Residential basement flooring system and method using pier capitals for supporting pre-cast slabs

Abstract

A residential flooring system is provided for use with expansive soil. The system includes a plurality of pre-cast slabs of hardened material such as concrete with or without structural members such as rebar and/or wire mesh. The system also includes structural members such as drilled piers, helical screws, caissons, or the like that contact the expansive soil and extend upward away from the expansive soil. The structural members have an upper contact surface that extends above the soil. Weight bearing members are attached to the structural members such as to their upper contact surfaces. Each of the weight bearing members includes a bearing surface that is larger (e.g., has a greater area) than the upper contact surface of the pier or other structural member. The pre-cast slabs are positioned on the weight bearing surfaces so that the slabs are supported by the structural members via the weight bearing members.

1 . A residential flooring system for use with in expansive soil, comprising: 
 a plurality of pre-cast slabs of hardened material;    structural members contacting the expansive soil and extending upward away from the expansive soil, the structural members having an upper contact surface; and    a plurality weight bearing members attached to the upper contact surface, wherein each of the weight bearing members comprises a weight bearing surface that is larger than the upper contact surface and wherein the pre-cast slabs are supported by the structural members by abutting the weight bearing surfaces of the weight bearing members.    
   
   
       2 . The flooring system of  claim 1 , wherein the pre-cast slabs and weight bearing members are formed of concrete.  
   
   
       3 . The flooring system of  claim 1 , wherein the weight bearing members comprise sides that extend upward and outward from the upper contact surfaces of the structural members.  
   
   
       4 . The system of  claim 3 , wherein the weight bearing members are frustoconical in shape and the sides extend upward and outward from the upper contact surfaces at an angle selected from the range of 40 and 80 degrees.  
   
   
       5 . The system of  claim 1 , wherein each of the pre-cast slabs comprises a planar member, a pair of edge beams extending from the planar member, and two or more monolithic ribs extending in a spaced-apart manner from the planar member between the edge beams.  
   
   
       6 . The system of  claim 5 , wherein the edge beams of each of the pre-cast slabs abuts the weight bearing surfaces such that the pre-cast slabs are supported above the expansive soil.  
   
   
       7 . The system of  claim 5 , wherein the pre-cast slabs further comprise insulation positioned between adjacent pairs of the ribs.  
   
   
       8 . The system of  claim 1 , further comprising a plurality of wall sections positioned upon the pre-cast slabs, whereby the wall sections are supported by the pre-cast slabs, the weight bearing members, and the structural members.  
   
   
       9 . A modular flooring system, comprising: 
 a plurality of concrete slabs comprising a planar member, a pair of edge beams extending from the planar member, and monolithic ribs extending in a spaced-apart manner from the planar member between the edge beams;    piers extending into soil and extending above the soil to expose a circular contact surface having a diameter; and    capitals extending from each of the piers comprising a circular weight bearing surface contacting the edge beams to support the concrete slabs, wherein a diameter of each of the weight bearing surface is greater than the diameter of the circular contact surface.    
   
   
       10 . The system of  claim 9 , wherein the diameter of the weight bearing surface is greater than about 20 inches and less than about 24 inches.  
   
   
       11 . The system of  claim 9 , wherein the capitals and the piers are formed of concrete that is provided in separate pourings.  
   
   
       12 . The system of  claim 9 , wherein the capitals are frustoconical in shape.  
   
   
       13 . The system of  claim 9 , where at least some of the capitals support at least two of the concrete slabs.  
   
   
       14 . The system of  claim 9 , further comprising a wall positioned on the concrete slabs on a surface opposite the capitals.  
   
   
       15 . The system of  claim 9 , wherein the concrete slabs further comprise insulating foam between adjacent pairs of the ribs.  
   
   
       16 . A method of assembling a modular residential flooring system for use with expansive soil, comprising: 
 casting a plurality of concrete slabs at a first location;    transporting the slabs to a second location;    at the second location, providing a plurality of structural members extending into the soil and extending upward out of the soil to expose a support portion;    forming weight bearing members on the support portion of the structural members, wherein each of the weight bearing members comprises a support surface with an area greater than the support portion; and    positioning the concrete slabs adjacent each other and in contact with the support surfaces of the weight bearing members, wherein the concrete slabs form a substantially planar surface and are supported by the structural members via the weight bearing members.    
   
   
       17 . The method of  claim 16 , further comprising forming foundation wall sections at a third location, transporting the wall sections to the second location, and positioning the wall sections in vertical orientation on the concrete slabs.  
   
   
       18 . The method of  claim 16 , wherein the casting of the concrete slabs comprises providing a form and filling the form with concrete, the form having internal surfaces such that each of the concrete slabs comprises a planar member, a pair of edge beams extending from the planar member, and monolithic ribs extending in a spaced-apart manner from the planar member between the edge beams.  
   
   
       19 . The method of  claim 18 , wherein the casting further comprises providing in each of the concrete slabs insulation between adjacent ones of the ribs.  
   
   
       20 . The method of  claim 16 , wherein the providing of structural members comprises spacing the structural members apart a distance such that at each of the concrete slabs is supported by at least four of the structural members.