Flooring sheet and modular flooring system

Abstract

A fibre reinforced cement flooring sheet ( 1 ) that is suitable for use in wet area flooring, is lower in density than conventional compressed fibre cement wet area flooring, and is nailable. The flooring sheet ( 1 ) includes connecting means ( 2 ) on longitudinal edges permitting the sheet to be interlockingly engaged with adjacent sheets to form a substantially coplanar support surface, suitable for use in wet areas.

1 . A fibre reinforced cement bound flooring sheet that is suitable for use in domestic wet area flooring, is lower in density than conventional compressed fibre cement wet area flooring, and is nailable, wherein said flooring sheet has a bending strength sufficient to withstand a uniformly distributed load of up to 5 kPa when supported at 450 mm centres along its length. 
   
   
       2 . A flooring sheet according to  claim 1 , wherein said sheet includes connecting means at opposed edges, such that the sheet may be interlockingly engaged with an adjacent complementary sheet to form a coplanar support surface. 
   
   
       3 . A flooring sheet according to  claim 1 , having a dry density of less than around 1.5 g/cm 3 . 
   
   
       4 . A flooring sheet according to  claim 1 , having a dry density of less than around 1.25 g/cm 3 . 
   
   
       5 . A flooring sheet according to  claim 1 , having a thickness of between 10 mm and around 30 mm. 
   
   
       6 . A flooring sheet according to  claim 1 , having a thickness of between 16 mm and around 22 mm. 
   
   
       7 . A flooring sheet according to  claim 1 , having a thickness of around 19 mm. 
   
   
       8 . A flooring sheet according to  claim 1 , having a bending strength sufficient to withstand a uniformly distributed load of up to 5 kPa when supported at 450 mm centres along its length, when dry or saturated with water. 
   
   
       9 . A flooring sheet according to  claim 1 , having a bending strength sufficient to withstand a uniformly distributed load of up to 9 kPa when supported at 450 mm centres along its length, when dry or saturated with water. 
   
   
       10 . A flooring sheet according to  claim 1 , having at least one surface sealed with a surface coating adapted to provide resistance to moisture absorption. 
   
   
       11 . A flooring sheet according to  claim 10 , wherein said surface coating is formed from a polymeric material. 
   
   
       12 . A flooring sheet according to  claim 10 , wherein said surface coating is applied to an outer surface of the sheet. 
   
   
       13 . A flooring sheet according to  claim 10 , wherein said surface coating is applied to substantially all surfaces of the sheet. 
   
   
       14 . A flooring sheet according to  claim 10 , wherein said surface coating is adapted to bond to tile adhesives and bedding materials. 
   
   
       15 . A flooring sheet according to  claim 1 , being reinforced with a substantially continuous layer of reinforcing material. 
   
   
       16 . A flooring sheet according to  claim 15 , wherein said reinforcing material is formed from one or more materials selected from the group consisting of metal, plastics, inorganic fibres, polymeric fibres, glass fibres, polymer-coated glass fibres and carbon fibres. 
   
   
       17 . A flooring sheet according to  claim 15 , wherein said reinforcing layer of reinforcing material is positioned between the outer surfaces of the sheet. 
   
   
       18 . A flooring sheet according to  claim 17 , wherein said reinforcing material is embedded between outer layers during green forming of said sheet. 
   
   
       19 . A flooring sheet according to  claim 17 , wherein said reinforcing material forms an outer surface of the sheet. 
   
   
       20 . A flooring sheet according to  claim 17 , wherein said reinforcing material is sandwiched between outer layers of the sheet after curing of the outer layers. 
   
   
       21 . A flooring sheet according to  claim 17 , wherein said reinforcing material is adapted to be alkali-resistant. 
   
   
       22 . A modular flooring system for a wet area, said flooring system including at least one flooring sheet, and complementary connecting means permitting said flooring sheet to be interlockingly engaged with an adjacent sheet to form a substantially coplanar support surface, wherein said at least one flooring sheet has a bending strength sufficient to withstand a uniformly distributed load of up to 5 kPa when supported at  450  mm centres along its length. 
   
   
       23 . A modular flooring system according to  claim 22 , wherein said adjacent sheet is formed substantially from particle board. 
   
   
       24 . A modular flooring system according to  claim 22 , wherein said adjacent sheet is a flooring sheet having a bending strength sufficient to withstand a uniformly distributed load of up to 5 kPa when supported at 450 mm centres along its length. 
   
   
       25 . A modular flooring system according to  claim 22 , wherein the flooring sheets are generally rectangular and wherein the connecting means are disposed on at least one longitudinal edge of each sheet. 
   
   
       26 . A modular flooring system according to  claim 25 , wherein the connecting means extend along both longitudinal edges of each flooring sheet. 
   
   
       27 . A modular flooring system according to  26 , wherein said connecting means include tongue and groove formations disposed respectively on opposite longitudinal edges of each flooring sheet, whereby the tongue on one sheet and the groove on the adjacent sheet cooperate to provide secure interlocking engagement between adjoining sheets. 
   
   
       28 . A modular flooring system according to  claim 27 , wherein the tongues are configured with protrusions along their lengths and the groove are configured with corresponding recesses along their lengths, thereby to provide a locking mechanism resisting disengagement of the adjoining sheets. 
   
   
       29 . A modular flooring system according to  claim 27 , wherein a longitudinal cavity is formed between the interlocking tongues and grooves, to permit insertion of a sealant or a glue between the adjoining sheets. 
   
   
       30 . A modular flooring system according to  claim 26 , wherein said connecting means include grooves disposed respectively on opposite longitudinal edges of each flooring sheet and a complementary joining member adapted for engagement with the grooves to provide secure interlocking engagement between adjoining sheets. 
   
   
       31 . A modular flooring system according to  claim 30 , wherein the joining member includes an elongate strip of joining material. 
   
   
       32 . A modular flooring system according to claim  59 , wherein the flooring sheets are formed substantially from a fibre reinforced cement formulation including microspheres, pearlite or volcanic ash. 
   
   
       33 . A method of installing a modular flooring system comprising the steps of aligning two or more of the flooring sheets on a support platform and engaging connecting means on the adjoining sheet so as to form a coplanar support surface wherein each of the flooring sheets has a bending strength sufficient to withstand a uniformly distributed load of up to 5 kPa when supported at 450 mm centres along its length. 
   
   
       34 . A method according to  claim 33 , wherein the support platform is formed from spaced apart framing members. 
   
   
       35 . A method according to  claim 33 , including the further comprising the step of securing the flooring sheets to the support surface. 
   
   
       36 . A method according to  claim 35 , wherein the flooring sheets are secured to the support surface by fastening means selected from the group consisting of nailing, screwing and gluing. 
   
   
       37 . A method according to  claim 33 , wherein the connecting means are formed using a production technique selected from the group consisting of machining, casting, extruding, and fastening.