Suspended concrete flooring system and method

• US 20020078646A1
• Filed: 10/15/2001
• Published: 06/27/2002
• Est. Priority Date: 10/16/2000
• Status: Active Grant

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Research Pty., Limited (James Hardie Industries Plc)
• Inventors: Eaton, Peter Francis
• Granted Patent: US 6,755,001 B2
• Time in Patent Office: Days
• US Class Current: 52/292
• CPC Class Codes: E04B 5/36 with form units as part of the floor
• CPC Class Codes: E04C 2003/0421 comprising one single unitary part
• CPC Class Codes: E04C 2003/043 the hollow cross-section comprising at least one enclosed cavity
• CPC Class Codes: E04C 2003/0465 square- or rectangular-shaped
• CPC Class Codes: E04C 3/07 at least partly of bent or otherwise deformed strip- or sheet-like material

Abstract

A suspended concrete flooring system (100) comprising a plurality of spaced-apart load-bearing members (110) or supporting walls that support a plurality of joists (122) having opposing sides and arranged substantially at right-angles to the load-bearing members. The joists have a support shelf (127) running the length of each opposing side for the purpose of supporting a plurality of fiber cement corrugated sheets (130) that span the space between the joists. A shrinkage control mesh (140) is arranged atop the corrugated sheets and is oriented generally in the direction of the load-bearing members and the joists. A thin layer of concrete (150) is formed over the corrugated sheets and the shrinkage control mesh, to form a flat, horizontal floor surface (151). The load-bearing members and the joists are made of strong, lightweight materials, such as steel. The combination of the light-weight structural materials, the fiber cement corrugated sheets, and the thin concrete layer allows for a suspended concrete floor system that is easily constructed and that has a relatively wide span as compared to conventional suspended concrete floor systems.

Claims

1. A flooring system suspended above the ground, comprising:

a plurality of spaced-apart load-bearing members arranged substantially parallel to one another;

a plurality of spaced-apart joists having opposing sides and arranged at substantially right-angles to said load-bearing members and supported by said load-bearing members, each joist having a support shelf formed along the length of at least one of said opposing sides;

a plurality of deck sheets having first and second edges and supported between said joists at said edges by said support shelves so as to span the space between said joists in the horizontal plane defined by the support shelves; and

a concrete topping layer formed atop the deck sheets and encompassing the shrinkage control mesh.

2. The system according to claim 1, wherein said load-bearing members are supporting walls.

3. The system according to claim 1, further including a shrinkage control mesh arranged atop said joists.

4. The system according to claim 1, further including one or more piers having a first end fixed to the ground and an opposing second end in contact with at least one of said load-bearing members.

5. The system according to claim 1, wherein each of said joists includes a rebate on at least one of said opposing sides adjacent said shelves, capable of engaging and securing said deck sheets.

6. The system according to claim 1, wherein each of said deck sheets is corrugated.

7. The system according to claim 6, wherein each of said deck sheets is made of fiber cement.

8. A method of installing a concrete flooring system suspended above the ground on upon a plurality of footings installed in the ground, the method comprising:

arranging on each of said footings a corresponding pier having a predetermined height;

positioning and securing a plurality of load-bearing members atop said piers;

positioning and securing a plurality of joists to said plurality of load-bearing members at substantially right-angles so that said joists are supported by said load-bearing members with a space between said joists;

placing a plurality of deck sheets in the space between said joists which support each said sheet in a horizontal plane with said joists so as to span the space between said joists;

arranging a shrinkage control mesh atop said joists; and

pouring concrete over said deck sheets so as to encompass said shrinkage control mesh and form a generally flat horizontal floor surface.

9. The method according to claim 8, further including, after placing a plurality of deck sheets, installing plumbing through said deck sheets.

10. A suspended flooring system comprising:

a plurality of spaced apart load bearing members or supporting walls arranged substantially parallel to each other and supported off the ground by supports fastened securely in the ground;

a plurality of spaced apart elongate joists mounted atop, and supported by, said load bearing members;

a plurality of deck sheets supported by said joists and forming a substantially horizontal deck spanning the distance between said joists;

a mesh placed above said deck sheets; and

a concrete topping poured onto said deck sheets and encompassing said mesh, the concrete being worked to form a smooth, flat, horizontal upper floor surface.

11. The system of claim 10, wherein said joists have opposing sides, and further comprising rebates formed along at least one elongate side and configured to receive an edge of said deck sheet and further configured to provide a support shelf for supporting an edge of said deck sheet in a substantially horizontal orientation.

12. The system of claim 11, wherein said mesh is placed on top of said joists.

13. The system of claim 10, wherein said deck sheets are corrugated.

14. The system of claim 13, wherein said deck sheets are made of fiber cement.

15. The system of claim 10, wherein said mesh is a steel shrinkage control mesh.