Methods and systems for flooring and substrate structures

Abstract

Methods and systems for forming and providing flooring members and substrates are provided. Flooring members are provided that are monolithic members operable to be provided in combination with, for example, modular building structures such as preformed bathroom pods. Methods are provided that allow for enhanced production efficiencies and waterproofing of building components.

What is claimed is: 
     
         1 . A substrate member, comprising:
 a perimeter having a predetermined shape;   a first side and an opposing second side;   an upstanding lip portion extending vertically above the first side and extending at least partially around the perimeter;   a drain extending through at least one of the first side and the second side;   wherein at least a portion of the first side is sloped such that liquid is operable to flow under gravity to the drain; and   wherein the substrate member comprises at least one of a poured and a cast member such that the member is substantially devoid of connected components.   
     
     
         2 . The substrate member of  claim 1 , wherein the member comprises glass fiber reinforced concrete. 
     
     
         3 . The substrate member of  claim 1 , further comprising a flange extending outwardly of the lip portion and wherein the flange is operable to provide a connection to at least one additional component. 
     
     
         4 . The substrate member of  claim 1 , wherein the perimeter comprises a polygonal shape that corresponds to the shape of a room to be formed when the member is provided in combination with a prefabricated modular building component. 
     
     
         5 . The substrate member of  claim 1 , further comprising a cove extending from the first side up and along at least a portion of the upstanding lip portion. 
     
     
         6 . The substrate member of  claim 5 , wherein the cove has a radius within a range of approximately 0.5 inches to approximately 1.25 inches. 
     
     
         7 . The substrate member of  claim 1 , further comprising at least one of a step, ledge, or recessed lip portion proximate to an upper edge of the upstanding lip portion, wherein the at least one of a step, ledge, or recessed lip is operable to receive at least one of a panel, wall, or tile. 
     
     
         8 . The substrate member of  claim 1 , further comprising a drainage feature within which the drain is disposed. 
     
     
         9 . The substrate member of  claim 8 , further comprising a drainage cover removably attachable to at least one of the first side and the drainage feature. 
     
     
         10 . The substrate member of  claim 1 , further comprising at least one of an aperture, recess, or blockout configured to maintain a space within which a fixture, or component thereof, is received. 
     
     
         11 . The substrate member of  claim 10 , wherein the at least one aperture, recess, or blockout is incorporated in the cast member and is therefore integral in the molded substrate member. 
     
     
         12 . The substrate member of  claim 1 , wherein the at least one of an aperture, recess, or blockout is disposed within the lip such that at least one of a top face of the lip is interrupted and a top face of the lip runs along the uppermost portion of the lip uninterrupted. 
     
     
         13 . The substrate member of  claim 1 , further comprising a gap within the perimeter configured to allow for ingress and egress of a user. 
     
     
         14 . A method of forming a flooring member for prefabricated building components, the method comprising:
 providing a mold comprising a void corresponding to shape of the flooring member to be provided;   introducing a material to an interior volume of the mold, the material comprising concrete; and
 wherein the step of introducing the material comprises pouring the material. 
   
     
     
         15 . The method of  claim 14 , further comprising at least one of ejecting the flooring member from the mold and removing the mold from the flooring member. 
     
     
         16 . The method of  claim 14 , further comprising coating the flooring member with a waterproof material. 
     
     
         17 . The method of  claim 14 , wherein the material further comprises fiber reinforced concrete. 
     
     
         18 . The method of  claim 14 , wherein the material further comprises glass fiber reinforced concrete. 
     
     
         19 . A prefabricated building flooring system, comprising:
 a substrate member mold corresponding to a shape of a flooring member;   a material receivable within an interior volume of the mold; and   a molded substrate member having a perimeter, a first side, a second side opposite the first side, a projection extending from the first side and at least partially about the perimeter, and a first aperture extending through the molded substrate member,   wherein the first aperture is configured to be used as a conduit,   wherein the molded substrate member is substantially devoid of connected components, and wherein the molded substrate member comprises a customizable polygonal shape that corresponds to a shape of a building space to be occupied.   
     
     
         20 . The system of  claim 19 , wherein the material comprises glass fiber reinforced concrete.