FIELD OF THE INVENTION

[0001 ] The present invention relates to a prefabricated floor panel for a flooring system, a flooring system incorporating such a prefabricated floor panel, a method of forming a prefabricated floor panel and a flooring system with the prefabricated floor panel.

BACKGROUND OF THE INVENTION

[0002] Traditional processes for laying a ground slab, such as a concrete slab for example, often involve varying and often lengthy construction times. The time it takes to lay a slab is affected by a number of factors including: inclement weather, a fickle labour force, and antiquated construction techniques. In addition, these traditional processes involve rising construction costs.

[0003] One known solution to the problems in the traditional processes is the use of prefabricated panels. Generally, a pre-fabricated panel uses pre-cast concrete delivered to site. However, these prefabricated solutions products are expensive when compared to the traditional processes. In addition, these prefabricated solutions are carbon intensive to produce, heavy in weight, cumbersome, and not environmentally friendly. In addition, they are very often difficult to transport, erect, and install. Additionally, the prefabricated solutions are not always compatible with existing construction techniques, which can lead to secondary damage to other building components. The solutions accordingly suffer from safety issues and involve construction delays.

[0004] The present invention seeks to overcome one or more of the disadvantages in the existing systems or at least to provide the public with a useful choice. BRIEF SUMMARY OF THE INVENTION

[0005] In a first aspect, the present invention broadly consists in a prefabricated floor panel adapted for use in a floor system, the prefabricated panel including: a first board, a second board, and a spacing element for spacing the first board apart from the second board to form a load bearing floor panel.

[0006] The spacing element may comprise at least one structural reinforcement connected to the first and second panels.

[0007] The structural reinforcement may comprise a timber or steel support frame.

[0008] The structural reinforcement may alternatively comprise a fibre reinforced polymer or a reinforced MgO board section. The structural reinforcement spaces the first and second boards from each other.

[0009] The floor panel may include a plurality of structural reinforcements, which are spaced apart from each other. In one embodiment, the plurality of structural reinforcements are spaced apart from each other, along a width of the first and second boards, by a distance of about 400mm to 900mm, preferably about 600mm.

[00010] The structural reinforcement, or at least one of the plurality of structural reinforcements, may have an l-shape in cross section. Alternatively, the structural reinforcement, or at least one of the plurality of structural reinforcements, may have a C-shape in cross section. Alternatively, the structural reinforcement, or at least one of the plurality of structural reinforcements, may have a rectangular cross-section, such as a rectangular solid. The structural reinforcement may for example be an I- joist, or a C-joist. In one embodiment, the structural reinforcement may include a diagonal structure.

[0001 1 ] In one embodiment, the structural reinforcement is an open web truss system extending along a length of the first and second boards. One such open web truss system is sold under the registered trade mark Posi-STRUT® which is owned by Mitek Holdings, Inc.

[00012] The floor panel may include an insulating material disposed between the first and second boards.

[00013] In one embodiment, the spacing element may comprise an insulating material extending between the first and second boards.

[00014] The insulating material may completely fill the space between the first and second boards. In this case, a structural reinforcement may not be required, provided the floor panel comprising the combination of the first and second boards and the insulating material has sufficient load bearing capacity for normal use.

[00015] The insulating material may include any one or more of the following: expanded polystyrene (EPS), extruded polystyrene (XPS), glass, glass wool, rockwool, polyester, fibreglass, foil, or paper.

[00016] At least one of the first and second boards may comprise a concrete- based or cement-based board, such as autoclaved aerated concrete or fibre cement.

[00017] In one embodiment, at least one of the first and second boards includes magnesium oxide (MgO). Magnesium oxide, sometimes called magnesia, is a mineral that can be used as part of a cement mixture, and cast into a thin cement panel known as a magnesium oxide board (MgO) board. Magnesium oxide boards have previously been used as structurally insulated wall panels, though they have generally not been regarded as suitable for load bearing floor panels. We have found that structurally insulated floor panels in accordance with the invention are effective for use as load bearing floor panels having spans of up to about 3 metres.

[00018] In other embodiments, the first board and/or the second board may comprise a wood-based board board, such as plywood or particle board. In one preferred embodiment, at least one of the first and second boards is an oriented strand board (OSB). Oriented strand boards are similar to particle board, and are formed by adding adhesives and compressing layers of wood stands or flakes in particular orientations. [00019] In an embodiment, each of the first and second boards has a thickness of greater than 3mm. Preferably, the thickness of each board is between about 3mm to 40mm. Preferably, the thickness of the first board is different from the thickness of the second board. The first board is preferably a top board and the second board is preferably a bottom board. The thickness of the top board is preferably greater than the thickness of the bottom board. Preferably, the thickness of the top board is between about 18mm and 24mm. Preferably, the thickness of the bottom board is between about 4mm and 12mm. Alternatively, the thickness of the first board may be the same as the thickness of the second board.

[00020] In one embodiment, the insulating material includes expanded polystyrene (EPS). The insulating material may additionally, or alternatively, include extruded polystyrene (XPS). The insulating material may additionally, or alternatively, include glass insulation. The insulating material may additionally, or alternatively, include glass wool, rockwool, polyester, or fibreglass material. The insulating material may additionally, or alternatively, include recycled paper or a foil. In the case where the insulating material may additionally or alternatively include air.

[00021 ] The first and second boards may be spaced apart from each other by a distance from about 100 to about 450mm. Preferably, the distance between the boards is from about 150mm to about 400mm. When the floor panel includes a structural reinforcement, the distance between the boards is preferably from about 200mm to about 400mm and more preferably the distance between the boards is from about 240mm to about 300mm. When the boards are spaced apart by insulating material without a structural reinforcement, the distance between the boards is preferably from about 100mm to about 300mm and more preferably the distance between the boards is from about 150mm to about 200mm.

[00022] In an embodiment, the first board includes an inlet aperture for to allow for access into a space between the first and second boards. The second board may include an outlet aperture, wherein the inlet aperture is in fluid communication with the outlet aperture in a space between the first and second boards. Preferably, a channel or conduit is provided between the inlet aperture and outlet aperture to provide the fluid communication between the inlet aperture and outlet aperture. Preferably, the inlet aperture, the outlet aperture, and the channel or conduit provides internal plumbing for the prefabricated panel.

[00023] In a second aspect, the present invention provides a method of forming a prefabricated floor panel, the method comprising: providing a first board, providing a second board spaced apart from the first board; and providing a spacing element between the first board and the second board to form a load bearing floor panel.

[00024] The method may include connecting at least one structural reinforcement to the first and second boards to form the spacing element between the first and second boards.

[00025] The method may include providing an insulating material between the first and second boards.

[00026] The insulating material may be injected into a space between the two boards. Alternatively, the insulating material may be glued to the first and/or second boards. Alternatively, the insulating material may be sprayed into the space between the two boards.

[00027] Other embodiments and features of the second aspect may be similar to the embodiments and features of the first aspect described above.

[00028] In a third aspect, the present invention provides a prefabricated floor panel when formed by the method of the second aspect described above.

[00029] In a fourth aspect, the present invention provides a floor system incorporating a prefabricated floor panel according to the first aspect or the third aspect described above.

[00030] The floor system may include at least one beam to which the prefabricated floor panel is secured. The at least one beam may be a precast beam, a prestressed concrete precast beam, a T-beam, or an I-beam.

[00031 ] In an embodiment, the prefabricated floor panel may include a hanger connection for attachment to the beam. [00032] In an embodiment, the floor system includes a screw pile or a bored pier for securing the beam to the ground. The screw pile may be a 'twin fin' type screw pile, such as the Katana™ Pile made by Katana Foundations Australia. Katana is a registered trade mark owned by Patented Foundations Pty Ltd.

BRIEF DESCRIPTION OF THE DRAWINGS

[00033] Embodiments of the present invention will now be described, by way of non-limiting examples, with reference to the accompanying drawings, in which:

[00034] FIGURE 1 shows an elevation view of a first embodiment of a floor panel;

[00035] FIGURE 2 shows a front view of a panel shown in Figure 1 ;

[00036] FIGURE 3 shows a perspective view of the floor panel of Figure 1 ;

[00037] FIGURES 4A to 4D show different front views of the floor panel of Figure 1 with different insulating material;

[00038] FIGURES 5A and 5B show schematic sectional views of a floor panel similar to Figure 1 incorporating a drain;

[00039] FIGURE 6A and 6B show a top perspective view and a side view respectively of parts of the drain of Figure 5;

[00040] FIGURES 7A to 7C show schematic sectional views of the floor panel of Figure 1 in example panel-to-wall assemblies with a precast beam;

[00041 ] FIGURE 8A to 8C show schematic sectional views of the floor panel of Figure 1 in example panel-to-wall assemblies with a T-beam;

[00042] FIGURE 9 shows a perspective view of a T-beam used in the panel-to- wall assemblies of Figures 8A to 8C;

[00043] FIGURES 10A to 10C show schematic sectional views of the floor panel of Figure 1 in example panel-to-wall assemblies with a prestressed concrete precast beam; [00044] FIGURES 1 1 A to 1 1 C show schematic sectional views of the floor panel of Figure 1 in example panel-to-panel assemblies with a precast beam;

[00045] FIGURES 12A to 12C show schematic sectional views of the floor panel of Figure 1 in example panel-to-panel assemblies with a T-beam;

[00046] FIGURES 13A to 13C show sectional side views of the floor panel of

Figure 1 in example panel-to-panel assemblies with a prestressed concrete precast beam;

[00047] FIGURE 14 shows an elevation view of a second embodiment of a floor panel;

[00048] FIGURE 15 shows a front view of the floor panel shown in Figure 14;

[00049] FIGURE 16 shows a perspective view of the floor panel of Figure 14;

[00050] FIGURES 17A and 17B show schematic sectional views of the floor panel of Figure 14 in example panel-to-wall assemblies with a precast beam;

[00051 ] FIGURES 18A and 18B show schematic sectional views of the floor panel of Figure 1 in example panel-to-wall assemblies with a T-beam;

[00052] FIGURE 19 shows a perspective view of a T-beam used in the panel- to-wall assemblies of Figures 18A and 18B;

[00053] FIGURES 20A and 20B show schematic sectional views of the floor panel of Figure 14 in example panel-to-wall assemblies with a prestressed concrete precast beam; and

[00054] FIGURES 21 A and 21 B show schematic sectional views of the floor panel of Figure 14 in example panel-to-panel assemblies

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[00055] Referring to Figures 1 to 3, a prefabricated floor panel 100 that is adapted for use in a flooring system comprises a first, top board 120 and a second, bottom board 140 that are spaced apart from each other. The boards 120, 140 may be formed from a concrete-based or cement-based material, and in one embodiment are magnesium oxide (MgO) boards. The boards 120, 140 may alternatively comprise fibre cement or autoclaved aerated concrete. In another embodiment, each board 120, 140 is preferably an Oriented Strand Board (OSB), though other wood-based materials may be used, such as plywood or particle board. Each board 120, 140 preferably has a thickness from about 3mm to about 40mm. The top board 120 may be thicker than the bottom board 140. or alternatively, the boards may have the same thickness, or In one embodiment, the top board 120 has a thickness of about 32mm, while the bottom board 140 has a thickness has a thickness between 4mm and 8mm, and preferably about 4mm. In other embodiments, the thickness of the first, top board may be the same as the thickness of the second, bottom board, or the bottom board 140 may be thicker than the top board 120. The first and second boards 120, 140 may be spaced apart from each other by a distance from about 150mm to about 450mm. In one embodiment, the boards are spaced apart from each other by a distance of about 248mm.

[00056] In the space 130 between the top board 120 and bottom board 140, there is provided a spacing element in the form of a structural reinforcement 160. The structural reinforcement 160 is connected to the top and bottom boards 120, 140 and may comprise an open web truss system of the type sold under the registered trade mark Posi-STRUT® which is owned by Mitek Holdings, Inc.

[00057] It will however be readily appreciated that, instead of or in addition to a Posi-STRUT®, the reinforcing structure may include any timber or steel support frame, for example having an l-shape cross-sectional area or a C-shape cross- sectional area. Alternatively other diagonally arranged structures may be used as the structural reinforcement.

[00058] As shown in Figure 2, the panel 100 includes a plurality of reinforcing structures 160 extending substantially along the length of the boards 120, 140. The reinforcing structures 160 are preferably spaced from each other by a distance from about 450mm to about 900mm. In one embodiment, the reinforcing structures are spaced from each other by a distance of about 555mm. The reinforcing structure 160 may have a hanger connection 162 along at least one side as shown in Figure 3 for allowing connection of the panel 100 to a wall or to an adjacent panel. In other embodiments of the panel, the hanger connection may not be provided. [00059] Still referring to Figure 2, the panel may be provided with an insulating material 180 in the space 130 between the two boards 120, 140. The insulating material 180 may comprise expanded polystyrene (EPS). The insulating material may additionally or alternatively include extruded polystyrene (XPS). The insulating material is preferably injected into a space between the two boards. The insulating material can additionally or alternatively include glass insulation, fibreglass material. In some embodiments, the space 130 between the boards 120, 140 and the reinforcing structures 160 may simply be filled with air. Figures 4A to 4D illustrate different insulating materials that can be provided in the space 130.

[00060] Referring to Figure 4A, the space 130 between the two boards 120, 140 is filled by glass wool insulation 182. Instead of glass wool insulation, the space between the two boards 120, 140 may be filled by a rockwool insulation or polyester insulation.

[00061 ] Referring to Figure 4B, an insulating foil 184 is provided in the space between the two boards 120, 140. The foil 184 is attached to the top board 120.

[00062] Referring to Figure 4C, the space between the two boards 120, 140 is at least partially filled with an expanded polystyrene insulating material 186. The expanded polystyrene is held in place in the space between neighbouring reinforcing structures 160.

[00063] Referring to Figure 4D, the space 130 between the two boards 120, 140 is filled with a foam insulating material 188, which is sprayed or injected into the space between the two boards 120, 140.

[00064] As shown schematically in Figures 5A and 5B, the floor panel 100 is provided with an inlet aperture 1 10 in the top board 120 and an outlet aperture 1 15 in the bottom board 140. A drain 1 1 1 is mounted in the inlet aperture 1 10 and is in fluid communication with the outlet aperture 1 15. Particularly, piping 1 50 is provided in the space 130 between the first and second boards 120, 140, to connect the inlet aperture 1 10 and drain 1 1 1 to the outlet aperture 130. The piping 150 forms a conduit or channel between the inlet aperture 1 10 and outlet aperture 1 15 to provide the fluid communication between the inlet aperture 1 10 and outlet aperture 130. In this configuration, the inlet aperture 1 10, the drain 1 1 1 , the outlet aperture 130, and the piping 150 provide internal plumbing for the prefabricated floor panel 100. The piping 150 can extends beyond the outlet aperture 1 15 to a suitable drainage point as shown in Figure 5A. The inlet aperture 1 10, outlet aperture 120 and/or space 180 between the first and second boards 120, 140 could be used for any type of piping or cabling. For example, in addition to the piping 150 shown, other purposes include electronic cabling or optical fibre cabling.

[00065] Figures 6A and 6B show different views of the drain 1 1 1 , which is mounted in the inlet aperture 1 10. The drain 1 1 1 has a hollow body 1 12 with an entry opening 1 14 on one side of the hollow body 1 12, and an exit opening 1 16 (shown in Figure 6B) on an opposite side of the hollow body 1 12. The hollow body 1 12 is provided with a lip 1 18 surrounding the entry opening 1 14, which is adapted to sit substantially flush with the top board of the prefabricated panel when the drain is positioned in the inlet aperture 1 10 in the floor panel. The entry opening 1 14 is larger than the exit opening 1 16.

[00066] As shown in Figure 5A, the panel 100 rests against a precast beam 400, with the hanger connection 162 of the reinforcing structure engaging the precast beam 400. A timber packer 440 is provided in the space between the precast beam 400 and the hanger connection 162 of the panel 100 to provide support for the hanger connection 162 on the precast beam 400. The panel 100 is secured to a side face of the precast beam 400 via a bolt 460, such as a Dynabolt™. The precast beam 400 supports a wall 300.

[00067] Referring to Figures 7A to 7C the precast beam 400 supporting the wall 300 can be secured to the ground in one of a variety of configurations. For example, the precast beam 400 can be secured to the ground using a screw pile. The screw pile may be a 'twin fin' type screw pile 520, such as a Katana™ Pile made by Katana Foundations Australia as shown in Figure 7A. Alternatively, a pile 540 having a plurality of steel tubes, such as a Surefoot™ pile, may be used as shown in Figure 7B. Where a screw pile is used, a thick galvanized steel cap plate 510 is provided to secure the screw pile to a side face and the lower face of the precast beam 400. Alternatively, the precast beam 400 can be secured to the ground using a bored pier 560 as shown in Figure 7C. Where the bored pier 560 is used, a dowel 530 is provided for securing the precast beam 400 and the bored pier 560 through the hanger connection of the panel 100. In one embodiment, the wall 300 is a brick veneer wall having inner and outer wall sections 310 and 320, with space 330 between the inner and outer wall sections 310, 320. The wall 300 shown in Figures 7 A to 7C is an exterior wall of a building, with compacted backfill 350 shown adjacent the exterior surfaces of the wall 300 and the upper ends of the respective piles 520, 540 or bored pier 560.

[00068] The precast beam 400 of Figure 7A to 7C may be replaced by a steel T-beam 600 as shown in Figures 8A to 8C and Figure 9, or by a prestressed concrete pre-cast beam 700 as shown in Figures 10A to 10C. Similar to the embodiments described with reference to Figures 7A to 7C, the steel T-beam plate 600 and the prestressed concrete pre-cast beam 700 can be secured to the ground using a screw piles, such as the Katana™ screw pile 520 or the Surefoot™ pile 540, or using a bored pier 560.

[00069] The T-beam is formed by an orthogonal arrangement of two plates 610 and 630, as shown in Figure 9. The plates 610, 630 are preferably made of a metal, more preferably steel, but may be made of other materials, such as MgO. The two plates 610 and 630 may be secured together or formed such that the arrangement forms a T-shape in cross-section by any convenient method. In the case of steel or other metal plates, the plates may be secured together by welding. Plates made of MgO may be laminated together. In other embodiments, the MgO plates can be arranged to form a cross-section having an l-shape, C-shape, or box shape.

[00070] Referring to Figures 8A to 8C, a floor panel 100' according to another embodiment is shown connected to a steel T-beam 600. Similar to the panel 100 shown in Figures 1 to 3, the panel 100' of this embodiment has a top board 120 spaced apart from the bottom board 140, with a reinforcing structure 160 provided between the boards 120, 140. However, unlike the panel 100 of Figures 1 to 3, the reinforcing structure 160 of the panel 100' of this embodiment does not have a hanger connection. When the panel 100' engages the T-beam, 600, the panel rests substantially flush against a face of the T-beam 600.

[00071 ] Referring to Figure 9, the T-beam 600 is provided with slots 620 in a section of the T-beam that is configured to engage the screw pile or bore pier. Fastening means, such as a screw or a bolt, secures the T-beam 600 to the screw- pile or bore pier through the slots 620. The slots 620 allow the T-beam to be horizontally adjusted in a direction 640 along the length of the T-beam during assembly.

[00072] The example assemblies shown in Figures 10A to 10C are similar to the example assemblies disclosed with reference to Figures 7A to 7C and like reference numerals indicate like parts. However, instead of a precast beam 400 as disclosed with reference to Figures 7A to 7C, the example assemblies of Figures 10A to 10C use a prestressed concrete pre-cast beam 700. While the embodiments with the prestressed concrete precast beam 700 are generally similar to the embodiments with the precast beam 400, for the embodiment of Figure 10C where a bored pier 560 is used, a dowel is not provided unlike for when the bored pier 560 is used for a precast beam.

[00073] Configurations similar to the panel-to-wall assemblies described with reference to Figures 7A to 10C above can also be used for panel-to-panel assemblies for creating a floor system from the prefabricated panels of the present invention. Figures 1 1 A to 1 1 C, 12A to 12C and 13A to 13C respectively show example panel-to-panel assemblies in accordance with embodiments of the present inventions. In these figures, like reference numerals as those used in Figures 7A to 10C parts indicate like parts.

[00074] Referring to Figures 1 1 A to 1 1 C, the adjacent panels 100 can be connected to form a floor system using the precast beam 400. The precast beam 400 can be secured to ground using a screw pile, such as a Katana™ screw pile 520, or a Surefoot™ pile 540, or a bored pier 560. Similar to the embodiments described with reference to Figures 7A to 7C, where a screw pile 520, 540 is used, a bolt, such as a Dynabolt™ may be used to secure each respective panel 100 to a side face of the precast beam 400. Where a bored pier 560 is used, a dowel can be provided through the hanger connection of the respective panel 100 and through the precast beam 400 into the bored pier 560 to secure the respective panel 100 to the bored pier 560. In these embodiments, the hanger connection of each panel 100 and the precast beam 400 are dimensioned such that, when hanger connections of adjacent panels 100 are positioned on a precast beam 400, the reinforcing structures of each panel are substantially adjacent to a side face of the precast beam 400, and hanger portions of adjacent panels 100 form a substantially continuous surface on the precast beam 400.

[00075] Referring to Figures 12A to 12C, adjacent panels 100' of the embodiment without hanger connections can be connected to form a ground slab using a T-beam 600. The T-beam 600 can be secured to ground using a screw pile, such as the Katana™ screw pile 520, or a Surefoot™ pile 540, or a bored pier 560.

[00076] Referring to Figures 13A to 13C, adjacent panels 100 can be connected to form a floor system using a prestressed concrete precast beam 700. The example assemblies of these embodiments are generally the same as the example assemblies described with reference to Figures 1 1 A to 1 1 C. However, for the embodiment of Figure 1 1 C where a bored pier 560 is used, a dowel is not provided unlike for when the bored pier 560 is used for a precast beam.

[00077] Referring to Figures 14 to 16, another embodiment of a prefabricated floor panel 800 adapted for use in a flooring system is shown. The floor panel 800 comprises a first, top board 820 and a second, bottom board 840 that are spaced apart from each other.

[00078] The floor panel 800 differs from the embodiment of Figures 1 to 3 in that the space 830 between the first and second boards 820, 840 is completely filled with insulating material 860, and there is no additional structural reinforcement.

[00079] Surprisingly, it has been found that with an appropriate choice of materials and thicknesses for the first and second boards 820, 840, and the insulating material 860, the floor panel 800 can withstand loads of up to 7kN/m ² . For most residential purposes, it is typically sufficient for the floor panels to withstand loads of up to about 3kN/m ² .

[00080] In one embodiment, the first and second boards 820, 840 are preferably magnesium oxide (MgO) boards, though they may be formed from other concrete-based or cement-based materials, such as fibre cement or autoclaved aerated concrete. [00081 ] In another embodiment, each board 820, 840 is preferably an Oriented Strand Board (OSB), though other wood-based materials may be used, such as plywood or particle board.

[00082] Each board 820, 840 preferably has a thickness from about 3mm to about 40mm. The top board 820 may be thicker than the bottom board 840, or alternatively, the boards may have the same thickness. In one embodiment, the top board 820 has a thickness of between about 18mm and 24mm, while the bottom board 840 has a thickness has a thickness between about 4mm and 12mm. In other embodiments, the thickness of the first, top board may be the same as the thickness of the second, bottom board, or the bottom board 840 may be thicker than the top board 820.

[00083] The insulating material 860 in the space 830 between the first and second boards 820, 840 may have a thickness from about 100mm to about 300mm. In one embodiment, the boards are spaced apart from each other by a distance of between 150mm and about 200mm.

[00084] The insulating material 860 in the space 830 between the two boards 820, 840 preferably comprises polystyrene, either in the form of expanded polystyrene (EPS) or extruded polystyrene (XPS), or another foam insulating material. The insulating material 860 may be injected, or sprayed into the space 830 between the two boards 820, 840. The insulating material can additionally, or alternatively, include glass insulation, such as glass wool insulation, fibreglass material, rockwool insulation, or polyester insulation.

[00085] The floor panel 800 may also be provided with a connecting structure 862 on at least one side edge to assist in connecting the floor panel 800 to a wall, or to another floor panel. The connecting structure 862 may be a hanger connection similar to the hanger connection of the embodiment of Figures 1 to 3, or another element, such as a concrete beam or steel plate which can be bolted or other secured to a beam of a wall or a similar beam of steel plate on an adjacent floor panel. [00086] Figure 17A shows the floor panel 800 secured to a precast beam 400 of a wall structure 300 by a bolt 920, such as a Dynabolt™ or Chemset™ bolt which extends through the connecting structure 862 and the precast beam 400.

[00087] The precast beam 400 can be secured to the ground in one of a variety of configurations. For example, the precast beam 400 can be secured to the ground using a screw pile. The screw pile may be a 'twin fin' type screw pile 520, such as a Katana™ Pile made by Katana Foundations Australia as shown in Figure 17A. Alternatively, a pile having a plurality of steel tubes, such as a Surefoot™ pile, may be used in similar manner to that shown in Figure 7B. Alternatively, the precast beam 400 can be secured to the ground using a bored pier 560 in similar manner to that shown in Figure 7C.

[00088] Figure 17B shows the floor panel 800 secured to the upper end of a bored pier 560 on which a wall structure 300 is supported. The floor panel 800 may be secured to the bored pier by bolts 980 which extend completely through the first and second boards 820, 840 and the insulating material 860 of the panel into the upper end of the bored pier 560.

[00089] The precast beam 400 of Figure 17A and 17B may be replaced by a T- beam plate 600 as shown in Figures 18A, 18B and 19 in similar manner to that described with reference to Figures 8A, 8B, 8C and Figure 9, and corresponding reference numerals have been applied to corresponding parts. Alternatively, the precast beam 400 of Figure 17A and 17B may be replaced by a prestressed concrete pre-cast beam 700 as shown in Figures 20A and 20B in similar manner to that described with reference to Figures 10A, 10B and 10C, and corresponding reference numerals have been applied to corresponding parts. Similar to the embodiments described with reference to Figures 17A and 17B, the steel T-beam plate 600 and the prestressed concrete pre-cast beam 700 can be secured to the ground using a screw pile 940, such as the Katana™ screw pile 940 as shown in Figures 18A and 20A, by another type of pile, such as a Surefoot™ pile (not shown), or by using a bored pier 960 as shown in Figures 18B and 20B.

[00090] The T-beam shown in Figure 19 is formed by an orthogonal arrangement of two plates 610 and 630, as shown in Figure 19. The plates 610, 630 are preferably made of a metal, more preferably steel, but may be made of other materials, such as MgO. The two plates 610 and 630 may be secured together or formed together such that the arrangement forms a T-shape in cross-section by any convenient method. In the case of steel or other metal plates, the plates may be secured together by welding. Plates made of MgO may be laminated together. In other embodiments, the MgO plates can be arranged to form a cross-section having an l-shape, C-shape, or box shape.

[00091 ] Figures 18 A and B show the floor panel 800 connected to a steel T- beam 600. When the panel 800 engages the T-beam, 600, an end surface of the panel rests substantially flush against the vertical plate 630 of the T-beam 600, and the second, bottom board of the floor panel 800 rests on the horizontal plate 610 of the T-beam 600 .

[00092] Referring to Figure 9, the T-beam 600 is provided with slots 620 in a section of the T-beam that is configured to engage the screw pile or bore pier. Fastening means, such as a screw or a bolt, secures the T-beam 600 to the screw- pile or bore pier through the slots 620. The slots 620 allow the T-beam to be horizontally adjusted in a direction 640 along the length of the T-beam during assembly.

[00093] The example assemblies shown in Figures 20A and 20B are similar to the example assemblies disclosed with reference to Figures 17A and 17B and like reference numerals indicate like parts. However, instead of a precast beam 900 as disclosed with reference to Figures 17A and 17B, the example assemblies of Figures 20A and 20B use a prestressed concrete pre-cast beam 950.

[00094] Referring to Figures 21 A and 21 B, adjacent panels 800, 800' can be connected to form a floor system. In Figure 21 A a connecting structure 862 is used. The connecting structure 862 can be secured to ground using a screw pile 520, such as a Katana™ screw pile as shown in Fig 21 A, or another type of pile, such as a Surefoot™ pile (not shown). In Figure 21 B the adjacent panels 800, 800' are secured to a bored pier 560. Similar to previous embodiments where a screw pile 520 is used, a bolt, such as a Dynabolt™ or Chemset™ bolt may be used to secure one panel 800 to an adjacent panel 800'. Where a bored pier 560 is used, a dowel 530 can be provided through each respective panel 800, 800' and into the bored pier 560 to secure the respective panel 100 to the bored pier 560.

[00095] In another embodiment (not shown), adjacent panels 800, 800' can be connected to form a floor system using a T-beam 600 in similar manner to that described with reference to Figures 18A and 18B.

[00096] It will be appreciated that various features of the different embodiments embodiments in the different drawings may be incorporated in other embodiments. For example, the embodiment of the floor panel 800 shown in Figures 14 to 16 could incorporate a drainage system having an inlet aperture, an outlet aperture and a conduit or piping as described with reference to Figures 5A to 5D.

[00097] Preferred embodiments have been described above by way of non- limiting example only. It will be readily appreciated that modifications can be made to the invention without departing from the scope of the invention.