Patent Publication Number: US-8122660-B2

Title: Possibility of special lightening, insulating and reinforcing intermediate floor constructions

Description:
TECHNICAL FIELD 
     The subject of the invention, generally speaking, belongs to the field of civil engineering. According to the International classifications of patents (ICP) the subject of the invention can be market with the following classification symbols: E 04 B 5/08, E 04 C1/24 and E 04 C 5/065. 
     THE TECHNICAL PROBLEM 
     The technical problem is to be solved with the invention is: how to construct a lightweight intermediate floor construction, so it should be lightweight, bearing, thermo insulating, prefabricated and semi-prefabricated with shorts only on the middle and on the ends of it. The expanded polystyrene on the bottom of lightweight intermediate floor construction should be a formwork, a hollow tile, a filling and the thermo insulation of the construction itself. 
     STATE OF TECHNOLOGY/BACKGROUND ART 
     There are lot of prefabricated and semi-prefabricated intermediate floor constructions, with ceramic or concrete filling, which are shored on several shorts during the mounting and the concreting. There is a lightweight intermediate construction with formwork made from expanded polystyrene, but it should be shorted on every 60 or 80 centimeters. That makes the floor construction expensive and non-practical, because there are lot of strut frames, which prevents the building below them. The present pre-stressed intermediate floor constructions are much more expensive, they are not thermo insulating and they are sensitive to the corrosion of the thin steel wires inside of them. 
     Document FR 1602 029 introduces plate elements for intermediate floor constructions made from burned clay. Building with those elements requires shuttering of the whole construction. Plate elements introduced in PCT/YU 2006/000029 are made from polystyrene and they allow the ability of making prefabricated mounting beams. The similarity between two solutions is in the fact that both of elements have channels for reinforcement, while the reinforcement is completely different. 
     Document WO 95/09953 introduces elements for intermediate floor constructions, which can be used to form prefabricated mounting beams. Building with those elements requires a lot of shores. Plate elements introduced in PCT/YU 2006/000029 are enabling, because they have cross ribs. Polystyrene elements in PCT/YU 2006/000029 are supported at three points, so the system is completely safe. 
     Document EP 0987 377 A2 introduces elements for beams with special shaped steel lattice built in elements. Those floor constructions do not have cross rigidity. Plate elements introduced in PCT/YU 2006/000029 forms longitudinal and cross channels, which enables rigidity of the construction in both directions. 
     Document U.S. Pat. No. 6,817,150 introduces elements for intermediate floor constructions made from polystyrene, with formed plate elements built in it, which are enabling rigidity of the construction during mounting and concreting. Still those floor constructions do not have cross rigidity, while floor constructions made from plate elements introduced in PCT/YU 2006/000029 are rigid in both directions. 
     THE ESSENCE OF THE INVENTION 
     Expanded polystyrene in granules up to 5 mm are placed in special formed moulds, and with already known technology, the specially shaped polystyrene floor elements are produced. These floor elements are formed to be filling floor elements with channel for reinforcement. The prefabricated or semi-prefabricated beam is thermo insulating, by its bottom side, so it prevents the warm air to enter the floor construction. 
     After specially shaped polystyrene floor elements are produced, the already present reinforcement made as space trusses are build in channels of elements. The lower part of those channels is filled with concrete, so the semi-prefabricated floor beams are done. The beams are placed on shorts, on the ends and on the middle of them. Prefabricated beams are made with same technology, but the concreting goes up to the top of the channels. The prefabricated beams are shorted only on the ends of them 
     The unique of this system is in building the beams with at least two space trusses, so there is no need for extra reinforcement. Double space trussing enables the use of minimum shorts, too. 
     In the aim to protect the reinforcement in concrete, special distance-elements are built in channels, which are enabling the distance between reinforcement and polystyrene and between reinforcement and concrete. 
    
    
     
       SHORT DESCRIPTION OF THE FIGURES 
       In the aim to better understanding the invention: great span intermediate floor construction with special reinforced semi-prefabricated small beams and universal filler blocks, the following figures are given: 
         FIG. 1  is a floor element made from polystyrene with slope sides by it bottom side; 
         FIG. 1-1  is a side end view of the floor element as disclosed in  FIG. 1 ; 
         FIG. 1-2  is an end view of the floor element as disclosed in  FIG. 1 ; 
         FIG. 1-3  is a top view of the floor element as disclosed in  FIG. 1 ; 
         FIG. 2  is a floor element made from polystyrene with rectangle channel; 
         FIG. 2-1  is a side view of the floor element as disclosed in  FIG. 2 ; 
         FIG. 3  is a distance element for reinforcement which are build in floor element with slope sides 
         FIG. 4  is a distance element which are build in floor element with slope sides 
         FIG. 5  is a distance element for reinforcement which are build in floor element with rectangle channel 
         FIG. 6  is a space truss made from at least two lattices, which are put on distance elements of floor elements 
         FIG. 7  is a space truss placed on the distance elements inside the channel of floor elements with slope sides 
         FIG. 8  is a space truss placed on the distance elements inside the rectangle channel 
         FIG. 9  is a plate floor element for increasing the height of a floor. 
         FIG. 10  is a mounted floor plate element with still space lattice 
     
    
    
     DETAIL DESCRIPTION OF THE INVENTION 
     This treaty is about producing specially shaped floor elements ( 1 ) from expanded polystyrene with already known technology. Floor element ( 1 ) is shaped as plate with moulding and channel ( 2 ) on the upper side of the element. Cross section of the channel ( 2 ) is consist of a trapezoid with equal flights ( 6 ) and the basic angle of 70° on the bottom side, the rectangle shaped prism with flat sides ( 4 ) on the middle, and of a trapezoid which flights ( 5 ) and the basic angle of 135°. In the aim to enabling the concrete support during the mounting one element ( 1 ) to another, the upper side ( 7 ) of the element is shorter than the lower side ( 8 ). The front and the backside of the element ( 1 ) are consisting of upper vertical ( 9 ), a slope ( 10 ), a horizontal ( 11 ) and a lower vertical ( 12 ). The lateral sides of the elements are moulded, so that one side has a convexity ( 13 ), while the other has a concavity ( 14 ), both of same dimensions and which enables the connections between prefabricated beams. Floor elements ( 15 ) are produced by same technology. The difference between elements ( 1 ) and ( 15 ) is in the shape of its channels. The cross section of the channel ( 16 ) of the element ( 15 ) is consist of rectangle on the bottom and of a trapezoid on the upper side, which is same as the upper trapezoid of the cross section of the channel ( 2 ) of the element ( 1 ). The plates ( 17 ) are produced by same technology. Those plates ( 17 ) enable the increase of the height of the floor constructions, by tying two beams in the construction. The upper side ( 18 ) of the element ( 17 ) is connected to the slope sides ( 19 ) by the angle of 45°. This slope sides are connected to the lateral sides ( 20 ), which are connected with another slope side ( 21 ) also by the angle of 45°. At last, slope sides ( 21 ) are connected to the base ( 22 ). The slope sides ( 19 ) and ( 21 ) are equal, as well as the upper side ( 18 ) and lower side ( 22 ). This enables to build several stratums of plate element ( 17 ) according to the demanded floor height. To protect the reinforcement, the distance elements ( 23 ) or ( 35 ) are built in the channel ( 2 ) of the element ( 1 ). The lateral sides ( 25 ) of the distance element ( 23 ) are built on the lower side ( 24 ). The lateral sides ( 25 ) are identical, placed one against other. Those lateral sides ( 25 ) are consist of a vertical ( 26 ), slope side ( 27 ), upper horizontal side ( 28 ) proceed with slope side ( 29 ), upper horizontal ( 30 ), middle horizontal ( 31 ), little lower slope side ( 32 ), lower vertical ( 33 ), which descents to the prism shaped inside ( 34 ) of the distance element ( 23 ). Distance element ( 23 ) is built in a produced element ( 1 ). 
     There is a possibility to produced floor element ( 1 ) with distance element ( 35 ), which is built in during the production. Distance element ( 35 ) has a prism base ( 36 ) with parallel chambers ( 37 ) and cylindrical tipple ( 38 ) for screw. Lateral sides ( 40 ) are symmetrically built on the upper side ( 39 ) of the distance element ( 35 ). Lateral side ( 40 ) are connected the lateral side ( 47 ) of the prism base ( 36 ) by vertical ( 41 ), slope side ( 42 ), upper slope side ( 43 ), upper horizontal ( 44 ), bucket ( 45 ) and lower horizontal ( 46 ). The steel space truss reinforcement is fixed on distance elements ( 35 ). The ceiling constructions are directly screwed on, so that prism base ( 36 ) is a couch in shorting the floor construction during mounting and concreting. Floor element ( 15 ) is produced with built-in distance elements ( 48 ). Thin walled distance element ( 48 ) with chambers ( 49 ) is consisting of lower base ( 50 ); slop sides ( 51 ), verticals ( 52 ), upper horizontals ( 53 ) and concavity ( 54 ). The inside of this concavity ( 54 ) are consist of horizontal ( 55 ), verticals ( 56 ), big slope sides ( 57 ) and small slope sides ( 58 ) that ends on upper horizontal ( 53 ). Cylindrical tipple ( 59 ) are placed in the middle of distance element ( 48 ), which can be used for screwing ceiling construction. The walls of distance element ( 48 ) are 3 mm thick. 
     At least one already known steel space truss are put inside the other space truss. Those steel space truss ( 60 ) are together placed inside the distance elements into the channel of polystyrene floor elements ( 1 ), or ( 15 ). Those elements ( 1 ) or ( 15 ) are filled with concrete up to 3 cm thickness. After hardening of concrete the bearing longitudinal bears are put along each other, with minimum shorting. After that the construction are concreted up to the full thickness. In the process of whole prefabrication the bears are concreted in whole thickness and than they are put on to the supports, with no shorts. 
     POTENTIAL APPLICATION OF THE INVENTION IN INDUSTRY OR ELSEWHERE 
     The invention can be completely produced in industry.