Modular-accessible-units and method of making same

• US 5,205,091 A
• Filed: 07/25/1991
• Issued: 04/27/1993
• Est. Priority Date: 03/18/1980
• Status: Expired due to Fees

• Current Assignee: John G. Brown
• Original Assignee: John G. Brown
• Inventors: Brown, John G.
• Primary Examiner(s): Raduazo, Henry E.
• Application Number:
  US07/737,885
• Time in Patent Office: 642 Days
• Field of Search: 52/126.6, 52/126.5, 52/98, 52/100, 52/480, 52/220, 52/221
• US Class Current: 52/126.6
• CPC Class Codes: E04F 15/02016 with sealing elements between flooring elements sealings of joints between building constructions in general E04B1/68
• CPC Class Codes: E04F 15/024 Sectional false floors, e.g. computer floors height-adjustable supports for terrace roof coverings E04D11/00; underfloor heating using water F24D3/142, using air F24D5/10; installation of cables, lines or protective tubing in floors H02G3/28
• CPC Class Codes: E04F 15/02429 the core material hardening after application
• CPC Class Codes: E04F 15/02447 Supporting structures
• CPC Class Codes: E04F 15/02494 with a plurality of base plates or like, each base plate having a plurality of pedestals upstanding therefrom to receive the floor panels
• CPC Class Codes: E04F 15/08 only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass E04F15/02005 takes precedence
• CPC Class Codes: E04F 15/186 Underlayers covered with a mesh or the like
• CPC Class Codes: E04F 15/20 for sound insulation

Abstract

A floor, ceiling, wall and partition system comprising an array of modular units disposed over a conductor-accommodating supporting layer disposed over a base surface. There are two sets of modular units, both sets being of similar shape and interchangeable with each other, the first set having a plurality of corners and the second set having one or more corners removed to accommodate accessible nodes. The supporting layer supporting modular floor, ceiling, wall and partition units allows the free passage of conductors between adjoining and opposing horizontal and vertical elements, allowing devices located in the horizontal and vertical elements to freely communicate with each other.

Claims

1. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system, comprising a supporting layer disposed over a base surface and an array of modular units disposed over said supporting layer, characterized in that said supporting layer comprises a plurality of spaced discrete support elements arranged in a first patterned layout;

said modular units including a first set of identical units having a plurality of corners and supported on said spaced discrete support elements in a second patterned layout, such that every corner in said second patterned layout is free of said spaced discrete support elements;

said second patterned layout further including a second set of units which are similar in shape to said first set of units and fully interchangeable with said first set of units;

each of said units in said second set of units having at least one corner removed and interspersed in said second patterned layout, thereby forming accessible nodes in said second patterned layout;

said nodes being movable by interchanging units from said first and second sets.

2. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said support elements comprise one or more load-bearing support types selected from the group consisting of node boxes, channels, plinths, flexible foam, and rigid foam.

3. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said support elements comprise two or more load-bearing support types selected from the group consisting of node boxes, channels, plinths, flexible foam, and rigid foam.

4. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said support elements comprise two or more support types selected from the group consisting of node boxes, channels, plinths, flexible foam, and rigid foam;

and in that at least one of said support types selected is load bearing.

5. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said modular units are made from a castable, settable mix to form containment-cast units and moldcast units.

6. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said castable, settable mix is selected from the group consisting of any type of cementitious concrete, polymer concrete, cementitious concrete terrazzo, polymer concrete terrazzo, gypsum plaster, gypsum cement plaster, acoustical fiber mix, acoustical mineral mix, acoustical ceramic mix, and acoustical fiber, mineral and ceramic mix.

7. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said modular units in said second patterned layout comprise cast plates.

8. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that each said modular unit in said second patterned layout comprises a rectangular cast plank having two long parallel opposed sides more than two times the length of two shorter parallel opposed ends.

9. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said moldcast units are formed by means of said castable, settable mix placed and pressed into containment molds and removed from said molds from the same face as said mix is placed and pressed into said molds.

10. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said moldcast units are formed by means of said castable, settable mix placed in molds and press extruded through said molds out the opposite side from which said mix is placed in said molds.

11. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said containment-cast units are formed by said castable, settable mix placed in a permanent structural open-faced tension reinforcement containment having a back surface and a plurality of sides.

12. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said sides of said structural reinforcement containment are integrally-formed turned-up sides.

13. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said sides of said structural reinforcement containment are applied to the perimeter of said back surface.

14. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said modular units have straight perpendicular sides or straight sloping sides.

15. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 6, characterized in that said castable, settable mix in said containment-cast and moldcast units has an integral wearing surface.

16. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment of modular floor units has perimeter bearing zones at said back surface.

17. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment of modular floor units in said second set of units has perimeter bearing zones at said back surface at the sides created by removal of at least one or more corners;

said first patterned layout reflecting a layout of said perimeter bearing zones.

18. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment of each of said units in said first set of units has perimeter bearing zones at said back surface, said first patterned layout reflecting a layout of said perimeter-bearing zones.

19. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment has perimeter bearing zones at two opposite sides created by removal of at least two corners of said units in said second set of units;

and in that each said modular unit bears on two or more channels positioned beneath said perimeter bearing zones; and

in that said first patterned layout reflects a layout of said perimeter bearing zones in said second patterned layout.

20. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment has perimeter bearing zones at two or more opposing sides where corners have not been removed from said units in said second set of units;

and in that each said modular unit bears on two channels or a plurality of boxes positioned beneath said perimeter bearing zones; and

in that said first patterned layout reflects a layout of said perimeter bearing zones in said second patterned layout.

21. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that modular floor units are loose laid and held in place over said supporting layer by gravity and friction.

22. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that each said modular unit comprises a polygon having sides of equal length and a back surface of generally inverted-hat shaped cross-sectional profile and generally parallel to a flat face surface.

23. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 8, characterized in that each said plank has a multiple span on one or more axes when disposed over said support elements;

and in that said castable, settable mix has a face surface reinforced by a plurality of reinforcing bars disposed just below said face surface; and

in that said reinforcing bars provide face tension reinforcement for negative moments created in said face surface under heavy rolling loads; and

in that a permanent structural bond is created between said mix, said reinforcement, and said containment.

24. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that each of said modular units comprises a polygonal configuration having sides of equal length, a flat back surface generally parallel to a flat face surface, and a rectangular cross-sectional profile.

25. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said modular unit comprises three or more alternating short sides of equal length, three or more alternating long sides of equal length, and a back surface generally parallel to a flat face surface, said back surface being generally flat or generally inverted-hat shaped.

26. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 22, characterized in that said inverted-hat shaped cross-sectional profile provides said modular unit with three structural zones comprising a flat center zone of greatest thickness and greatest internal moment and shear strength, a sloped intermediate transition zone of intermediate internal moment and shear strength, and a flat perimeter edge zone of lesser thickness, lesser internal moment and adequate shear strength to carry an internal shear force near perimeter bearing zones at said sides.

27. A conductor-accommodating supporting layer for use in a front, ceiling, wall or partition system according to claim 6, characterized in that said castable, settable mix has an integral wearing surface;

and in that said integral wearing surface is precision ground for flatness; and

in that said modular units are precision gauged for thickness; and

in that said integral wearing surface is precision fine ground and polished for appearance grade and a functional flat wearing surface.

28. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said castable, settable mix forms a face surface generally flush with the top of said sides of said structural reinforcement containment.

29. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that an applied wearing surface is adhered to the face surface of said mix after said mix has cured;

and in that said applied wearing surface is higher than the top of said sides of said containment by the thickness of said applied wearing surface.

30. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 29, characterized in that said applied wearing surface is selected from the group consisting of any type of floor wearing surface, ceiling appearance grade surface, and wall or partition appearance grade surface.

31. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment has a tension-carrying capacity;

and in that said castable, settable mix has a structural bond to said containment enhanced by means selected from the group consisting of a plurality of inwardly disposed perforations in said back surface of said containment, a plurality of inwardly disposed perforations in said sides of said containment, and a combination of said perforations in said back surface and said sides.

32. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment has a plurality of inner surface;

and in that said inner surfaces are textured to enhance bond between said containment and said castable, settable mix by means of sandblasting, scarifying, texturing, embossing, perforating or roughening.

33. A conductor-accommodating supporting layer for use in a floor ceiling, wall or partition system according to claim 5, characterized in that said castable, settable mix forms a face surface generally lower than the top of said sides of said structural reinforcement containment and accommodates applied wearing surfaces, densified wearing surfaces, and coating wearing surfaces.

34. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 33 characterized in that said densified searing surface is integrally applied onto said face surface of said mix during casting or immediately after casting;

and in that said densified wearing surface comprises polymer or cementitious concrete with bonded metallic filings; and

in that said bonded metallic filing s are troweled to form said densified wearing surface.

35. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 33, characterized in that said applied wearing surface is adhered to said face surface after said mix has cured whereby said applied wearing surface is flush with said top of said sides;

and in that said applied wearing surface is selected from the group consisting of any type of floor wearing surface, ceiling appearance grade surface, and wall or partition appearance grade surface.

36. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 33, characterized in that a coating wearing surface is applied to said mix after curing of said mix;

and in that said coating wearing surface comprises a coating selected from the group consisting of urethane, polyester, vinyl, vinylester, acrylic, melamine and epoxy.

37. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment is fabricated of one or more virgin and recycled materials selected from the group consisting of metal, plastic, polymer concrete, fiber-reinforced cementitious board, hardboard, fiberboard, a multi-layer scrim impregnated with concrete, and a multi-layer scrim impregnated with resin.

38. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said containment-cast modular units are engaged and supported by means of screw fasteners 392 disposed through apertures in said modular units;

in that a decorative cover or plug 411 is disposed over the head of each said screw fastener 392;

in that said screw fasteners 392 mate with complementary apertures in said support elements 214;

in that and in that said screw fasteners 392 engage with flanges in a containment 56 of said modular unit formed by said apertures.

39. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 7, characterized in that corners removed from said second set of units in said second patterned layout are rounded to accommodate a round complementary accessible node;

and in that said corners have a concave or a convex shape and accommodate passage of single conductors, groups of small conductors, and fasteners.

40. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said accessible nodes in said second patterned layout are positioned in modules comprising multiples of 1 to 16 of said modular units between said nodes.

41. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said accessible nodes in said second patterned layout occupy activated, non-activated, and potential accessible node sites;

and in that said nodes are selected from the group consisting of passage nodes, poke-through nodes, device nodes, sensor nodes, connection nodes and juncture nodes.

42. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 41, characterized in that node boxes are placed in said node sites;

and in that connectivity, juncture, and splicing of connectors takes place within said node boxes and in conductor-accommodating passages within said supporting layer.

43. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 41, characterized in that passage node boxes are placed in said supporting layer;

and in that an aperture in the sides of said boxes accommodates the passage of multiple types of conductors and assemblies into said boxes; and

in that said aperture is closed off by a cover plate having an aperture sized to fit and secure the passage of said multiple types of conductors; and

in that said boxes are covered by access covers having knockouts accommodating the passage of cordsets from above said array.

44. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system system according to claim 41, characterized in that said accessible nodes have load-bearing flush decorative access covers comprising solid covers, sliding covers, hinged covers, and direct plug-in covers;

and in that said solid covers are modifiable during use to provide one or more notches, cutouts, drillouts, knockouts and breakouts to allow passage of conductors.

45. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 41, characterized in that access openings for said accessible nodes are formed where corners removed from adjacent units in said second set of units meet;

and in that said openings accommodate plugging in and disconnecting cordsets and servicing receptacles for multiple utility services in said nodes.

46. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 41, characterized in that said accessible nodes accommodate selectively insertable node boxes to selectively define conductor-accommodating passages and connectivity sites accessible beneath said second set of units in said second patterned layout.

47. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 8, characterized in that said plank accommodates passage of conductors through one or more partial apertures formed by notches in one or more of said sides and narrow linear plank nodes in one or more ends or said sides;

and in that said partial apertures become full apertures when said plank in mated with one or more similarly modified planks.

48. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition according to claim 41, characterized in that preassembled conductor assemblies are disposed between two or more of sad accessible nodes, provide mating receptacles within said nodes, and accommodate direct plug-in of premanufactured equipment cordsets;

and in that conventional conductors are hardwired to other conductors and said preassembled conductor assemblies are connected to other preassembled conductor assemblies within said supporting layer and to junction boxes, hubs, cluster panels, and branch panels within said supporting layer and above said array to interconnect with a horizontal branch conductor management system.

49. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system partition system according to claim 41, characterized in that said accessible nodes allow connectivity, juncture and splicing within said nodes of conductors and pressembled conductor assemblies located within said supporting layer;

and in that said nodes allow passage of said conductors and conductor assemblies to spaces above said array for connection to hubs and branch panels of an extended horizontal branch conductor management system within said supporting layer; and

in that said nodes allow passage of premanufactured equipment cordsets from equipment located above said array for direct plug-in to receptacles and mating connectors of said conductors and assemblies located within said nodes and conventional conductors for hardwiring to other conventional conductors.

50. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 49, characterized in that said connectivity, juncture, and splicing of said conductors, assemblies, and cordsets takes place within one or more node boxes or conductor channels.

51. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 50, characterized in that one or more apertures in the sides of said boxes and said channels accommodate the mounting of connector receptacles;

and in that said connector receptacles mate with said connectors and with plugs on said conductors, assemblies and cordsets.

52. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said nodes are multi-functional and accommodate one or more connectors, plugs and receptacles and one or more conductors selected from the group consisting of voice, data, text, video, power, sensor, control and fluid conductors.

53. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said supporting layer accommodates one or more connectors, plugs and receptacles and allows connectivity, juncture and splicing of conductors.

54. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 49, characterized in that said preassembled conductor assemblies are disposed between two or more of said accessible nodes and between one or more of said accessible nodes and said hubs or said branch panels, provide mating receptacles within node boxes positioned within said nodes, and accommodate direct plug-in of said cordsets;

and in that said assemblies are connected to other assemblies within said supporting layer and to said junction boxes, hubs, cluster panels, and branch panels within said supporting layer and above said array to form said horizontal branch conductor management system.

55. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 49, characterized in that said pressembled conductor assemblies are disposed between two or more channels, provide mating receptacles within said channels, and accommodate direct plug-in of said cordsets;

and in that said assemblies are connected to other assemblies within said supporting layer and to said junction boxes, hubs, cluster panels, and branch panels within said supporting layer and above said array to form said horizontal branch conductor management system.

56. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 49, characterized in that said conductors comprise power, electronic, fiber optic, fluid, power superconductivity, power semiconductivity, electronic superconductivity, or electronic semiconductivity conductors.

57. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 49, characterized in that said conductors comprise at least one type of conductor selected from the group consisting of digital, analog, power, fiber, and superconductors.

58. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 56, characterized in that said fluid conductors serve at least one system selected from the group consisting of plumbing systems, plumbing fixture systems, fluid systems, working fluid systems, refrigerant systems, exhaust systems, hydraulic systems, compressed air systems, vacuum systems, life safety detection and sensing systems, sprinkler systems, fire suppression systems, standpipe systems, low Delta t hot and cold supply and return systems, hot and chilled water supply and return systems, steam supply and return systems, and heat pump systems.

59. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said modular units are joined one to another by an accessible flexible assembly joint comprising an elastomeric sealant, an elastomeric sealant with any type of filler, foam, a magnet or an open joint.

60. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that a cushioning layer comprising an elastic foam is disposed between said supporting layer and said base surface.

61. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that a cushioning layer comprising an elastic foam is disposed between said supporting layer and said modular units.

62. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that modular floor units are held in place over said supporting layer also by gravity, friction and registry;

and in that said registry is obtained by mating two or more of said support elements with complementary points of registry and bearing comprising mating registry indentations in said back surface of said containment.

63. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that modular floor units provide grounded drainoff electrostatic discharge by means of using discretely controlled conductive materials for said structural reinforcement containment, said castable settable mix, and a finished wearing surface;

and in that said conductive materials in said modular floor units are conductively joined one to another by a quality grounding means; and

in that said modular floor units are conductively joined one to another and to conductive node boxes accommodated within said accessible nodes and are grounded to a quality grounding source; and

in that controlled conductivity of said mix is provided for draining off said electrostatic discharge.

64. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment is a conductive containment comprising one or more conductive materials;

and in that grounded electromagnetic interference shielding and grounded radio frequency interference shielding are provided to conductors disposed within said supporting layer by means of said conductive containment; and

in that said shielding materially limits unauthorized use of electronic devices to sense and appropriate electronic voice, data, text and video signals carried by said conductors; and

in that persons and equipment located above said modular units are shielded by said conductive containment from electromagnetic fields surrounding said conductors contained within said supporting layer; and

in that said conductive materials in said modular units are conductively joined one to another by a quality grounding means; and

in that said modular units are conductively joined one to another and to node boxes in said accessible nodes and are grounded to a quality grounding source.

65. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 64, characterized in that said conductive materials are selected from the group consisting of conductive metal, conductive plastic, conductive cementitious concrete, conductive polymer concrete, conductive ceramics, conductive minerals, conductive powder, conductive fiber-reinforced cementitious board, a conductive multi-layer scrim impregnated with concrete, and a conductive multi-layer scrim impregnated with resin.

66. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment integrally forms a composite layer of back reinforcement;

and in that when said castable, settable mix is cured a plurality of load-bearing, dimensionally stable modular units is formed; and

in that said back reinforcement increases the ability of said modular units to handle positive internal moments created by single simple spans at removed corners of said units in said second set of units.

67. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment forms a layer of back reinforcement;

and in that said containment is reinforced by back reinforcement means tied, welded, fused or adhered to one or more inner surfaces of said containment and placed fractionally above said back surface of said containment; and

in that when said castable, settable mix is cured a plurality of load-bearing, dimensionally stable modular units is formed; and

in that said back reinforcement increases the ability of said modular units to handle positive internal moments created by single simple spans at removed corners of said units in said second set of units in said second patterned layout, to increase bond between said containment, said mix, and said reinforcement.

68. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment forms a layer of back reinforcement;

and in that one or more layer of face reinforcement is placed generally parallel to said face surface and said back surface of said castable, settable mix; and

in that said face reinforcement is supported fractionally below said face surface by support means tied, welded, fused or adhered to the back of said face reinforcement; and

in that when said mix is cured a plurality of load-bearing, dimensionally stable modular units is formed.

69. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 68, characterized in that said face reinforcement increases the ability of said modular units to handle negative internal moments created by single simple spans without removed corners, said single simple spans with cantilevers with and without said removed corners, and multiple continuous spans with said removed corners, and said multiple continuous spans without said cantilevers with and without said removed corners, and to increase bond between said containment, said mix, and said reinforcement.

70. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 68, characterized in that said structural reinforcement containment is reinforced by back reinforcement means tied, welded, fused or adhered to one or more inner surfaces of said containment and placed fractionally above said back surface of said containment;

and in that said back reinforcement increases the ability of said modular units to handle positive internal moments and increases structural bond between said mix and said containment.

71. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said castable, settable mix contains one or more aggregates selected from the group consisting of natural stone chips, manmade stone chips, washed and graded gravels, ceramic spheres, ceramic granules, minerals, oxides, additives, and extenders.

72. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 6, characterized in that an embossed wearing surface finish is applied to said castable, settable mix before curing;

and in that said embossed wearing surface finish enhances slip resistance, crank resistance and appearance of said cast units.

73. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said castable, settable mix is densified by means of continuous shocking, continuous vibration, intermittent periodic shocking, intermittent periodic vibration or a combination of intermittent periodic shocking and intermittent periodic vibration to achieve ultra high compressive strengths ranging from 5,000 to 20,000 pounds per square inch;

and in that an enhanced permanent structural bond is achieved between said mix and said containment; and

in that when said mix is cured a load-bearing, dimensionally stable unit is formed.

74. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said system has a discretely unique combined thickness ranging from 1/4 inch to greater than 6 inches comprising said modular units and said supporting layer;

and in that said thickness is measured from the top of said base surface to the top of said modular units.

75. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 12, characterized in that said turned-up sides have inwardly extending horizontal flanges or inwardly extending, folded-over horizontal flanges.

76. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 13, characterized in that said sides comprise a generally vertical, inwardly facing angle having a horizontal leg affixed to said back surface of said containment.

77. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 13, characterized in that said sides comprise an inwardly facing metal channel affixed to said back surface of said containment.

78. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 12, characterized in that said turned-up sides of said structural reinforcement containment comprise a portion integrally formed with said containment and have a flange extending into a slot prepared in a perimeter reinforcement strip having a generally flat face surface;

and in that said flat face surface comprises the face edge of said containment; and

in that said flange extends generally horizontally, vertically or angularly into said reinforcement strip; and

in that said flange in said slot positions and aligns said reinforcement strip, stiffens said back surface of said containment, and enables said reinforcement strip to be held in place while said castable, settable mix is being placed in said containment.

79. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 78, characterized in that said reinforcement strip is selected from the group consisting of plastic, rubber, vinyl, wood, metal, elastomeric materials, laminated high-pressure laminates, laminated melamine, natural stone and manmade stone.

80. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 78, characterized in that said reinforcement strip is adhered to said back surface of said containment.

81. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that reinforcement strips are adhered to said back surface of said structural reinforcement containment and form said sides;

and in that said reinforcement strips have an inner face adjoining said castable settable mix which is inwardly sloped or outwardly sloped and complements an outer sloped perimeter edge of said mix.

82. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 12, characterized in that said turned-up sides of said structural reinforcement containment have outwardly extending horizontal flanges of outwardly extending, folded-over horizontal flanges.

83. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 12, characterized in that said turned-up sides of said structural reinforcement containment have inwardly extending horizontal flanges with a return extending downward vertically or at an angle.

84. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 12, characterized in that said turned-up sides of said structural reinforcement containment comprise vertical sides integrally formed with said containment and have a single edge or a folded-over double edge.

85. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that each said side of said structural reinforcement containment comprises a separate edge piece having a face surface of a back flange attached to an offset in the perimeter edge of said surface of said containment;

and in that said turned-up side forms a horizontal slot approximately at midheight to receive a flexible horizontal spline; and

in that said spline aligns and joins together two adjacent modular units.

86. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that each said side of said structural reinforcement containment comprises a separate edge piece having a face surface of a back flange attached to an offset in the perimeter edge of said back surface of said containment;

and in that said side is folded over to form a double edge with a horizontal flange extending horizontally into said castable settable mix approximately at midheight.

87. A conductor-accommodating supporting layer for use with a floor, ceiling, wall or partition system according to claim 6, characterized in that said castable, settable mix contains one or more additives selected from the group consisting of silica fume, latex, acrylic, latex-acrylic, polyester and epoxy;

and in that said additives provide increased ductility and strength for said cementitious concrete and enhanced bond to a containment.

88. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said castable settable mix has a face surface comprising cementitious concrete terrazzo or polymer concrete terrazzo;

and in that said face surface is precision ground for flatness; and

in that said modular units are precision gauged for thickness; and

in that said face surface is precision fine ground and polished for appearance grade and a functional wearing surface.

89. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 59, characterized in that said elastomeric sealant produces a cuttable, resealable joint.

90. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 6, characterized in that said cementitious concrete is selected from the group consisting of normal weight concrete, lightweight concrete, insulating concrete, and foam concrete.

91. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said supporting layer comprises granular materials.

92. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said moldcast units have perimeter bearing zones at the entire perimeter of said units in said first set of units and said second set of units.

93. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said moldcast units have perimeter bearing zones in at least two opposing sides or opposing sides created by the removal of corners from said units.

94. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 2, characterized in that said channels are disposed on two or more axes on one or more levels;

in that a first set of channels on a first level creates a first set of adjacent coplanar parallel conductor passages within and adjacent to said first set of channels;

in that a second set of channels on a second level creates a second set of adjacent coplanar parallel conductor passages within and adjacent to said second set of channels;

in that said conductor passages are formed within said channels and in the spaces between and defined by said channels on said first level and said second level;

in that said second set of channels and conductor passages is disposed crosswise to said first set of channels and conductor passages;

in that conductors in said first level pass through said first set of channels and conductor passages;

in that conductors in said second level pass through said second set of channels and conductor passages;

in that said conductors in said first level pass over said conductors in said second level;

in that said conductors in said second level pass under said conductors in said first level;

in that said channels and said conductor passages accommodate devices and node boxes; and

in that said first set of channels is attached to said second set of channels by any type of attachment means.

95. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said conductor-accommodative supporting layer supporting modular floor, ceiling, wall and partition units allows the free passage of conductors between adjoining and opposing horizontal and vertical elements;

and in that said free passage of said conductors allow devices, node boxes, and conductors in said adjoining and opposing horizontal and vertical elements to freely communicate with each other.

96. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment of modular ceiling units has perimeter bearing zones on the face for lay-in support and on said back surface for suspension support.

97. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment of modular wall and partition units has perimeter bearing zones on said back surface, on the face, and at two or more sides.

98. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said containment-cast units provide an enhanced, accessible sound barrier by means of sound absorption materials on the face of said modular units and a fire barrier by means of a metallic containment.

99. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said moldcast units are covered with an acoustical fabric wrapping 401 comprising a sound-absorbent ceiling, wall or partition surface.

100. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said castable, settable mix accommodates sound-absorbent materials having acoustical properties.

101. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that said containment-cast units are made by placing the dry ingredients of said castable, settable mix in a containment, dispersement spraying or pouring a polymer resin and catalyst over said dry ingredients in one or more applications, allowing said resin and catalyst to percolate down through said dry ingredients, and curing the resulting blended mix.

102. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 41, characterized in that preassembled conductor assemblies are disposed between two or more of said accessible nodes or two or more channels within said supporting layer, or between said nodes and one or more micro or mini hubs, cluster panels, branch panels with circuit breakers and switching, or channels concealed from view within said supporting layer behind said array of modular units, providing mating receptacles and accommodating all functions related to a horizontal branch conductor management system for power and electronic systems and networking.

103. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that modular ceiling units are held in place over said supporting layer at accessible support elements by attachment means selected from the group consisting of lay-in, suspension, applied, hold-in channels, touch fasteners, registry engagement, concentric fasteners, linear male concentric engagement tees, magnetic coupling, and mechanical fastening.

104. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that modular floor, wall and partition units are held in place over said supporting layer at accessible support elements by attachment means selected from the group consisting of magnetic coupling, touch fasteners, registry engagement, concentric fasteners, linear male concentric engagement tees, mechanical fastening, and hold-in channels.

105. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 59, characterized in that said elastomeric sealant is conductive and provides enhanced grounding for isolation of electromagnetic interference, electrostatic discharge, and radio frequency interference.

106. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said supporting layer contains said support elements comprising channels arranged on one or more levels and one or more crosswise axes;

in that conductor passages are formed within said channels and in the spaces between and defined by said channels on said one or more levels and one or more axes;

in that said channels and said conductor passages accommodate devices node boxes, and conductors;

in that said supporting layer supports said modular units that are removable, reconfigurable and recyclable; and

in that said conductors selectively and accessibly pass freely and unobstructed through said supporting layer 386,387 from floor to wall and partition to ceiling.

107. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 106, characterized in that said devices, node boxes, and conductors freely interconnect and communicate within said supporting layer in floors, ceilings, walls and partitions by means of free and unobstructed passage 386,387 of said conductors.

108. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 11, characterized in that said structural reinforcement containment 56 has two or more apertures in said back surface;

in that a viscoelastic registry engagement fastener 373 has a large head sandwiched between the containment 56 of said modular unit and a shaft projecting outward through each said aperture in said containment 56;

in that said shaft has a plurality of concentric vee grooves which engage with an aperture in said support element.

109. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 4, characterized in that one or more shortened channels are positioned crosswise inside and attached to one or more channels 359,361 by attachment means selected from the group consisting of magnetic coupling 366,367, touch fastening 383, foam tape 357, a layer of adhesive-backed tape, a sealant, an adhesive 416, and mechanical fastening 392 to form channel node boxes 462,463,464;

and in that said channel node boxes are removable, relocatable, reconfigurable, and recyclable.

110. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 4, characterized in that micro positioning adjustment of said modular units supported by magnetic coupling and touch fastening means is accomplished along the x and y axes by repositioning said modular units over magnets 366,367 and touch fasteners 383.

111. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 2 characterized in that said support elements comprise continuous linear rigid foam tees 453, each having a linear female engagement slot 399 to receive a complementary linear male concentric engagement tee 434,435;

in that said linear male concentric engagement tee 434,435 comprises linear flanges having a vee groove which forms a linear weakened plane 431 on the outside at the top of a common stem and linear vee grooves on opposite sides of said common stem;

in that said linear male concentric engagement tees engage and support modular units 368,369,370; and

in that said linear weakened plane 431 facilitates the removal of one or more of said modular units from said array while said complementary linear male concentric engagement tees 434,435 are still engaged in said linear female engagement slots 399.

112. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that each said support element comprises a hold-in, press-together and spring-back support channel 429 having an extended throat 460 between two outwardly extending flanges which engage and support said modular units;

and in that said support channels 429 are attached to a base surface 380 or other support elements by means selected from the group consisting of magnetic coupling 366,367, touch fastening 383, foam tape 357, a layer of adhesive-backed tape, a sealant, an adhesive 416, and mechanical fastening 392.

113. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1;

characterized in that a magnetic attraction layer comprising a metallic magnetic attraction blank 412, a magnet keeper 388,425 or a magnet 366,367 is attached by adhesion or mechanical fastening means to the back surface of each said modular unit;

in that magnets 366,367 are attached to one or more types of said support elements selected from the group consisting of plinths, boxes, and channels; and

in that said modular units are magnetically coupled to said support elements by means of said magnets 366,367.

114. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 113, characterized in that said magnet keeper 389 attached to said back surface of a wall or partition unit bears on the top edge of said magnets 366;

367; and

in that, said modular unit is magnetically coupled to said support elements and supported by said magnets 366,367.

115. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that a magnet 456 is attached by adhesion or mechanical attachment means to the back surface of each said modular unit for walls and partitions;

in that said magnet 456 comprises one part of a mating two-part magnetic registry assembly;

in that said magnet 456 has a plurality of alternating ribbon or grid magnetic poles disposed so as to maximize the magnetic coupling between the opposite magnetic poles on a mating magnet 456 attached to a support element and to maximize the holding power against gravity; and

in that said magnetic registry assembly magnetically couples said modular units and said support elements.

116. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that a plurality of channels 362 having outwardly extending flanges 374 are magnetically coupled by the web 461 to a metallic floor, ceiling, wall or partition base surface 380 by means of flexible magnets 367;

in that metallic containments 56 of modular units 368,369,370 are magnetically coupled to said flanges 374 by means of magnets 366 attached to the bottom surface of said flanges 374; and

in that sound isolation, fire, smoke, and vapor integrity are preserved within said supporting layer by avoidance of penetrations of said base surface 380 by mechanical fasteners, devices, and boxes.

117. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 116, characterized in that a metallic continuous keeper channel 425 is disposed crosswise between said flanges 374 and said modular units;

and in that said magnets 366 are disposed within said continuous keeper channel 425 and magnetically couple said flanges 374 of said channel 362 to said containment 56 of said modular units 368,369,370.

118. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 2, characterized in that a plurality of said channels 362,444,445 are attached to said base surface 380 by outwardly extending flanges 374 by any attachment means;

in that said channels create enclosed pull channel raceways accommodating conductors; and

in that adjacent conductor passages 403,406,407 are formed in spaces between said channels and accommodate lay-in conductors.

119. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 2, characterized in that lay-in conductors are attached to said support elements and said base surface by any type of attachment means.

120. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 118, characterized in that said channels contain one or more secondary apertures selected from the group consisting of slotted apertures 384 accommodating the passage of conductors, slotted apertures 418 running lengthwise, slotted apertures 419 running crosswise, and round and rectangular apertures 459;

in that said apertures occur in flanges, sides and webs of said channels;

in that said apertures accommodate secondary attachments of conductors, boxes, devices, and conductor ties to said channels, of channels to each other, and of channels to plinths 214; and

in that said apertures are disposed singly or in a pattern layout of intermittent apertures.

121. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 2, characterized in that a plurality of said channels 359,362 having outwardly extending flanges 374 are attached to a base surface 380 by the web 461 by any attachment means;

in that lay-in conductors are disposed within said channels; and

in that lay-in conductors are disposed within adjacent conductor passages 403,406,407 formed in spaces between said channels.

122. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 121, characterized in that adjacent edges of said flanges 374 are positioned to form a slot accommodating insertion and removal of said lay-in conductors.

123. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 121, characterized in that one or more modular apertures 282-287 are positioned in one or more sides of said channels;

and in that said apertures accommodate lay-in and pass-through passage of preassembled conductor assemblies 209 and the mounting of connector receptacles for power, voice, data, video, control, sensing and sound in a horizontal branch conductor management system 281.

124. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that said support elements are attached to said base surface 380 by one or more means selected from the group consisting of magnetic coupling 366,367, touch fasteners 383, foam tape 357, mechanical fasteners 392, rigid foam 355, a layer of adhesive-backed foam, a sealant, and an adhesive 416.

125. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 106, characterized in that said channels arranged on more than one level and crosswise to each other are attached to each other by any attachment means.

126. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 4, characterized in that said channels comprise a plurality of upper channels 359,361,362,364, 378,420,443,444,445,449,457 attached by the web to a ceiling base surface 380 by any attachment means;

in that said upper channels accommodate a plurality of said plinths 214;

in that a plurality of lower channels is disposed crosswise to said upper channels;

in that mechanical fasteners 392 having torquing means and threaded at opposing ends project through apertures in the webs of said lower channels and are engaged in complementary threaded apertures in said plinths 214;

in that said lower channels have outwardly extending flanges 374; and

in that ceiling modular units 368 are attached to said flanges 374.

127. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 126, characterized in that said modular units 368 are attached to said flanges 374 by attachment means selected from the group consisting of magnets 366,367 and touch fasteners 383.

128. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 4, characterized in that said channels comprise a plurality of lower channels 359,361,362,420,443, 444,445,457 attached to a floor base surface 380 by any attachment means;

in that a plurality of upper channels 359,362,425,444,445 is disposed crosswise and attached by any attachment means to said lower channels;

in that containments 56 of floor modular units 370 are magnetically coupled to the web of said upper channel 362 by means of flexible magnets 367 attached to said web; and

in that joints between said modular units 370 are closely spaced and centered in said flexible magnets 367.

129. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 4, characterized in that said channels comprise a plurality of lower channels 359,361,362,364,420, 443,444,445,449,457 attached to a floor base surface 380 by any attachment means;

in that a plurality of upper channels 359,361,362,364,420,425,443,457 is disposed crosswise and attached by any attachment means to said lower channels;

in that floor modular units 370 are attached to the web of said upper channel 362 by means of touch fasteners 383 attached to said modular units 370 and mating with a complementary touch fastener 383 attached to a shared web; and

in that joints between said modular units 370 are closely spaced and centered in said web.

130. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 1, characterized in that flat conductor cable, ribbon conductor cable, and any other type of conductor pass in and out of said supporting layer through open joints between said modular units;

in that any other type of conductor passes in and out at a corner confluence of one or more corners removed from said modular unit; and

in that the shape of said corners removed is concave, convex or straight.

131. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 106, characterized in that said base surface 380 is free of penetration by said boxes, devices, mechanical fasteners, and conductors.

132. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 121, characterized in that lay-in conductors in said conductor passages are supported by and attached to said plinths 214, said boxes 107, any type of channel, and said base surface 380 by any attachment means.

133. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 94, characterized in that said channels comprise cee channels selected from the group consisting of channels having no flanges, channels having outwardly extending flanges 374, and channels having inwardly extending flanges 375.

134. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 3, characterized in that said channels comprise a plurality of lower channels 359,361,362,364,420, 443,444,445,449,457 attached to a floor base surface 380 by any attachment means;

in that a plurality of upper channels 359,361,362,364,420,443,444,445 having spaced-apart flanges is disposed crosswise and attached by any attachment means to said lower channels;

in that magnets 366,367 are attached to the back surface of moldcast floor modular units 370 by adhesion or mechanical means; and

in that said modular units are magnetically coupled to flanges of said lower channels by means of said magnets.

135. A conductor-accommodating supporting layer for use in a floor, ceiling, wall or partition system according to claim 5, characterized in that a magnetic attraction layer comprising a plurality of metallic magnet keepers 389,425 is attached by mechanical fastening means to a plurality of through slotted apertures 419 running crosswise to the web of said channel 362;

and that said slotted apertures provide micro positioning adjustment of said modular units along the y axis.