|
(11) | EP 1 528 170 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
|
|
|
|
|||||||||||||||||||||||
| (54) | Floor system, prefabricated element and process for manufacturing the prefabricated element |
| (57) Floor system for use in the building industry, comprising a plurality of prefabricated
elements (100, 101) meant for positioning onto walls (40) or supporting beams of an
underlying storey and as a basis for walls (41, 42) of a storey above, whereby the
prefabricated elements (100, 101) have a layered structure, of which a first layer
(1) is formed by a loadbearing structure (10) for obtaining a loadbearing capacity,
of which a second layer (2) is formed by an insulation layer (20) for acoustic insulating
the underlying storey from the storey above, and of which a third layer (3) is formed
by a cover floor (30) for covering the adjacent layer (10, 20). |
[0001] The invention relates to a floor system for use in the building industry, as described in the preamble of the first claim. The invention also relates to a prefabricated element as part of such a floor system and to a process for manufacturing the prefabricated element.
[0002] According to the present state of the art storeys in for instance apartment buildings are build up as shown in figure 1. First a loadbearing floor 6 is laid spanning two walls. This loadbearing floor 6 comprises a prefabricated ("prefab") thin skin and a constructional concrete layer, which is poured onto the thin skin. On top of the loadbearing floor a first topping 7 is applied. If so desired conduits 5 may be incorporated in the first topping 7, by placing them beforehand onto the loadbearing floor 6. In order to acoustically insulate the storey on top from the storey below, a layer 8 from an acoustic insulating material is applied onto the first topping 7. Onto this insulation layer 8 a so-called sprung floor 9 is subsequently applied, which is applied as a second topping.
[0003] A floor build up in this manner has the disadvantage of having a high risk for sound leaks, which may affect the acoustic insulation capacity of the floor.
[0004] It is an aim of the present invention to provide a floor system for use in the building industry, by which an improved acoustic insulation between the storey on top and the underlying storey may be obtained.
[0005] This aim is achieved according to the invention by providing a floor system having the technical characteristics of the characterizing part of the first claim.
[0006] According to the invention a floor is build up from a plurality of prefabricated elements with a layered structure. A first layer of the layered structure is formed by a loadbearing structure, which essentially takes care of the loadbearing capacity of the prefabricated elements. A second layer of the layered structure is formed by an acoustic insulation layer. A third layer of the layered structure is formed by a cover layer.
[0007] In a first preferred embodiment according to the invention the second layer is situated above the first layer in the height direction, and the third layer above the second layer. In this preferred embodiment the third layer acts as sprung floor (hereinafter referred to as cover floor), whereby the second layer supports the cover floor.
[0008] In a second preferred embodiment the second layer is situated in the height direction below the first layer, and the third layer below the second layer. The second layer is attached to the underside of the first layer with the aid of fastening means suitable for this purpose. The third layer is for its part attached to the underside of the first and/or second layer with the aid of fastening means suitable for this purpose. In this preferred embodiment, the third layer acts as false ceiling (hereinafter referred to as ceiling cover layer).
[0009] An analysis of the insulation problem of the state of the art has revealed that the high risk for sound leaks is due to the fact that the insulation layer is only applied until during the finishing phase of the building, which takes place after the rough structure has been erected. Due to this late application of insulation there is a real chance for impurities to end up in the insulation layer. Furthermore there is a real possibility for making assembly faults during placement of the insulation layer. The impurities and assembly faults may lead to sound leaks, finally causing a lower level of insulation of the floors in the building than anticipated.
[0010] In the floor system according to the invention the insulation layer is already present in the prefabricated elements, which are delivered to the construction site as one integrated unit. When placing the prefabricated elements, which happens in the rough structure construction phase of the building, the insulation layer is therefore applied at once also, hereby obviating the need for applying an insulation layer in a later phase of the construction. Furthermore the insulation layer is already enclosed the moment it arrives on the construction site, either between the loadbearing structure and the cover floor, or between the loadbearing structure and the ceiling cover layer. This significantly reduces the risk for entrapment of impurities. This all leads to a considerable reduction of the risk for sound leaks and may prevent that the final insulation achieved is lower than aimed for.
[0011] The floor system according to the state of the art moreover frequently suffers from the fact that sound insulation between adjacent storeys does not extend to the walls of these adjacent storeys. This is caused by the fact that the insulation layer is only applied until after the rough structure construction phase has been finished, and it is therefore no longer possible to acoustically separate walls of two adjacent storeys. Therefore sound waves may be transmitted unhindered through the walls from one storey to the other.
[0012] In the floor system according to the invention the insulation layer is already provided in the prefabricated elements. These are placed onto the walls of an underlying storey during the rough structure construction phase, and serve as basis for the walls of a storey on top of the underlying storey. As a result the insulation layer also extends to between the walls of adjacent storeys, so that the acoustic insulation capacity of the floor system according to the invention may be increased.
[0013] Incidentally, by 'prefabricated element' is meant in the context of this application any element that has already been assembled before arrival on the construction site and may be delivered off factory. However an element assembled on the construction site from the different layers (loadbearing structure, acoustic insulation layer and cover layer) likewise falls under the definition of 'prefabricated element'. This is in particular applicable when at least one of the different layers as such is transported to the construction site and assembled there, and very in particular when all layers as such are transported as prefabricated element to the construction site and assembled there.
[0014] The floor system according to the invention further has the advantage that one topping may be saved. The conduits may indeed be placed onto the cover floor of the prefabricated elements, where after one topping suffices to obtain a smooth whole. This not only advantageously yields a gain in time on the construction site, but also lowers the weight of the floor system.
[0015] The acoustic insulating intermediate layer of the prefabricated elements according to the invention is advantageously formed by a plurality of discrete elements of an acoustic insulating material. This has the advantage of minimising the contact surface for transmitting sound vibrations between adjacent storeys. Further a mass-spring-mass system is hereby created, whereby in the first preferred embodiment the masses are formed by the loadbearing structure and the cover floor, and the spring by the discrete elements. In the second preferred embodiment the masses are formed by the loadbearing structure and the ceiling cover layer, and the spring by the discrete elements. By limiting the dimensions of the discrete elements and increasing the space between the elements, the springy capacity of the discrete elements is increased and the mass-spring-mass system is optimised. This all may lead to a considerable increase of the acoustic insulating capacity of the floor system according to the invention.
[0016] The discrete elements are advantageously distributed over the insulation layer in a regular pattern, for instance according to a screen.
[0017] The discrete elements are advantageously embedded into a neutral material, such as for instance a plastic foam with low density, in order to fill up the space between the discrete elements. Hereby is prevented that dust particles and the like end up in the space between the discrete elements, which again may lead to sound leaks. Further it appeared that a better acoustic insulation is achieved than may be expected on the basis of either the sole application of a plastic foam, or the sole application of a number of discrete elements.
[0018] At the underside of the prefabricated elements there exists a zone of support. This is a zone that comes into contact with the walls of the underlying storey, when the prefabricated elements are placed onto these walls. This zone may be provided with an additional acoustic insulation, in order to further increase the insulating capacity of the floor system according to the invention.
[0019] The loadbearing structure of the prefabricated elements advantageously has longitudinal sides shaped such that a longitudinal side together with the longitudinal side of the loadbearing structure of an adjacent prefabricated element forms a fillable joint. Such a joint is in general substantially V-shaped, such that the underside of the loadbearing structure is wider than the upper side. Filling up the joint causes a lateral connection of the prefabricated elements, whereby a loadbearing unity is created.
[0020] In the first preferred embodiment the second layer extends over almost the entire width of the upper side of the loadbearing structure. The cover floor (the third layer) is slightly set back as a result of which it is narrower than the insulation layer (the second layer) and therefore also narrower than the upper side of the loadbearing structure (the first layer). In order to prevent the joints from acting as acoustic leaks between two storeys, the insulation layer is for instance folded upwards at the sides along the cover floor, the joint subsequently filled up, whereafter, before applying the upgoing masonry, the joint is completely covered with additional acoustic insulating elements. These acoustic insulating elements are for instance applied onto the cover floor and have sufficient width such that overlap is created between an acoustic insulating element and two adjoined cover floor elements. It is likewise possible not to fold over the second layer. In this case, advantageously after closure of the joint, acoustic insulating covering elements are provided between the cover floors of two adjacent floor elements, onto the second layer of the adjacent floor elements.
[0021] In the second preferred embodiment the insulation layer and the ceiling cover layer extend over almost the complete width of the underside of the loadbearing structure. This embodiment has the additional advantage of not needing additional acoustic insulating elements to acoustically insulate the joints, since these joints are already automatically uncoupled acoustically.
[0022] In a third preferred embodiment the floor system according to the invention is characterized in that the second layer is present above the first layer and the third layer above the second layer, the third layer thereby forming a floor cover layer, whereby the third layer has longitudinal sides that extend somewhat slantwise so that the third layer narrows somewhat in the upward direction, thus forming a fillable joint with an adjacent floor element. By providing the joint between two adjacent floor elements within the third layer, this joint is as such insulated acoustically thereby ensuring that sound leakage of a storey to the underlying storey through the joints between the floor elements is significantly reduced.
[0023] Since in the third preferred embodiment the lateral connection between the floor elements runs through the third layer, the load transfer from one element to a subsequent element is better distributed. It has advantages to provide the third layer with reinforcement to improve this load distribution.
[0024] If desired, the longitudinal sides of the first layer of the floor element according to the third preferred embodiment may also extend somewhat slantwise, so as to form a second joint between both first layers upon placing two floor elements adjacent to each other, in addition to the first joint formed by the adjacent longitudinal sides of the third layer.
[0025] The process for manufacturing the prefabricated elements according to the invention comprises the following steps. In a first step a concrete loadbearing structure is made, for instance by pouring concrete in a mould or in a mobile shuttering device, such as for instance a sliding formwork or an extrusion device. In order to manufacture the first preferred embodiment the plurality of discrete elements of an acoustic insulating material is subsequently applied onto the loadbearing structure, whereafter the cover floor is applied onto the discrete elements. In order to manufacture the second preferred embodiment first the ceiling cover layer is made, whereafter a certain amount of discrete elements of an acoustic insulating material is fixed onto the ceiling cover layer with the aid of fastening means, suitable for this purpose. The loadbearing structure is subsequently applied whereby the fastening means ensure the anchoring of the ceiling cover layer to the loadbearing structure.
[0026] To fasten them, the discrete elements are advantageously pressed into the concrete of the loadbearing structure and/or the ceiling cover layer before this is hardened. If desired the discrete elements may also be applied first onto the cover floor, for instance by adhesive bonding, whereafter this whole is applied onto the loadbearing structure. It is also possible to apply the discrete elements onto the loadbearing structure first, for instance by adhesive bonding, whereafter this whole is applied onto the ceiling cover layer.
[0027] In an alternative preferred embodiment the discrete elements are embedded into a film of neutral material, which covers the upper- and/or underside of the loadbearing structure almost entirely. Herewith the possibility arises to apply the cover floor by pouring concrete onto the film. It is also possible to turn around the loadbearing structure of the element after its manufacture, apply the film with discrete elements onto it, and pour the ceiling cover layer onto that. These embodiments of the process, whereby use is made of a film into which the discrete elements are embedded are advantageous, since the layers may be applied onto each other in a continuous process, for instance in a mobile shuttering device.
[0028] Advantageously the floor system according to the second preferred embodiment is characterized in that the fastening means comprise a tubular element with at least two lips, by which the element is anchored into the first layer and in which element at least a part of the second layer is received, which part is connected with the third layer through a T-shaped element.
[0029] The invention will now be further elucidated by means of the description below and the accompanying figures, without however being limited hereto.
Figure 1 shows a cross-section of a floor system according to the state of the art.
Figure 2 shows a cross-section of a
prefabricated floor element according to the first preferred embodiment of the invention.
Figure 3 shows in perspective how a floor system according to the first preferred embodiment of the invention is build up.
Figure 4 shows in perspective and in underview how a floor system according to the second preferred embodiment of the invention is build up, whereby a ceiling cover layer is applied.
Figure 5 shows a number of cross-sections of a prefabricated floor element according to the third preferred embodiment of the invention.
Figure 6 finally shows a detail of the fastening means, which are used for the second preferred embodiment of the invention.
[0030] The prefabricated element 100 of figure 2 has a layered structure with superimposed a lower layer 1, an intermediate layer 2 and an upper layer 3. The lower layer 1 is formed by a loadbearing structure 10, which is provided to achieve a load bearing capacity. The intermediate layer 2 is formed by an acoustic insulation layer 20, to achieve acoustic insulation between a storey on top, and an underlying storey. The upper layer 3 is formed by a cover floor 30, which is provided to cover the insulation layer 20 and to act as formwork for the pouring of a topping 4. This topping therefore is not part of the prefabricated element 100.
[0031] The acoustic insulation layer 20 comprises a plurality of discrete elements 21 of an acoustic insulating material, which are embedded into a film 22 of neutral material, such as for instance a plastic foam with low density. The discrete elements 21 may be applied into the insulation layer 20 point wise, in rectangular supports, or likewise, in strips, but advantageously in the shape of a regular screen. By neutral material is meant that this material essentially does not need to have loadbearing capacity, unless as formwork, in the case the cover floor 30 is applied by pouring concrete on top of the insulation layer 20. The film 22 prevents that dust particles or the like end up in the spaces between the discrete elements 21. The insulation layer 20 may if desired also be formed by discrete elements which are mutually separated by intermediate spaces, or by a continuous layer of an acoustic insulating material, or by alternating elements of different acoustic insulating materials, or by any other acoustic insulation layer known by the person skilled in the art.
[0032] The discrete elements 21 are advantageously made of an acoustic insulating material of rubberlike composition, in one or more layers adhesively bonded onto each other. Examples of suitable materials are polyurethane foams, resin-bonded rubbers and cork elastomers, but also other materials known to the person skilled in the art are possible. The density of the material is selected in accordance with the compression load to be taken. The unloaded thickness of the material is advantageously not higher than 30 mm. It is further desirable for the material to satisfy the creep criterion, i.e. that the maximum compression per time decade in minutes amounts to 2%, with respect to the initial thickness. The compression per time decade is hereby viewed logarithmically, i.e. first for 1 minute (first time decade), then for 10 minutes (second time decade), then for 100 minutes (third time decade) and so on.
[0033] Further, the dynamic stiffness and the static stiffness of the discrete elements are taken into account. The dynamic stiffness is the extent to which the material can resist a vibration. The dynamic stiffness is therefore a function of the frequency of the vibration. The static stiffness is the extent to which the material can resist a continuous load. The dynamic stiffness factor, i.e. the ratio of the dynamic stiffness over the static stiffness of the material is advantageously not higher than 3, so that a good vibro-acoustic operation of the floating cover floor is achieved.
[0034] The loadbearing structure 10 is made keeping the desired loadbearing capacity in mind. Hereby the following physical properties of the concrete play a role: compressive and tensile strength, and the modulus of elasticity. In most cases reinforced concrete will be selected, prestressed or not, whereby, with respect to the reinforcement, attention is paid to the number and the diameters of the threads and/or strands, the quality of the steel, the initial tension and the position of the threads in the height and width direction.
[0035] In the prefabricated element of figure 2a the loadbearing structure 10 has cavities 11 in the longitudinal direction to save weight. A solid loadbearing structure is also possible. If desired, spaces may be provided in the loadbearing structure to accommodate electrical or other conduits.
[0036] In the prefabricated element of figure 2a the cover floor 30 is a solid concrete slab. If necessary the cover floor 30 may likewise be provided with reinforcement.
[0037] The loadbearing structure 10 has longitudinal sides 12 and 13, which extend somewhat slantwise causing the loadbearing structure 10 to narrow somewhat towards the upper side. This tapering of the longitudinal sides 12, 13 is chosen such as to obtain a fillable joint between two adjacent prefabricated elements 100, 101. The cover floor 30 is slightly set back causing it to be narrower than the insulation layer 20 and the upper side of the loadbearing structure 10. If the insulation layer 20 is folded back at the sides in the upward direction along the cover floor 30 the joints need to be covered almost completely with additional acoustic insulating elements 31 after having been filled up and before applying the upward masonry, in order to avoid that the joints cause acoustic leaks. The acoustic insulating elements 31 are positioned onto the cover floor 30 and have a width such that sufficient overlap is created between the acoustic covering elements 31 and the cover floor 30. In case the insulation layer 20 is not folded back covering elements 31 need to be provided onto the insulation layers 20 of the adjacent floor elements 100, 101, after filling the joints between the cover floors 30 of two adjacent floor elements 100, 101, such as shown in figures 2b, 2c and 3. As shown in figure 2c the elements 31 may, if desired, have another shape than the beam shape, and/or may be executed hollow, for instance to guide cables, and the like.
[0038] In figure 3 it is also shown how a storey is constructed in a building with the aid of the prefabricated elements 100, 101. The prefabricated elements 100, 101 are positioned onto the walls 40 of an underlying storey with their longitudinal sides directed towards each other. Subsequently, the joint 14, formed by the adjacent longitudinal sides 12, 13 of the prefabricated elements 100, 101, is filled up with joint filler. Hereby, the loadbearing structures 10 of the prefabricated elements 100, 101 are mutually joined and a loadbearing entity is obtained. The joints 14 are hereafter covered by cover floor elements 31. In case the insulation layer 20 is being folded back in the upward direction along the cover floor 30, the cover floor elements 31 rest onto the cover floors 30 of adjacent floor elements 100, 101, as shown in figure 2a. In case the insulation layer 20 is not folded back upwardly along the cover floor 30, the cover floor elements 31 rest directly onto the insulation layer 20 at the longitudinal sides 12, 13 of the adjacent prefabricated elements 100, 101 (see figures 2b and 2c). The entity formed by the cover floor 30 of the prefabricated elements 100, 101 and the cover floor elements 31 forms the basis for the walls 41, 42 of the storey on top.
[0039] Hereby, the floor system of figure 3 has the advantage that the insulation layer 20 extends between the walls 40 of the underlying storey and the walls 41, 42 of the storey above it. This increases the insulating capacity of the floor system. An insulation layer 50 is applied as additional insulation in the floor system of figure 3 onto the support zone of the underside of the loadbearing structure 10.
[0040] In addition, the floor system of figure 3 has the advantage that cover floor 30 is already positioned on top of the insulation layer 20, when the prefabricated elements 100, 101 arrive on the construction site. The insulation layer 20 is therefore protected, so that the risk for sound leaks and therefore an insufficient sound insulation between the superimposed storeys is being limited.
[0041] As an alternative to placing the cover floor elements 31 above the joints 14, the space between the cover floors 30 of the prefabricated elements 100, 101 may also be filled with the aid of the joint filling material. In this embodiment prefabricated elements 100, 101 are used, in which the insulation layer 20, advantageously the film 22 with discrete elements 21, extends further than the longitudinal sides 12, 13 of the loadbearing structure 10. The protruding part of the insulation layer 20 is in this case folded over upwardly, for instance adhesively bonded against the cover floor 30, when the prefabricated elements 100, 101 arrive on the construction site. After the joint 14 has been filled, the protruding part of the insulation layer 20 is lowered, thereby also covering the joint 14 with the insulation layer 20. The development of a sound leak at this position may thus be prevented. It is hereby possible that the edges of the insulation layer 20 of the adjacent prefabricated elements 100 and 101 mutually overlap. Finally then, the space between the cover floors 30 of the prefabricated elements 100 and 101 is further filled with the joint filling material (see figure 2d).
[0042] Figure 4 shows how a storey has been laid in a building with the aid of prefabricated elements 100, 101 according to the second preferred embodiment, whereby use is made of prefabricated elements 100, 101, provided with a ceiling cover layer at the underside of the loadbearing structure, and in between an insulation layer 20. Such a construction has the additional advantage of not having to cover the joints with additional acoustic elements 31, after they have been filled. Indeed, acoustic insulation at joints height is automatically obtained when using the prefabricated elements 100, 101, according to the second preferred embodiment through the intermediate layer 20 present in them, which intermediate layer 20 is positioned at the underside of the joint. The fastening means 71 shown in figure 4 comprise the discrete elements 21, as is described below. It also has advantages to provide additional discrete elements 21 between loadbearing structure 10 and ceiling layer 80, which are, if desired, embedded in a neutral material.
[0043] In the second preferred embodiment of the prefabricated floor element the third layer (the ceiling layer) is connected with the first layer (the loadbearing structure) through fastening means 71. These consist of a tubular element 72, anchored into the first layer and which cooperates with a T-shaped element 73, anchored in the third layer 3, as shown in figure 6. The tubular element 72 is provided with at least two lips 72a, 72b, with which the element 72 is anchored into the first layer 1. The tubular element 72 has an opening in its lower wall through which passes the T-shaped element 73, which is therefore partly received in the cavity of the tubular element 72. The T-shaped element 73 finds support on the lower wall of the tubular element 73 through at least part of the second layer 2, in particular a number of discrete elements 21 of the second layer 2. The discrete elements 21 shown in figure 6 are provided with an opening through which element 73 may be inserted. The opening may simply be produced, for instance by perforating the discrete elements 21 beforehand.
[0044] Several examples of the third preferred embodiment of a floor element according to the invention are shown in figures 5(a), 5(b) and 5(c). Such a floor element provides a solution to the problem of having acoustic leaks in the vicinity of joints between two adjacent elements 100, 101. The prefabricated floor element 100 of figure 5 has a layered structure with superimposed a lower layer 1, an intermediate layer 2 and an upper layer 3. The lower layer 1 is formed by a loadbearing structure 10, which is provided to obtain a loadbearing capacity. An acoustic insulation layer 20, to achieve acoustic insulation between a storey on top and an underlying storey, forms the intermediate layer 2. The upper layer 3 is formed by a cover floor 30, which is provided to cover the insulation layer 20 and to act as formwork for pouring of a topping 4, if desired.
[0045] The floor elements 100 shown in figure 5 are provided with a third layer 3 of which the longitudinal sides 52, 53 extend somewhat slantwise causing the third layer 3 to narrow somewhat in the upward direction, thereby forming a fillable joint 60 with an adjacent floor element 101. By providing the joint 60 between two adjacent floor elements 100, 101 in the third layer 3, the joint 60 is automatically insulated acoustically. This significantly reduces sound leakage from a storey to the storey underneath through the joint 60 between the floor elements 100, 101.
[0046] Because in the third preferred embodiment the lateral connection between the floor elements 100, 101 occurs by means of the third layer 3 the load transfer from one element 100 to a next element 101 is distributed better. As indicated in figure 5(b) the third layer 3 is, if desired, provided with cavities to further reduce the element's weight. It also has advantages to provide the third layer 3 with reinforcement to improve load distribution.
[0047] If desired, the longitudinal sides 12, 13 of the first layer 1 of the floor element according to the preferred embodiment may likewise extend somewhat slantwise, such that when positioning two floor elements 100, 101 adjacent to each other a second joint 14 is formed between both first layers, in addition to the first joint 60 formed by the adjacent longitudinal sides 52, 53 of the third layer 3. This has the additional advantage of a better distribution of the loads.
[0048] It is also possible to have the longitudinal sides 12, 13 of the first layer 1 to extend substantially vertical, such that the longitudinal sides 12, 13 of two adjacent floor elements 100, 101 contact each other over nearly their total surface.
[0049] To further improve the load distribution the third layer 3 has advantageously a larger thickness at the sides, such that the third layer is provided with a U-shaped cross-section with legs 54 and 55, as shown in figures 5(a) and 5(c). This enables to increase the dimensions of the joint 60 whereby, for a same joint material strength, a larger load may be transferred from element 100 to element 101. The cross-section of the first layer 1 is, in this embodiment, adapted such that it may cooperate with the U-shaped cross-section of the third layer 3. The first layer 1 is hereto provided with parts 54a, 54b reduced in height at the sides. This ensures that the total height of the floor element 100 remains unchanged.
[0050] If desired, cavities 11 may be applied in the first layer 1 to reduce the weight and/or to improve the acoustic insulation. It is possible to completely include the cavities 11 in the loadbearing structure 10, as shown in figures 5(a) and 5(b), and/or to provide the cavities in direct connection with the second layer 2, as shown in figure 5(c).
1. Floor system for use in the building industry, comprising a plurality of prefabricated
elements (100, 101), meant for positioning onto walls (40) or supporting beams of
an underlying storey and as a basis for walls (41, 42) of a storey above, characterized in that, the prefabricated elements (100, 101) have a layered structure, of which a first
layer (1) is formed by a loadbearing structure (10) for obtaining a loadbearing capacity,
of which a second layer (2) is formed by an insulation layer (20) for acoustic insulating
the underlying storey from the storey above, and of which a third layer (3) is formed
by a cover layer (30).
2. Floor system according to claim 1, characterized in that the second layer (2) is located above the first layer (1) and the third layer (3)
above the second layer (2), such that the third layer (3) thus forms a floor cover
layer (30).
3. Floor system according to claim 1, characterized in that the second layer (2) is located underneath the first layer (1) and the third layer
(3) underneath the second layer (2), and that the third layer (3) is attached to the
first layer (1) with suitable fastening means (71).
4. Floor system according to claim 2, characterized in that the third layer (3) has longitudinal sides (52) and (53) which extend somewhat slantwise
such that the third layer (3) narrows somewhat in the upward direction, thereby forming
a fillable joint (60) between two adjacent floor elements 100, 101.
5. Floor system according to any one of claims 1-4, characterized in that the insulation layer (20) is formed by a plurality of discrete elements (21) of an
acoustic insulating material.
6. Floor system according to claim 5, characterized in that the discrete elements (21) are distributed over the insulation layer in the pattern
of a regular screen.
7. Floor system according to claim 5 or 6, characterized in that the discrete elements (21) are embedded in a neutral material (22) to fill the space
between the discrete elements.
8. Floor system according to any one of the preceding claims, characterized in that the prefabricated elements (100, 101) are, at the underside, provided with a support
zone, where the loadbearing structure contacts the walls (40) of the underlying storey,
and that in this support zone advantageously an additional acoustic insulation (50)
is being provided.
9. Floor system according to any one of the preceding claims, characterized in that the loadbearing structure (10) of the prefabricated elements has longitudinal sides
(12, 13), whereby each longitudinal side (12) is provided to form a fillable joint
(14) with the longitudinal side (13) of the loadbearing structure of an adjacent prefabricated
element, whereby the insulation layer (20) of the prefabricated elements extends to
against these longitudinal sides (12, 13) and the cover floor (30) is set back with
respect to these longitudinal sides (12, 13), and that the floor system further comprises
cover floor elements (31) for covering the joint (14).
10. Prefabricated element as part of a floor system for use in the building industry,
whereby the prefabricated element (100, 101) comprises a loadbearing structure (10)
for obtaining a loadbearing capacity, characterized in that the prefabricated element has a layered structure, of which a first layer (1) is
formed by a loadbearing structure (10) for obtaining a loadbearing capacity, of which
a second layer (2) is formed by an insulation layer (20) for acoustic insulating the
underlying storey from the storey above, and of which a third layer (3) is formed
by a cover layer (30).
11. Prefabricated element according to claim 10, characterized in that the second layer (2) is located above the first layer (1) and the third layer (3)
above the second layer (2), such that the third layer (3) thus forms a floor cover
layer (30).
12. Prefabricated element according to claim 11, characterized in that the second layer (2) is located underneath the first layer (1) and the third layer
(3) underneath the second layer (2), and that the third layer (3) is attached to the
first layer (1) with suitable fastening means (71), thereby forming a ceiling cover
layer (80).
13. Prefabricated element according to claim 11, characterized in that the third layer (3) has longitudinal sides (52) and (53) which extend somewhat slantwise
such that the third layer (3) narrows somewhat in the upward direction, thereby forming
a fillable joint (60) between two adjacent floor elements 100, 101.
14. Prefabricated element according to any one of claims 10-13, characterized in that the insulation layer (20) is formed by a plurality of discrete elements (21) of an
acoustic insulating material.
15. Prefabricated element according to claim 14, characterized in that the discrete elements (21) are distributed over the insulation layer in the pattern
of a regular screen.
16. Prefabricated element according to claim 13 or 14, characterized in that the discrete elements (21) are embedded in a neutral material (22) to fill the space
between the discrete elements.
17. Prefabricated element according to any one of claims 10-16, characterized in that the prefabricated element (100) comprises at its underside a support zone, provided
to contact the walls (40) of an underlying storey, and that in this support zone advantageously
an additional acoustic insulation (50) is being provided.
18. Prefabricated element according to any one of claims 10-17, characterized in that the loadbearing structure (10) has one or more longitudinal sides (12), which are
provided to form a fillable joint (14) with the longitudinal side (13) of the loadbearing
structure of an adjacent prefabricated element, whereby the insulation layer (20)
of the prefabricated element (100) extends to against these longitudinal sides (12)
and the cover floor (30) is set back with respect to these longitudinal sides (12),
such that a space is formed to accommodate cover floor elements (31) for covering
the joint (14).
19. Process for the manufacture of a prefabricated element for use in a floor system,
whereby in a first step a loadbearing structure (10) is made, characterized in that the process comprises the following steps:
a) placing a plurality of discrete elements (21) of an acoustic insulating material onto the upper- and/or underside of the loadbearing structure (10);
b) placing a cover floor (30) onto the upper side of the element;
c) if desired, placing a ceiling cover layer (80) at the underside of the element.
20. Process according to claim 19, characterized in that the discrete elements are pressed into the concrete of the loadbearing structure
(10) before the concrete has been hardened.
21. Process according to claim 20, characterized in that the discrete elements (21) are embedded in a film of a neutral material (22), which
completely covers the upper- and/or underside of the loadbearing structure (10), and
that the cover floor (30) is placed by pouring concrete.
22. Process according to any one of claims 19-21, characterized in that the loadbearing structure (10) is made by pouring concrete in a mould.
23. Process according to any one of claims 19-21, characterized in that the loadbearing structure (10) is made by pouring concrete in a mobile shuttering
device, such as for instance a sliding formwork or an extrusion device.