FLOOR PANEL WITH INTEGRATED LIQUID COLLECTION AND REMOVAL SYSTEM

Field of the invention

The present invention relates to a liquid-tight floor or ground arrangement, more in particular to a liquid-tight floor or ground arrangement having connectable floor panels provided with an integrated liquid collection and removal system, and to such a floor panel.

Background of the invention A floor or ground arrangement that is impermeable to liquids is used, in general, wherever it is to be prevented that substances and liquids harmful to the soil can penetrate into the soil or the sub-soil owing to particular activities, which includes human activities.

The current national and international legislation on environmental control and protection of the soil, for example, obliges professional activities that involve a risk of soil pollution to comply with regulations relating to collection facilities, waste water management, and other protective and preventive measures.

Precautions and measures are to be taken on the basis of these national and international regulations so as to prevent pollution of the soil and ground water caused by, for example, fuels, oils, cooling liquids, hydrocarbons, or other chemical or oxidizing agents, liquids such as alkaline liquids, acids, and washing liquids, so that the risk of leakage thereof into the soil is made negligibly small. This may relate, inter alia, to the provision of liquid-tight floor arrangements in those locations where there is a high or increased risk of spillage, leakage, calamities and the like owing to which hazardous situations and soil pollution may arise.

Examples of this are fuel intake or fuel outlet points, fuel distribution points, washing areas for objects and/or vehicles, storage and trans-shipment areas for (bulk) liquids, storage and (un)loading of bulk and piece goods, distribution depots, storage and trans-shipment areas for chemicals, industrial production spaces, or spaces for process activities such as the collection, treatment and discharge of waste water or process water, airports, agricultural industry such as the construction of stables, and the like.

In addition to the specific requirements with which such liquid-tight floor arrangements have to comply and other relevant environmental measures, it is of course also necessary to have a liquid-tight discharge system, sludge collection system and/or separator system for receiving the liquids and other substances caught by such a liquid-tight floor arrangement, such as clay, sludge and other impurities carried along with the liquids.

Various kinds of liquid-tight floor or ground arrangements are known and in use. These known arrangements typically have a civil construction. The materials used are often elements of reinforced or plain concrete, locally poured reinforced or plain concrete, bituminous compounds such as inter alia asphalt, ceramic systems, metal systems, or combinations thereof. Most floor arrangements that are impermeable to liquids are not moved during their expected operational life. In recent years geomembrane collection systems in the form of product-resistant foil systems have also been used, as well as a sand-bentonite-polymer gel layer, for example as an impermeable sub-layer in an industrial location, a (waste) water basin, a parking lot, a refuse dump or the like.

Additional provisions such as waste water discharge systems of, for example, industrial sewers, gutters, catchment chambers, soakage pits and separators are also among the usual necessary collection, discharge, and treatment facilities. Such collection and discharge systems are connected to a liquid-tight floor arrangement or to the liquid or refuse collection system thereof.

Both the individual resistance and the interrelationship between a durable resistance to dynamic and static mechanical loads and a thermal and chemical resistance of the conventional, known floor and ground arrangements which are liquid-tight has its limitations. Those limitations may manifest themselves inter alia in the formation of cracks, crumbling, subsidence, shifting, disengagement, deformation and dissociation of the materials used owing to attacks by the collected liquids or other substances, or forces exerted thereon by vehicles running over them or installations placed on top of them. A floor arrangement that is constructionally liquid-tight has the object of being and staying impermeable to liquids during use while at the same time it is the base that supports installations as well as traffic running thereon in the form of (often considerable) static and dynamic wheel loads, point loads or wheel load repetitions. The robustness of floor arrangements that are constructionally liquid- tight, therefore, is often a sub-optimal combination of the function of carrier of dynamic and static axle and point loads and the impermeability function.

Many conventional liquid-tight floor or ground arrangements, furthermore, have a limited or selective resistance to short-term or durable attacks by the chemical, oxidizing substances, alkaline substances or acids, or other attacking (liquid) substances which the system is to receive. Metal, for example, may corrode or be subject to metal fatigue and thus loose its properties. Concrete, for example, has a very poor resistance to acids owing to its lime content.

In addition, concrete is strong under pressure but weak under tension, which is to be compensated for by a special reinforcement. Any cracks formed accordingly run counter to the requirement of impermeability to liquids. A concrete construction thus has to be given a particularly heavy design for certain heavy loads.

Bituminous constructions are less resistant to, for example, oily products. Certain thermal loads such as alternating heat and cold, but also UV influences, in addition impose limitations on their use. Fatigue and weathering of the materials also limit their operational life. Certain point loads in concrete constructions often lead to crumbling, which directly affects the liquid-tightness. Point loads at a certain temperature lead to irreversible deformation in the case of asphalt.

Non-constructional floor catchment provisions impermeable to liquids, such as collection troughs or frame-supported basins, are less suitable for major static or dynamic (wheel) loads, so that their function is usually limited to liquid-tight collection units suitable for a limited group or type of substances while having a limited durability. To keep the limitation of the durability as small as possible, liquid-tight collection arrangements are manufactured with a given specific resistance to the substances to be collected and are applied under certain limiting conditions of use. This may relate to the resistance to UV, to thermal loads (heat and cold), to corrosion such as by electrochemical attacks, and to dynamic and static loads. Some constructional elements excluded, the removal of traditional arrangements moreover involves a deformation whereby the entire liquid-tight floor and catchment arrangement with all its connections is to be regarded as lost.

Netherlands Patent NL 1040025 discloses a movable liquid-tight floor or ground arrangement and is constructed from mutually adjoining couplable floor elements made of synthetic resin so as to constitute a driving lane with an integrated liquid collection arrangement.

US Patent Application US 2005/0204662 describes a system of elongate floor or deck plates manufactured in one piece from synthetic resin, in particular polyvinylchloride (PVC), each plate having an upper surface or top face in which a system of parallel discharge channels is formed for the removal in a longitudinal (axial) direction across the surface of the floor plate of liquid caught by the floor plate towards a liquid collection arrangement located at one or both of the end faces next to and outside the floor plate, each discharge channel issuing into this liquid collection arrangement.

These floor or deck plates can be coupled transversely so as to adjoin, the cooperating coupling means of adjoining floor plates forming an assembled discharge channel in longitudinal (axial) direction of the coupled floor plates for discharging liquid that leaks through the intervening space (coupling seam) between adjoining floor plates from the top face. The floor plate is formed as an open structure for a lower weight, with a number of hollow chambers that extend in longitudinal direction under the top face of the floor plate.

International Patent Application WO 00/62603 discloses a matting of elongate matting modules which, viewed in transverse direction, can be placed so as to be mutually adjoining by their long edges. Each matting module is provided with openings in and distributed over the surface to be loaded, which openings issue or merge into discharge channels that extend in longitudinal direction across and below the surface of a matting module to be loaded. These discharge channels connect to a liquid collection unit placed at the end faces next to and outside a matting module.

The floor plates or floor panels and the grid disclosed in

US2005/0204662 and WO 00/62603, respectively, do not offer an integrated solution for the discharge of liquids from coupled floor panels. As a result, these known floor plates or floor panels and the matting arrangement are unsuitable for a flexible and fast laying, without wide-ranging constructional preparations, of a floor arrangement that is liquid-tight and that has longitudinal and transverse dimensions which are a multiple of those of a single floor element, floor plate, or matting module. Furthermore, the constructions described are by no means suitable for implementing a liquid-tight floor arrangement that can support installations as well as traffic running over it, inter alia in the form of (often heavy) static and dynamic wheel loads, point loads, or wheel load repetitions.

Although the liquid-tight floor or ground arrangement known from N L 1040025 does indeed provide for a fast and flexible laying of a liquid-tight floor arrangement with an integrated removal system and with longitudinal and transverse dimensions which are a multiple of those of a single floor element, it does involve the use of grid or bridge plates for covering the discharge channels of coupled floor elements of the surface that is or is to be loaded.

Summary of the invention

It is a main object of the invention to provide a liquid-tight floor or ground arrangement without the described drawbacks involved in fixed constructional liquid-tight floor or ground arrangements, and whose construction is suitable for the manufacture of a widely applicable liquid-tight floor arrangement that may serve as a support of installations but in particular also of traffic running onto or over it in the form of, inter alia, (often heavy) static and dynamic wheel loads, point loads, or wheel load repetitions.

More specifically, this implies that the present invention during operation continues to comply as much as possible with both individual standards and combinations of standards and requirements in the field of dynamic, static, mechanical, thermal and chemical resistance in combination with a dimensional flexibility of the envisaged liquid-tight floor or ground arrangement, while in addition it should be possible to assemble the latter quickly and without wide-ranging constructional preparations and to remove it easily and quickly again, as required.

The present invention accordingly provides a liquid-tight floor arrangement comprising adjacently connectable rectangular floor panels having respective first and second mutually opposed circumferential edges and third and fourth mutually opposed circumferential edges, wherein each floor panel comprises a closed floor surface that is to be operationally loaded, an unloaded surface for placement on a base surface, and an integrated liquid collection and removal system that is accessible to liquids from the surface to be loaded, characterized in that, each floor panel is provided with a first liquid collection duct that extends along the first circumferential edge, that is provided in the floor panel, and that is open to the surface to be loaded, a flange or lip extending parallel to the surface to be loaded with a nose-shaped ridge pointing away from the surface to be loaded such that, in the case of adjacently coupled floor panels, the nose-shaped ridge of one floor panel fits into the first liquid collection duct of the other floor panel, and a liquid discharge channel extending along the third circumferential edge, provided in the floor panel, and open to the surface to be loaded, wherein the first liquid collection duct discharges into the liquid discharge channel and is closed at the fourth circumferential edge, and wherein the surface to be loaded is at a deepened level at least with respect to the first, second and fourth circumferential edges.

In this removable liquid-tight floor arrangement, the mechanical functions for adjacently connecting the floor panels and the functions of an impermeable liquid collection and removal have been fully integrated. The nose- shaped ridge and duct coupling renders the floor panels eminently suitable for an easy and fast assembly of a liquid-tight floor arrangement of comparatively small up to comparatively large dimensions without the necessity of using grid or bridge plates or external liquid ducts for the coupling of connectable floor panels in the manufacture of a liquid-tight floor or ground arrangement.

The expression 'liquid-tight' as used and meant in the present description and claims, and as also defined and interpreted in the current national and international legislation in the field of environmental control and conservation of the soil, implies that no liquid from the surface to be loaded of the liquid-tight floor or ground arrangement, i.e. from the surface used for operational activities, must reach the unloaded surface of the floor or ground arrangement, i.e. the surface of the floor or ground arrangement that rests on a base surface. The integration of the mechanical coupling functions and the liquid collection and removal system in the floor panel itself, renders the liquid collection and removal system impermeable to liquids in the sense of the above definition.

Such a liquid-tight floor or ground arrangement made of, for example, wood, a multiplex material, or a fibre-reinforced synthetic composite material in the form of a sandwich construction fully enveloped in or enclosed by a synthetic resin skin, such as a multi-layer glass fibre skin glued with resin, is lighter than a concrete or asphalt arrangement of the same dimensions by a factor of 3 to 5 or more. Due to the nature and composition of the floor panels, the allowable axle loads or point loads are more favourable by an equivalent factor of approximately 8 compared with traditional floor arrangements of concrete or asphalt. Floor panels with a length of 5 m or more and a width of 2 m or more can be manufactured in this manner in practice, which panels are easy to handle and to transport, for example by road, i.e. without the necessity of using particularly heavy equipment or transport means. Panels of smaller dimensions may, of course, also be manufactured.

The invention thus provides for the manufacture of a liquid-tight floor or platform arrangement without grid or bridge plates extending transversely to the driving direction of vehicles across the surface to be loaded of two or more coupled floor panels, which driving direction may be chosen to be transverse to the first and second circumferential edges. For a given axle, point, or liquid load, the expected operational life of the liquid-tight floor or ground arrangement according to the invention as a result is substantially improved with respect to the known connectable floor elements. The construction according to the invention is particularly suitable for supporting axle loads of approximately 20 tons or more, corresponding to traffic class 600.

This allows for a method being carried out on or above this floor arrangement of cleaning, washing and fuelling of (possibly electric) vehicles, emptying and filling of installations, catching and removing of (possibly liquid) chemicals, and catching, separating and treating of (possibly liquid) soil pollutants and waste water in and adjacent the relevant collection arrangement. The arrangement can be readily made electrically insulating through the use of panels made of synthetic resin or wood.

The expression 'liquid collection and removal or discharging' in the present description and claims relates not only to the collecting and discharging of liquids, but also to that of other substances, whether or not pollutants of the soil, such as clay, sludge or other impurities which are carried along by the liquid(s).

In an embodiment of the floor arrangement according to the invention, each floor panel is provided with a second liquid collection duct which extends along the fourth circumferential edge and is provided in the floor panel and is open to the surface to be loaded, which second liquid collection duct discharges into the first liquid collection duct and is closed at the second circumferential edge.

In order to allow as much liquid as possible to flow away from the surface to be loaded of the floor panel into the liquid discharge channel, the invention provides that the surface to be loaded is stepwise deepened from the fourth circumferential edge towards the third circumferential edge. That is, the deepened level of the surface to be loaded increases in a direction to the third circumferential edge, where the liquid discharge channel is located. A floor panel having three levels was realized in practice. The deepening may also be implemented so as to be continuous or stepwise continuous.

In a yet further embodiment of the invention, at least the first, second, and fourth circumferential edges of a floor panel are each provided with an integrated barrier or threshold raised with respect to the surface to be loaded and of equal height measured from the unloaded surface of the floor panel. This again provides an improved guiding of the liquid removal towards the liquid discharge channel and precludes the necessity for the liquid collection ducts to be excessively wide and/or deep in order to prevent them flowing over, which would also have repercussions on the thickness of a floor panel and accordingly the weight of a floor panel.

For reasons of force transmission, in particular in the case of vehicles driving over the surface to be loaded of coupled floor panels, an embodiment of the invention provides that the raised barrier or threshold merges obliquely, at an obtuse angle, with the surface to be loaded of the floor panel, for example an obtuse angle of 120 degrees or more measured from the surface to be loaded.

Again to prevent unnecessary forces on coupled adjoining floor panels as much as possible, and also for aesthetic reasons, the invention preferably provides that the thickness of the flange or lip and the nose-shaped ridge at the second circumferential edge and the depth of the first liquid collection duct and the height of the first circumferential edge bounding this liquid collection duct are dimensioned such that floor panels coupled by their respective first and second circumferential edges connect flush to each, i.e. forming a planar joint.

In the case of adjoining floor panels that each have also a second liquid collection duct at the fourth circumferential edge, the invention further provides that the depth of this second liquid collection duct and the height of the fourth circumferential edge bounding this second liquid collection duct are dimensioned such that floor panels coupled by their respective fourth circumferential edges by means of a coupling plate engaging the respective second liquid collection ducts from the surface to be loaded, are flush to each other, i.e. form a planar joint.

In an embodiment, the floor panel is provided with a higher raised barrier or threshold at its third circumferential edge, which threshold bounds the liquid discharge channel and forms an abutment for a screen wall that is to be provided on the surface to be loaded of the floor panel.

The use of a coupling plate is not disadvantageous in the case of floor panels whose dimensions have a length/width ratio of approximately 2: 1 , for example with a length of approximately 5 to 6 m and a width of approximately 2 to 3 m, and wherein the first and the second circumferential edge are at the long sides and the third and the fourth circumferential edge are at the short sides of the floor panel, because these coupling plates do not lie at the surface to be loaded of the coupled floor panels in a direction transversely across the driving direction of vehicles, which driving direction being transverse to the first and second circumferential edges in practice.

The invention further has for its object to connect the floor panels of the floor arrangement to one another and to a single central discharge system in a manner that renders it intrinsically impermeable to liquids, while all its functions are retained. It is here that each floor panel has at least one integrated liquid collection and removal system for receiving from the surface to be loaded liquids and other substances as mentioned above, while the liquid removal system is situated at the third circumferential edge of each floor panel and, in an embodiment of the floor arrangement according to the invention, the liquid discharge channel terminates at either end thereof in a tubular or semi-tubular outlet or inlet opening so as to form an interconnected liquid discharge system when the floor panels are coupled.

For an easy coupling of the tubular or semi-tubular outlet or inlet openings, the invention further provides that at the first circumferential edge of the floor panel the outlet or inlet opening does not project beyond the first circumferential edge to the exterior and at the second circumferential edge terminates at a distance from the nose-shaped ridge such that corresponding inlet and outlet openings connect to one another when the floor panels are coupled by their respective first and second circumferential edges.

The corresponding outlet and inlet openings may be externally connected to one another in a simple and effective manner, made impermeable to liquid to the exterior by means of a coupling sleeve or socket around the connection. Alternative closing means for the mutually connecting outlet and inlet openings of coupled floor panels are also possible, for example in that the relevant outlet and inlet openings are given different dimensions such that one can fit into the other.

In an alternative embodiment, the invention provides a liquid discharge channel with outlet openings that discharge into the third circumferential edge, in particular two outlet openings located at the first and the second circumferential edge, for connection to a liquid discharge system situated outside the floor panels.

The floor arrangement according to the invention, besides the matching ridge-and-duct coupling and the coupling by means of a coupling plate as described above, is preferably also provided with further mechanical coupling means for connecting mutually adjoining floor panels to one another and/or for connecting objects to a floor panel.

In an embodiment, the further coupling means comprise coupling elements, such as, for example, threaded bushes, bayonet connecting bushes and similar coupling bushes, which are located at a distance from and along at least one circumferential edge, fixed in the floor panel, and accessible from the surface to be loaded, for the accommodation and the - preferably detachable - coupling of fastening means in these bushes.

This renders it further possible to connect adjoining floor panels mechanically to one another by means of coupling strips that are secured to mutually facing coupling bushes by means of screws or otherwise. The coupling bushes or coupling elements may alternatively be used for fixing upright posts to a floor panel for constructing, for example, a canopy or the like. The invention further provides for a drive-on and drive-off plate that is to be connected by the coupling means and that extends preferably along a first circumferential edge of a relevant floor panel. The further coupling means are preferably located at a distance from and along the third and fourth circumferential edges of a floor panel so that objects will not be mounted in the path of vehicles passing over the surface to be loaded. When crane hooks are detachably coupled to the further coupling means or coupling elements such as, for example, threaded bushes or bayonet connecting bushes, floor panels can be hoisted and placed into a desired position in a simple manner and can obviously be easily moved onto and from vehicles for transporting the panels.

In an embodiment, the invention provides substantially S-shaped coupling plates having a major or elongated side or leg applied to the loaded surface of the floor panel and a short side or leg applied to the edge or threshold at the third circumferential edge. Such coupling plates are used inter alia for mounting a protective screen wall along and on the surface to be loaded of a floor panel or on coupled floor panels.

The invention has further for its object to have the floor arrangement integrally and particularly durably comply with the relevant requirements, provisions and standards, among which NEN, Euro and CUR standards for dynamic, static, mechanical, thermal and chemical resistance while retaining the characteristic of impermeability to liquids. A distinguishing feature herein is that the composition of each floor panel can comprise a self-supporting construction capable of carrying heavy loads without any risk of delamination as known from traditional constructions.

To achieve this, the invention provides, inter alia, a floor panel made in one piece of a fibre reinforced composite synthetic material or a glass fibre reinforced laminate of synthetic material or wood, which also includes a sandwich of multiplex material, with a total thickness of the order of 70 mm.

To achieve a perfect embedding and compensation of level differences, the floor arrangement according to the invention further comprises that the floor panels are placed on a cushion-type support layer that is filled with sand.

The invention also has for its object to provide that the arrangement can be coupled and detached in a comparatively simple manner, can be stacked and stored in sea containers, if desired, and can be moved to any other location where it is put into operation again while retaining all its functions. In a preferred embodiment, accordingly, each floor panel is of rectangular shape with a length/width ratio of approximately 2: 1. The first and second circumferential edges are then located at the long sides and the third and fourth circumferential edges at the short sides. The present invention also has for its object to offer an economic improvement over the conventional applications through the use of the durable and light-weight materials described above. This implies that the requirements imposed on the supporting foundation are alleviated. In addition, major structural savings can be achieved, inter alia, in transport, processing, maintenance and repair, and in economic or technical write-off, which savings constitute a marked improvement on the conventional arrangements.

In a further development, the design and composition of the entire liquid collection and removal system is such that installations, utilities, and tubing and wiring can be placed above ground on, at, in or adjacent the collection system or be included therein and be disconnected again. The entire collection and removal system can be comparatively easily moved to any other location by this design, composition, and the above-mentioned characteristics.

The construction and choice of materials are such that the original design, the composition and the dynamic, static, mechanical, thermal and chemical properties of the floor panels and of the liquid collection and removal system do not change under the influence of the collected (liquid) materials. This may relate to (liquid) substances freed upon cleaning and washing, but also fuelling, filling and draining of automotive liquids such as engine oil, cooling liquid or window spray liquid, or the storage or trans-shipment of acids or alkaline liquids and other oxidizing agents and (liquid) chemicals.

In a further development, the floor arrangement with the integrated liquid collection and removal system is suitable for being driven over repeatedly, i.e. withstanding all usual wheel or axle loads such as very heavy fixed and mobile loads of industrial traffic over the public highway in accordance with traffic class 600.

The invention is based on the insight that industrial activities involving soil threatening (liquid) substances have to take place on or above collection arrangements that are liquid-tight, and that it is economically advantageous to realize a removable, light-weight, durable and permanently impermeable floor arrangement that is and remains suitable for supporting heavy and light loads and that remains to be traversed by heavy or light axle loads.

The invention also relates to a floor panel for use in a floor arrangement as described above, in particular a floor panel comprising a body reinforced with a glass fibre cloth, having a sandwich construction, and surrounded by a skin that is impermeable to liquid and that extends at least over the surface to be loaded and from there continues over the flange or lip and the nose-shaped ridge into the liquid collection duct and the liquid discharge channel.

For purposes of registration and inspection, the invention further provides that each floor panel is provided with its own, unique identification, in particular an RFID tag or any other identification that can be read out by remote radiographic control.

In a further aspect, the invention provides a method of manufacturing a pressure bed suitable for constructing a floor arrangement with floor panels according to any of the preceding embodiments, comprising the steps of:

- spreading a tarpaulin or cloth of synthetic resin material on a base surface, the tarpaulin or cloth having dimensions being at least twice the dimensions of the floor arrangement to be constructed,

- providing an adjustment frame on a half of the spread tarpaulin or cloth, the frame having dimensions and a contour corresponding to the dimensions and contour of the floor arrangement to be constructed, and having a frame height that is at least equal to a height required for evening out inequalities in the base surface or paving and for obtaining a desired gradient or slope in the floor arrangement,

- providing a pressure bed of sand, granulate, or preferably sand mixed with cement within the adjustment frame to a height equal to the frame height,

- providing an other half of the tarpaulin or cloth over the pressure bed so as to form a cushion-type base layer,

- closing the cushion-type base layer thus formed at its edges by fastening the tarpaulin or cloth to the adjustment frame.

One or more floor panels are subsequently provided on the closed, cushion-type base layer so as to construct the floor arrangement as disclosed above. The adjustment frame may be made of wood, synthetic resin, or metal, and the tarpaulin or cloth may be fastened to the adjustment frame by stapling, screwing, or other methods.

These and other aspects, features and advantages of the present invention will be explained in more detail below in the ensuing description of embodiments of a removable installation comprising a durable, light-weight, floor arrangement that is impermeable to liquids, resistant to heavy and light vehicles or axle loads, whether resting or driving thereon, capable of supporting installations and equipment fastened thereon, suitable for cleaning, washing and fuelling of vehicles on or above the liquid collection arrangement, and capable of collecting, separating and treating (liquid) soil pollutants and waste water in and adjacent this floor arrangement.

Brief description of the figures

Figure 1 is a perspective view of a self-supporting floor panel according to an embodiment of the invention.

Figure 2 shows a detail in cross-section on an enlarged scale of two coupled floor panels of the type shown in figure 1 .

Figure 3 shows a detail on an enlarged scale of two coupled floor panels of the type shown in figure 1 with the respective outlet and inlet openings of their liquid discharge channels connected to one another.

Figure 4 is a perspective view of two coupled self-supporting floor panels according to a further embodiment of the invention.

Figure 5 shows a detail on an enlarged scale of the outlet opening of the liquid discharge channel of the embodiment of the floor panel shown in figure 4.

Figure 6 shows a detail on an enlarged scale of the outlet openings of the liquid discharge channels of the coupled floor panels shown in figure 4.

Figure 7 is a perspective view, partly in elevation, of coupling plates fastened to connected floor panels and a frame for fastening a screen wall thereto.

The figures are given by way of example wherein identical components or components having the same function have been given the same reference numerals. The invention is by no means limited to the embodiments shown and described.

Detailed description

Figure 1 is a schematic perspective view of a rectangular floor panel 1 , illustrating a possible embodiment of the present invention. The floor panel 1 comprises a surface 2 to be loaded, i.e. the surface on which activities take place as discussed above, and an unloaded surface 3 with which the floor element 1 rests on a base surface (not shown).

The panel 1 is delimited by first 4 and second 5 mutually opposed circumferential edges and third 6 and fourth 7 mutually opposed circumferential edges. In the embodiment shown, the first and second circumferential edges 4, 5 lie along the longer sides of the rectangular floor panel 1 , and the third and fourth circumferential edges 6, 7 lie along the shorter sides of the rectangular floor panel 1 .

The floor panel 1 is provided with a first liquid collection duct 8 that extends along the first circumferential edge 4 and is provided in the floor panel 1 , the duct 8 being open at the surface 2 to be loaded for receiving liquid from the surface 2 to be loaded. A flange or lip 9 extends along the second circumferential edge 5 parallel to the surface 2 to be loaded and comprises a nose-shaped ridge 10 that points away from the surface 2 to be loaded.

A preferred length/width ratio for each floor panel is approximately

2: 1 , the maximum length and width dimensions being chosen such that a single panel or a set of stacked panels can fit into a sea container or a road vehicle so as to be transported. Examples are dimensions of approximately 5 - 6 m by 2 - 3 m.

In the embodiment shown, the floor panel 1 is also provided with a second liquid collection duct 1 1 which extends along the fourth circumferential edge 7, which is provided in the floor panel 1 , and which is open to the surface 2 to be loaded. This second liquid collection duct 1 1 discharges 12 into the first liquid collection duct 8 and is closed 14 at the second circumferential edge 5.

A liquid discharge channel 15 provided in the floor panel 1 and open to the surface 2 to be loaded extends along the third circumferential edge 6. The first liquid collection duct 8 discharges 13 into the liquid discharge channel 15. If the floor panel 1 has no second liquid collection duct 1 1 , the first liquid collection duct 8 will be closed at the fourth circumferential edge 7.

The surface 2 to be loaded is at a lower level compared with the first 4, second 5, and fourth 7 circumferential edges. In the embodiment of the floor panel 1 as shown, the surface 2 to be loaded is gradually deepened, i.e. reduced to lower levels, from the fourth circumferential edge 7 down to the third circumferential edge 6 in three successive steps 16, 17, and 18. This creates a gradient for discharging liquids and other substances present on the surface 2 to be loaded, such as clay, sludge, dust and other pollutants, etc. , to the liquid discharge channel 15.

The floor panel 1 in the embodiment shown is provided with integrated raised barriers or thresholds at the first 4, second 5, and fourth 7 circumferential edges, i.e. raised with respect to the surface 2 to be loaded, referenced 19, 20, 21 , respectively, and having the same height measured from the unloaded surface 3 of the floor panel 1 .

The height of the threshold 19, 20, 21 is chosen such that the surface 2 to be loaded of the floor panel 1 can collect a desired, given quantity of liquid without this liquid flowing over the threshold 19, 20, 21 into the first and second liquid collection ducts 8, 1 1 . For example a quantity of approximately 100 litres.

As is shown, the raised barrier or threshold 19, 20, 21 merges obliquely with the surface 2 to be loaded of the floor panel 1 at an obtuse angle.

The liquid discharge channel 15 terminates at either end 22, 23 thereof into a tubular or semi-tubular outlet or inlet opening, as applicable. Semi- tubular outlet and inlet openings are shown in the floor panel 1 shown in figure 1 .

The first and second liquid collection ducts 8, 1 1 and the liquid discharge channel 15 form an integrated liquid collection and removal system that is accessible from the surface 2 to be loaded of a floor panel 1.

The dimensions of the nose-shaped ridge 10 of the floor panel 1 are such that it fits into the first liquid collection duct 8 of a next floor panel so as to achieve a mechanical coupling of adjoining floor panels, as is shown in more detail in figure 2.

Figure 2 shows a coupling that is liquid-tight between two mutually adjacent floor panels 1 , 1 ' which are partly shown and are both of the type shown in figure 1 . The floor panels 1 , 1 ' are interconnected and coupled into one liquid-tight assembled floor arrangement 25 because the nose-shaped ridge 10 projecting from the flange or lip 9 of the one floor panel 1 fits along the length of the second circumferential edge 5 into the first liquid collection duct 8' that extends along the length of the first circumferential edge 4' of the other floor panel 1 '.

Liquid coming from the surface 2 to be loaded is caught in the first liquid collection duct 8' via the slot or opening 24 formed at the boundary between the mating floor panels 1 , 1 '. The flange or lip 9 of the floor panel 1 connects securely to the adjoining first circumferential edge 4' of the floor panel 1 '. This adjoining connection is designed first and foremost such that a vertical movement transverse to the surface 2 to be loaded of the floor panel 1 also bears on the floor panel 1 ', so that the force is distributed over the two floor panels 1 , 1 '. Any horizontal movements are limited in that the nose-shaped ridge 10 and the first liquid collection duct 8' fit snugly into each other, the mass of the individual floor panels placed against each other admitting no further motion.

The thickness of the flange or lip 9 and the nose-shaped ridge 10 at the second circumferential edge 5, the depth of the first liquid collection duct 8 or 8' and the height of the first circumferential edge 4 or 4' delimiting this liquid collection duct, all measured in a direction transverse to the surface 2 to be loaded, are dimensioned such that floor panels 1 , T coupled by their respective first circumferential edges 4, 4' and second circumferential edges 5, 5' lie in one plane, i.e. flat or flush, without differences in height, as shown in figure 2.

Although not explicitly shown, the depth of the second liquid collection duct 1 1 and the height of the fourth circumferential edge 7 delimiting this second liquid collection duct 1 1 are so dimensioned or provided with recesses that floor panels 1 coupled at their respective fourth circumferential edges 7 by means of a coupling plate engaging the corresponding second liquid collection ducts 1 1 from the surface 2 to be loaded will also combine into a flat or flush planar surface.

Such a coupling plate has a mechanical coupling function as well as a covering function while still fulfilling all mechanical, chemical, and durability conditions. The coupling plate may be closed in principle, or be provided with openings for collecting liquid from the coupling plate into a second liquid collection duct 7, and is preferably made from a suitably resistant material such as stainless steel.

The floor panel 1 shown in figure 1 is provided with further mechanical coupling means for coupling adjoining floor panels 1 and/or coupling objects to a floor panel. In the embodiment shown, the floor panel 1 is for this purpose provided with coupling elements which are fixedly located in the floor panel 1 at a distance from and alongside at least one circumferential edge and which are accessible from the surface 2 to be loaded, such as threaded bushes, bayonet connection bushes, and similar coupling bushes. These bushes serve for a, preferably detachable, coupling of fastening means such as strips or bars of metal that mechanically couple mutually adjoining floor panels additionally securely to one another so as to comply with requirements and standards for the dynamic, static, mechanical, thermal and chemical properties of the assembled floor system 25.

For this purpose, four pairs of coupling bushes 27, 28, 29, 30 are fixedly anchored in the floor panel 1 at a distance from and alongside the third and fourth circumferential edges 6, 7; for example at a distance of approximately 30 cm from each circumferential edge and with a space between each pair of coupling bushes adapted to the fastening of any upright posts or the like (not shown) on the surface 2 to be loaded.

These coupling bushes may preferably also be used for fastening a drive-on and drive-off plate to the floor panel 1 , for example to the first circumferential edge 4 thereof (not shown).

The coupling elements or coupling bushes 26 are accommodated in the floor panel in such a manner that the surface 13 to be loaded of a floor element adjoining the liquid collection and removal system is closed, i.e. there are no openings in this part, so that a floor element 1 complies with desired strength and durability requirements and the surface 2 to be loaded thereof can be universally used.

The coupling bushes 26 and the fastening means engaging them and the drive-on and drive-off plate are preferably made of, for example, stainless steel or galvanized steel such that the mechanical, chemical and durability conditions are fulfilled.

The outlet or inlet opening of the liquid discharge channel 15 does not project beyond the first circumferential edge 4 of the floor panel 1 to the exterior at the end 23 located adjacent the first circumferential edge 4. At the end 22 adjacent the second circumferential edge 5, the liquid discharge channel 15 terminates at a distance from the nose-shaped ridge 10 such that the corresponding inlet and outlet openings are in exact communication when the floor panels are coupled by their respective first and second circumferential edges.

Figure 3 shows in more detail the mutually matching outlet and inlet openings of the liquid discharge channels 15, 15' of two, partly shown, coupled floor panels 1 , 1 '. A coupling sleeve or socket 31 gripping across the connection ensures that the mutually matching liquid discharge channels 15, 15' have a connection that is liquid-tight to the exterior. During operation, the coupling sleeve or socket 31 is first passed over the tubular or semi-tubular end 22 of the liquid discharge channel 15, whereupon the floor panels 1 , 1 ' are coupled together via the ridge/duct coupling 10, 8' such that the tubular or semi-tubular ends 22, 23' exactly match. The sleeve 31 is subsequently pushed back towards the connection end 23' so that it envelops the connection opening between the ends 22 and 23'. The sleeve 31 is then securely clamped around the connected tubular ends by means of clamping rings 32. The sleeve 31 is also known as a flex seal.

In the case of semi-tubular ends 22, 23', a semi-tubular tube section is first placed over the connecting semi-tubular ends 22, 23' after the panels 1 , T have been coupled, if necessary with a flat middle section for preventing deformation of the semi-tubular ends during clamping of the sleeve 31.

Where the outlet or inlet opening at an end 22, 23 of the liquid discharge channel 15 terminates freely in a circumferential edge 4 or 5 at an outer side of the floor panel 1 , the outlet or inlet opening is sealed off, or the relevant outlet or inlet opening is connected, in a liquid-tight manner, to a separately arranged equally liquid-tight discharge line which passes the collected substances on via a soakage pit or sludge separator and a checkpoint to a general collection system such as, for example, a public sewer (not shown).

In a further embodiment, an outlet/inlet cover (not shown) may be mounted for connecting the liquid collection and removal channel 15 to a traditional discharge system in order to conduct the liquids to, for example, a suitable waste water treatment plant.

Figure 4 schematically shows in perspective view two coupled rectangular floor panels 41 , 41 ' according to a further embodiment of the invention. Components having accented reference numerals have the same construction and shape as components having the same reference numerals without accents in figure 4. The accent merely indicates that the components belong to a particular floor panel. The two floor panels 41 , 41 ' correspond substantially to the floor panel 1 , 1 ' as described above except for the shape of the liquid discharge channel 45, 45' and the outlet openings 46, 47; 46', 47' connecting therewith. Furthermore, the floor panels 41 , 41 ' have a planar surface 2, 2' to be loaded.

The liquid discharge channel 45 in the embodiment shown has two outlet openings 46, 47 located in a raised barrier or threshold 50 at the third circumferential edge 6 of the floor panel 41 . The first outlet opening 46 lies adjacent the first circumferential edge 4 and the second outlet opening 47 lies adjacent the second circumferential edge 5 of the floor panel 41 . For the removal of liquids and other products caught by the surface 2 to be loaded of the floor panel 41 , the outlet openings 46, 46'; 47, 47' are each connected via a tube connection piece 48 to a discharge line or discharge system 49. The raised barrier 50 in an embodiment of the invention projects approximately 5 to 6 cm above the surface 2 to be loaded of the floor panel 41.

The discharge system 49 in the embodiment shown extends parallel to the coupled third circumferential edges 6, 6' for the removal and further processing of the collected products, for example in a sludge separator (not shown) connected to the discharge system 49.

Figure 5 schematically shows in perspective view and on an enlarged scale a detail of the single floor panel 41 with the second outlet opening 47 formed at the third circumferential edge 6 adjacent the second circumferential edge 5 and in the raised barrier 50.

The outlet opening 47 is tubular in shape and discharges into the liquid discharge channel 45 transversely thereto. An approximately U-shaped opening 53 is for this purpose provided in the raised barrier 50 for accommodating a connection tube 54. The U-shaped opening 53 is closed off with an equally U-shaped adapter piece 52 after the connection tube 54 has been fitted. The first outlet opening 46 has the same shape as described above for the second outlet opening 47. Several outlet openings may obviously be formed in the raised barrier 50, or only a single outlet opening, depending inter alia on the quantity of liquid to be disposed of.

Figure 6 is a schematic perspective view on an enlarged scale of a detail of the outlet openings 46', 47 of the coupled panels 41 , 41 ' as shown in figure 4. At the point 13 where the first liquid collection duct 8' discharges into the liquid discharge channel 45', the flange or lip 9 of the floor panel 41 is provided with a recess 55 and an elevation 51 transverse thereto, as can be seen in more detail in figure 5. This achieves a satisfactory removal of liquids and other products collected on the flange or lip 9 in the case of coupled floor panels 41 , 41 ' also at this point 13.

As is apparent from figure 4, the floor panel 41 is provided with pairs 42 of coupling bushes 26 also along the first circumferential edge 4, inter alia for fixedly fastening mounting parts for equipment, guide rails and, for example, screen walls to a floor panel 41 , as is schematically shown in figure 7.

Figure 7 schematically shows in perspective view a detail of the fastening of upright posts 60, 61 and transverse connectors 62 which together form a frame 59 for mounting panes or screen panels therein or thereon of a screen wall to be fixedly mounted along the barrier 50, 50' to the third circumferential edge 6, 6' of the coupled floor panels 41 , 41 ', for example so as to form a car wash unit or the like in conjunction with the floor panels 41 , 41 '.

Substantially S-shaped coupling plates 65, whose elongate or major sides or legs 69 bear on the surface 2, 2' to be loaded and whose shorter sides or legs 68 terminate and bear on the upper side of the barrier 50, are mounted on the surface 2, 2' to be loaded of the floor panels 41 , 41 '.

On this surface 2, 2' to be loaded, the coupling plates 65 are fixedly connected to the pairs of coupling bushes 29, 30; 29', 30' by means of bolts, for example socket head bolts. The posts 60 are fastened to the shorter sides 68 of the coupling plates lying on the barrier 50 via coupling strips 70 and bolt/nut connections 71. For further robustness, substantially L-shaped coupling pieces 66 are provided which rest with one leg under a floor panel 41 , 41 ', i.e. against the unloaded surface 3, 3', and which are connected to the coupling strips 70 with the other leg and a bolt/nut connection 72. A secure fastening of the posts 60 on a floor panel 41 , 41 ' is obtained thereby. The posts 60 are interconnected by coupling strips 73 that extend parallel to the barrier 50 for further robustness.

The frame 59 thus formed for accommodating the panes or screen panels (not shown) therein or thereon adjoins the surface 2, 2' to be loaded at the raised barrier 50, 50', i.e. the liquid discharge channel 45, 45' of the floor panel 41 , 41 '. The barrier 50, 50' here constitutes an abutment for the screen wall, whereby an adequate collection of liquid and other pollutants and the like hitting the screen panels is achieved, as is schematically indicated by the reference numeral 74.

The coupling plates 65, coupling pieces 66, coupling strips 70, posts 60, 61 and transverse connectors 62 as well as the bolt/nut connections used are preferably made of stainless steel or some other low-corrosion material. The panes or screen panels may be made from a translucent synthetic material such as polycarbonate or glass or from an opaque synthetic material or a metal such as, for example, aluminium. Obviously, a complete canopy over the floor arrangement, for example, may also be realized in the manner described.

The liquid-tight floor panel 1 , 41 is preferably entirely formed as a body that has for its basis a glass fibre cloth reinforced matrix of multiplex wood layers that is completely surrounded by a closed composite skin of one or more layers of glass fibre cloth, the various components being joined together into one sandwich construction by means of vacuum under a supply of resin glue. This sandwich construction combines a low weight, a high rigidity, and durability. The construction differs from generally used constructions made from synthetic resins in that in the present invention a floor panel 1 does not suffer delamination and the shape, rigidity and durability remain permanently intact.

Composite material consists mainly of glass fibres such as E-glass fibres, C-glass fibres, ECR-glass fibres, S-glass fibres, basalt fibres, carbon fibres, such as low modules, intermediate modules, high modules, high strength modules, polyaramide fibres with ultrahigh molecular weight polyethylene (U HMWP), and hybrids of such fibres. Furthermore, synthetic materials consisting of primary thermosetting polymers such as polyester, vinylester, acrylate, polyurethanes, and epoxies are also eligible. E-glass fibres in polyester are particularly suitable. C-glass fibres in vinylester are suitable for use in surroundings where aggressive substances are processed.

Combinations of the above or further fibres are also possible, as are combinations of the above synthetic materials and combinations of synthetic composite materials with metal products, such as steel products, which includes metal plates in the form of a sandwich construction constituting a hybrid version of a floor element.

The floor panel 1 , 41 may comprise further materials or layers such as substances for counteracting degeneration owing to UV, for roughening a surface for anti-slip purposes, for counteracting moss deposits, an anti-wear layer or colourings for marking lines and/or compartments. In particular, a skin impermeable to liquids extends over the surface 2 to be loaded and continues over the flange or lip 9 and the nose-shaped ridge 10 into the liquid collections ducts 8, 1 1 and the liquid discharge channel 15, 45.

More in detail, each floor panel 1 , 41 can satisfy the standard requirements as to dynamic, static, mechanical, thermal and chemical loads. Standard requirements in this connection are understood to be inter alia: TGB 1990, NEN 6702, NEN 6706, Eurocodes and CUR 96 so as to comply with traffic class 600.

In an embodiment, floor panels are manufactured to a thickness (or height) of approximately 7 to 9 cm. The floor panels may advantageously be placed on an existing paving of stone or the like, preferably with an interposed cushioning layer 35 filled with sand 34 and built up from continuously joined compartments 33, as is schematically shown in figure 2.

In the locations where floor panels are coupled to one another or merge into one another, or where floor panels can lie against each other, connection seams or slots, which also includes the point of attachment of the flange or lip 9 of a floor panel in the first liquid collection duct 8 of another panel, may be sealed by means of a well-adhering, chemically resistant compound or cement for further safeguarding the impermeability of the floor arrangement. This may be, for example, a silicone sealing compound of the Ottoseal® S34 type or similar.

To manufacture a liquid-tight floor arrangement from floor panels on an existing paved surface or base of sufficient supporting power, the invention in particular provides a method whereby a pressure bed is laid on the paved surface or base over the entire surface area of the floor arrangement to be provided.

To this end a sturdy cloth or tarpaulin made of, for example, polypropylene or a similar synthetic material is first spread out on the subsoil. The dimensions of the cloth are at least twice those of the floor arrangement to be manufactured.

A bed of sand, of granulate, or preferably of sand mixed with cement is provided on one half of the cloth to a thickness sufficient for evening out any irregularities in the subjacent surface and for obtaining a slope or gradient of a few degrees in the direction of the liquid discharge channel 15, 45 for removing liquids and the like present on the surface 2 to be loaded. The bed is laid in an adjustment frame whose dimensions and contour correspond to the dimensions and contour of the impermeable floor arrangement to be manufactured. The height of the adjustment frame or the pressure bed depends on the irregularities to be compensated in the supporting surface and on the desired gradient or slope.

Once the bed is ready, the other half of the cloth or tarpaulin is provided over the bed, of course without disturbing the latter, and the cushion-type base layer thus obtained is closed at the edges in that the cloth or tarpaulin is fastened to the adjustment frame. A single cushion-type base layer is obtained thereby similar to the cushion-type base layer shown in figure 2, but with only one compartment. A liquid-tight floor arrangement is subsequently laid over the pressure bed thus obtained with floor panels according to the invention as described above.

The adjustment frame may be manufactured from wood, inter alia, but also from a synthetic material or metal, and the cloth or tarpaulin may be fastened to the adjustment frame by means of stapling, screwing or some other method.

Such a supporting structure forms an excellent and durable pressure bed because the filling of the bed cannot be washed away and it can be manufactured quickly and at an acceptable cost while complying with the highest loading requirements that may be imposed on a floor arrangement according to the invention.

The invention also relates to a marking or identifying of each floor panel with its own unique identification, in particular an identification that is automatically readable via remote control such as, for example, a radio frequency label or so-termed RFID tag 75, 75', which identification is indicated with broken lines in figure 4 by way of example. Each floor panel can thus be recognized, for example for inspection purposes, and the age, operational history and other particulars of a floor panel can be coupled thereto and be kept up to date in a computer file. Such an RFID tag, which is preferably of the passive type, can be integrated in the material of the floor panel or, for example, in a logo or emblem to be provided thereon.

Further modifications and adaptations will suggest themselves to an expert in the field on the basis of the embodiments described above, which further modifications and adaptations are deemed to be all included in the following claims.