Building structure

Abstract

There is disclosed a building structure comprising: a footing arrangement; a plurality of wall assemblies supported by the footing arrangement; a compacted hardcore layer surrounded by the plurality of wall assemblies; a load bearing slab layer arranged above and supported by the compacted hardcore layer, wherein: the load bearing slab layer comprises an expanded foam material.

Description

BUILDING STRUCTURE

[0001] The present disclosure relates to a building structure and a method of producing a building structure.Background

[0002] Conventionally, building structures comprise subfloor structures which provide support to the floor of the building structures. Various forms of subfloors are known, and have changed and developed as building techniques have changed overtime. Typically, building structures comprise a layer of concrete as part of the subfloor. The concrete layer performs the function of a load bearing layer which provides a base of support and bears the loads that are to be placed on the floor of the building structure.

[0003] In order to produce the concrete layer in the form of a monolithic (i.e., single structure) layer, concrete is typically mixed on-site and poured in a manner appropriate for producing the desired concrete layer. Large and / or expensive machinery may be required in order to produce the concrete layer. Producing the concrete layer also requires significant time, including the time needed for the concrete to set. The production of the concrete layer may also be hindered by adverse weather conditions, such as rain, adding further to the time taken up in the production of the concrete layer.

[0004] Even aside from concrete, typical building materials can be heavy and the construction of the building structure is a significant task requiring time.

[0005] The present applicant has recognised the need for alternative solutions to providing building structures which address at least some of these shortcomings.Summary

[0006] According to a first aspect of the present disclosure, there is provided a building structure comprising: a footing arrangement; a plurality of wall assemblies supported by the footing arrangement; a compacted hardcore layer surrounded by the plurality of wall assemblies; a load bearing slab layer arranged above and supported by the compacted hardcore layer, wherein: the load bearing slab layer comprises an expanded foam material.

[0007] Advantageously, there is provided a building structure in which the load bearing slab layer comprises an expanded foam material. Accordingly, there is provided an alternative load bearing layer to a concrete load bearing layer. The load bearing slab layer comprising expanded foam has advantages in its own right even when not directly compared to concrete. A layer comprising expanded foam may be pre prepared. For example, pieces of the load bearing slab layer may be produced off-site, ready to be transported to the building site and installed. For example, the shortcomings of using concrete as a material for a load bearing layer may be avoided. For example, producing the load bearing slab layer comprising the expanded foam layer may be cheaper, faster and / or more cost effective.

[0008] Furthermore, it will be appreciated that expanded foam materials may provide greater thermal insulation than a concrete layer for example. While additional insulation layers may also be included in the subfloor arrangement of the building structure, the load bearing slab layer provides the dual functions of load bearing and also thermal insulation. In addition, advantageously, expanded foam materials may provide appropriate, or even improved, compressive strength properties in the context of load bearing slab layers of a building structure.

[0009] Optionally, the load bearing slab layer is in the form of a load bearing slab assembly comprising a plurality of load bearing slab elements.

[0010] Advantageously, the plurality of load bearing slab elements may easily be transported to the building site. The load bearing slab elements may be handled easily (due to being relatively lightweight, for example), and may be manipulated by hand. For example, the load bearing slab elements may be assembled into the load bearing slab assembly without the need to deploy more complex processes such as preparing a concrete mixture, for example.

[0011] Optionally, the load bearing slab layer defines a top portion of a concrete monolithic layer free subfloor; and the compacted hardcore layer defines a bottom portion of the concrete monolithic layer free subfloor.

[0012] Advantageously, the load bearing slab layer and the compacted hardcore layer form at least some of the main components of the subfloor, and the subfloor is concrete monolithic layer free. Accordingly, not only is the load bearing layer devoid of concrete, thus providing the above-described advantages, the entire subfloor is concrete monolithic layer free. This advantageously means that the shortcomings resulting from the use of concrete are avoided for the production of the entire subfloor. Therefore, the entire subfloor may be produced at a reduced cost, more quickly, and more efficiently.

[0013] Optionally, the building structure comprises a flooring layer arranged atop, and supported by, the load bearing slab layer.

[0014] Advantageously, the load bearing slab layer provides appropriate support for the flooring layer of the building structure. For example, the load bearing slab layer has the appropriate compressive strength. In addition, it is straightforward to create a flat surface with a load bearing slab layer comprising expanded foam.

[0015] Optionally, the building structure comprises an upper damp proof layer between the flooring layer and the load bearing slab layer.

[0016] Advantageously, there is placed a damp proof layer between the flooring layer and the load bearing slab layer so as to provide damp proofing.

[0017] Optionally, the upper damp proof layer extends into the plurality of wall assemblies.

[0018] Advantageously, such extension of the upper damp proof layer better protects the building structure from damp and / or water ingress by enhancing the damp proofing at a potential weak point (as it pertains to damp ingress) which is the wall assembly portion near to the ground level (e.g., near to the sub floor).

[0019] Optionally, the building structure comprises a lower damp proof layer between the compacted hardcore layer and the load bearing slab layer.

[0020] Advantageously, there may be provided a damp proof layer between the compacted hardcore layer and the load bearing slab layer alternatively, or in addition, tothe upper damp proof layer. In this manner, there is provided the option to supply more or less damp proofing, as desired, according to the local environment where the building structure is being installed. In some examples, the damp proofing is enhanced by providing both the upper and the lower damp proof layer.

[0021] Optionally, the load bearing slab layer has a thickness of between 0.02 meters and 0.35 meters, preferably between 0.025 meters and 0.3 meters.

[0022] Advantageously, such a thickness range provides that the expanded foam material provides the appropriate level of load bearing support, in some cases better support than a traditional concrete load bearing slab layer, while at the same time allowing the advantages of the use of the expanded foam material being realized.

[0023] Optionally, the expanded foam material comprises one of: Polystyrene; Polypropylene; and Phenolic foam.

[0024] Advantageously, a relatively cost effective foam material may be chosen. For example, Polystyrene may be the cheapest of these three materials, Polypropylene may be the next cheapest and Phenolic foam may be the most expensive of the three (although still relatively cost effective). Polystyrene may be least effective of the three in terms of thermal insulation (although still relatively very effective, e.g., as compared to concrete or other materials forming part of the subfloor), Phenolic foam may be most effective in terms of thermal insulation, and the effectiveness of Polypropylene may be in between Polystyrene and Phenolic foam in terms of thermal insulation. In this way a selection may be made according to need in which reduction in cost effectiveness is offset by an increase in effectiveness in thermal insulation.

[0025] According to a second aspect of the disclosure, there is provided a method of producing a building structure, the method comprising: providing a footing arrangement; providing a plurality of wall assemblies supported by the footing arrangement; providing a compacted hardcore layer surrounded by the plurality of wall assemblies; providing a load bearing slab layer arranged above and supported by the compacted hardcore layer, wherein: the load bearing slab assembly comprises an expanded foam material.

[0026] Advantageously, the method according to the second aspect provides for the production of the building structure according to the first aspect. Therefore, the method according to the second aspect allows for the advantages of the building structure according to the first aspect to be realized.

[0027] Optionally, in the method according to the second aspect, the load bearing slab layer is provided in the form of a load bearing slab assembly, and the method comprises: providing a plurality of load bearing slab elements; and assembling the load bearing slab layer using the load bearing slab elements.

[0028] Advantageously, assembling the load bearing slab layer with the load bearing slab elements provides for easier, time and cost efficient installation of the load bearing slab layer. For example, the load bearing slab layer can be pieced together without requiring a complicated process to mix and pour the concrete, for example. In addition, the assembly may be carried out in weather conditions which may otherwise hinder the installation of a concrete load bearing slab layer.

[0029] Optionally, in the method according to the second aspect, assembling the load bearing slab layer comprises positioning the load bearing slab elements by hand.

[0030] Advantageously, machinery for moving heavy items in not required for the assembly. Assembling by hand provides a level of flexibility and ease in installation not possible in the case of a concrete load bearing slab layer.

[0031] Optionally, the method according to the second aspect comprises cutting one or more of the load bearing slab elements to a respective desired size and shape prior to assembly into the load bearing slab layer.

[0032] Advantageously, the load bearing slab elements can easily be adapted such that there is provided enhanced flexibility in the shape / configuration / arrangement of the sub floor layer thus created.

[0033] Optionally, the method according to the second aspect comprises: providing the footing arrangement, the plurality of wall assemblies, the compacted hardcore layer andthe load bearing slab layer in a manner so as to provide a concrete monolithic layer free subfloor.

[0034] Advantageously, not only is the load bearing layer devoid of concrete, thus providing the above-described advantages, the entire subfloor is concrete monolithic layer free. This advantageously means that the shortcomings resulting from the use of concrete are avoided for the production of the entire subfloor. Therefore, the entire subfloor may be produced at a reduced cost, more quickly, and more efficiently.

[0035] Various other features and advantages will become apparent from the following description.Brief Description of the Drawings

[0036] Examples of the present disclosure will now be described with reference to the accompanying drawings, in which:

[0037] Figure 1 is a simplified schematic cross-sectional view of a building structure, according to examples;

[0038] Figure 2 is a simplified schematic plan view of a load bearing slab assembly, according to examples; and

[0039] Figure 3 is a flow diagram illustrating a method of producing a building structure, according to examples.Detailed Description

[0040] Figure 1 is a simplified schematic cross-sectional view of a building structure 100, according to examples. The building structure 100 comprises a footing arrangement 102, and a plurality of wall assemblies 104. The plurality of wall assemblies 104 are supported by the footing arrangement 102. The building structure 100 comprises a compacted hardcore layer 106 surrounded by the plurality of wall assemblies 104. The building structure 100 also comprises a load bearing slab layer 108 arranged above and supported by the compacted hardcore layer 106.

[0041] For example, the footing arrangement 102 may be in the form of slabs of a supportive material, which slabs are arranged so that they are positioned where the wall assemblies 104 are to be erected. In some examples, the footing arrangement 102 comprises concrete. In other examples, the footing arrangement may comprise a material other than concrete. For example, the footing arrangement may comprise slabs of natural stone.

[0042] Those skilled in the art will appreciate that the building structure 100 may have various numbers of wall assemblies, each wall assembly forming a respective side of the building structure 100. For example, in a simple case of a rectangular building structure in plan view, there may be four wall assemblies, one wall assembly for each of the sides of the building structure. Each wall assembly 104 may comprise an inner wall layer 104a and an outer wall layer 104b. In some examples, the inner wall layer 104a is an inner brickwork layer 104a, and the outer wall layer 104b is an outer brickwork layer 104b. For example, different kinds of bricks may be deployed for the inner and the outer layer, as appropriate. Other structures may exist between the inner wall layer 104a and the outer wall layer 104b, however, these are not indicated in Figure 1 for simplicity. For example, there may be an air cavity, an insulation layer, and the like. Those skilled in the art will appreciate that these are merely some examples of wall assemblies that may be included as part of the building structure 100.

[0043] For example, the compacted hardcore layer 106 comprises solid and stable material which serves to create a base of support as part of a sub floor structure for loadbearing. For example, the compacted hardcore layer 106 comprises material which does not easily degrade (for example, over the expected lifespan of the building structure 100). Various aggregates of material may be compressed in order to form the compacted hardcore layer 106. For example, a suitable, clean concrete rubble may be used. For example, pieces of bricks may be used. For example, material with gypsum may be avoided so as to avoid any adverse reactions. Those skilled in the art will be aware of the materials which are suitable for a hardcore material to be compressed into the compacted hardcore layer 106. Typically, chemically inert materials are chosen.

[0044] As regards the compacted hardcore layer 106, those skilled in the art will also appreciate that the shape and size of the aggregates used is also a factor to consider. In addition, the thickness of the compacted hardcore layer 106 may be chosen inaccordance with the desired characteristics of the building structure 100, for example an amount of load expected to be supported by the subfloor and the like.

[0045] The compacted hardcore layer 106 supports the load bearing slab layer 108. As previously described, the load bearing slab layer 108 comprises an expanded foam. In some examples, the load bearing slab layer 108 comprises one of: Polystyrene; Polypropylene; and Phenolic foam. For example, the load bearing slab layer 108 may comprise expanded polystyrene (EPS), expanded polypropylene (EPP), Phenolic foam, and the like.

[0046] Advantageously, there is used a load bearing slab layer comprising expanded foam, which may replace the traditional concrete monolithic load bearing slab of the prior art. Among the many advantages, a notable aspect is the benefits gained by avoiding the use of concrete. For example, a concrete slab layer would not be pre-prepared offsite, whereas a layer comprising expanded foam can be pre-prepared offsite.

[0047] For example, pouring concrete to create a monolithic slab layer may be subject to delay due to inclement weather, among other factors. Concrete would also need to be mixed on-site and poured appropriately, which requires time and labour. Furthermore, time is required for the concrete to set. Such disadvantages can be reduced or entirely avoided with the use of expanded foam materials. For an expanded foam slab layer, material does not need to be prepared on site. Interference from weather conditions is reduced because rain and the like cannot interfere with a mixing process, and the like, in the context of expanded foam. Time and labour required for pouring a concrete slab is advantageously replaced with a simpler and faster process of simply positioning the expanded foam material. For example, producing the load bearing slab layer comprising the expanded foam layer may be cheaper, faster and / or more cost effective, as compared to a concrete load bearing slab layer.

[0048] Those skilled in the art will also appreciate that an expanded foam material, such as EPS, EPP and Phenolic foam, for example, may provide better thermal insulation than a concrete slab of equal thickness. Therefore, using the load bearing slab layer 108 comprising expanded foam improves thermal insulation in comparison to a concrete slab as the load bearing slab. These materials are also relatively cost effective and light compared to concrete.

[0049] Also, advantageously, it is possible to deconstruct / remove the load bearing slab layer 108, unlike a concrete load bearing slab layer, which would have to be broken up using heavy machinery, for example. In addition, advantageously, expanded foam materials may provide appropriate, or even improved, compressive strength properties in the context of load bearing slab layers of a building structure. In some examples, the load bearing slab layer 108 has a compressive strength which is suitable for domestic applications. However, in some examples, the load bearing slab layer 108 has a compressive strength which is even suitable for commercial building structures (e.g., building structures with notably higher demands in terms of the load bearing the floor must accommodate). For example, the load bearing slab layer 108 may be configured (e.g., by selecting an appropriate expanded foam and an appropriate thickness of said expanded foam) to provide appropriate compressive strength for use in the subfloor of a heavy goods warehouse, and the like.

[0050] Advantageously, such compressive strength provides appropriate load bearing support at the subfloor. In some cases, the compressive strength is such that the load bearing performance is better than a concrete load bearing slab layer of similar thickness. In such examples, not only are the previously described cost, time efficiency, and the like, benefits are realized, but the load bearing performance is actually also improved.

[0051] In this way, the shortcomings of using concrete as a material for a load bearing layer may be avoided. It should be noted that expanded foam being used in the load bearing slab layer 108 has advantages in its own right compared to many materials and method used in prior art construction. For example, expanded foam pieces are relatively easy to handle and install, and can be removed and / or deconstructed more easily.

[0052] In some examples, the load bearing slab layer 108 may be produced / manufactured as a single piece according to the required dimensions of the building structure 100. For example, such examples may be appropriate where the size of the building structure 100 is small enough, for example, so that the load bearing slab layer 108 is of a size that can be transported by road relatively easily (for example, without requiring very large road faring vehicles).

[0053] An advantage of the load bearing slab layer 108 comprising expanded foam is that the load bearing slab layer 108 can be light enough to be manipulated more easily, as compared to a concrete load bearing slab layer, which has to be poured in-situ. For example, even for a single load bearing slab layer 108 for a small building structure 100, the load bearing slab layer 108 may be manipulated and positioned using appropriate tools and machinery.

[0054] However, in some examples, the load bearing slab layer 108 is in the form of a load bearing slab assembly comprising a plurality of load bearing slab elements. Figure 2 is a simplified schematic plan view of a load bearing slab assembly 200, according to examples. The load bearing slab assembly 200 comprises the load bearing slab elements 202.

[0055] For example, the load bearing slab elements 202 may be produced in a manufacturing process which takes place offsite, in an expanded foam manufacturing facility, and brought on to the site where the building structure 100 is being constructed, for assembly. For example, the load bearing slab elements 202 may have a thickness dimension according to the desired thickness of the load bearing slab layer 108. For example, referring to Figure 1 , the thickness of the load bearing slab layer 108 is the spatial dimension in the vertical direction indicated by numeral 110. In other words, the thickness relates to how far above the compacted hardcore layer 106 the top of the load bearing slab layer 108 reaches. The other two spatial dimensions of the load bearing slab elements 202 may be chosen so as to allow easy manipulation by hand. For example, the load bearing slab elements 202 may be made small enough (so they are each light enough) to be handled by a construction engineer involved in constructing the building structure 100. Such sizing may also make transport of the load bearing slab elements 202 even more convenient.

[0056] In some examples, the load bearing slab layer 108 has a thickness 110 of between 0.02 meters and 0.35 meters, preferably between 0.025 meters and 0.3 meters. Advantageously, such a thickness range provides that the expanded foam material provides the appropriate level of load bearing support, in some cases better support than a traditional concrete load bearing slab layer, while at the same time allowing the advantages of the use of the expanded foam material being realized. For example, a thickness may be chosen according to the desired application. In the case of thicknessat towards the lower end of the described thickness range, handling becomes even easier, whereas even such a thin layer of concrete would still require mixing, pouring and drying / setting steps.

[0057] In this manner, the load bearing slab layer 108 may be constructed in a very simple and easy manner. In addition, to accommodate unconventionally shaped corners and the like, the load bearing slab elements 202 may be cut to an appropriate shape. Such cutting to appropriate shape may also be done in the case of a load bearing slab layer 108 which is a single piece. However, when the smaller load bearing slab elements 202 are deployed, the load bearing slab elements 202 are easier to handle and cut to the desired shape. In some examples, the expanded foam may be cut / shaped as desired using a hot cutting implement.

[0058] In some examples, the load bearing slab layer 108 defines a top portion of a concrete monolithic layer free subfloor, and the compacted hardcore layer 106 defines a bottom portion of the concrete monolithic layer free subfloor. In other words, the subfloor is concrete monolithic layer free (i.e. , the subfloor does not have a concrete monolithic layer). For example, while the compacted hardcore layer 106 itself may be formed by compacting concrete pieces, there is no monolithic slab of concrete which has to be prepared by mixing, pouring and setting the concrete. As described above, there are advantages to using a material easier to prepare and handle than concrete in the form of a monolithic slab for the load bearing slab layer 108. Advantageously, in the examples, there are no other concrete layers in the subfloor structure either, so that disadvantages of concrete monolithic slabs are avoided in relation to the entire subfloor of the building structure 100. Therefore, the entire subfloor may be produced at a reduced cost, more quickly, and more efficiently.

[0059] In addition, the load bearing slab layer 108 provides multiple functions due to the use of expanded foam. Not only does the load bearing slab layer 108 provide the appropriate load bearing support, it also provides thermal insulation, as discussed above. For this reason, it is not needed to provide separate layers of material for these different functions. In examples where the described concrete monolithic layer free subfloor is provided, the subfloor is also more space efficient in that fewer layers are required. In some examples, the depth required for the subfloor can be reduced. Alternatively, or in addition, the space saved by a single layer performing two functions can be used forother advantages. E.g., the load bearing slab layer 108 can be made deep to significantly enhance thermal insulation and / or additional damp proofing layers (and the like) can be added.

[0060] In some examples, as in the case of the examples of Figure 1 , the building structure 100 comprises a flooring layer 112 arranged atop, and supported by, the load bearing slab layer 108. It should be noted that the flooring layer 112 may be arranged atop and supported by the load bearing slab layer 108 by being in direct contact with it, or via another layer present between the flooring layer 112 and the load bearing slab layer 108. For example, while in some examples the flooring layer 112 may be in direct physical contact with the load bearing slab layer 108, in other examples, there may be one or more other layers between the flooring layer 112 and the load bearing slab layer 108.

[0061] Advantageously, the load bearing slab layer 108 provides appropriate support for the flooring layer 112 of the building structure. The load bearing slab layer 108 has the structural integrity (e.g., compressive strength) to support the floor. In addition, it is straightforward to create a flat surface with a load bearing slab layer comprising expanded foam.

[0062] In some examples, such as in the examples of Figure 1 , the building structure 100 comprises an upper damp proof layer 114 between the flooring layer 112 and the load bearing slab layer 108. Therefore, advantageously, damp proofing is enhanced. In some such examples, the upper damp proof layer 114 extends into the plurality of wall assemblies 104. For example, in the case of a cavity wall (e.g., where there is a cavity between the inner wall layer 104a and the outer wall layer 104b - whether not filled or filled), the upper damp proof layer 114 may extend through at least the inner wall layer 104a. For example, in the case of a solid wall (e.g., not having inner and outer layers with an unfilled or filled cavity), the upper damp proof layer 114 may extend through the solid wall. For example, the upper damp proof layer 114 comprises damp proof course. Those skilled in the art will appreciate the various examples of damp proof course which may be deployed. For example, for the upper damp proof layer 114, Polyethene, lead, bit-core, engineering bricks and the like, may be used.

[0063] In these examples, the extension of the upper damp proof layer 114 into the wall assemblies 104 better protects the building structure from damp and / or water ingress by enhancing the damp proofing at a potential weak point (as it pertains to damp ingress) which is the wall assembly portions near to the ground level (e.g., near to the sub floor).

[0064] In some examples, as in the case of the examples of Figure 1 , the building structure 100 comprises a lower damp proof layer 116 between the compacted hardcore layer 106 and the load bearing slab layer 108. For example, the lower damp proof layer 116 may be the same type or a different type to the upper damp proof 114, where present.

[0065] For example, the lower damp proof layer 116 may be provided alternatively, or in addition to the upper damp proof layer 114. In this manner, there is provided the option to supply more or less damp proofing, as desired, according to the local environment where the building structure is being installed. In some examples, the damp proofing is enhanced by providing both the upper and the lower damp proof layer.

[0066] There may be provided a method of producing a building structure, such as the building structure 100 according to any of the described examples. Figure 3 is a flow diagram illustrating examples of said method 300. At block 302 of the method 300, there is provided a footing arrangement (e.g., the described footing arrangement 102 according to any of the described examples). For example, the footing arrangement 102 is deployed at the building site according to the size and shape of the building structure 100 to be constructed. Those skilled in the art will appreciate the various methods that may be used to construct the footing arrangement 102, for example, using concrete and the like.

[0067] At block 304 of the method 300, there is provided a plurality of wall assemblies (e.g., the described wall assemblies 104 according to any of the described examples) supported by the footing arrangement. For example, the inner and outer wall layers 104a, 104b may be erected, supported by the footing arrangement 102. At block 306 of the method 300, there is provided a compacted hardcore layer (e.g., the described compacted hardcore layer 106 according to any of the described examples) surrounded by the plurality of wall assemblies. Those skilled in the art will appreciate the methods for deploying a compacted hardcore layer. At block 308 of the method 300, there isprovided a load bearing slab layer (e.g., the described load bearing slab layer 108 according to any of the described examples) arranged above and supported by the compacted hardcore layer, wherein: the load bearing slab layer comprises an expanded foam material.

[0068] As previously described, the load bearing slab layer 108 may be provided as a single unit. However, in some examples, the load bearing slab layer 108 may be provided as the load bearing slab assembly 200 made up of the described load bearing slab elements 202. In such examples, the method 300 may comprise providing a plurality of load bearing slab elements and assembling the load bearing slab layer using the load bearing slab elements.

[0069] Advantageously, assembling the load bearing slab layer with the load bearing slab elements provides for easier, time and cost efficient installation of the load bearing slab layer. For example, the load bearing slab layer can be pieced together without requiring a complicated process to mix and pour the concrete to form a monolithic layer, for example. In addition, the assembly may be carried out in weather conditions which may otherwise hinder the installation of a concrete load bearing slab layer.

[0070] In some examples, assembling the load bearing slab layer 108 comprises positioning the load bearing slab elements 202 by hand. As previously described, in some examples, the load bearing slab elements 202 may be dimensioned so that they are small enough and light enough to handle easily. In these examples, the assembly of the load bearing slab layer 108 may be carried out very simply by appropriately positioned the load bearing slab elements 202 by hand. Advantageously, machinery for moving heavy items in not required for the assembly. Assembling by hand provides a level of flexibility and ease in installation not possible in the case of a concrete load bearing slab layer.

[0071] In some examples, the method 300 may comprise cutting one or more of the load bearing slab elements 202 to a respective desired size and shape prior to assembly into the load bearing slab layer 108. For example, as part of this assembly process, certain of the load bearing slab elements 202 may be cut to the desired shape and size to fit particular corners, edges and the like. Advantageously, the load bearing slab elements can easily be adapted such that there is provided enhanced flexibility in theshape / configuration / arrangement of the sub floor layer thus created. For example, a construction engineer may simply cut a load bearing slab element 202 using a cutting device such as a knife, a saw and the like. In some examples, the cutting device may be heated, which may significantly increase the ease with which the expanded foam may be cut in the desired manner. However, in some examples, particular tools and / or machinery may be used.

[0072] In some examples of the method 300, the method 300 comprises providing the footing arrangement, the plurality of wall assemblies, the compacted hardcore layer and the load bearing slab layer in a manner so as to provide a concrete monolithic layer free subfloor. Advantageously, not only is the load bearing layer devoid of a monolithic concrete layer, thus providing the above-described advantages, the entire subfloor is concrete monolithic layer free. This advantageously means that the shortcomings resulting from the use of concrete are avoided for the production of the entire subfloor. Therefore, the entire subfloor may be produced at a reduced cost, more quickly, and more efficiently. Various advantages of the concrete monolithic layer free subfloor have also been discussed above.

[0073] The method 300 may further comprise deploying the various other elements of the building structure described above, such as the damp proofing layers, flooring layer and the like.

[0074] Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

[0075] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0076] In the above description, various specific examples are described. The invention is not restricted to the details of the foregoing example(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS1. A building structure comprising: a footing arrangement; a plurality of wall assemblies supported by the footing arrangement; a compacted hardcore layer surrounded by the plurality of wall assemblies; a load bearing slab layer arranged above and supported by the compacted hardcore layer, wherein: the load bearing slab layer comprises an expanded foam material.

2. The building structure according to claim 1 , wherein: the load bearing slab layer is in the form of a load bearing slab assembly comprising a plurality of load bearing slab elements.

3. The building structure according to claim 1 or claim 2, wherein: the load bearing slab layer defines a top portion of a concrete monolithic layer free subfloor; and the compacted hardcore layer defines a bottom portion of the concrete monolithic layer free subfloor.

4. The building structure according to any one of the preceding claims, comprising: a flooring layer arranged atop, and supported by, the load bearing slab layer.

5. The building structure according to claim 4, comprising: an upper damp proof course layer between the flooring layer and the load bearing slab layer.

6. The building structure according to claim 5, wherein: the upper damp proof course layer extends into the plurality of wall assemblies.

7. The building structure according to any one of the preceding claims, comprising: a lower damp proof layer between the compacted hardcore layer and the load bearing slab layer.

8. The building structure according to any one of the preceding claims, wherein:the load bearing slab layer has a thickness of between 0.02 meters and 0.35 meters.

8. The building structure according to any one of the preceding claims, wherein: the expanded foam material comprises one of:Polystyrene;Polypropylene; andPhenolic foam.

9. A method of producing a building structure, the method comprising: providing a footing arrangement; providing a plurality of wall assemblies supported by the footing arrangement; providing a compacted hardcore layer surrounded by the plurality of wall assemblies; providing a load bearing slab layer arranged above and supported by the compacted hardcore layer, wherein: the load bearing slab assembly comprises an expanded foam material.

10. The method according to claim 9, wherein: the load bearing slab layer is provided in the form of a load bearing slab assembly, and the method comprises: providing a plurality of load bearing slab elements; and assembling the load bearing slab layer using the load bearing slab elements.11 . The method according to claim 10, wherein: assembling the load bearing slab layer comprises positioning the load bearing slab elements by hand.

12. The method according to claim 10 or claim 11 , comprising: cutting one or more of the load bearing slab elements to a respective desired size and shape prior to assembly into the load bearing slab layer.

13. The method according to any one of claims 9 to 12, comprising:providing the footing arrangement, the plurality of wall assemblies, the compacted hardcore layer and the load bearing slab layer in a manner so as to provide a concrete monolithic layer free subfloor.

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