replaced by a T- beam plate 600 as shown in Figures 18A, 18B and 19 in similar manner to that described with reference to Figures 8A, 8B, 8C and Figure 9, and corresponding reference numerals have been applied to corresponding parts.
  • the precast beam 400 of Figure 17A and 17B may be replaced by a prestressed concrete pre-cast beam 700 as shown in Figures 20A and 20B in similar manner to that described with reference to Figures 10A, 10B and 10C, and corresponding reference numerals have been applied to corresponding parts.
  • the steel T-beam plate 600 and the prestressed concrete pre-cast beam 700 can be secured to the ground using a screw pile 940, such as the KatanaTM screw pile 940 as shown in Figures 18A and 20A, by another type of pile, such as a SurefootTM pile (not shown), or by using a bored pier 960 as shown in Figures 18B and 20B.
  • a screw pile 940 such as the KatanaTM screw pile 940 as shown in Figures 18A and 20A
  • another type of pile such as a SurefootTM pile (not shown)
  • a bored pier 960 as shown in Figures 18B and 20B.
  • the T-beam shown in Figure 19 is formed by an orthogonal arrangement of two plates 610 and 630, as shown in Figure 19.
  • the plates 610, 630 are preferably made of a metal, more preferably steel, but may be made of other materials, such as MgO.
  • the two plates 610 and 630 may be secured together or formed together such that the arrangement forms a T-shape in cross-section by any convenient method. In the case of steel or other metal plates, the plates may be secured together by welding. Plates made of MgO may be laminated together. In other embodiments, the MgO plates can be arranged to form a cross-section having an l-shape, C-shape, or box shape.
  • Figures 18 A and B show the floor panel 800 connected to a steel T- beam 600.
  • an end surface of the panel rests substantially flush against the vertical plate 630 of the T-beam 600
  • the second, bottom board of the floor panel 800 rests on the horizontal plate 610 of the T-beam 600 .
  • the T-beam 600 is provided with slots 620 in a section of the T-beam that is configured to engage the screw pile or bore pier.
  • Fastening means such as a screw or a bolt, secures the T-beam 600 to the screw- pile or bore pier through the slots 620.
  • the slots 620 allow the T-beam to be horizontally adjusted in a direction 640 along the length of the T-beam during assembly.
  • FIG. 20A and 20B are similar to the example assemblies disclosed with reference to Figures 17A and 17B and like reference numerals indicate like parts.
  • the example assemblies of Figures 20A and 20B instead of a precast beam 900 as disclosed with reference to Figures 17A and 17B, the example assemblies of Figures 20A and 20B use a prestressed concrete pre-cast beam 950.
  • adjacent panels 800, 800' can be connected to form a floor system.
  • a connecting structure 862 is used.
  • the connecting structure 862 can be secured to ground using a screw pile 520, such as a KatanaTM screw pile as shown in Fig 21 A, or another type of pile, such as a SurefootTM pile (not shown).
  • the adjacent panels 800, 800' are secured to a bored pier 560.
  • a bolt such as a DynaboltTM or ChemsetTM bolt may be used to secure one panel 800 to an adjacent panel 800'.
  • a dowel 530 can be provided through each respective panel 800, 800' and into the bored pier 560 to secure the respective panel 100 to the bored pier 560.
  • adjacent panels 800, 800' can be connected to form a floor system using a T-beam 600 in similar manner to that described with reference to Figures 18A and 18B.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mining & Mineral Resources (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Paleontology (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Floor Finish (AREA)

Abstract

La présente invention concerne un panneau de plancher préfabriqué (100, 800) qui est conçu pour être utilisé dans un système de plancher. Le panneau de plancher (100, 800) comprend un premier panneau (120, 820) et un second panneau (140, 840) espacé du premier panneau (120, 820) par un élément d'espacement qui est disposé dans l'espace (130, 830) entre les premier et second panneaux (120, 140 ; 820, 840) pour former un panneau de plancher porteur. L'élément d'espacement peut comprendre au moins un renfort structurel (160) raccordé aux premier et second panneaux (120, 140) et/ou à un matériau isolant (860) qui remplit l'espace (130, 830) entre les premier et second panneaux (120, 140 ; 820, 840). Dans un système de revêtement de plancher, le panneau de plancher (100, 800) peut être fixé à un panneau de plancher adjacent et/ou à une structure murale. Le panneau de plancher (100, 800) peut également incorporer un système de drainage.
PCT/AU2018/050163 2017-02-24 2018-02-26 Panneau préfabriqué pour un système de revêtement de plancher, procédé de formation d'un tel panneau préfabriqué, et système de revêtement de plancher WO2018152589A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2017900629A AU2017900629A0 (en) 2017-02-24 Prefabricated panel for a flooring system, method of forming such a prefabricated panel, and a flooring system
AU2017900629 2017-02-24

Publications (1)

Publication Number Publication Date
WO2018152589A1 true WO2018152589A1 (fr) 2018-08-30

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10870990B1 (en) 2019-05-10 2020-12-22 Peter Baruch Mueller Closed panel building systems
WO2022220719A1 (fr) * 2021-04-13 2022-10-20 Klara 500/1 Ab Élément de fondation de construction préfabriqué, procédé de fabrication dudit élément de fondation et procédé de construction d'une fondation de construction
WO2023062608A1 (fr) * 2021-10-16 2023-04-20 Sabery Mohammad Fondation modulaire préfabriquée destinée à des bâtiments résidentiels à étage unique

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5685114A (en) * 1995-03-20 1997-11-11 Tanaka Masakatsu Design Office Co., Ltd. Structural member, floor structure, and roof structure for wooden building and a method of building with the same
US20060254208A1 (en) * 2004-09-28 2006-11-16 Mike Clark Paneling system and method
US20100325990A1 (en) * 2009-05-22 2010-12-30 Thermapan Industries Inc. Structural flooring panel and floor structure incorporating the same
US8667755B1 (en) * 2013-03-14 2014-03-11 Finfrock Industries, Inc. Dual panel composite truss apparatus

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5685114A (en) * 1995-03-20 1997-11-11 Tanaka Masakatsu Design Office Co., Ltd. Structural member, floor structure, and roof structure for wooden building and a method of building with the same
US20060254208A1 (en) * 2004-09-28 2006-11-16 Mike Clark Paneling system and method
US20100325990A1 (en) * 2009-05-22 2010-12-30 Thermapan Industries Inc. Structural flooring panel and floor structure incorporating the same
US8667755B1 (en) * 2013-03-14 2014-03-11 Finfrock Industries, Inc. Dual panel composite truss apparatus

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10870990B1 (en) 2019-05-10 2020-12-22 Peter Baruch Mueller Closed panel building systems
US12345046B2 (en) 2019-05-10 2025-07-01 Peter Mueller Closed panel building systems
WO2022220719A1 (fr) * 2021-04-13 2022-10-20 Klara 500/1 Ab Élément de fondation de construction préfabriqué, procédé de fabrication dudit élément de fondation et procédé de construction d'une fondation de construction
WO2023062608A1 (fr) * 2021-10-16 2023-04-20 Sabery Mohammad Fondation modulaire préfabriquée destinée à des bâtiments résidentiels à étage unique

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