Background of the invention
[0001] The invention relates to a floor part as a part for a floor construction such as
an insulation floor, a floor construction, and a method for constructing an insulation
floor, and a building provided with an insulation floor.
[0002] In
NL2005380 a floor is provided with subfloor-boards and girders provided with one or more bearing
surfaces for bearing the subfloor-boards, and a layer of concrete that constructionally
connects the girders and covers the subfloor-boards. At least a part of the girders
consists of a girder material that in case of the same bearing capacity of the girder
results in a lower weight per running unit of length of the girder than reinforced
or prestressed concrete does. The girders may for instance be made of a synthetic
material, such as a composite, or of a sheet metal, shaped into the desired profile.
[0003] There is room for improvement of the processability of such floors and renovation
floors.
[0004] According to its abstract,
US6085479 describes a premanufactured structural building panel for promoting the efficient
construction of the exterior wall members of a building having improved insulation,
sound absorption, fire retardant and structural properties. The premanufactured structural
building panels consist of a number of C-shaped structural channels. The panels are
provided with a fire retarding board secured to opposing angle members and a foam
insulation member secured to the fire retarding board. A plurality of retaining members
are provided for additional structural support. The structural panels are supported
on wall support members and connected to each other in a side-by-side fashion to form
an exterior wall member of a building. The panels are arranged such that the C-shaped
channels are protected from conditions external to the building by a portion of the
foam insulation members. The exterior wall members include vertical sidewalls, a horizontal
roof and ceiling wall, and a pitched roof system. The interior surface of the walls
can be prepared for finishing. Affixed to the exterior of the wall members is a weatherable
covering. This document does not relate to interior floors for a building.
Summary of the invention
[0005] It is an object of the invention to provide a floor part that is easier in terms
of construction and use. It is a further or additional object to provide a floor part
that can be manufactured in an economically advantageous fashion.
[0006] For that purpose the invention provides a floor construction according to claim 1.
[0007] In one embodiment the floor part is used as insulation floor, in particular a ground
floor insulation floor, in the construction of houses. This floor concept will in
one embodiment be used in particular in new builds, renovations, refurbishments and
small extensions.
[0008] By using the floor parts, which are generally premanufactured, also called "Prefab",
a simple and quick construction of a complete floor in a building can be realised.
The production takes place at a location that is remote from the building site.
[0009] The floor parts comprise floor elements of an expanded synthetic material or a synthetic
foam. An example of such materials are expanded polyethylene (EPP), expanded polypropene
(EPP), expanded polystyrene (EPS), polyurethane foam (PUR). A material that is suitable
in terms of its properties, acceptance in construction work, and costs, is EPS. The
floor elements are substantially block-shaped. As a result they can be fitted well
into a building. It is of course possible to adapt outer ends to the building walls
that are not straight.
[0010] The edges of the floor elements may be adapted so that the top surface and the profile
parts provide a substantially flat top surface. For instance the top faces of the
floor elements may at their longitudinal sides be provided with a recess for the flanges.
As a result the top face of the floor parts can provide a flat surface.
[0011] The floor elements may be provided with a longitudinal groove for accommodating the
flanges of the U-profile parts. A vertical cold bridge is thus avoided. The longitudinal
groove will have been arranged at least a few centimetres above the bottom face. Said
groove will usually be fitting to the flange, optionally clamping it. A simple incision
or longitudinal cut may suffice to accommodate a flange.
[0012] A similar effect of avoiding a vertical cold bridge can be achieved by means of a
floor element of a first block-shaped floor element member having a thickness fitting
between the flanges of a U-profile part. The floor element furthermore comprises a
second floor element member having a width adapted to the distance between the bodies
of opposing U-profiles of a floor part. In one embodiment the width of the second
floor element member substantially corresponds with the width of a floor part. A second
floor element member may have a higher compression strength than the first floor element
member.
[0013] Optionally the length of a second floor element member may be shorter than the length
of the first floor element member. When the outer ends of the U-profiles have been
supported on support members, one or more second floor element members may extend
between the support members.
[0014] Usually the flanges of the U-profiles will be thin, a few millimetres at the most.
A face of the second floor element member adjacent to the first floor element member
may be provided with a recess for a flange. Alternatively the face of the first floor
element member may be provided with a recess for a flange. A recess could also be
divided over both floor element members.
[0015] The U-profile parts are shape-retaining and in one embodiment made of metal.
[0016] Suitable metals are for instance iron and/or galvanised steel. In particular galvanised
steel having a thickness of 0.5-2 mm is suitable, more in particular 0.7-1.5 mm. Other
materials providing a corresponding rigidity and strength may also be suitable. In
terms of costs galvanised steel is suitable.
[0017] The U-profile parts of abutting floor parts may be connected to each other back-to-back
by means of snap members, or be connected by means of bolts or screws.
[0018] The invention furthermore relates to a floor construction comprising floor parts
as described, comprising a series of floor parts in longitudinal direction adjacent
to each other, wherein the U-profile parts in longitudinal direction extend beyond
the floor elements, and wherein the floor construction furthermore comprises a circumferential
formwork border provided with a support ledge for supporting the outer ends of the
U-profile parts and with an upright edge.
[0019] The invention furthermore relates to a method for constructing an insulation floor
in a building using a floor part according to the invention, wherein the floor parts
are laid in longitudinal direction adjacent to each other on a floor or support member
with the body of one of the U-profile parts of a floor part against the body of one
of the U-profile parts of a next floor part, back-to-back, for providing a continuous
insulation floor.
[0020] The invention further relates to a method for constructing an insulation floor in
a building for obtaining a floor construction as described, wherein the formwork border
is attached to a part of a building, the floor parts are laid in longitudinal direction
adjacent to each other with the body of one of the U-profile parts of a floor part
against the body of one of the U-profile parts of a next floor part, back-to-back,
for providing a continuous insulation floor, and with the outer ends of the U-profile
parts that in longitudinal direction extend beyond the floor elements and that support
on the support ledges.
[0021] In one embodiment the U-profile parts may first be connected to each other back-to-back,
after which the floor elements of synthetic foam are placed in between them. In that
way H-profiles can in fact be provided and floor elements of synthetic foam, the longitudinal
sides of which extend fully or in part in between such H-profile parts.
[0022] The invention further relates to a floor part for an insulation floor for a ground
floor for buildings, comprising a substantially block-shaped floor element of synthetic
foam provided with a top and bottom face and opposing longitudinal sides, and wherein
along the opposing longitudinal sides the floor element is provided with shape-retaining,
substantially rectangular U-profile parts provided with a body and flanges, wherein
the bodies abut the longitudinal sides, a flange abuts a top face, and a flange is
embedded in the floor element spaced apart from the bottom face.
[0023] The floor construction makes a self-supporting, insulating floor possible.
[0024] The invention furthermore relates to a floor part provided with one or more of the
characterising measures described in the attached description and/or shown in the
attached drawings.
[0025] It will be clear that the various aspects mentioned in this patent application can
be combined and that each individually may qualify for a divisional patent application.
Brief description of the drawings
[0026] In the attached drawings an embodiment of a floor construction is shown in which:
Figure 1 shows an example of a part of a floor of a building in which the floor parts
can be used, in perspective view;
figure 2 shows a perspective view of an embodiment of the floor parts provided with
projections;
figure 3 shows a detail of figure 1,
figure 4 shows an alternative or additional embodiment provided with a formwork border.
Description of the embodiments
[0027] Figure 1 shows an example of a floor provided with a subfloor, in this case a bearing
subfloor. On the subfloor an insulating floor construction with floor parts 2 has
been placed, and atop of it, partially interrupted, a finishing floor 6. Such a finishing
floor may for instance be a wooden flooring, or a (snap-together) laminate flooring,
or a pressure layer of poured material such as concrete.
[0028] The floor parts 2 here comprise block-shaped floor elements 3 of synthetic foam.
Alongside both longitudinal sides each floor element 3 is provided with a U-profile
part 5. The U-profile parts 5 have a body 7 and flanges 8. In this embodiment the
floor elements comprise a first floor element member 3 and a second floor element
member 4. By using a second floor element member 4 there is no or hardly any heat
contact between the lowermost flanges 8 of the U-profiles 5 and the subfloor, and
the environment. In that way a vertical cold bridge due to the U-profiles 5 is prevented.
In terms of thickness the first floor element members 3 fit in between the flanges
8 of the U-profiles 5. In this solution, if so desired a material of the second floor
element member 4 can be chosen to have a greater pressure resistance than the material
of the first floor element member.
[0029] In an alternative embodiment a floor element 3 is provided with opposing cuts or
longitudinal grooves for accommodating one of the flanges 8 of a U-profile part 5.
[0030] In figure 2 the top surface of a floor element 3 is provided with projections 10.
In this case the projections have a flat top face. Between the projections pipes 11
such as heating pipes for underfloor heating can be laid. The projections 10 have
here been arranged on a fixed grid, in this case a rectangular grid. The diameter
of the projections will usually be 5-20 cm, mostly 5-15 cm. The height of the projections
may be selected in between 1 and 3 cm.
[0031] Figure 3 shows a detail of figure 1.
[0032] In an alternative embodiment the floor parts 2 have not been arranged on a subfloor.
An example thereof is shown in figure 4. In this embodiment the outer ends of the
U-profiles 5 are supported by construction members 15. A floor part 2 here comprises
a floor element 3, along both longitudinal sides provided with profile parts 5 extending
beyond the floor parts. In the embodiment shown, the construction members 15 are a
circumferential beam 15 or a small wall 15. The chosen construction 1 further accelerates
the method, can be used for various storeys in a building, and provides an accurate
finishing height for an optional pressure layer by using a circumferential formwork
border 12. In this case the formwork border 12 is made of the same material as the
profile parts 5. In one embodiment, as shown in the figure, the formwork border 12
comprises an upright edge 13 and a support ledge 14. Support ledge 14 can easily be
placed on a supporting member such as the said circumferential beams of an interior
wall. Optionally a dampening layer may have been placed in between the construction
and the support ledge 14. In an alternative embodiment the formwork border with the
upright edge 13 can be secured to a wall and the support ledge 14 provides a ledge
for the profile parts 5. A separate bearing profile may also be screwed to the wall
and the formwork border may then support thereon.
[0033] In this case the profile parts 5 extend beyond the floor elements 3. The floor elements
3 have here been provided with the longitudinal cut so that the flanges 8 of the profile
parts 5 have been accommodated therein and the insulation extends beyond the profile
parts and the profile parts do not form a cold bridge. In between the outer ends of
the profile parts 5, in particular their flanges 8, and the support ledge of the formwork
border further layers can be applied for insulation, for instance rubber strips or
parts of synthetic material. The space in between the outer ends of floor elements
3 and the upright edge 13 of the formwork border 12 may be filled with insulation
blocks 16. In the embodiment intermediate spaces 17 have furthermore been left open.
In this case the construction 1 has furthermore been provided with a floor, in this
case a pressure layer 6 on which a finishing flooring such as parquet, laminate flooring
or a carpet may be placed. The pressure layer may be of a poured material, such as
for instance concrete. The intermediate spaces 17 can then be filled with the poured
material so that support members 18 are created for additional bearing properties
of the pressure layer.
[0034] A floor element 2 in one embodiment consists of a polystyrene foam (EPS) core enclosed
on both sides by a metal U-profile 5.
[0035] The thickness of the floor depends on the desired RC-value and the span and the load
that will be on the floor. In a specific embodiment this floor has a thickness of
200 mm. By using various qualities of EPS, different RC-values can be achieved.
[0036] In one embodiment the width of the floor element is for instance 500 mm. Other widths
can be made for fitting pieces. The length of the floor element depends on the desired
floor length of the building project and this may vary from 1.5 to 8 metres. The metal
U-profile is formed according to the specifications required according to the Dutch
calculation rules for floor loads. The present U-profile has a height of 200 mm with
two flanges that are folded back of approximately 40 mm, but depending on the span,
the required loading capacity, the width of the flanges, the thickness of the profile
the height of the U-profile may vary. The thickness now is approximately 1 mm. The
thickness may vary, taking among others the span and the load to be borne into account.
[0037] A complete floor consists of various floor elements.
[0038] What is unique about this product is:
* a floor element which unites the load bearing capacity and the insulation in one
element.
* the floor element is made to length in the factory in conformity with the specifications
of the project; As a result it will no longer be necessary to measure the floor elements
at the project site.
* it is lightweight and as a result the mounting time, processing time is much shorter
than is the case with existing systems. Mounting time can be reduced down to 15% of
the conventional mounting time.
* use of a concrete pressure layer is also possible.
* due to the specifications of the metal profile a so-called pressure layer will not
be required, as is the case for concrete bearing girders, and a wooden or laminated
top plate will suffice.
* optionally EPS-caps can be integrated or integrally formed on the EPS part, as a
result of which underfloor heating pipes or electricity pipes can be laid quickly.
This will reduce the height of the overall floor.
* in case of a wooden or laminated top layer a border formwork will no longer be required
due to the set-up of this floor element.
* the entire set-up of the floor is cost-reducing.
[0039] Further additions:
* when the floor elements have been mounted, wooden or laminated floor boards can
be screwed onto the steel girders, resulting in an improved stability and it can also
be used as a finishing layer for parquet or carpet.
* Optionally the U-profile may project at the outer ends of the floor element in order
to achieve a better support. In one embodiment 5-15 cm of the outer ends of the U-profiles
sit on the support beams. Optionally the complete floor elements may be supported
in such an end range.
[0040] It will be clear that the above description is included to illustrate the operation
of preferred embodiments of the invention and not to limit the scope of the invention.
Starting from the above explanation many variations that fall within the spirit and
scope of the present invention will be evident to an expert.
1. Floor construction (1) for an insulation floor for a floor, particularly a ground
floor, for buildings, comprising floor parts (2) comprising a substantially block-shaped
floor element (3) of synthetic foam provided with an top and bottom face and opposing
longitudinal sides, and wherein along the opposing longitudinal sides the floor element
is provided with shape-retaining, substantially rectangular U-profile parts (5) provided
with a body (7) and flanges (8), wherein the bodies substantially abut the longitudinal
sides, a flange substantially abuts a top face, and a flange is substantially embedded
in the floor element (3) spaced apart from the bottom face, wherein the floor construction
(1) comprises a series of the floor parts (2) adjacent to each other in longitudinal
direction, wherein the U-profile parts (5) in longitudinal direction extend beyond
the synthetic foam floor elements (3), and wherein the floor construction (1) furthermore
comprises a circumferential formwork border (12) provided with a support ledge (14)
for supporting the outer ends of the U-profile parts (5) and with an upright edge
(13), wherein the floor construction (1) is furthermore provided with a concrete finishing
layer (6) wherein the upright edge (13) extends above the U-profile parts (5) and
the floor elements (3) as formwork border when pouring the concrete finishing layer
(6).
2. Floor construction according to claim 1, wherein the floor element comprises a first
block-shaped floor element member having substantially a thickness fitting between
the flanges of the U-profile parts, and a second floor element member extending over
a bottom face of the first floor part for providing a synthetic foam layer extending
from a flange and the first floor element member, having a width of substantially
the distance between the bodies of the U-profile parts, in particular having a thickness
of the second floor element member of 3-15 cm.
3. Floor construction according to claim 1, wherein the longitudinal sides are provided
with a longitudinal groove for accommodating a flange of the U-profile part, in one
embodiment a longitudinal cut.
4. Floor construction according to any one of the preceding claims,
wherein the floor element is substantially made of polystyrene foam (EPS).
5. Floor construction according to any one of the preceding claims,
wherein the floor element has a thickness of at least 150 mm.
6. Floor construction according to any one of the preceding claims,
wherein the floor element has a width of 20-60 cm.
7. Floor construction according to any one of the preceding claims,
wherein the floor element has an RC value of at least 3.5 m2K/W.
8. Floor construction according to any one of the preceding claims,
wherein on a surface the floor element is provided with projections of the foamed
synthetic foam, in particular the projections are substantially cylindrical having
a substantially flat surface, specifically having a diameter of 5-20 cm, more specifically
having a height of 1-5 cm, in particular the projections are integrally formed.
9. Floor construction according to any one of the preceding claims,
wherein the shape-retaining profile parts are U-profiles, in particular U-profiles
having a rectangular cross-section.
10. Floor construction according to any one of the preceding claims, wherein the U-profile
is a metal U-profile, preferably of galvanised steel.
11. Floor construction according to any one of the preceding claims, wherein the U-profile
has flanges of 35-90 mm, wherein the flanges can be folded back.
12. Floor construction according to any one of the preceding claims, wherein the U-profiles
in longitudinal direction extend beyond the synthetic foam floor elements, for being
supported on a foundation.
13. Method for constructing an insulation floor in a building using a floor construction
according to any one of the preceding claims 1-12, wherein the floor parts are laid
in longitudinal direction adjacent to each other on a floor or support member with
the body of one of the U-profile parts of a floor part against the body of one of
the U-profile parts of a next floor part, back-to-back, for providing a continuous
insulation floor.
14. Method according to claim 13, wherein the formwork border is attached to or at a part
of a building, the floor parts are laid in longitudinal direction adjacent to each
other with the body of one of the U-profile parts of a floor part against the body
of one of the U-profile parts of a next floor part, back-to-back, for providing a
continuous insulation floor, and with the outer ends of the U-profile parts that in
longitudinal direction extend beyond the floor elements and that support on the support
ledges.
15. Method according to any one of the preceding claims 13-15,
wherein the U-profile parts in longitudinal direction extend beyond substantially
block-shaped floor elements of synthetic foam, wherein the floor parts are laid in
longitudinal direction adjacent to each other on a floor with the body of one of the
U-profile parts of a floor part against the body of one of the U-profile parts of
a next floor part, back-to-back, for providing a continuous insulation floor, wherein
with the parts of the U-profiles that extend beyond the substantially block-shaped
floor elements of synthetic foam are supported on a construction part, particularly
a foundation of the construction part.