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WO1998023824A1 - Serviceable open floor system - Google Patents

Serviceable open floor system Download PDF

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Publication number
WO1998023824A1
WO1998023824A1 PCT/US1997/022310 US9722310W WO9823824A1 WO 1998023824 A1 WO1998023824 A1 WO 1998023824A1 US 9722310 W US9722310 W US 9722310W WO 9823824 A1 WO9823824 A1 WO 9823824A1
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WIPO (PCT)
Prior art keywords
adjacent
chord
parallel
truss
trusses
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Ceased
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PCT/US1997/022310
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French (fr)
Inventor
Robert L. Brungraber
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Individual
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Individual
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Publication of WO1998023824A1 publication Critical patent/WO1998023824A1/en
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/12Load-carrying floor structures formed substantially of prefabricated units with wooden beams

Definitions

  • This invention most generally relates to a flooring system for low rise buildings. More particularly this invention relates to a flooring system for residential type buildings. Most particularly this invention relates to a building fiooring system which combines two existing arts: timber joists and light-weight, wooden, trusses and/or beams. The combination produces a floor structure which is: simple to install, extraordinarily easy to fit with ancillary services, particularly convenient to repair and retrofit with new services, relatively sound proof, attractive from below, and familiar from above.
  • Disentanglement and separation of structure and services are known in the art but the systems are based on removable or semi -removable floor tiles laid over usually a concrete subfloor. These prior art systems work in concrete industrial or apartment buildings, where access from below is difficult structurally and complicated by concerns of neighbors below.
  • U.S. patent 4,676,036 describes an integrated raised flooring system for an office setting.
  • the system utilizes flooring panels placed between, and attached to raised, supporting pedestals which rest on a subfloor.
  • the floor panels do not rest on the top of the pedestals as is common with such flooring systems.
  • This flooring system is designed to be multi-tiered, to create more than one space between the subfloor and the ultimate office floor. Thus, several layers of flooring panel may be attached to the pedestals at various heights.
  • This system allows the various levels to act as separators for containing and isolating selected groups of utilities, for example to prevent noise interference, and to prevent wiring from resting directly on the subfloor to be subjected to possible water damage.
  • the flooring panels are removable, allowing access to the various utilities contained on the various levels.
  • U.S. patent 4,930,277 discloses a panel assembly and support structure for elevated floors in an office setting.
  • This particular system has two different flooring panels, access panels and base floor panels, arranged in a checkerboard fashion to provide support and easy adjustability of the floor system.
  • the system is designed for multi-level floors for areas such as stock trading pits.
  • the system is designed so that the levels of flooring may be quickly and easily readjusted to accommodate changing uses of the floor and the room.
  • This system uses panels placed on pedestals, and has detachable riser beams to provide assembly of multi-level, stepped, raised floors.
  • Vertical "closure panels" are provided to connect the various levels of flooring and close off the vertical space between the stepped flooring levels. There is space between the subfloor and the various floor levels, through which utilities may be run, but that is not the object of the invention.
  • U.S. patent 5,265,386 addresses a method and device for laying access floors, and access floor support. This invention is also directed to raised floors for an office setting, installed over a subfloor, and under which utilities may be run. The primary emphasis of this invention is directed to a method of installing multiple pedestals at once, onto a pre-marked grid. The pedestal heights are then adjusted with a frame device which is leveled to an "ancillary plane", such that when the floor panels are laid onto the pedestals, the floor is even and level, adjusted for fluctuations in the level of the subfloor.
  • U.S. patent 5,412,914 discloses a raised access flooring system. This system is also primarily designed for office building use or other "commercial" use. Instead of having flat panels placed across pedestals, this invention uses floor “modules” which comprise a "space frame web” of support members upon which is fixedly attached a flooring member or panel. These modules provide the same access to the space between the subfloor and the floor member and are supported by pedestals as are conventional raised access floor systems. However, the space frame web support of the module allows the weight and thickness of the floor member panel to be decreased without a decrease in strength or support. Also cuts may be made in the floor member and space frame web to accommodate installation of "electrical boxes” without compromising the strength of the module to the degree such a cut and removal of a section of floor panel would compromise the strength of prior flooring system panels.
  • U.S. patent 5,440,841 covers a pedestal module for a raised floor, and a raised floor.
  • the floor system disclosed is primarily for use in an office setting. Space is provided between a subfloor and a raised floor in which utilities may be run.
  • the pedestal and raised floor member are all one unit.
  • the pedestal member comprises a flat base with four legs.
  • the units are placed next to each other to create the raised floor.
  • the units are held in place by a pedestal module lock with four hollow, integrally formed leg-receiving apertures.
  • One leg of each of four modules is placed into each module lock to hold the modules together in place.
  • the base portion is also constructed to allow a hole to be cut in its center to receive an electrical connection receptacle.
  • U.S. patent 5,477,649 discloses a raised floor cable trough system.
  • This floor system is also primarily for office building use and is laid over a subfloor.
  • the cable trough system disclosed can be used with new or existing raised floor assemblies which have removable upper floor panels supported at a height above a subfloor by a series of pedestals.
  • the troughs are installed connected to the pedestals and suspended in the space between the upper floor panels and the subfloor.
  • the troughs are also connected to each other such that a network of troughs is formed below the floor panels.
  • Cable or wiring is laid in the trough system such that various groups of cable and wiring can be physically separated from each other, and so that none of the wiring or utilities rests directly on the subfloor to be potentially damaged by water buildup.
  • the troughs are suspended just below the floor panels such that the floor panels serve as the covering for the troughs thus protecting the enclosed wiring and preventing overfilling of the troughs (because the flooring will not lay
  • U.S. patent 5,483,776 discloses a utility floor construction.
  • the floor is designed primarily for office building use, to be laid over a subfloor.
  • the construction includes interconnectable base tiles supported on a floor surface. Each base tile has multiple upstanding pedestals.
  • Floor tiles are then supported on and attached to the pedestals to create a cavity between the base and floor tiles.
  • Various utilities, including wiring for equipment and lighting, and HVAC may then be run in the cavity, and may be easily accessed for repair or modification by removing the upper floor panels.
  • the invention also includes inverted U-shaped "separator channels" to cover and isolate various groupings of wiring laid along the base tiles.
  • the present invention provides an open building flooring system wherein there are substantially three subsystems, a structural subsystem, an interstitial space subsystem and a trim subsystem.
  • the three subsystems inter-relate one to the other in such a manner as to render them substantially integral unto themselves.
  • the interstitial space subsystem is substantially completely disentangled from the structural subsystem and from the trim subsystem.
  • the subsystems more particularly relate to each other in that utilities (heating, air conditioning, electrical, plumbing, communications and the like) may be initially or retrofittingly installed into a building within the interstitial subsystem without altering in any substantial manner either the structural or the trim subsystem.
  • the building flooring system combines two existing types of structural systems; timber joists and light-weight, parallel-chord trusses. The combination produces a floor structure which is: simple to install, extraordinarily easy to fit with ancillary services, particularly convenient to repair and retrofit with new services, relatively sound proof, attractive from below and familiar from above.
  • exposed heavy timber joists comprising one layer
  • exposed heavy timber joists are overlaid with concealed and mutually perpendicular light-weight, wooden trusses and/or beams comprising a second layer.
  • the timber joists support the trusses above, across relatively large distances in the building between supporting walls or posts.
  • the light-weight upper trusses run only across the distances between the supporting timber joists.
  • a sound isolation cushion buffers the contact area between the two layers to deaden sound transmission.
  • the top of the truss layer of the structural subsystem is covered with standard panel, subfloor products such as plywood or oriented strand board.
  • the trusses allow for easy access to the services and/or utilities concealed in the interstitial space subsystem.
  • the space between the joists provides ready access to the interstitial space subsystem between the top and bottom chords of the trusses for initial installation of utilities such as HVAC, plumbing, and electrical services.
  • the supporting timber joists can be left exposed to view.
  • the exposed underside of the trusses is covered by the trim subsystem consisting of various types of panel and edge trim packages. By removing the underside trim panels, subsequent repairers and remodelers have easy access to existing services and other areas of the building.
  • the floor system may be used as an integral part of a timber framed building, or as only a floor layer of an otherwise standard "stick-built" structure as known to those skilled in the art of housing construction.
  • Yet another object of the invention is to provide a flooring system which offers convenient access to installed services to repair previously installed services and retrofit with new services.
  • Still another object of the invention is to provide a flooring system which is relatively sound proof between floors of a building.
  • Another object of the invention is to provide a flooring system which is attractive from below and familiar from above.
  • FIG. 1 is a perspective cut-away axonometric view of an embodiment of the flooring system partially installed in a timber-framed building as seen from above.
  • FIG. 2 is a perspective view of the building floor system, from above, according to an embodiment of the invention.
  • FIG. 3 is a perspective view of the building flooring system looking up from below and showing an embodiment of the trim subsystem.
  • FIG. 4 is an exploded cross sectional view of an embodiment of the flooring system showing utilities installed in the interstitial space subsystem.
  • FIG. 5 is an expanded cross sectional view showing in detail an embodiment of the trim subsystem.
  • the present invention is directed to a flooring system for use in timber frame, or standard "stick-built" modern residential structures wherein there are substantially three subsystems, a first, or structural, subsystem, a second, or interstitial space, subsystem and a third, or trim, subsystem.
  • the three subsystems inter-relate one to the other in such a manner as to render them substantially integral unto themselves.
  • the second, or interstitial space, subsystem is substantially completely disentangled from the first, or structural, subsystem and from the third, or trim, subsystem.
  • Utilities such as heating, air conditioning, electrical, plumbing, and communications services for example, may be initially or retrofittingly installed into a building within the interstitial space subsystem without altering in any substantial manner either the structural or the trim subsystems.
  • the present invention as shown in Figure 1 partially installed in a two story building, and Figure 2 in more detail, comprises a building flooring system 10 having a first, or structural, subsystem 8 comprising a plurality of adjacent and substantially horizontally disposed heavy timber joists 12 which in a preferred embodiment, are simple squared timbers, separated from the adjacent timber joists by a joist-to-joist spacing distance, depending on the desired usage and load-bearing capability required.
  • Timber joists 12 each have two ends 32, an upper surface 34, a lower surface 36 and two parallel, opposing, length- wise side surfaces 38
  • Timber joists 12 preferably span a length in the range of about 8-18 feet in length and have width dimensions in the range of about 4" wide to about 8" wide and height dimensions in the range of about 6" to about 12", the overall size of the timber joists 12 also depending on the desired usage and load-bea ⁇ ng capability required
  • Timber joists 12 are supported on the walls of the building or on timber girders of a timber framed structure
  • the ceilings of a building with a flooring system 10 of the present invention are preferably in the range of about 6"- 12" above the lower surface 36 of timber joists 12 which lower surface extends down to a distance in the range of about 8' to 10' above the floor below
  • the timber joists 12 support a plurality of overlaid, mutually perpendicular lightweight trusses and/or beams 14 (shown in the Figures as trusses) which, in the preferred embodiment, arc parallel-chord trusses made of light-weight lumber members and which are separated by a truss-to-truss spacing distance in the range of about 1 ' or less to about 3' or greater on center, preferably about 2' on center for normal residential usage, and supported by timber joists 12
  • the parallel-chord trusses preferably have a maximum length of about 40', and have a truss height dimension in the range of about 6" to 12" in depth
  • An embodiment of the parallel-chord trusses is comprised of an upper 16 and a lower 18 parallel chord separated and supported by secondary support members or elements 20
  • the upper 16 and lower 18 chords of parallel-chord trusses 14 are regularly interconnected to the secondary support members or elements 20 using moment-resisting connections 20
  • Between joists 12 and parallel-chord trusses 14 may be a plurality of sound isolation bearing pads 22 or cushions which are, in the preferred embodiment, made of resilient mate ⁇ al and are intermittent squares, segments, or st ⁇ ps secured to the upper surface 34 of each joist 12 Sound isolation bearing pads 22 do not cover the entire width of the upper surface 34 of each joist 12
  • the sound isolation bearing pads 22 have dimensions preferably in the range of about 1/4" to about 1" thick
  • the sound isolation bearing pads 22 cushion the interface between joists 12 and parallel-chord trusses 14 and dampen sound between the floors or stories of a building.
  • Stair openings and other large apertures in the floo ⁇ ng system are framed, defined, and supported by structural elements of a similar depth to parallel-chord trusses 14, but with higher load and span capacities
  • Timber joists 12 may be interrupted and/or up sized to accommodate large openings
  • Timber joists 12 can be supported at either the building pe ⁇ meter or along an interior line, on heavy timber girders or standard load-bea ⁇ ng wall construction
  • the third, or trim, subsystem 6 of the flooring system comprises upper surface subfloor paneling mate ⁇ al 24 attached, preferably by nails or screws, to the upper chord 16 of parallel-chord trusses 14 of the structural subsystem 8
  • This upper surface subfloor paneling mate ⁇ al 24 of the trim subsystem 6, which becomes the subfloor of the upper level of a two- story building, in the preferred embodiment, is a standard building panel product, for example, tongue and groove plywood, oriented strand board, or other materials commonly used as floor underlayment
  • This upper surface paneling or subfloor mate ⁇ al 24 can, in turn, be covered by finished flooring 24a such as, but not limited to, carpet, hardwood, floor boards, or linoleum sheet goods for example
  • finished flooring 24a such as, but not limited to, carpet, hardwood, floor boards, or linoleum sheet goods for example
  • the intersections of the walls of a building and the finished floo ⁇ ng, where the flooring meets the wall could be covered by t ⁇ m molding
  • the third, or trim, subsystem 6 further comprises lower surface trim paneling pieces 26 which can be attached to the lower chords 18 of parallel-chord trusses 14 of the first, or structural, subsystem 8, preferably by screws and which become the ceiling of the lower floor of a building
  • the lower surface t ⁇ m paneling pieces 26 can be formed of various mate ⁇ al including but not limited to wood boards, plywood of various appearances, 1/2" dry wall - pre-painted or pre-wallpapered, or fabric for example
  • the edges and butt joints of the lower surface trim paneling pieces 26, where lower surface t ⁇ m paneling pieces 26 meet joists 12 at about a 90 degree angle, and the seams where two lower surface trim paneling pieces meet, are concealed with various edge trim pieces 28 which can be attached to the lower surface t ⁇ m paneling pieces 26 and/or to the timber joists 12 such that joint compound and painstaking edging is obsolete
  • Lower surface trim paneling pieces 26 may also rest on edge t ⁇ m pieces 28, or on joists
  • both the lower surface t ⁇ m paneling pieces 26 and the edge t ⁇ m pieces 28 are installed with attractive and exposed screws, or recessed and covered screws
  • the lower surface t ⁇ m paneling pieces 26 and edge trim pieces 28 are installed after all the utilities and services have been installed
  • the second, interstitial space, subsystem 30 is formed when the fust, or structural, subsystem 8 is enclosed by the upper surface subfloor paneling mate ⁇ al 24 and lower surface trim paneling pieces 26
  • Utilities can be conveniently installed in interstitial space subsystem 30 before or after upper surface subfloor paneling mate ⁇ al 24 and lower surface trim paneling pieces 26 are installed
  • interstitial space subsystem 30 is concealed from view by installation of upper surface subfloor paneling mate ⁇ al 24 and lower surface t ⁇ m paneling pieces 26
  • Fiberglass or other types of insulation for heating, cooling or further sound dampening can also be installed in interstitial space subsystem 30
  • subsequent repairers and remodelers can easily remove all or part of the edge trim pieces 28 and all or part of lower surface trim paneling pieces 26 of the third, or t ⁇ m, subsystem to reveal the second, or interstitial space, subsystem 30 and its contained utilities and service hardware such as air or heating duct 40a, plumbing such as drain waste vent 40b, elect ⁇ city 40c, water lines 40d,
  • the flooring system of the present invention is installed following construction of the frame of the building including the exterior and interior walls and interior beams, first with installation of timber joists 12 followed by the sound isolation bearing pads 22, then parallel- chord trusses 14, or if desired, beams Next, the upper surface subfloor paneling mate ⁇ al 24 is installed followed by insulation, pipes, wires, and ducts as for example duct 40a and plumbing 40b, then the finished flooring 24a, and finally optional lower surface t ⁇ m paneling pieces 26 and edge t ⁇ m pieces 28 are installed after all utilities have been installed in interstitial space subsystem 30
  • FIG 4 more particularly illustrates flooring system 10 with utilities such as heat or air duct 40a, plumbing 40b, elect ⁇ cal 40c, water lines 40d, installed in interstitial space subsystem 30 Recessed lighting, for example 40e, can also be run through interstitial space subsystem 30 and lower surface t ⁇ m paneling pieces 26 Also shown in Figure 4 are the locations of sound isolation bearing pads 22 on upper surface 34 of joists 12 and the location of lower surface trim paneling pieces 26 relative to sound isolation bearing pads 22, joists 12 and edge t ⁇ m pieces 28
  • FIG. 5 illustrates, in greater detail, a section of the flooring system 10
  • the location and size of sound isolation bearing pad 22 and lower surface t ⁇ m paneling pieces 26 on upper surface 34 of joist 12 is illustrated, and in one embodiment, lower surface trim paneling pieces 26 can be installed resting on upper surface 34 of joist 12
  • Lower surface trim paneling pieces 26 can extend onto joist 12 far enough to be secure in position, but do not extend so far as to be immovable
  • any installed edge trim pieces 28 are removed and the lower surface trim panel piece 26 is moved horizontally in one direction to free one side from a joist 12 such that one side of the lower surface trim panel piece 26 can be freed and dropped followed by the other side No puncturing or cutting of lower surface t ⁇ m paneling pieces 26 is necessary
  • Lower surface trim paneling piece 26 is then reinstalled in the same manner b) installing one side first
  • lower surface trim paneling pieces 26 may be cut to fit in between, but not resting on, joists 12 In such an embodiment, edge t ⁇ m pieces 28 would be required to conceal the possibly uneven intersection between joist 12 and lower surface t ⁇ m paneling pieces 26 However, lower surface t ⁇ m paneling pieces 26 could be installed simply resting on edge trim pieces 28 Removal of lower surface trim paneling pieces 26 in this embodiment would be extremely easy, involving only the removal of the edge t ⁇ m pieces 28 upon which lower surface trim paneling pieces 26 would drop.

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Abstract

The present invention is directed to a building flooring system (10) comprising three subsystems; a first, or structural, subsystem (8) of exposed, heavy timber joists (12), overlaid with concealed and mutually perpendicular light-weight, parallel-chord trusses (14) having upper surfaces subfloor material (24) installed over the parallel-chord trusses (14) and finished flooring (24a) installed over the subfloor material (24). A sound isolation bearing pad (22) buffers the intersections of the joists (12) and trusses (14) to deaden sound transmission. A third, or trim, subsystem (6) is formed by covering the exposed underside of the trusses (14) with various types of paneling (26) and edge trim (28) packages. A second, or interstitial space, subsystem (30) is formed by the space between the coverings (24, 26) of the top and bottom chords (16, 18) of the trusses (14) and is readily accessible to initial installers of utilities such as HVAC, plumbing, and electrical services. By removing the underside edge trim (28) and paneling (26), subsequent repairers and remodelers have easy access to existing services and other areas of the building. This open floor system allows builders and owners to disentangle and separate the structure of the building and the services such that the structure is not altered when it is desired to access or change the services and utilities.

Description

SERVICEABLE OPEN FLOOR SYSTEM BACKGROUND OF THE INVENTION HELD OF THE INVENTION
This invention most generally relates to a flooring system for low rise buildings. More particularly this invention relates to a flooring system for residential type buildings. Most particularly this invention relates to a building fiooring system which combines two existing arts: timber joists and light-weight, wooden, trusses and/or beams. The combination produces a floor structure which is: simple to install, extraordinarily easy to fit with ancillary services, particularly convenient to repair and retrofit with new services, relatively sound proof, attractive from below, and familiar from above.
Most low rise building flooring systems are currently based on a structure of one concealed layer of solid wood joists or composite wooden I-beams. These members must be penetrated, or through-punched by the tradesmen installing ducts, pipes, wires, and all the other service hardware found in modern buildings. The initial service installers spend a great deal of effort with saws and drills, damaging the only recently installed structural members. Subsequent remodelers and repairers are confronted with barriers to their progress on a regular basis. The present invention seeks to disentangle and separate structure and service hardware. The lower structural layer, timber joists, have been in the art for thousands of years. The upper structural layer is formed of inexpensive, light-weight, parallel -chord, wooden trusses.
Disentanglement and separation of structure and services are known in the art but the systems are based on removable or semi -removable floor tiles laid over usually a concrete subfloor. These prior art systems work in concrete industrial or apartment buildings, where access from below is difficult structurally and complicated by concerns of neighbors below.
DESCRIPTION OF THE RELATED PRIOR ART
All of the prior art addresses the basic concept of providing a raised floor for an industrial or office setting, under which utilities may be run. However, none of the prior art directly addresses the problem of access to utilities for residential buildings, and none of the raised flooring systems of any of the prior art make up any of the structural support of the buildings in which they would be installed. ->
Seven U.S. patents are considered representative of the most relevant prior art. The seven patents are U.S. Patent Numbers: 5,483,776 to Poppe, 5,477,649 to Bessert, 5,440,841 to Greenfield, 5,412,914 to Daw et. al., 5,265,386 to Muhlethaler, 4,930,277 to Krumholz, and 4,676,036 to Bessert.
U.S. patent 4,676,036 describes an integrated raised flooring system for an office setting. The system utilizes flooring panels placed between, and attached to raised, supporting pedestals which rest on a subfloor. The floor panels, however, do not rest on the top of the pedestals as is common with such flooring systems. This flooring system is designed to be multi-tiered, to create more than one space between the subfloor and the ultimate office floor. Thus, several layers of flooring panel may be attached to the pedestals at various heights. This system allows the various levels to act as separators for containing and isolating selected groups of utilities, for example to prevent noise interference, and to prevent wiring from resting directly on the subfloor to be subjected to possible water damage. The flooring panels are removable, allowing access to the various utilities contained on the various levels.
U.S. patent 4,930,277 discloses a panel assembly and support structure for elevated floors in an office setting. This particular system has two different flooring panels, access panels and base floor panels, arranged in a checkerboard fashion to provide support and easy adjustability of the floor system. The system is designed for multi-level floors for areas such as stock trading pits. The system is designed so that the levels of flooring may be quickly and easily readjusted to accommodate changing uses of the floor and the room. This system uses panels placed on pedestals, and has detachable riser beams to provide assembly of multi-level, stepped, raised floors. Vertical "closure panels" are provided to connect the various levels of flooring and close off the vertical space between the stepped flooring levels. There is space between the subfloor and the various floor levels, through which utilities may be run, but that is not the object of the invention.
U.S. patent 5,265,386 addresses a method and device for laying access floors, and access floor support. This invention is also directed to raised floors for an office setting, installed over a subfloor, and under which utilities may be run. The primary emphasis of this invention is directed to a method of installing multiple pedestals at once, onto a pre-marked grid. The pedestal heights are then adjusted with a frame device which is leveled to an "ancillary plane", such that when the floor panels are laid onto the pedestals, the floor is even and level, adjusted for fluctuations in the level of the subfloor.
U.S. patent 5,412,914 discloses a raised access flooring system. This system is also primarily designed for office building use or other "commercial" use. Instead of having flat panels placed across pedestals, this invention uses floor "modules" which comprise a "space frame web" of support members upon which is fixedly attached a flooring member or panel. These modules provide the same access to the space between the subfloor and the floor member and are supported by pedestals as are conventional raised access floor systems. However, the space frame web support of the module allows the weight and thickness of the floor member panel to be decreased without a decrease in strength or support. Also cuts may be made in the floor member and space frame web to accommodate installation of "electrical boxes" without compromising the strength of the module to the degree such a cut and removal of a section of floor panel would compromise the strength of prior flooring system panels.
U.S. patent 5,440,841 covers a pedestal module for a raised floor, and a raised floor. The floor system disclosed is primarily for use in an office setting. Space is provided between a subfloor and a raised floor in which utilities may be run. In this invention, the pedestal and raised floor member are all one unit. The pedestal member comprises a flat base with four legs. The units are placed next to each other to create the raised floor. The units are held in place by a pedestal module lock with four hollow, integrally formed leg-receiving apertures. One leg of each of four modules is placed into each module lock to hold the modules together in place. The base portion is also constructed to allow a hole to be cut in its center to receive an electrical connection receptacle.
U.S. patent 5,477,649 discloses a raised floor cable trough system. This floor system is also primarily for office building use and is laid over a subfloor. The cable trough system disclosed can be used with new or existing raised floor assemblies which have removable upper floor panels supported at a height above a subfloor by a series of pedestals. The troughs are installed connected to the pedestals and suspended in the space between the upper floor panels and the subfloor. The troughs are also connected to each other such that a network of troughs is formed below the floor panels. Cable or wiring is laid in the trough system such that various groups of cable and wiring can be physically separated from each other, and so that none of the wiring or utilities rests directly on the subfloor to be potentially damaged by water buildup. The troughs are suspended just below the floor panels such that the floor panels serve as the covering for the troughs thus protecting the enclosed wiring and preventing overfilling of the troughs (because the flooring will not lay evenly if the troughs are overfilled).
U.S. patent 5,483,776 discloses a utility floor construction. The floor is designed primarily for office building use, to be laid over a subfloor. The construction includes interconnectable base tiles supported on a floor surface. Each base tile has multiple upstanding pedestals. Floor tiles are then supported on and attached to the pedestals to create a cavity between the base and floor tiles. Various utilities, including wiring for equipment and lighting, and HVAC may then be run in the cavity, and may be easily accessed for repair or modification by removing the upper floor panels. The invention also includes inverted U-shaped "separator channels" to cover and isolate various groupings of wiring laid along the base tiles.
All of the references disclose office flooring systems which must be laid over a subfloor. All of the systems do provide an "interstitial space" through which utilities may be run. But all the references are directed towards a commercial or office application. In addition, the flooring systems disclosed in the prior art do not make up any part of the structural support of the building. The systems are merely laid on top of a subfloor which is already in place. None of the prior systems provides access to utilities between levels or stories of the building. Presumably utilities between stories would be run through the walls and could only be accessed for each level from above, through the flooring systems, not through the ceiling below.
The use of the truss system combined with floor and ceiling panels to provide an interstitial space through which to run utilities solves the problems of the prior art in providing easy, repeatable access for installation and repair of utilities between floors of a building.
SUMMARY OF THE INVENTION
The present invention provides an open building flooring system wherein there are substantially three subsystems, a structural subsystem, an interstitial space subsystem and a trim subsystem. The three subsystems inter-relate one to the other in such a manner as to render them substantially integral unto themselves. The interstitial space subsystem is substantially completely disentangled from the structural subsystem and from the trim subsystem. The subsystems more particularly relate to each other in that utilities (heating, air conditioning, electrical, plumbing, communications and the like) may be initially or retrofittingly installed into a building within the interstitial subsystem without altering in any substantial manner either the structural or the trim subsystem. The building flooring system combines two existing types of structural systems; timber joists and light-weight, parallel-chord trusses. The combination produces a floor structure which is: simple to install, extraordinarily easy to fit with ancillary services, particularly convenient to repair and retrofit with new services, relatively sound proof, attractive from below and familiar from above.
More particularly, in the structural subsystem, exposed heavy timber joists comprising one layer, are overlaid with concealed and mutually perpendicular light-weight, wooden trusses and/or beams comprising a second layer. The timber joists support the trusses above, across relatively large distances in the building between supporting walls or posts. The light-weight upper trusses run only across the distances between the supporting timber joists. A sound isolation cushion buffers the contact area between the two layers to deaden sound transmission. The top of the truss layer of the structural subsystem is covered with standard panel, subfloor products such as plywood or oriented strand board. The trusses allow for easy access to the services and/or utilities concealed in the interstitial space subsystem. The space between the joists provides ready access to the interstitial space subsystem between the top and bottom chords of the trusses for initial installation of utilities such as HVAC, plumbing, and electrical services. The supporting timber joists can be left exposed to view. The exposed underside of the trusses is covered by the trim subsystem consisting of various types of panel and edge trim packages. By removing the underside trim panels, subsequent repairers and remodelers have easy access to existing services and other areas of the building. The floor system may be used as an integral part of a timber framed building, or as only a floor layer of an otherwise standard "stick-built" structure as known to those skilled in the art of housing construction.
It is therefore an object of the invention to provide an easily installable flooring system.
It is still another object of the invention to provide a flooring system which is easy to fit with ancillary services.
Yet another object of the invention is to provide a flooring system which offers convenient access to installed services to repair previously installed services and retrofit with new services.
Still another object of the invention is to provide a flooring system which is relatively sound proof between floors of a building.
Another object of the invention is to provide a flooring system which is attractive from below and familiar from above.
These and further objects of the present invention will become apparent to those skilled in the art to which this invention pertains after a study of the present disclosure of the invention. BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective cut-away axonometric view of an embodiment of the flooring system partially installed in a timber-framed building as seen from above.
FIG. 2 is a perspective view of the building floor system, from above, according to an embodiment of the invention.
FIG. 3 is a perspective view of the building flooring system looking up from below and showing an embodiment of the trim subsystem.
FIG. 4 is an exploded cross sectional view of an embodiment of the flooring system showing utilities installed in the interstitial space subsystem.
FIG. 5 is an expanded cross sectional view showing in detail an embodiment of the trim subsystem.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to a flooring system for use in timber frame, or standard "stick-built" modern residential structures wherein there are substantially three subsystems, a first, or structural, subsystem, a second, or interstitial space, subsystem and a third, or trim, subsystem. The three subsystems inter-relate one to the other in such a manner as to render them substantially integral unto themselves. The second, or interstitial space, subsystem is substantially completely disentangled from the first, or structural, subsystem and from the third, or trim, subsystem. Utilities such as heating, air conditioning, electrical, plumbing, and communications services for example, may be initially or retrofittingly installed into a building within the interstitial space subsystem without altering in any substantial manner either the structural or the trim subsystems.
Referring now in detail to the drawings, wherein similar reference numerals denote similar elements throughout the drawings, the present invention, as shown in Figure 1 partially installed in a two story building, and Figure 2 in more detail, comprises a building flooring system 10 having a first, or structural, subsystem 8 comprising a plurality of adjacent and substantially horizontally disposed heavy timber joists 12 which in a preferred embodiment, are simple squared timbers, separated from the adjacent timber joists by a joist-to-joist spacing distance, depending on the desired usage and load-bearing capability required. Timber joists 12 each have two ends 32, an upper surface 34, a lower surface 36 and two parallel, opposing, length- wise side surfaces 38
Timber joists 12 preferably span a length in the range of about 8-18 feet in length and have width dimensions in the range of about 4" wide to about 8" wide and height dimensions in the range of about 6" to about 12", the overall size of the timber joists 12 also depending on the desired usage and load-beaπng capability required Timber joists 12 are supported on the walls of the building or on timber girders of a timber framed structure The ceilings of a building with a flooring system 10 of the present invention are preferably in the range of about 6"- 12" above the lower surface 36 of timber joists 12 which lower surface extends down to a distance in the range of about 8' to 10' above the floor below
The timber joists 12 support a plurality of overlaid, mutually perpendicular lightweight trusses and/or beams 14 (shown in the Figures as trusses) which, in the preferred embodiment, arc parallel-chord trusses made of light-weight lumber members and which are separated by a truss-to-truss spacing distance in the range of about 1 ' or less to about 3' or greater on center, preferably about 2' on center for normal residential usage, and supported by timber joists 12 The parallel-chord trusses preferably have a maximum length of about 40', and have a truss height dimension in the range of about 6" to 12" in depth An embodiment of the parallel-chord trusses is comprised of an upper 16 and a lower 18 parallel chord separated and supported by secondary support members or elements 20 The upper 16 and lower 18 chords of parallel-chord trusses 14 are regularly interconnected to the secondary support members or elements 20 using moment-resisting connections 20a These secondary support members 20 and the moment-resisting connections 20a prevent the trusses 14 from twisting or collapsing The secondaiy support members 20 may be made of various material and are, in a preferred embodiment, made of preferably about a 2"x4" flat piece of solid wood Secondary members or elements 20 of parallel-chord trusses 14 are spaced at a range of about 12" to about 24", and preferably about 16" on center Secondary support members 20 could also be diagonal steel webbing in tension, or diagonal wooden supports, to support and separate the parallel chords 16 and 18, although such embodiments are not shown in the Figures Upper chord 16 is preferably about a 2"x3" flat piece of wood with a load capacity of about 80 plf (pounds per linear foot) live - meaning with added weight due to occupancy of a building, and about 20 plf dead - meaning weight of the floor alone Lower chord 18 is preferably about a 2"x3" flat piece of wood with a load bearing capacity of about 20 plf dead
Between joists 12 and parallel-chord trusses 14 may be a plurality of sound isolation bearing pads 22 or cushions which are, in the preferred embodiment, made of resilient mateπal and are intermittent squares, segments, or stπps secured to the upper surface 34 of each joist 12 Sound isolation bearing pads 22 do not cover the entire width of the upper surface 34 of each joist 12 The sound isolation bearing pads 22 have dimensions preferably in the range of about 1/4" to about 1" thick The sound isolation bearing pads 22 cushion the interface between joists 12 and parallel-chord trusses 14 and dampen sound between the floors or stories of a building.
Stair openings and other large apertures in the flooπng system are framed, defined, and supported by structural elements of a similar depth to parallel-chord trusses 14, but with higher load and span capacities Timber joists 12 may be interrupted and/or up sized to accommodate large openings Timber joists 12 can be supported at either the building peπmeter or along an interior line, on heavy timber girders or standard load-beaπng wall construction
The third, or trim, subsystem 6 of the flooring system comprises upper surface subfloor paneling mateπal 24 attached, preferably by nails or screws, to the upper chord 16 of parallel-chord trusses 14 of the structural subsystem 8 This upper surface subfloor paneling mateπal 24 of the trim subsystem 6, which becomes the subfloor of the upper level of a two- story building, in the preferred embodiment, is a standard building panel product, for example, tongue and groove plywood, oriented strand board, or other materials commonly used as floor underlayment This upper surface paneling or subfloor mateπal 24 can, in turn, be covered by finished flooring 24a such as, but not limited to, carpet, hardwood, floor boards, or linoleum sheet goods for example In addition, the intersections of the walls of a building and the finished flooπng, where the flooring meets the wall, could be covered by tπm molding
As best shown in Figures 3, 4, and 5, the third, or trim, subsystem 6 further comprises lower surface trim paneling pieces 26 which can be attached to the lower chords 18 of parallel-chord trusses 14 of the first, or structural, subsystem 8, preferably by screws and which become the ceiling of the lower floor of a building The lower surface tπm paneling pieces 26 can be formed of various mateπal including but not limited to wood boards, plywood of various appearances, 1/2" dry wall - pre-painted or pre-wallpapered, or fabric for example The edges and butt joints of the lower surface trim paneling pieces 26, where lower surface tπm paneling pieces 26 meet joists 12 at about a 90 degree angle, and the seams where two lower surface trim paneling pieces meet, are concealed with various edge trim pieces 28 which can be attached to the lower surface tπm paneling pieces 26 and/or to the timber joists 12 such that joint compound and painstaking edging is obsolete Lower surface trim paneling pieces 26 may also rest on edge tπm pieces 28, or on joists 12 such that very few, if any, nails or screws are needed to secure lower surface trim paneling pieces 26 in place Once edge trim pieces 28 arc removed, lower surface tπm paneling pieces 26 can be easily removed to provide access to interstitial space subsystem 30 If lower surface tπm paneling pieces 26 arc resting on joists 12, edge tπm pieces are optional because there will be no unsightly, uneven intersection between the lower surface tπm paneling pieces 26, and joists 12 The various edge trim pieces 28 may be sparse and simple, for example quarter rounds at the edges, and battens at the joints, or may be ornate and elaborate, with vaπous oak strips on a one foot or two foot grid, as shown in Figure 3 and, to celebrate and create the coffered ceiling look
In a preferred embodiment, both the lower surface tπm paneling pieces 26 and the edge tπm pieces 28 are installed with attractive and exposed screws, or recessed and covered screws The lower surface tπm paneling pieces 26 and edge trim pieces 28 are installed after all the utilities and services have been installed
The second, interstitial space, subsystem 30 is formed when the fust, or structural, subsystem 8 is enclosed by the upper surface subfloor paneling mateπal 24 and lower surface trim paneling pieces 26 Utilities can be conveniently installed in interstitial space subsystem 30 before or after upper surface subfloor paneling mateπal 24 and lower surface trim paneling pieces 26 are installed Lastly, interstitial space subsystem 30 is concealed from view by installation of upper surface subfloor paneling mateπal 24 and lower surface tπm paneling pieces 26 Fiberglass or other types of insulation for heating, cooling or further sound dampening can also be installed in interstitial space subsystem 30 After initial construction, subsequent repairers and remodelers can easily remove all or part of the edge trim pieces 28 and all or part of lower surface trim paneling pieces 26 of the third, or tπm, subsystem to reveal the second, or interstitial space, subsystem 30 and its contained utilities and service hardware such as air or heating duct 40a, plumbing such as drain waste vent 40b, electπcity 40c, water lines 40d, and/ or recessed lighting 40e as shown in Figure 4 Interstitial space subsystem 30 preferably has a duct capacity in the range of about 6" to about 12" and has a height of about of 6" to about 12", and preferably about 9 1/2", equaling the space between the upper 16 and lower 18 chords of parallel-chord trusses 14 and defined by the length or height of the secondary vertical support members 20 interposed between and supporting the parallel chords 16 and 18 Installed ducts or other utilities or services can be run in any direction within interstitial space subsystem 30, for example parallel to joists 12 or parallel to trusses 14 or both
The flooring system of the present invention is installed following construction of the frame of the building including the exterior and interior walls and interior beams, first with installation of timber joists 12 followed by the sound isolation bearing pads 22, then parallel- chord trusses 14, or if desired, beams Next, the upper surface subfloor paneling mateπal 24 is installed followed by insulation, pipes, wires, and ducts as for example duct 40a and plumbing 40b, then the finished flooring 24a, and finally optional lower surface tπm paneling pieces 26 and edge tπm pieces 28 are installed after all utilities have been installed in interstitial space subsystem 30
Figure 4 more particularly illustrates flooring system 10 with utilities such as heat or air duct 40a, plumbing 40b, electπcal 40c, water lines 40d, installed in interstitial space subsystem 30 Recessed lighting, for example 40e, can also be run through interstitial space subsystem 30 and lower surface tπm paneling pieces 26 Also shown in Figure 4 are the locations of sound isolation bearing pads 22 on upper surface 34 of joists 12 and the location of lower surface trim paneling pieces 26 relative to sound isolation bearing pads 22, joists 12 and edge tπm pieces 28
Figure 5 illustrates, in greater detail, a section of the flooring system 10 The location of moment-resisting connections 20a, between upper chord 16 and lower chord 18, and secondary vertical support members 20, is shown The location and size of sound isolation bearing pad 22 and lower surface tπm paneling pieces 26 on upper surface 34 of joist 12 is illustrated, and in one embodiment, lower surface trim paneling pieces 26 can be installed resting on upper surface 34 of joist 12 Lower surface trim paneling pieces 26 can extend onto joist 12 far enough to be secure in position, but do not extend so far as to be immovable When it is desired to remove lower surface trim paneling pieces 26, any installed edge trim pieces 28 are removed and the lower surface trim panel piece 26 is moved horizontally in one direction to free one side from a joist 12 such that one side of the lower surface trim panel piece 26 can be freed and dropped followed by the other side No puncturing or cutting of lower surface tπm paneling pieces 26 is necessary Lower surface trim paneling piece 26 is then reinstalled in the same manner b) installing one side first In this embodiment, no edge trim pieces 28 are necessary
In another embodiment, not shown, lower surface trim paneling pieces 26 may be cut to fit in between, but not resting on, joists 12 In such an embodiment, edge tπm pieces 28 would be required to conceal the possibly uneven intersection between joist 12 and lower surface tπm paneling pieces 26 However, lower surface tπm paneling pieces 26 could be installed simply resting on edge trim pieces 28 Removal of lower surface trim paneling pieces 26 in this embodiment would be extremely easy, involving only the removal of the edge tπm pieces 28 upon which lower surface trim paneling pieces 26 would drop.
It is thought that the present invention, the Serviceable Open Floor System, and many of its attendant advantages is understood from the foregoing description and it will be apparent that various changes may be made in the forms, sizes, construction and arrangement of the parts thereof without departing from the spirit and scope of the invention or sacrificing its material advantages, the form herein before described being merely a preferred or exemplary embodiment thereof.

Claims

CLAIMS I claim
1 A building flooring system comprising a structural subsystem wherein said structural subsystem compπses, a plurality of adjacent and substantially horizontally disposed timber joists, wherein each said timber joist of said plurality of adjacent and substantially horizontally disposed timber joists is separated from the adjacent said timber joist by a joist-to-joist spacing distance, a plurality of adjacent parallel -chord trusses wherein said plurality of adjacent and substantially hoπzontally disposed timber joists is perpendicularly overlaid with said plurality of parallel-chord trusses, wherein each said parallel-chord truss is separated from each adjacent parallel-chord truss by a truss-to-truss spacing distance, and wherein each said parallel-chord truss comprises an upper chord and a lower chord separated by a truss height distance and supported and connected by a plurality of support members, an upper surface subfloor mateπal secured to the upper chord of each said adjacent parallel-chord truss across the truss-to-truss spacing distance between said parallel-chord trusses, and an interstitial space subsystem formed by said structural subsystem such that utilities are installable and removable within said interstitial space subsystem without altering said structural subsystem
2 The flooring system according to claim 1 wherein said flooring system further comprises a trim subsystem wherein said trim subsystem compπses lower tπm paneling pieces secured to and below the lower chord of each of said parallel-chord trusses across the truss-to-truss spacing distance between said parallel-chord trusses, and across the joist-to-joist spacing distance between said plurality of adjacent and substantially horizontally disposed timber joists and intersecting at least one of said plurality of adjacent and substantially hoπzontally disposed timber joists, and edge tπm pieces secured along the intersection between said lower tπm paneling pieces and each of said adjacent and substantially hoπzontally disposed timber joists where said lower tπm paneling pieces meet said adjacent and substantially hoπzontally disposed timber joists, and edge trim pieces secured along intersections between said lower tπm paneling pieces, such that the intersections are concealed from view 3 The flooπng sj stem according to claim 1 wherein said building flooring system further comprises finished flooring mateπal secured over said upper surface subfloor mateπal and along the intersection between said upper surlace subfloor mateπal and walls of a room where said upper surface subfloor mateπal meets a wall such that the intersection of said upper surface subfloor material and the wall is concealed from view
4 The flooπng system according to claim 2 wherein said interstitial space subsystem is concealed by the enclosing of said structural subsystem by installation of said upper surface subfloor mateπal and said lower tπm paneling pieces
5 The flooring
Figure imgf000015_0001
according to claim 1 wherein said flooring system further comprises at least one sound isolation bearing pad interposed between each of said plurality of adjacent and substantially horizontally disposed timber joists and each of the lower chords of said parallel -chord trusses, wherein sound is dampened by said sound isolation bearing pads
6 A building flooπng system comprising a plurality of adjacent and substantially horizontally disposed timber joists each separated by a joist to joist spacing distance and perpendicularly overlaid with a plurality of adjacent parallel-chord trusses each separated by a truss to truss spacing distance and each comprising an upper chord and a lower chord separated by a truss height distance and supported and connected b> a plurality of support members, and upper surface subfloor mateπal secured to the upper chords of said parallel-chord trusses
7 The building flooring system according to claim 6 wherein said flooring system further comprises at least one sound isolation bearing pad disposed between each said adjacent and substantially horizontally disposed timber joist and the lower chord of each said parallel- chord truss
8 The building flooπng system according to claim 6 wherein said flooring system further compπses finished flooπng mateπal secured to said upper surface subfloor mateπal wherein said finished flooring is chosen from the group consisting of linoleum sheet, hard wood, soft wood, carpeting, and tile such that the intersection of said upper surface subfloor material and the walls of a building is hidden from view
9 The flooπng system according to claim 6 wherein said flooring system further comprises a trim package secuied between each of said adjacent and substantially horizontally disposed timber joists and intersecting said adjacent and substantially horizontally disposed timber joists 10 The flooπng system according to claim 9 wherein said trim package further compπses lower tπm paneling pieces secured to and below the lower chord of each of said parallel -chord trusses across the truss to truss spacing distance between said parallel-chord trusses, and across the joist-to-joist spacing distance between said plurality of adjacent and substantially hoπzontally disposed timber joists and intersecting at least one of said plurality of adjacent and substantially hoπzontally disposed timber joists, and edge trim pieces secured along the intersection between said lower tπm paneling pieces and each of said adjacent and substantially hoπzontally disposed timber joists where said lower trim paneling pieces meet said adjacent and substantially hoπzontally disposed timber joists such that the intersection between said lower trim paneling pieces and said adjacent and substantially hoπzontally disposed timber joists is hidden from view
11 A method for constructing flooring in a building, wherein the installation of utilities is separated and isolated from the structure of the building and the flooring, compπsing installing a plurality of adjacent and substantially horizontally disposed timber joists each separated by a joist-to-joist spacing distance , securing perpendicularly over said plurality of adjacent and substantially hoπzontally disposed timber joists, a plurality of adjacent parallel-chord trusses each separated by a truss-to- truss spacing distance, said parallel-chord trusses each compπsing an upper chord and a lower chord separated b} a truss height distance and supported and connected by a plurality of support members, wherein said method creates an interstitial space between the upper and lower chords of said parallel-chord trusses through which utilities are run and accessed without altering the structure of the building
12 The method according to claim 11 wherein the method further comprises secuπng at least one sound isolation bearing pad on top of each said adjacent and substantially horizontally disposed timber joist before securing said plurality of adjacent parallel-chord trusses perpendicularly over said plurality of adjacent and substantially horizontally disposed timber joists such that said at least one sound isolation bearing pad dampens sound between levels of a building
13 The method according to claim 11 wherein said method further comprises securing upper surface subfloor mateπal to the upper chords of said parallel-chord trusses
14 The building flooring system according to claim 13 wherein said method further comprises installing finished flooπng mateπal over said upper surface subfloor mateπal wherein said finished flooπng is chosen from the group consisting of linoleum sheet, hard wood, soft wood, carpeting, and tile such that the intersection of said upper surface subfloor material and the walls of a building is hidden from view
15 The method according to claim 11 wherein said method further comprises installing a trim package to and below the lower chords of said parallel-chord trusses across the truss-to-truss spacing distance between said parallel-chord trusses, and across the joist-to-joist spacing distance between said plurality of adjacent and substantially horizontally disposed timber joists and intersecting at least one of said plurality of adjacent and substantially hoπzontally disposed timber joists
16 The method according to claim 15 wherein said trim package further comprises lower trim paneling pieces secured to and below the lower chords of said parallel-chord trusses and between and intersecting said adjacent and substantially hoπzontally disposed timber joists
17 The flooring system according to claim 16 wherein said trim package further comprises edge tπm pieces secured along the intersection between said lower trim paneling pieces and said adjacent and substantially horizontally disposed timber joists such that the intersection between said lower trim paneling pieces and said adjacent and substantially honzontally disposed timber joists is hidden from view
PCT/US1997/022310 1996-11-28 1997-11-21 Serviceable open floor system Ceased WO1998023824A1 (en)

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GB2345497A (en) * 1998-12-23 2000-07-12 Maca R & D Ltd Timber floor/ceiling panel with void for service access
ES2190701A1 (en) * 2000-07-11 2003-08-01 Izquierdo Ramon Collado A floor
EP1251212A3 (en) * 2001-04-21 2003-09-24 Marlow & Co. Ltd. Improvements in and relating to flooring
GB2413572A (en) * 2004-04-30 2005-11-02 Peter Sully Load bearing unit
CN104018607A (en) * 2014-05-15 2014-09-03 昆山生态屋建筑技术有限公司 Spliced space truss interlayer floor
US9771726B2 (en) 2015-05-18 2017-09-26 Innovative Construction Technologies, LLC Flooring product and method of manufacturing same
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GB2345497A (en) * 1998-12-23 2000-07-12 Maca R & D Ltd Timber floor/ceiling panel with void for service access
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US9771726B2 (en) 2015-05-18 2017-09-26 Innovative Construction Technologies, LLC Flooring product and method of manufacturing same
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