US20240287796A1

US20240287796A1 - Structural composite pre-fabricated floor system

Info

Publication number: US20240287796A1
Application number: US18/115,432
Authority: US
Inventors: John W. Fuller; Bernardo GOMEZ-GONZALEZ
Original assignee: Individual
Current assignee: Individual
Priority date: 2022-02-28
Filing date: 2023-02-28
Publication date: 2024-08-29

Abstract

The invention provides a modular structural prefabricated floor system, its manufacture, choice or options of the materials used, dependent on its use or specific application, are all commercially available standard construction materials or elements which are field, or job site assembled and then installed unto the main principal structure. A method of forming a modular floor system and a kit of parts for forming a modular floor system are also provided.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/314,857 filed Feb. 28, 2022, the contents of which are hereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

The invention provides a modular structural prefabricated floor system, its manufacture, choice or options of the materials used, dependent on its use or specific application, are all commercially available standard construction materials or elements which are field, or job site assembled and then installed into the main principal structure.

BACKGROUND OF THE INVENTION

The present invention relates to a structural floor system totally prefabricated of commercially available construction materials, assembled in the construction site, and using a construction crane of adequate capacity to lift the floor system to its designed for location in the principal structure and structurally attaching it thereto. The weight advantage or light weight characteristics of the invention combined with the rapidity of the field assembly and construction, not requiring form or false work or concrete pumping, create a beneficial overall cost and time advantage. As the higher and more stories to be built the advantage multiplies. Likewise its reduced weight is very beneficial, reducing principal structure weights and foundation, having been proven by mathematically integrating this design into existing buildings exposed to tornados up to EF4 of the Fujita Scale, hurricane winds category 5 Saffir-Simpson, and seismic loads of high risk zone Site Class “F” of ASCE applying a structural finite element analysis (ETABS, MIDAS Gen, commercially available finite element software) to confirm its structural compliance and behavior. This floor system may be utilized in structures that are totally steel, totally concrete, composite, or steel and concrete.
The modular floor system is firstly defined as an integral element of the principal structure, or ideally as being exclusively a floor system within the principal structure. Based on this definition of structural criteria the principal structural element of the floor system, the peripheral frame, and the support lattice of structural elements is analyzed and designed based on the live, accidental and dead loads for the particular case at hand and determining the sizing of the structural elements involved. Criteria varying from the structural configuration of the principal structure, it being totally steel, totally concrete, composite or steel and concrete and its criteria of workloads dead and/or live.

SUMMARY OF THE INVENTION

In one aspect, provided is a modular floor system. The modular floor system includes a perimeter frame of C-shaped channels; a primary lattice support of “S or W” “I” beams or a wide flange structural element of a transverse section made up of two horizontal flanges on the extremes of a vertical web, connected to the perimeter frame; a secondary lattice support transverse to and attached to the primary lattice support; and a floor membrane above the primary and secondary lattice supports comprising rigid precast aerated concrete or laminated wood pre-fabricated panels or sections of post tensed recycled plastic, and a flexible or rigid floor surface.
In another form, the modular floor system, the primary lattice support beams are fabricated from three steel plates or from post tensed recycled plastic.
In another form, the secondary lattice support can be fabricated from cold rolled light steel “HSS” or a post tensed recycled plastic.
In another form, the floor surface material can be a flexible concrete impregnated cloth or rigid floor elements of precast aerated concrete or laminated structural wood.
In another form, the perimeter “C” channels are end welded to form a rectangle or other configuration corresponding to a desired floor quadrant and include pre-welded supports that serve as connector joints between the primary lattice support beams and the perimeter frame.
In another form, the primary lattice support beams have shop attached connectors to receive and attach the secondary lattice beams.
In another form, the modular floor system can form a portion of a primary structure, or can be inserted into a primary structure.
In another aspect, provided is a modular floor system comprising: a perimeter frame of structural steel C-shaped channels; a support lattice formed by primary beams “S or W” “I” made of structural steel; precast aerated concrete slabs which are supported on angles welded to the support lattice beams; and a floor membrane above the support lattice comprising rigid precast aerated concrete or laminated wood pre-fabricated panels or sections of post tensed recycled plastic, and a flexible or rigid floor surface.
In this form, the precast aerated concrete slabs are connected to act as stiffeners of the support lattice and support the floor membrane.
Also in this form, the perimeter “C” channels are end welded to form a rectangle or other configuration corresponding to a desired floor quadrant and include pre-welded supports that serve as connector joints between the primary lattice support beams and the perimeter frame.
Also in this form, the primary lattice support beams have shop attached connectors to receive and attach the precast aerated concrete slabs.
Also in this form, the floor surface material can be a flexible concrete impregnated cloth or rigid floor elements of precast aerated concrete or laminated structural wood.
Also in this form, the modular floor system can form a portion of a primary structure, or can be inserted into a primary structure.
In yet another aspect, provided is a method of forming a modular floor system. The method includes the steps of providing a perimeter frame of structural steel C-shaped channels; providing a support lattice formed by primary beams “S or W” “I” made of structural steel; providing precast aerated concrete slabs which are supported on angles welded to the support lattice beams; and providing a floor membrane above the support lattice comprising rigid precast aerated concrete or laminated wood pre-fabricated panels or sections of post tensed recycled plastic, and a flexible or rigid floor surface.
In some forms, the perimeter “C” channels are end welded to form a rectangle or other configuration corresponding to a desired floor quadrant and include pre-welded supports that serve as connector joints between the primary lattice support beams and the perimeter frame.
In some forms, the primary lattice support beams have shop attached connectors to receive and attach the precast aerated concrete slabs.
In some forms, the floor surface material is a flexible concrete impregnated cloth or rigid floor elements of precast aerated concrete or laminated structural wood.
In a further aspect, a kit of parts for forming a modular floor system is provided. The kit of parts includes a perimeter frame of structural steel C-shaped channels; a support lattice formed by primary beams “S or W” “I” made of structural steel; precast aerated concrete slabs which are supported on angles welded to the support lattice beams; and a floor membrane above the support lattice comprising rigid precast aerated concrete or laminated wood pre-fabricated panels or sections of post tensed recycled plastic, and a flexible or rigid floor surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is susceptible to various modifications and alternative forms, specific exemplary implementations thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific exemplary implementations is not intended to limit the disclosure to the particular forms disclosed herein.

FIG. 1 is a perspective view of a floor system module according to the present invention.

FIG. 2(A) is a cutaway section view in the long dimension of the module of FIG. 1 , and FIG. 2(B) is the same view in perspective.

FIG. 3(A) is a cutaway section and FIG. 3(B) is the perspective in the short dimension of the module in FIG. 1 .

FIG. 4 is a perspective view of alternative configuration for the floor module detailed in FIG. 1 .

FIG. 5(A) is a cutaway section and FIG. 5(B) is the perspective in the long dimension of the module in FIG. 4 .

FIG. 6(A) is a cutaway section and FIG. 6(B) is the perspective in the short dimension of the module in FIG. 4 .

FIG. 7 is a perspective view of recycled extruded plastic beams to form an alternative support lattice according to the present invention.

FIGS. 8 (A & B) is a perspective view of the placing of the membrane, flexible and rigid, on the support lattice, of light steel or recycled post tensed beams, according to the present invention.

FIG. 9 is a side view of a typical connections between primary lattice steel beams in FIG. 1 .

FIG. 10 is a side view of the connection between primary lattice beams to the perimeter frame girder and its post tensioned tendon according to the present invention.

FIG. 11 is a perspective view of a mounting frame attached to a composite membrane used to place and attach the composite membrane floor system to a principal building structure according to the present invention.

FIG. 12 is a perspective view of the connection between the diagonal tensors to the principal quadrant columns according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Various aspects will now be described with reference to specific forms selected for purposes of illustration. It will be appreciated that the spirit and scope of the apparatus, system and methods disclosed herein are not limited to the selected forms. Moreover, it is to be noted that the figures provided herein are not drawn to any particular proportion or scale, and that many variations can be made to the illustrated forms.
Each of the following terms written in singular grammatical form: “a,” “an,” and “the,” as used herein, may also refer to, and encompass, a plurality of the stated entity or object, unless otherwise specifically defined or stated herein, or, unless the context clearly dictates otherwise. For example, the phrases “a device,” “an assembly,” “a mechanism,” “a component,” and “an element,” as used herein, may also refer to, and encompass, a plurality of devices, a plurality of assemblies, a plurality of mechanisms, a plurality of components, and a plurality of elements, respectively.
Each of the following terms: “includes,” “including,” “has,” “having,” “comprises,” and “comprising,” and, their linguistic or grammatical variants, derivatives, and/or conjugates, as used herein, means “including, but not limited to.”
It is to be understood that the various forms disclosed herein are not limited in their application to the details of the order or sequence, and number, of steps or procedures, and sub-steps or sub-procedures, of operation or implementation of forms of the method or to the details of type, composition, construction, arrangement, order and number of the system, system sub-units, devices, assemblies, sub-assemblies, mechanisms, structures, components, elements, and configurations, and, peripheral equipment, utilities, accessories, and materials of forms of the system, set forth in the following illustrative description, accompanying drawings, and examples, unless otherwise specifically stated herein. The apparatus, systems and methods disclosed herein can be practiced or implemented according to various other alternative forms and in various other alternative ways.
It is also to be understood that all technical and scientific words, terms, and/or phrases, used herein throughout the present disclosure have either the identical or similar meaning as commonly understood by one of ordinary skill in the art, unless otherwise specifically defined or stated herein. Phraseology, terminology, and, notation, employed herein throughout the present disclosure are for the purpose of description and should not be regarded as limiting.
The present invention relates to a structural floor system totally prefabricated of commercially available construction materials, assembled in the construction site.
Advantageously, the composite membrane pre-fabricated structural floor system of the present invention is a fraction of the weight of present day floor systems, can be totally pre-fabricated, so as to require no form work or concrete pumping, precisely fabricated for a quick and precise field assembly and most of all made from materials all commercially available with the exception of one of the optative solutions replacing the cold rolled steel and standard steel beams support lattice with recycled extruded plastic (e.g. PET) post tensioned beams or laminated wood beams. The main floor support beams are designed for specific unsupported lengths with a capacity index of element strength versus load equal to one or more based on the application criteria or specific use of the integral structure from a minimum of 1.0 to an acceptable factor of safety. The admissible flexure considered being clear span/360 which corresponds to the limit in the ASCE-SEI-7-16 (Minimum Design Loads and Criteria for Buildings and Other Structures). This limit may be adjusted for more strict design conditions as a function of “comfort” or level of accepted vibration of this structural element under the various live and accidental loads (seismic, wind, cyclone, tornado, etc.)
The invention provides a modular structural pre-fabricated floor system, its manufacture being a choice or selection of options of all the possible materials previously here in mentioned, dependent on its use or application, are all commercially available standard construction materials or elements which are dimensioned and prepared in the fabricating facility followed by transporting to the building site and field or job site, assembled and then installed and being permanently fastened to the principal structure. One of the main features of the floor system is its versatility of the choice of the structural elements and architectural finish materials that can efficiently and structurally be integrated to obtain the desired design criteria required.
Another great advantage of this invention is that it gives a vast range of choices of the structural elements and the structural joining of these as long as the analysis, fabrication, installing and jointing is carried out following established ASCE and AISC norms, guidelines and criteria for its analysis, design and fabrication procedures to fulfill and comply with all and every of their requirements.
In the case of the smaller geometric floor systems, its installation and attachment to the principal structure is such that it virtually has no restraining effect to its structural design and capacity, leaving it free to deflect with little or no restraint or stiffening relieving it of additional constraints that add to the stresses on it.
The design criteria can include structural elements extruded from recycled plastic (e.g. PET) and the combinations of geometric configuration resulting in a structurally compliant floor plus sound, heat and fire insulation or retardation, without affecting the very reduced weight in comparison to conventional concrete cast floor systems other modular pre-fabricated floors and yet totally complying with the required structural requirements (ASCE, AISC,).
Having resolved the basic structural criteria the further advantage of this invention is of its versatility in resolving the sound, heat and fire resistant or retardation using the various options of the floor surface materials that have specific characteristics to resolve these mentioned requirements and additionally resolve structural aspects simultaneously.
Referring now to FIGS. 1-12 , the main floor supports/beams (2, 4) are defined/designed/selected as well as the secondary stiffening beams (3, 4′) placed between the main floor beams. The main floor support beams (2, 4) are designed for specific unsupported lengths with a capacity index of element strength versus load equal to one or more based on the application criteria or specific use of the integral structure from a minimum of 1.0 to an acceptable factor of safety. The admissible flexure considered being clear span/360 which corresponds to the limit in the ASCE-SEI-7-16 (Minimum Design Loads and Criteria for Buildings and Other Structures). This limit may be adjusted for more strict design conditions as a function of “comfort” or level of accepted vibration of this structural element under the various live and accidental loads (seismic, wind, cyclone, tornado, etc.).
FIG. 1 is a perspective view of the modular floor system with a perimeter “C” channel (1) a structural element forming the perimeter of steel in the shape of a thin walled channel type C according to the shape and specifications in accordance of the AISC (American Institute of Steel Construction), or of dimensions such that permit the correct connection to the other elements of this invention, and using a steel lattice primary support of “S or W” “I” beam or wide flange structural element (2) a structural element of a transverse section made up of two horizontal flanges on the extremes of a vertical web, of equal or different thicknesses that comply with the sections, shape and specifications the S, W, or WT in accordance of the AISC (American Institute of Steel Construction) or any section maintaining the said configuration and specification can be fabricated from three steel plates to permit the correct connection to the other elements of this invention, or instead using post tensed recycled plastic (e.g. PET) extruded or cast beams (4) structural elements of post tensed recycled plastic (e.g. PET) whose transverse section is formed of two horizontal flanges and one vertical web of such dimensions that permit its correct extrusion or casting and permits the correct connection to the other elements of this invention with a secondary support of cold rolled light steel “HSS” (3) or a post tensed recycled plastic (e.g. PET) extruded or cast beams (4) or elements of post tensed recycled plastic (e.g. PET) whose transverse section is formed of two horizontal flanges and one vertical web of such dimensions that permit its correct extrusion or casting and permits the correct connection to the other elements of this invention, to which the secondary beams, that are cold rolled light steel “HSS” (3) or post tensed recycled plastic (e.g. PET) extruded beams (4′) are connected structural steel tubular square or rectangular that comply with the specifications of tubular steel type HSS in accordance of the AISC (American Institute of Steel Construction) or any other steel tubular section that maintains the proportions specified and may be conformed of the use of four steel plates whose dimension permits the correct connection to the other elements of this invention as per description of (4). Supported on (3) or (4′) is the floor membrane, rigid or flexible (this particular figure represents a flexible concrete impregnated cloth (7) as the membrane or membrane such as is commercially known product “Concrete Canvas” or similar membranes of structural capacity. The perimeter “C” channels (1) are end welded to form the rectangle or other configuration corresponding to the floor quadrant with pre-welded supports (see FIG. 9 ) that serve as connector joints between the primary lattice support beams (2) or (4) and the perimeter frame elements (1). Similarly, the primary lattice support beams (2) have shop attached connectors to receive and attach the secondary lattice beams (3) or (4′), which are generally transverse to the primary lattice support beams. Supported on (3) or (4′) is the floor membrane, rigid precast aerated concrete (5) or laminated wood pre-fabricated panels (6) or sections of post tensed recycled plastic (e.g. PET) of a tubular transverse section of such dimensions that permit its extrusion and the correct connection to the other elements of this invention and flexible (7) (this particular figure represents a flexible concrete impregnated cloth (7) as the membrane).
FIG. 2(A) is a cutaway section view in the long dimension of the module detailed in FIG. 1 , and FIG. 2(B) is the same view in perspective, this formed by the perimeter “C” channel (1), using a steel lattice primary support of “S or W” “I” beam (2), or post tensed recycled plastic (e.g. PET) extruded beams (4), with a secondary support of “HSS” (3) or post tensed recycled plastic (e.g. PET) extruded beams (4′), in contact and supporting the membrane (7) and precast aerated concrete (5) that increases sound and heat insulation as well as fire retardation. It also illustrates a sectioned view of the composite membrane, using a light steel or post tensed recycled plastic (e.g., PET) extruded beams lattice support, according to the present invention, in perspective FIG. 2(B) and the and the cut-away view FIG. 2(A) in the long dimension of composite membrane. These sections identify the elements and their relative configurations with one another. The perimeter beam “C” channel (1), the lattice primary support beam “S or W” “I” beam (2) or post tensed recycled plastic (e.g. PET) extruded beams (4) and lattice secondary support beam “HSS” (3) or post tensed recycled plastic (e.g. PET) extruded beams (4′).
FIG. 3(A) is a cutaway section and FIG. 3(B) is the perspective in the short dimension of the module in FIG. 1 . This is formed by the perimeter “C” channel (1) using a steel lattice primary support of “S or W” “I” beam (2) or post tensed recycled plastic (e.g. PET) extruded beams (4), with a secondary support of HSS (3) or post tensed recycled plastic (e.g. PET) extruded beams (4′) in contact and supporting the membrane (7) and precast aerated concrete (5) that increases sound and heat insulation as well as fire retardation. It also illustrates a sectioned view of the composite membrane, using a light steel or post tensed recycled plastic (e.g. PET) extruded beams lattice support, according to the present invention, in perspective FIG. 3 (B) and the cut-away FIG. 3 (A) in the short dimension of the composite membrane. These sections identify the elements and their relative configurations with one another. The perimeter beam “MC” channel (1), the lattice primary support beam “S or W” “I” beam (2) or post tensed recycled plastic (e.g. PET) extruded beams (4) and lattice secondary support beam “HSS”(3) or post tensed recycled plastic (e.g. PET) extruded beams (4′).
The floor surface is then defined, complying with the architectural requirements, live load usage, fire retardant qualities, sound transmission and structural contribution to the floor system. Floor surface materials or elements to consider are impregnated cloth membrane (7), prefabricated light weight or aerated rigid floor elements of pre-cast concrete (8), laminated structural wood (9).
The next step prior to developing the fabrication drawings and specification is the design and detail of all the joints between structural elements and the selected flooring material to the flooring support structure considering the design criteria employed in the analysis, be it welded, bolted and/or pin jointed. See FIGS. 9 and 10 .
FIG. 4 illustrates another embodiment of the composite membrane according to the present invention, using an all lightweight steel support lattice that is integrated to a framed perimeter which is an “C” channel of structural steel (1). The support lattice formed by primary beams “S or W” “I” beam (2) to which the precast aerated concrete slabs (5) which are supported on angles (2′) welded to (2) and in turn, are connected to act as stiffeners of (2) and supporters of the floor membrane, rigid element (5) and flexible membrane (7) (this particular figure represents a flexible concrete impregnated cloth (7) as the membrane). The perimeter “C” channels (1) are end welded to form the rectangle or other configuration corresponding to the floor quadrant with pre-welded supports (see FIG. 9 ) that serve as connector joints between the primary lattice support beams (2) and the perimeter frame elements (1). Similarly the primary lattice support beams (2) have shop attached connectors to receive and attach the precast aerated concrete slabs (5) are connected to act as stiffeners of (2) and support of the floor membrane, rigid (5) and flexible (7) (this particular figure represents a flexible concrete impregnated cloth (7) as the membrane).
FIGS. 5 (A & B) illustrates a sectioned view of the composite membrane, using a steel primary beam (2) with the precast aerated concrete slabs (5) which are supported on angles (2′) welded to (2) and in turn, are connected to act as stiffeners of (2) and supported of the floor membrane according to the present invention, in perspective FIG. 5 (B) and the cut-away section FIG. 5 (A) in the long dimension of composite membrane. These sections identify the elements and their relative configurations with one another: The perimeter beam “C” channel (1), the lattice primary support beam “S or W” “I” beam (2) and the precast aerated concrete slabs (5).
FIGS. 6 (A & B) illustrates a sectioned view of the composite membrane, using a steel primary beam (2) with the precast aerated concrete slabs (5) that are connected to act as stiffeners of (2) and support of the floor membrane according to the present invention, in perspective FIG. 6(B) and the cut-away view FIG. 6(A) in the short dimension of the composite membrane. These sections identify the elements and their relative configurations with one another: The perimeter beam “C” channel (1), the lattice primary support beam “S or W” “I” beam (2) and the precast aerated concrete slabs (5).
FIG. 7 is a perspective view of the recycled extruded plastic beams that, post tensed, can be used to form the support lattice according to the present invention. The primary beam post tensed recycled plastic (e.g. PET) extruded beams (4) whose critical dimension is its height, which is defined by the length of the short dimension of the particular case of the composite membrane and the corresponding design loads, live and dead, of the case at hand. Similarly, the secondary beams (4′) height is defined likewise by the dead and live loads, of the case at hand, plus the particular membrane's being used, maximum shear capacity, Modulus of Elasticity, and flexure tolerances of the particular membrane and or the recycled plastic used in the beams.
FIGS. 8 (A & B) is a perspective view of a manner of placing of the membrane, flexible and rigid, on the support lattice, of light steel or recycled post tensed beams, according to the present invention. In the case of a flexible membrane it may be from one or more rolls, dependent on the composite membranes dimensions, or in the case of the rigid membranes, whose dimensions are adjustable to the overall composite membrane's. The fastening of flexible (7) or rigid membranes (6) to the support lattice is carried out complying with the membrane's manufacturers specifications and recommendations. Prior to lifting the flooring system to its final position in the main structure the actual floor surface materials or elements be it the impregnated cloth, prefabricated light weight rigid floor elements of pre-cast concrete, laminated structural wood or similar structurally attached and fixed to the flooring systems primary and secondary structural beams.
FIG. 9 is a side view of a typical connections between primary lattice steel beams (2) connecting to the perimeter frame girder (1) according to the present invention. Load capacity and transfer will define the choice of which plate thickness to use in the box joint (1 a) and its particular characteristics, including if simple or multiple pin joint union or bolted, or other type of connector (1 b) etc. and the connection of the box joint (1 a) to the perimeter frame girder (1).
Prior to lifting the flooring system to its final position in the main structure, the actual floor surface materials or elements whether the impregnated cloth membrane (7), pre-fabricated light weight rigid floor elements of pre-cast concrete (5), laminated structural wood or similar (6), is structurally attached and fixed to the flooring system's primary and secondary structural beams.
FIG. 10 is a side view of the connection between primary lattice beams to the perimeter frame girder and its post tensioned tendon (4 a) according to the present invention. The primary lattice support beam of recycled plastic (4) is fastened by means of this post stressed tendon (4 a) to the perimeter beam “C” (1). This post tensed recycled plastic (e.g. PET) extruded beam (4′) is placed at a distance “h” from the top surface of the superior flange where the distance “h” is the height of the secondary lattice support beam of recycled plastic.
The floor system requires a mounting frame that reinforces and reduces the flexure of the total flooring system during its lift to its final position and fixation to it. This mounting or lifting frame is designed to fit all geometric sizes (whatever range of geometric shapes from squares to rectangles or other geometry as per the floor shapes in the building they are to be integrated to) in the particular configuration of each flooring system required. To do so the lifting frame(s) are made to have adjustable lengths and widths or shape that is simply mechanically connected to execute the lift and fastening to the principal structure and quickly disconnected upon termination of the fastening to the main or principal structure.
FIG. 11 is a perspective view of the mounting frame attached to a composite membrane used to place and attach the composite membrane floor system to the principal building structure according to the present invention. The mounting frame (B) is connected to the flooring system or composite membrane (A). The mounting frame is adjustable to the geometry of the flooring system to be raised. It is “quick” connected to the flooring system using eyebolts (9) that are temporarily inserted into the main exterior frame (1) of the flooring system and connected to the mounting frame (B) by means of equal length steel rods (8) that in turn connect to fixed eyebolts (9) attached to the mounting frame (B). The mounting frame is connected to the construction cranage system via the connector (C). The flooring system or composite membrane (A) having been lifted to its definite or final position in the buildings main structure is attached by means of varied connectors dependent of the principal structures structural elements. These being by means of welding or bolting according to the specific main structures design. The floor system, when not an integral structural element of the principal structure, requires a mounting frame that reinforces and reduces the flexure of the total floor system during its lift to its final position and fixation to it. This mounting or lifting frame is designed to fit all geometric sizes (whatever range of geometric shapes from squares to rectangles or other as per the floor shapes in the building they are to be integrated to) in the particular configuration of each flooring system required. To do so the lifting frame(s) are made to have adjustable lengths and widths or shape that is simply mechanically connected to execute the lift and fastening to the principal structure and quickly disconnected upon termination of the fastening to the main or principal structure. It is to be noted that, dependent on the structural analysis, the diagonal tendons used as bracing between the principal columns may be substituted by a rolled steel section forming a rigid bracing that upon placing in its final location interconnects the main structure's principal columns. In this case this bracing is the first element assembled prior to the floor system which is assembled on top of the bracing and connected to it so as to be raised to its final position in the principal structure as one unit.
A set of diagonal tensors (12) or rigid bracing elements are connected to the columns as bracing elements. In the case of the smaller geometric range of floor systems, the tensors (12) are attached to the connectors (11) which in turn are attached to the column via plate (10) and torqued to the predefined tension. The said plate (10) wraps around the said column as an integral connector plate and forms part of the principal column. In the case of the larger geometric floor systems a rigid bracing (12′) is attached to the columns by means of a connector plates (11 and 11′), this bracing is temporarily pre-attached to the perimeter frame of the flooring system whether the type of main structure be totally steel, concrete and steel, all concrete or composite, to be raised into its final position to be attached to the structures principal columns defining the floor system panel area. The permanent attachment of the bracing to these columns is via two plates (11′), one above and one below the rigid bracing (12′) that are themselves in turn welded to a plate (10′) that forms an integral part of the structure's principal columns, this plate (10′) wraps around the said column as an integral connector plate.
FIG. 12 is a perspective view of the connection between the diagonal tensors to the principal quadrant columns according to the present invention. A set of diagonal tensors are connected to the columns that frame the composite membrane and torqued to the predefined tension. The principal or quadrant columns, be they concrete or steel, are reinforced with a steel plate “strap” (10) wrapped around the column to which it is structurally attached to the column. In case of concrete column, the plate is attached by means of anchor bolts and in the case of steel columns the “strap” plate is welded to it. The tendon/tensor (12) with a tensing bolt at each extreme, has a set of two angle connectors prior to the bolt (11). The first angle connector plate is welded to the “strap” plate and the tendon/tensor (12) duly post tensed to the design stress(torque), at this time the second connector angle is placed in contact with the steel “strap” and welded to it. Below this figure is the rigid bracing solution of a rigid bracing in substitution of the tendon/tensor (12′) for a rigid bracing using rolled steel element that is pre-assembled to the floor system and attached to the floor system for raising to its structural location in the building and the principal connector to it. In the case of the concrete column the tensor (12′) is connected to the concrete column by two plates (11′) to column strap (10′).
The systems and methods disclosed herein are applicable to the building and construction industry.
It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where the claims recite “a” or “a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
It is believed that the following claims particularly point out certain combinations and subcombinations that are directed to one of the disclosed inventions and are novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower, or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.

Claims

What is claimed:

1. A modular floor system, comprising:

a perimeter frame of C-shaped channels;

a primary lattice support of “S or W” “I” beams or a wide flange structural element of a transverse section made up of two horizontal flanges on the extremes of a vertical web, connected to the perimeter frame;

a secondary lattice support transverse to and attached to the primary lattice support; and

a floor membrane above the primary and secondary lattice supports comprising rigid precast aerated concrete or laminated wood pre-fabricated panels or sections of post tensed recycled plastic, and a flexible or rigid floor surface.

2. The modular floor system of claim 1, wherein the primary lattice support beams are fabricated from three steel plates or from post tensed recycled plastic.

3. The modular floor system of claim 1, wherein the secondary lattice support is fabricated from cold rolled light steel “HSS” or a post tensed recycled plastic.

4. The modular floor system of claim 1, wherein the floor surface material is a flexible concrete impregnated cloth or rigid floor elements of precast aerated concrete or laminated structural wood.

5. The modular floor system of claim 1, wherein the perimeter “C” channels are end welded to form a rectangle or other configuration corresponding to a desired floor quadrant and include pre-welded supports that serve as connector joints between the primary lattice support beams and the perimeter frame.

6. The modular floor system of claim 1, wherein the primary lattice support beams have shop attached connectors to receive and attach the secondary lattice beams.

7. The modular floor system of claim 1, which forms a portion of a primary structure.

8. The modular floor system of claim 1, which is inserted into a primary structure.

9. A modular floor system, comprising:

a perimeter frame of structural steel C-shaped channels;

a support lattice formed by primary beams “S or W” “I” made of structural steel;

precast aerated concrete slabs which are supported on angles welded to the support lattice beams; and

a floor membrane above the support lattice comprising rigid precast aerated concrete or laminated wood pre-fabricated panels or sections of post tensed recycled plastic, and a flexible or rigid floor surface.

10. The modular floor system of claim 9, wherein the precast aerated concrete slabs are connected to act as stiffeners of the support lattice and support the floor membrane.

11. The modular floor system of claim 9, wherein the perimeter “C” channels are end welded to form a rectangle or other configuration corresponding to a desired floor quadrant and include pre-welded supports that serve as connector joints between the primary lattice support beams and the perimeter frame.

12. The modular floor system of claim 9, wherein the primary lattice support beams have shop attached connectors to receive and attach the precast aerated concrete slabs.

13. The modular floor system of claim 9, wherein the floor surface material is a flexible concrete impregnated cloth or rigid floor elements of precast aerated concrete or laminated structural wood.

14. The modular floor system of claim 9, which forms a portion of a primary structure.

15. The modular floor system of claim 9, which is inserted into a primary structure.

16. A method of forming a modular floor system, comprising:

providing a perimeter frame of structural steel C-shaped channels;

providing a support lattice formed by primary beams “S or W” “I” made of structural steel;

providing precast aerated concrete slabs which are supported on angles welded to the support lattice beams; and

providing a floor membrane above the support lattice comprising rigid precast aerated concrete or laminated wood pre-fabricated panels or sections of post tensed recycled plastic, and a flexible or rigid floor surface.

17. The method of claim 16, wherein the perimeter “C” channels are end welded to form a rectangle or other configuration corresponding to a desired floor quadrant and include pre-welded supports that serve as connector joints between the primary lattice support beams and the perimeter frame.

18. The method of claim 16, wherein the primary lattice support beams have shop attached connectors to receive and attach the precast aerated concrete slabs.

19. The method of claim 9, wherein the floor surface material is a flexible concrete impregnated cloth or rigid floor elements of precast aerated concrete or laminated structural wood.

20. A kit of parts for forming a modular floor system, comprising:

a perimeter frame of structural steel C-shaped channels;