Insulated Floor System for Grade or Basement Floors

Abstract

Insulating floor system including (i) a grooved base layer formed from base layer grooved portions, (ii) a transverse peripheral edge rail formed from transverse peripheral edge rail portions, (iii) a parallel peripheral edge rail formed from parallel peripheral edge rail portions, and (iv) interior rails formed from interior rail portions. The base layer includes grooves in an upper surface. Each of the transverse peripheral edge rail portions include a plurality of downwardly projecting mating protrusions that mate within the base layer grooves. Each of the parallel peripheral edge rail portions include a downwardly projecting protrusion that mates within a peripheral groove of the base layer. At least one of the interior rails can be a locking rail, where locking rail portions defining the locking rail include a plurality of downwardly projecting mating protrusions that mate within terminal grooves of adjacent base layer grooved portions, locking such portions together.

Claims

1. An insulating floor system comprising: (i) a grooved base layer formed from one or more foam base layer grooved portions, the grooved base layer including grooves in an upper surface thereof; (ii) a transverse peripheral edge rail formed from one or more foam transverse peripheral edge rail portions, wherein each of the one or more transverse peripheral edge rail portions include a plurality of downwardly projecting mating protrusions to mate within the grooves of the grooved base layer; (ii) a parallel peripheral edge rail formed from one or more foam parallel peripheral edge rail portions, wherein each of the one or more parallel peripheral edge rail portions include a downwardly projecting mating protrusion to mate within a peripheral groove of the grooved base layer; (iii) optionally one or more interior rails formed from one or more foam interior rail portions, wherein at least one of the interior rails is an interior locking rail, the interior locking rail including one or more interior rail portions including a plurality of downwardly projecting mating protrusions to mate within terminal grooves of adjacent base layer grooved portions, locking such adjacent base layer grooved portions together.

2. The insulating floor system as recited in claim 1, wherein the insulating floor system comprises the one or more interior rails formed from one or more foam interior rail portions, wherein at least one of the interior rails is an interior locking rail, the interior locking rail including one or more interior rail portions including a plurality of downwardly projecting mating protrusions to mate within terminal grooves of adjacent base layer grooved portions, locking such adjacent base layer grooved portions together.

3. The insulating floor system as recited in claim 1, wherein the base layer portions are positioned directly on a grade, without any concrete slab, or any underlying concrete footing.

4. The insulating floor system as recited in claim 1, wherein the base layer portions include grooves formed in an upper surface, the grooves being formed at even increments so alternating male and female protrusions and grooves are the same size, sized to mate into one another.

5. The insulating floor system as recited in claim 1, wherein the system includes at least two transverse peripheral edge rails.

6. The insulating floor system as recited in claim 1, wherein the system includes at least two parallel peripheral edge rails.

7. The insulating floor system as recited in claim 2, wherein at least one of (i) the transverse peripheral edge rails, (ii) the parallel peripheral edge rails, or (iii) the interior locking rails include a longitudinal channel adjacent a top surface of such rails for receipt of a nailer strip for attachment of a subfloor.

8. The insulating floor system as recited in claim 2, wherein the one or more interior rails further comprises one or more additional interior rails that do not lock adjacent base layer grooved portions together, but which include one or more interior rail portions including one or more downwardly projecting mating protrusions to mate within interior grooves of the base layer grooved portions.

9. The insulating floor system as recited in claim 8, further comprising one or more filler rails extending between adjacent interior rails.

10. The insulating floor system as recited in claim 1, further comprising a concrete footing poured between the parallel peripheral edge rail and an adjacent interior rail.

11. The insulating floor system as recited in claim 9, further comprising a concrete footing poured between (i) the transverse peripheral edge rail and (ii) adjacent ends of the one or more interior rails and the filler rails extending between such interior rails.

12. The insulating floor system as recited in claim 11, further comprising a concrete footing poured between the parallel peripheral edge rail and an adjacent interior rail, wherein the concrete footing extends around a full perimeter of the insulating floor system, wherein the concrete footing is surrounded at bottom and at sides by the base layer and the rails.

13. The insulating floor system as recited in claim 2, wherein the interior rails each include a longitudinal channel adjacent a top surface of such rails, each such longitudinal channel housing a nailer strip, the system further comprising a subfloor attached over the interior rails, the subfloor being attached to the interior rails through nails, screws or other fasteners extending through the subfloor into the nailer strip.

14. The insulating floor system as recited in claim 13, wherein the transverse peripheral edge rails and the parallel peripheral edge rails each include a longitudinal channel adjacent a top surface of such rails, each such longitudinal channel housing a nailer strip.

15. The insulating floor system as recited in claim 1, wherein the rails have a height ranging from about 4 inches to about 4 feet.

16. The insulating floor system as recited in claim 1, wherein the rails have a height ranging from about 4 inches to about 12 inches.

17. The insulating floor system as recited in claim 1, wherein the rails have a height ranging from about 2 feet to about 4 feet, the system further comprising a crawl space defined between a top of the grooved base layer and a subfloor attached over a top of the rails.

18. The insulating floor system as recited in claim 1, further comprising a structural tie used to aid in securing the rails in place when secured to the underlying foam base layer.

19. The insulating floor system as recited in claim 1, wherein at least one of the foam base layer portions, or at least one of the foam rail portions are formed from expanded polystyrene beads, at least some of the beads comprising graphite or another contrast agent.

20. The insulating floor system as recited in claim 1, wherein beads comprising graphite or another contrast agent are present in an amount of from 5% to 50% by weight or by volume of the foam base layer portion or foam rail in which they are present.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0022] To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The drawings illustrate several embodiments of the invention, wherein identical reference numerals refer to identical or similar elements or features in different views or embodiments shown in the drawings.

[0023] FIGS. 1A-1B are isometric views showing exemplary insulating floor systems according to an embodiment of the present invention.

[0024] FIGS. 2A-2B illustrate an exemplary foam base layer grooved portion, one or more of which may be used to form a grooved base layer of the present insulating floor systems.

[0025] FIGS. 3A-3B illustrate an exemplary foam transverse peripheral edge rail portion, one or more of which may be used to form a transverse peripheral edge rail of the present insulating floor systems.

[0026] FIGS. 4A-4B illustrate an exemplary foam parallel peripheral edge rail portion, one or more of which may be used to form a parallel peripheral edge rail of the present insulating floor systems.

[0027] FIGS. 5A-5B illustrate an exemplary foam interior rail portion, one or more of which may be used to form an interior rail of the present insulating floor systems.

[0028] FIGS. 6A-6B illustrate an exemplary filler rail which may be positioned between adjacent interior rails, e.g., for use in forming a concrete footing within the floor system.

[0029] FIG. 7 illustrates a grooved base layer formed by positioning a plurality of foam base layer grooved portions adjacent to one another, in an abutting relationship.

[0030] FIG. 8 illustrates transverse and parallel peripheral edge rail portions having been mated into the grooves along the perimeter of the grooved base layer of FIG. 7.

[0031] FIG. 9 illustrates a plurality of elevated interior rails having been mated into grooves of the grooved base layer. FIG. 9 also shows a plurality of filler rails having been mated into the grooves of the grooved base layer, between adjacent interior rails, in preparation for pouring of a concrete footing adjacent the transverse peripheral edge rails.

[0032] FIG. 10 illustrates installation of rough plumbing within the space defined between the top of the grooved base layer and the top of the interior rails.

[0033] FIG. 11 illustrates a concrete footing having been poured into the peripheral space between (i) the peripheral rails and (ii) the adjacent interior rails and filler rails. FIG. 11 also illustrates an interior concrete footing or pad poured into a space defined between two interior rails and filler rails positioned to define such interior concrete pad or footing. FIG. 11 also shows anchor plate components (e.g., pressure-treated lumber) having been placed around the perimeter, over the concrete footing.

[0034] FIG. 12 illustrates placement of a subfloor over the interior and peripheral rails, placement of stick frame construction walls, and any of various other constructions that may be supported on the insulating floor system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Definitions

[0035] Some ranges may be disclosed herein. Additional ranges may be defined between any values disclosed herein as being exemplary of a particular parameter. All such ranges are contemplated and within the scope of the present disclosure.

[0036] Numbers, percentages, ratios, or other values stated herein may include that value, and also other values that are about or approximately the stated value, as would be appreciated by one of ordinary skill in the art. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result, and/or values that round to the stated value. The stated values for example thus include values that are within 10%, within 5%, within 1%, etc. of a stated value.

[0037] All numbers used in the specification and claims are to be understood as being modified in all instances by the term about, unless otherwise indicated. The use of about, substantially and the like may particularly include values within the above stated variance (e.g., within 10%, 5%, 1%). Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the subject matter presented herein are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0038] It must be noted that, as used in this specification and the appended claims, the singular forms a, an and the include plural referents unless the content clearly dictates otherwise.

[0039] Any directions or reference frames in the description are merely relative directions (or movements). For example, any references to top, bottom, up down, above, below or the like are merely descriptive of the relative position or movement of the related elements as shown, and it will be understood that these may change as the structure is rotated, moved, the perspective changes, etc.

[0040] All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.

II. Introduction

[0041] An embodiment of the present disclosure is directed to an insulating floor system comprising: a grooved base layer formed from one or more foam base layer grooved portions, where the grooved base layer includes grooves (e.g., a series of longitudinal parallel grooves and parallel protrusions, alternating with one another) in an upper surface thereof. The system also includes a transverse peripheral edge rail formed from one or more foam transverse peripheral edge rail portions, wherein each of the one or more transverse peripheral edge rail portions include a plurality of downwardly projecting mating protrusions to mate within the grooves of the grooved base layer. The system also includes a parallel peripheral edge rail formed from one or more foam parallel peripheral edge rail portions, wherein each of the one or more parallel peripheral edge rail portions include a downwardly projecting mating protrusion to mate within an outermost peripheral groove of the grooved base layer. The system also includes one or more interior rails formed from one or more foam interior rail portions, wherein each of the one or more interior rail portions include a plurality of downwardly projecting mating protrusions to mate within terminal grooves of adjacent base layer grooved portions, locking such adjacent base layer grooved portions together. The protrusions adjacent the terminal grooves of the base layer grooved portions may be half-width, relative to the other protrusions of the base layer grooved portions, so that when two base layer grooved portions are abutted together, the abutted half-width protrusions at the ends form a full-width protrusion, which mates into a corresponding groove of the interior rail, locking such grooved portions together.

III. Exemplary Construction Systems and Methods

[0042] FIG. 1A shows a partial exploded view of an insulating floor system 100 according to an embodiment of the present disclosure. As shown, the floor system 100 includes a grooved base layer 110 formed from one or more foam base layer grooved portions 110a, one or more transverse peripheral edge rails 120 formed from one or more foam transverse peripheral edge rail portions 120a, one or more parallel peripheral edge rails 130 formed from one or more parallel peripheral edge rail portions 130a, and typically one or more interior rails 140 formed from one or more foam interior rail portions 140a. In a very small construction, the interior rails may not necessarily be present, e.g., where the construction is so small that a sheet of OSB or plywood may itself span the distance between the various peripheral edge rails, and no locking of individual grooved portions 110a may be needed. FIG. 1A also shows the presence of several filler rails 150, e.g., positioned so as to extend and fill the end space between adjacent interior rails 140. Such filler rails 150 could additionally be placed between an interior rail 140 and a parallel peripheral edge rail, should such be desired.

[0043] Insulating floor system 100 is positioned on a simple graded surface 102. There is no need for different elevation levels within the subgrade, as may typically be the case in conventional constructions. In addition, no concrete slab is needed, significantly reducing the need for concrete in constructing a basement for a home or commercial building using such system, even in a cold weather climate where concrete slabs for basements and slab on grade construction are the norm.

[0044] FIG. 1B illustrates a similar system 100, but in which a subfloor (e.g., plywood or OSB sheeting 160) is being placed over the peripheral and/or interior rails, to form an interior floor for a home, commercial building, shed, greenhouse, warehouse or similar construction. FIG. 1B also shows how a concrete footing portion 162a can be poured between the transverse peripheral edge rail and filler rails 150, as well as the terminal ends of interior rails 140. A concrete footing portion 162b can similarly be poured between the parallel peripheral edge rail 130 and the adjacent interior rail 140, as shown. Such concrete footing portions 162a and 162b may be continuous with one another, connecting in corners 164. It will be apparent that in such a manner, a continuous perimeter concrete footing can be poured within the insulating floor system, extending around the full perimeter of the building construction's floor system. If desired, a discontinuity in such concrete footing could easily be provided, e.g., by inserting a filler rail in between the parallel peripheral edge rail and the adjacent interior rail at a desired location. A similar discontinuity could be provided by extending any desired interior rail so that it abuts the transverse peripheral edge rail. Such modifications could be used to provide a discontinuity within any poured concrete footing, where such footing otherwise extends around the perimeter of the floor system.

[0045] The concrete footing 162 surrounded by insulating foam within the floor system can be used to support any desired structure, just as conventional concrete footings are employed (e.g., anchor plate 166 with stick frame construction wall 168, a vertical concrete wall 170, or the like).

[0046] In addition to providing such a peripheral concrete footing, interior concrete footing pads can also be provided, e.g., at 163, as shown, e.g., by defining the boundaries of such a concrete footing pad 163 between interior rails 140 and filler rails 150.

[0047] FIGS. 2A-2B illustrate an exemplary base layer grooved portion 110a in greater detail. A plurality of such portions 110a can be abutted together, to form a desired grooved base layer 110, with the grooves of one portion aligned with the grooves of the next portion. As with the other rail components of the system, as such portions are formed from foam, they may be easily cut, to accommodate any needed geometry for the floor system to be constructed (e.g., any polygonal shape, or even with curved cuts).

[0048] As shown, base layer grooved portion 110a includes a flat planar bottom 112, with a plurality of grooves 114 formed in an upper surface of portion 110a. Between each groove 114 is an upward protrusion 116. At each end is a half-width protrusion 116a, so that upon abutting one base layer grooved portion 110a adjacent another base layer grooved portion 110a, with half-width protrusions 116a abutting one another, a full-width protrusion is formed, spanning the two adjacent portions 110a. Where such an interface is located internally within the insulating floor system, the two adjacent portions 110a may be locked together by interior rail portions 140a (FIGS. 5A-5B), pressed over such abutting half-width protrusions 116a.

[0049] In an embodiment, the depth of the grooves 114 (and height of the protrusions 116/116a) may typically range from 0.5 to 10 inches, from 1 to 8 inches, from 1 to 4 inches, or from 1 to 3 inches) (e.g., about 2 inches) The width of grooves 114 (and width of protrusions 116) may typically range from 0.5 to 10 inches, from 1 to 8 inches, from 1 to 4 inches, or from 2 to 4 inches (e.g., about 3 inches). The width of the half-width protrusions 116a may be half of such values. It is important to note that the width of the protrusions 116 is substantially the same as the width of grooves 114, so that a friction fit results when pressing a protrusion 116 into a groove 114. For similar reasons, the height of the protrusions is substantially the same as the depth of the grooves. This also allows cutting or otherwise forming 2 such grooved portions 110a from a rectangular block of foam (e.g., expanded polystyrene), by cutting (e.g., hot wire cutting), with little to no waste, as the 2 portions 110a are cut from a configuration where they are mated into one another. An exemplary portion 110a may have dimensions of about 4 feet by about 4 feet, 4 feet by 8 feet, 2 feet by 8 feet, or 2 feet by 4 feet. More generally speaking, one side may measure from 2 to 8 feet in length, while the other side may similarly measure from 2 to 8 feet in width. Thickness including the height of the protrusion may range from 4 inches to 12 inches, or from 6 inches to 12 inches. Various other sizes and dimensions are of course also possible.

[0050] FIGS. 3A-3B illustrate an exemplary transverse peripheral edge rail portion 120a. As shown, transverse peripheral edge rail portion 120a includes a plurality of downwardly projecting mating protrusions 122, configured to mate within (e.g., friction fit) grooves 114 of base layer grooved portion 110a. Each protrusion 122 may be substantially identically sized and shaped (height and width) as protrusions 116 of base layer grooved portion 110a, so that protrusions 122 can be pressed into grooves 114. Rail portion 120a is also shown as including a longitudinal channel 124 adjacent a top surface of such rail portion 120a, for receipt of a nailer strip. Such a nailer strip facilitates easy attachment of a subfloor (e.g., OSB or plywood sheeting) using nails, screws or other fasteners. As shown, as the rail portion 120a can be formed by hot wire cutting on a CNC machine, a thin access cut line 126 may be present at the top of rail portion 120a, e.g., centered relative to channel 124. As shown, rail portion 120a may include a ledge 128 between top and bottom portions of such rail portion, with an inclined exterior face 129 extending downward from the ledge 128, towards the bottom face from which protrusions 122 extend. The longitudinal channel 124 may therefore be within the top portion of such rail portion 120a, while the inclined exterior face 129 may be within the bottom portion of rail portion 120a, with ledge 128 defining the transition from bottom portion to top portion. As is apparent from FIGS. 1A-1B, the exterior facing ledge 128 may provide a brick ledge, e.g., where an exterior veneer (e.g., brick, stone, stucco, a composite board that mimics the appearance of concrete, or the like) may be attached and supported.

[0051] FIGS. 4A-4B illustrate an exemplary parallel peripheral edge rail portion 130a. As shown, parallel peripheral edge rail portion 130a includes a downwardly projecting mating protrusion 132, configured to mate within (e.g., friction fit) a peripheral groove 114 of base layer grooved portion 110a. Protrusion 132 may be substantially identically sized and shaped (height and width) as a protrusion 116 of base layer grooved portion 110a, so that protrusion 132 can be pressed into peripheral (the terminal or last) groove 114 of a base layer grooved portion 110a. Rail portion 130a is also shown as including a longitudinal channel 134 and cut line 136 adjacent a top surface of such rail portion 130a, for receipt of a nailer strip for attachment of a subfloor (e.g., OSB or plywood sheeting) using nails, screws or other fasteners. Similar to rail portion 120a, rail portion 130a may include a ledge 138 between top and bottom portions of such rail portion, with an inclined exterior face 139 extending downward from the ledge 138, towards the bottom face from which protrusion 132 extends. The longitudinal channel 124 may therefore be within the top portion of such rail portion 130a, while the inclined exterior face 139 may be within the bottom portion of rail portion 130a, with ledge 138 defining the transition from bottom portion to top portion. Ledge 138 and inclined exterior face 139 may be substantially identical to ledge 128 and inclined exterior face 129 of rail portion 120a, provided for the same purposes.

[0052] FIGS. 5A-5B illustrate an exemplary interior rail portion 140a. As shown, interior rail portion 140a includes two downwardly projecting mating protrusions 141, defining a groove 142 therebetween, configured to mate with (e.g., friction fit) a protrusion 116 of base layer grooved portion 110a. Groove 142 may be substantially identically sized and shaped (depth and width) as a groove 114 of base layer grooved portion 110a, so that groove 142 can be pressed over a given protrusion 116 of a base layer grooved portion 110a. Similarly, when joining two portions 110a together, the groove 142 can be pressed over abutted half-width protrusions 116a, of adjacent abutting portions 110a, so that rail portion 140a locks such portions 110a to one another. Rail portion 140a is also shown as including a longitudinal channel 144 and cut line 146 adjacent a top surface of such rail portion 140a, for receipt of a nailer strip for attachment of a subfloor (e.g., OSB or plywood sheeting) using nails, screws or other fasteners. In contrast to rail portions 120a and 130a, rail portion 140a may not include any ledge or inclined exterior face, but is of a simpler, generally rectangular configuration, with parallel sides, and a parallel top and bottom face (other than groove 142 in the bottom face).

[0053] FIGS. 6A-6B illustrate an exemplary filler rail 150. As shown, filler rail 150 includes a plurality of (e.g., two) downwardly projecting mating protrusions 152 with a groove 154 defined therebetween, configured to mate with (e.g., friction fit) grooves 114 and protrusions 116 of base layer grooved portion 110a. Protrusions 152 may be substantially identically sized and shaped (height and width) as protrusions 116 of base layer grooved portion 110a, and groove 154 may be substantially identically sized and shaped (depth and width) as grooves 114 so that protrusions 152 can be pressed into adjacent grooves 114 of a base layer grooved portion 110a, with the protrusion 116 between such grooves being received into groove 154. This configuration allows such a filler rail 150 to be inserted between two interior rails, or between an interior rail and a peripheral edge rail 130. As shown in the Figures, filler rails 150 may be placed so as to be parallel to the transverse peripheral edge rails 120, and perpendicular to the parallel peripheral edge rails 130. Interior rails 140 are placed so as to be parallel to the parallel peripheral edge rails 130, and perpendicular to the transverse peripheral edge rails 120. By way of example, filler rails 150 may be placed when it is desired to define a channel within which a concrete footing or pad is to be poured, within the insulating floor system, surrounded by the foam insulating base layer on bottom, and various rails on the sides. Of course the top of such concrete may remain uncovered by foam.

[0054] FIGS. 7-12 illustrate a progression, showing how the various components of the floor system can be used together, to construct an insulating floor system on which any building construction can then be built, without the need for a concrete slab that covers the entire footprint of the floor. Such a slab is expensive and time consuming to put down. In addition, the entire subgrade may be provided simply, at one even elevation, without the need for lower elevation portions to accommodate footings. The present floor systems provide an alternative, greatly reducing the cubic yardage of any required concrete, while also advantageously providing a floor system that is insulated, insulating both any peripheral concrete footings or interior pads that may be desired to be poured, as well as providing an insulated floor that is much more comfortable (without the hardness of concrete) for the end user.

[0055] As shown in FIG. 7, the desired location (e.g., whether a basement or at grade) may simply be leveled out. A gravel base may be provided over the leveled surface 102, if desired. The required number of foam base layer portions 110a may be laid out, over the leveled surface 102, as shown, with the half-width protrusions 116a at the ends of each portion 110a abutting one another, to form a protrusion having the same width as a full-width protrusion 116.

[0056] FIG. 8 shows rough plumbing drain 172 (e.g., for a drain associated with one or more plumbing fixtures such as toilets, sinks, washing machines or other appliances using water) having been installed, and the peripheral edge rails 120 and 130 having been pressed into the grooves 114, along the periphery of the floor system 100.

[0057] FIG. 9 shows the addition of the interior rails 140 and filler rails 150. As described, the interior rails are pressed over desired protrusions 116 (while also being used to lock two adjacent base layer grooved portions 110a together, by pressing over two abutting terminal half-width protrusions 116a). Filler rails 150 are pressed down, so that their protrusions 152 mate into grooves 114, and their groove 154 mates with protrusion(s) 116/116a. As shown in FIG. 9, the filler rails 150 have been positioned so as to define a perimeter footing, into which concrete can be poured, to provide an insulated concrete footing around the entire perimeter of the floor system 100. Additional filler rails 150 have also been positioned to define a location where an interior concrete pad can be poured (e.g., to support a structural column to be supported thereon).

[0058] FIG. 10 shows additional rough plumbing lines 174 having been run within the interior space, between various interior rails 140. In FIG. 11, the concrete perimeter footing 162 and interior concrete footing pad 163 have been poured. Anchor plates (e.g., pressure treated lumber) 166 may be positioned over the concrete footing 162, as shown, e.g., secured by bolts or other fasteners into the footing 162. Any desired structural ties, straps or the like may also be provided, e.g., for securing any superstructure to the anchor plate 166. Rebar or other reinforcements may of course be provided within the concrete, as desired.

[0059] FIG. 12 shows how stick frame wall constructions 168, concrete vertical walls 170, OSB and/or plywood subfloor 160, and the like may then be installed, over such insulating floor system 100. FIG. 12 illustrates a structural beam (e.g., steel vertical beam) 176 having been installed over the concrete pad 163, with any load applied to beam 176 transferred into concrete pad 163, as will be appreciated by those of skill in the art.

[0060] The various rail and base layer components may be formed from an insulating foam material, such as expanded polystyrene (EPS) foam. In an embodiment, some portion of graphite infused styrene beads may be incorporated into the styrene beads, from which the EPS foam components are formed, providing a darker color, contrast, and other benefits. In particular, the inclusion of graphite infused beads reduces glare and reflection, making it easier to see the configuration of a given component (sometimes edges and other features are washed out where everything is white, with no contrast). This is particularly helpful in bright sunlight. In addition, the inclusion of such graphite infused beads greatly reduces the risk of sunburn to those working with such materials, during installation of such a floor system, which benefit is also particularly beneficial in bright sunlight. While graphite is an exemplary contrast enhancing additive, it will be appreciated that other contrast agents could alternatively be used (e.g., other dyes, pigments, or the like). Graphite is an advantageous contrast agent as it has insulative properties similar or superior to styrene.

[0061] Such contrasting color beads may be present in the blend of beads used to form the base layer and/or rail components in any desired range, e.g., from 5% to 95%, although more typically in an amount of up to 50%, such as from 20% to 50%, or from 20% to 40% (e.g., about 30%). Such fractions may be by weight or by volume (e.g., density of the polystyrene beads may be similar to the graphite infused polystyrene beads, so that there may be little if any difference between a weight or volume basis). Sufficient graphite is provided in such beads to make them noticeably darker in appearance. Such graphite infused beads (or other contrast agent infused beads) may be sourced from any suitable commercial source.

[0062] Such an insulating floor system provides numerous advantages over conventional construction. For example, using expanded polystyrene foam for the base layer and various rails is advantageous, as such foam provides a compressive strength of about 2000 lbs/ft.sup.2. This is greater than that provided by typical underlying soil, which typically provides a compressive strength of 1500 to 1800 lb/ft.sup.2. The present system advantageously provides insulation to the structural footing, as it is wrapped and surrounded by the insulating components positioned between such footing and the ground. The system advantageously acts as a square and tape measure, eliminating any need to lay out the floor or building configuration on the footing. This is due to the provided grooves and protrusions of the base layer portions, and the fact that the other components (e.g., the rails) mate into these highly accurately dimensioned structures of the base layer, ensuring proper dimensions, without a need to measure, or lay out such dimensions/measurements. The system advantageously allows one to easily adjust footing widths, e.g., by adjusting where the outermost interior rail 140 is positioned. This is simply determined by pressing the outermost interior rail 140 into the grooved base layer to provide the desired footing width. A similar process is used to determine where to press the filler rails into the grooved base layer, to provide the desired footing width adjacent the transverse peripheral edge rails. It will be appreciated that infinite variability is available in positioning the filler rails, while the positioning of the interior rails is incremental, dependent on the groove spacing in the base layer.

[0063] The system also advantageously allows for the formation of internal footings (e.g., footing pad 163, as described) anywhere within the interior space of the floor system. Another advantage is provided in that the space provided between any of the given rails can be used for running any of various utilities, such as plumbing, HVAC, electrical wiring, main sewer line connection, or the like. The height of the rails may be selected based on the desired height of such available utility space. A relatively high rail height (e.g., up to 4 feet) could be provided, to provide a significant crawl space within such space, under the subfloor. Such a space could be used for any of a wide variety of purposes, e.g., cooling within a data center application, HVAC, wiring, personnel access, etc.

[0064] The present floor system advantageously eliminates the need for a concrete slab that covers the entire basement or what would otherwise be a slab on grade construction. Normally, as such a concrete slab is present, one must preform all basement or other below grade plumbing before pouring such slab (which is normally done early in construction). The elimination of such a concrete slab is an enormous practical advantage, as there is no need to jack-hammer an already poured concrete slab when changes may be desired in the floorplan layout (e.g., moving a bathroom, or a kitchen, which require plumbing drain connections in the ground under such locations). In addition, because the floor system is formed from foam, it is relatively lightweight, and is easily moved by hand, without the need for heavy equipment (e.g., a crane or the like), before any concrete footing is poured within the floor system. It is sufficiently lightweight, that it can easily be pushed to one side or the other, if needed. Such a flooring system provides an advantageous replacement to conventional slab on grade or basement slab constructions.

[0065] Furthermore, because the concrete footing is insulated from the ground, it is not required that the footing extend down below grade to below any applicable frost line. As a result, there is no need to dig trenches for the needed footings. All that is needed is to level the ground where the building is to be constructed, or excavate a basement, and level out that basement area, where the floor system can then be installed. In addition, in such basement and slab on grade replacement applications, the present system provides all the benefits of a subfloor (warmer, softer (less hard) floors), as compared to construction methods that rely on a concrete slab.

[0066] In addition, because the subfloor is elevated in a basement application, the flooring system can be isolated from any foundation walls, so that any water infiltration into the basement is less likely to damage expensive flooring (e.g., carpet) in such a living space. In addition, the floor system can breath, and a force ventilation system can be used in combination with a vapor barrier to minimize radon accumulation, which is a health issue in many locations where basements are built.

[0067] As the floor system eliminates the need for a concrete slab, and simplifies grading (a simple grade at a single elevation is all that is needed) it also becomes less expensive, given the high (and rising) cost of concrete, and grading work.

[0068] The overall system provides a grid base, with rails that simply press into the grid base. The various rails can be perforated or scored to allow a user to more easily cut them to a desired length. For example, such perforations or scoring could be provided at any desired interval length (e.g., 6 inches, 1 foot, 2 feet, or the like). The subfloor within the present floor system is not structural or load bearing, but the system bears directly on the ground. As a result, there is no practical limitation on the spans of such a floor system (the floor can be made as wide as desired).

[0069] The various rails can be held in place through friction fit, although an adhesive (e.g., a urethane adhesive) can be applied between the mating surfaces of the various rails and the base layer, as desired. Where no adhesive is used, the system is reversible, allowing the floor system to be disassembled, for reassembly elsewhere, or in a different configuration, if no concrete footing is poured therein. One could also add a structural tie, e.g., to better hold the various rails (particularly the peripheral rails) in place. Such ties may also be used when attaching a pressure treated anchor plate over the concrete footing.

[0070] Another advantage is that because the footing location is insulated, the concrete can be poured in winter, even during freezing conditions. Such is normally a problem in cold weather climates, because footings are normally not poured in an insulated location. The heat of the earth is sufficient to keep such a footing from freezing, because of the wrapped, insulated characteristics of the present footings.

[0071] It will also be appreciated that the present claimed invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.