CA1078128A - Sheet metal structural shape and use in building structures - Google Patents

Abstract

SHEET METAL STRUCTURAL SHAPE AND USE
IN BUILDING STRUCTURES

Abstract of the Disclosure A sheet metal structural shape for use as a stud or mullion in wall construction or a purlin or sub-purlin in deck construction which is symmetrical about a vertical bisecting plane having a central vertical web, two diagonal legs projecting downwardly from one end of the web forming an included angle of about 30° to about 90°, each of the diagonal legs having a leg projecting downwardly at its extremity in a plane substantially parallel to the web, each of the parallel legs having flanges extending outwardly at their extremity, a closure side extending between the extremities of the flanges enclosing the area formed by the diagonal sides, parallel sides and closure side, and a stiffening member at the other end of the web. A wall structure utilizing a spaced series of the metal structural shapes with a wall material attached to the flanges of adjacent structural shapes. Also included in this invention is a double wall construction wherein a second wall material is attached between adjacent metal structural shapes to a flat face of the stiffening member of the structural shape. The wall structure is particularly suited to shaft wall construction. A poured concrete or a precast deck structure utilizing a series of the metal structural shapes of this invention providing deck structures of superior insulation, fire resistance and uplift resistance.

Description

11~'7~1~8 Cross Reference to Related Application This application is a continuation-in-part of my earlier filed application Serial No. 457,996, filed April 4, 1974, now U.S. Patent 3,965,641.

This invention relates to a sheet metal struct-ural shape and its use in building construction. The structural shape is particularly useful as a stud or mullion in wall construction or as a purlin or sub-purlin in deck construction. This invention includes interior and exterior building wall construction using the sheet metal structural shape of this invention. This invention includes interior deck and roof.deck construction using the sheet metal structural shape of this invention. "

The wall construction according to this invention provides erection processes wherein all of the structural steel, the studs or mullions, may be completely erected and the wall material applied thereafter from one side.
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important in shaft wall construction where it i~
important to effect early closure of a dangerous open shaft. Previous methods of~ shaft wall erection, such as disclosed in U. S. Patent 3,702,044, require that the c~osure walls and the studs b~
erected together by fitting the wall board ~nto the slot of the stud creating a dangerous work environment at the edge of a ~haft.
The structural shape of this invention is particularly useful as a sub-purlin or purlin in an insulated roof structure and method providing superior fire protection and insulation properties.
The deck or roof structure of this invention may be a poured gypsum or other poured concrete like deck system wherein gypsum formboard is laid on novel sheet metal structural shape sub-purlin or purlin structure. A foamed synthetic organic polymer board having openings vertically therethrough to permit moisture from the poured concrete to penetrate to the gypsum formboard for drying is placed adjacent and above the formboard. Reinforcing wire mesh, the poured concrete and a standard weatherproof barrier is then applied résulting in a unitized structure affording high strength, high insulation properties, D-116 3~
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fire resistance and design versatility. Precast boards may also be used between the structural shapes for decks according to this invention.
Previously, most efficient lntegral insulation properties were most frequently obtained ~hen convent~onal metal roof decks were installed followed by ~oam insulation covered wlth a weather-proof barrier or traffic layer, such as bitumen and roofing felt. However, such structures do contribute to the spread of a fire in a building under such a metal roof deck. U. S. Patent No. 3,466,222 is illustrative of recent attemp~s to overco~e such disadvantages. However, the structure shown in the

3,466,222 patent only slows down fire damage and does not eliminate it, the roof being susceptible to total destruction by the foam disintegrating and -pe1~itting the wea~herproofing matPrials to burn even when utilizing an expensive metal deck roof system.
Poured gypsum roof deck systems have long been recognized as economical and furnishing a fire- -proof roof structure. In the conventional poured gypsum roof deck system, gypsum ormboard is la;d over the steel sub-purlin assembly, a layer of interwoven D-116 -4~

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steel reinforcing mesh placed over the gypsum form- .
board and poured in place slurry of gypsum concrete applied to conventional two inches thick. Such roof systems are known to provide satisfactory two hour fire ratings and low 1ame spread ratings. However, attempts to provide insulation to such roof deck systems has not proved satisfactory. One attempt has been to use perlite a8gregate in the gypsum concrete, however, this does not give desired însulation properties.
Another attempt has been to provide insulation beneath the roof deck structure, however, such insulation either adds to combustion in the interior of the building;
or is expensive if incombustible mineral fiber is used~
Other attempts to provide both satisfactory insulation and fireproof properties have been to utilize formboard which is both fireproof and has insulating properties.
Such formboards are those manufactured from ~ineral ~iber materials and fiber glass materials, but these are both exp~nsive and do not provide the desired insulation properties while being more difficu~t to use in field erection.
It is an object of this invention to overcome the above disadvantages.-D-116 ~5~

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It is an ob~ect of this invention to provide a sheet metal structural shape which may be used in building construction.
It is a further object of thi.s invention to provide a wall structure utili2ing a series of the metal structural shapes of this invention especially suitable ~or interior and exterior.
In accordance with the pr~sen~ invention, there is provided a sheet metal structural shape for use in building construction which is symmetrical abou-t a bisecting plane through a central web having:
a central web;
two diagonal legs projecting downwardly from one end of the web forming an included angle of about 30 to about 90 between the legs and having its vertex at the bottom of the web, the diagonal legs having a vertical height of about ~-1-1/8 to about 10 inches, the vertical height being substantially -greater than the length of the central web;
each diagonal leg having a leg projecting down-ward at its extremity in a plane substantially parallel to the web, the legs being substantially parallel; ~.
each of the parallel legs having a flange extending outwardly at their extremityi a closure side extending between the extremities of the flanges enclosing the area ~ormed by the diagonal siaes, the parallel sides and the closure side; and . ' jrr~ 6 -, ~78~%~3 a stiffening member at the other end of the web, the stiffening member being narrower than the flanges and substantially less height than the height of the diagonal legs.

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~8i~8 These and other objects, advantages and features of this invention will be apparent from the description and by reference to the drawings wherein preferred embodi-ments are shown as:
Fig. 1 is a perspective cutaw~y vlew o:E a double wall structure of one preferred embodiment of this invention:
Fig. 2 is a sectional view of one embodiment of a sheet metal structural shape of this invention;
Fig. 3 is a sectional view of another embodiment of a sheet metal structural shape of this invention;
Fig. 4 is a cross-sectional view of the wall shown in Fig. l;
Fig. 5 is a cross-sectional view of one embodiment of an insulated wall according to one embodiment of this invention;
Fig. 6 is a perspective cutaway view showing a poured roof deck according to this invention; and Fig. 7 is a perspec~ive cutaway view showing a pre-cast slab roof deck according to this invention.
The sheet metal structural shape of this invention provides excellent structural characteristics while reducing weight and providing a structural shape which can be readily fabricated from sheet metal. It is highly desirable to fabricate structural shapes from sheet metal to minimize energy ; requirements in production and to conserve steel. Prior attempts to JRR~

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~ 7~Z~3 utilize sheet metal shapes in poured roof construction have not been satisfactory. Some prior attempts have utilized sheet metal ~ shapes as substitutes for bulb tees in roof deck construction. These sheet metal ~ shapes while providing sufficient strength in the composite assembled poured roo do not have satisfactory strength characteristics themselves and in the erection, bend over ox roll when walked tpon by the erectors. This results in a very dangerous situation ~or the workers. The sheet metal structural shapes of this invention provide desirable strength characteristics themselves and sufficient streng~h characteristics to be walked upon during erection without dangerous bending or rolling.
When used as studs or mullions in wall construction, the sheet metal shapes of this invention provide a wall structure wherein ali o~ the studs or mullions may be erected and ~hen a double wall applied from one side. This is especially important in shaft wall construction, such as in elevator shafts.
The sheet metal shape of this invention may also be utilized for other construction purposes, sùch as supports for suspended ceilings.

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Referring to Figs. 2 and 3, the sheet metal shape of this invention is symmetrical aboue a bisecting plane through a central web. Shape 13 has a central web ~3 from which two diagonal legs 24 and 25 project downwardly for equal lengths at an included angle, shown in Fig. 2 as "A", of about 30~ to about 90 between the legs having its vertex at the bottom of the web, preferably about ~Oc.
Each diagonal leg has substantially parallel legs 26 and 27 pxojecting downward at its lower extremity at ~he angle "B". Legs 26 and 27 are parallel and in a plane substantially parallel to web 23. Each of the parallel legs 26 and 27 have a flange 28 and 29, respectively, extending outwardly at their extremity. The space between the parallel legs is closed by side 30. As shown in Fig. 1, side 30 .
is adjacent to flanges 2B and 29.
: Another embodi~ent of the sheet metal shape of this invention is shown in Fig. 3 wherein side 30 is spaced from flanges 28 and 29 by box sides 31 and 32. Box sides 31 and 32 extend from the extremity of flanges 29 and 28, respectively, in planes substantiaily parallel to web 23.

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~O~zs The upper edge o~ web 23 has a structur~lly s~ ening member such ~s a flang~, box shape or a triangle which provide a flat ollter surface at substantially 90 to web 23. Preferred flange configurations are shown in Figs~ 2 and 3~ The box shaped configuration is shown in Fig. lb and the triangle configuration in Fig. 1 of the parent application.

~ The structu:ral shape o~ this application differs from ~he shape disclosed in U.SO Patent 3,965,641 by parallel le~s 26 ~nd 27 and side 30 which closed the space between the parallel legs. :

Parallel legs 26 and 27 provide-greater resistance to deflection along the plane of web 23 to suit -desired design characteristics and provide for arying-wall thicknesses. Closure side 30 results .
in a shape which does not spread as a result of forces acting upon diags:~nal legs 24 and 25. Closure side 30 also provides a shape which provides a raceway for wires, pipes and ~he like~ as well as ducts for distributing condit-ioned air throughout a building structure. In cases of use for air distribu~ion, openings may be cut in desired locations in closure side 30 and a suitable mani- ..
fcld system located at each end of the shape.

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, ~078~%~3 Flanges ~8 and 29 may vary in length suitable to hold the desired form~oard or other decking or facing material. I have found from about 1/2 to about 1 inch to be suitable. The height of the diagonal legs 24 and 25 may be varied to suit the strength requirements of the desired span. I have found about 1-1/8 to about 4 inches satisfactory when using the shapes as sub-purlins, studs or mullions and about 4 to about 10 inches satisfactory when using the shapes for purlins or other major structural memberY. The included angle of legs 24 and 25 is suitably about 30 to about 90~, about 30 to about 60~ being preferred. Web 23 is important to suppl~
resistance to forces at right angles to the longi-tudinal axis of the shape and also to prevent bending or rolling of the shapes whën they are used in deck structures and walked upon by erection workers. I have found a suitable dimension for web 23 is about 3/8 to 5/8 inch, about 1/2 inch being preferred. The height of parallel legs may be varied ~o suit strength require~ents of desired spans. About 3¦8 to about 3/4 inFh is satisfactory wben using tne shapes ' , .
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as sub-purlins, studs or mullions. When using the shapes for purlins or other major structural member, the height may be increased to as much as about 4 inches. - ~
Box sides 31 and 32, as shown in Fig. 3, may be any suitable length to provide desired structural characteristics. Box sides of abou~
1/~ to about 2 inches are preferred.
As pointed out above, various forms may be utilized as stiffeners on the upper edge of web 23. A preferred shape of sti~fener are flanges ~1 and 22 extending in opposite directions at substant;ally 90~ to web 23 as shown in F~g. 2.
The stiffener flanges may be of suitable length for holding wall board or other facing material.
I have found about 3/8 to about 3/4 inch to be suitable. When the stiffener is box or triangle shaped, Lt is preferred that the sides in parallel planes to web 23 be about 3/16 to about 1/2 inch, preferably about 1/4 inch when the shape is used as a sub-purlin or stud and about 3/8 to about 3/4 inch, preferably about 1/2 inch when the shape is used as a purlin or exterior mullion. It is preferred the flat portion of the box or triangular ::. .. - - , , ~ . ~ , - , .

~.~7~ 8 stiffener be about 5/16 to about 3/4 lnch;
preferably ~bout l/2 inch when the shape is used as a sub-purlin or interior wall stud and about l/2 to about l-l/4 inch, preferably about 3/4 inch when the shape ~s used as a purlin or exterior wall mullion. It is desired that the stiffener shape permit poured concrete or grouting to flow both under and over the stiffener to prevent vertical displacement or uplift when the shape is used in deck construction.
The sheet metal sections o~ this invention may be fabricated by well known roll forming techniques from sheet steel from about 12 gauge to about 25 gauge, about 16 to 20 gauge being suitable for sub purlins, about 12 to 16 gauge being suitable for purlins, about 20 to 25 gauge being suitable or interior wall studs and about 12 to 20 gauge being suitable for exterior wall mullions.
On'e preferred embodiment of a wall structure according to this invention is shown in Fig. l. The wall structure shown in Fig. l i5 especially well suited for interior and shaft walls, .. ..
The wall structure shown in Fig. 1 spans the . , , `
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~78~LZ8 distance between floors or between a floor and a oeiling or roof structure. The wall structure is erected by placing a suita~le anshoring structure at the base of the wall, such as ~ill ,angle-14, and the corresponding structure at the ;~ ~op or a cap angle. Any suitable shape may be used which provides a backing against which to fasten the sheet metal studs 13 and not obstructing entry of the wall board from the narrow side o~
studs i3. For example, a channel may be used at the base and an angle at the top. Studs 13, being of sheet metal, may be readily cut to suitable length at the job site, erected at desired spacings and fastened to the sill structure at the bottom and the corresponding cap structure at the top. The sheet metal studs may be spot , welded or attached in any other suitable fashion known to the art. It should be noted that in~the structure of this inventionJ all of the studs may be put into place at the desired spac7ng as soon as the sill and cap structures are installed, thus, affording quick and safe pro- ;
tection of open shafts and the like. The studs may be co~pletely installed from the building side , '. ` ` , ~` ~ ~ . .

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o~ ehe shaft without the necessity ~or scaffolding or even leaning into the shaft area~ After the spaced studs are erected, the inner shaft wall filler board 12 may be attached to the studs from the building si~e of the shaft simply by placing the wall board against the flanges o the studs as shown in Fig. 1 and applying screws shown as 16 at desired locatio~s through the inner `shaft wall and into the stud flange.
While Fig. 1 shows the use of the shape as shown in Fig. 2, the shape shown in Fig. 3 may be used Pqually as well and i~ the same manner w~th the advantage that the screws are completely within the box section of the structural shape.
Outer shaft wall il may be applied by placing the ou~er shaft wall board in ~he desired .
position and applying screws or other fastenin~s through ~he outer shaft wall board and the fla~
portioQ of the stiffener structure of the stud.
Thus, the entire double wall assembly may be completely assembled from one side.
A preferred embodiment of a shaft wall is shown in ~ig. i wherein the studs are spaced on centers of ~he width of standard aYailable.wall .
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board. The inner shaft wall board 12 is cut narrower than the ~uter shat wall board 11 to provide insert 17 which fits between the parallel legs 26 and 27 of the structural shape thus providing additional fire resistance to the wall structure. Of course, the space between inner shaft wall i2 and outer shaft wall 11 may be filled with any type of insulation material desired. The wall closure material fastened to the flanges of adjacent structural shapes may be of any suitable material. As shown in Fig. 1, with particular reference to sha~t wall construction, gypsum board may be used in interior construction. Alternatively, ply-wood, various composition boards, metal panels and a wide variety of composi~ion panels with various desired interior surface finishes 9 may be used to obtain texture, color and acoustical properties. The wall construction of this invention is also suitable for exterior walls and in such cases, the wall closurc material facing the exterior would suitably be a weather~ ;
resistant material and may be faced with any desired texture or colored material to obtain .

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, ~ 078~Z8 the desired appearance. For example, Venetian corru~ated metal ~ich is available in long roll~
and surfaced in a variety of stone and brick textures may be readily cut to length at the 30b site snd applied wi_h self-tapping screws.
- For exterior wall construction, the thickness of insulation between the inner and outer wall closure material, shown as 34 in F~g. 5, may be of any desired thic~ness by utilization o~
iller blocks 36. Also, in exterior construction as well as interior, the structural shape of this inve~tion may be filied with any suitabl~
insulation material or may be filled with gypsu~
concrete to provide added fire resistance~
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shown as 35 in Fig. 5~ When utilizing the building wall structure of this invention for exterior walls, it is preferred to use the embodiment of the structural shape shown in - ;~ -Fig. 3 for added strength. Thus, either single or double wall construc~ion may be readily obtained by use of the sheet ~etal str~1ctural shapes according to this invention.
It is readily apparent that when the wall structure, as described above, i~ erected '~' ' , ' ' ' ' ' '"

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~C178~L2~3 in horizontal or near-horizontal planes, the structures provide a sui~able building deck structure. Thus, a building deck structure may be obtained by simply utiliz- -ing suitable materials in the decking a.ssembly to provide a suitable ceiling structure shown as 12 in Fig. 5, suit-able insulation, if desired, shown as 34 in Fig. 5, and a suitable floor structure shown as 11 in Fig. 5, the deck-ing assembly made up of the ceiling structure 12, insulation 34 and floor structure 11, may be prefabricated and set in place as a unit using fasteners 15. In such case, fasteners 16 may be eliminated or, if desired, driven from the opposite direction then shown in Fig. 5. For interior decks, the ceiling structure 12 may be any suit-able acoustical material while the deck surface structure 11 may suitably be plywood with polystyrene or polyure- ~
thane foam between. -The sheet metal structural shape of the present invention may also be directly substituted for the struct-ural shape disclosed and claimed in my parent application, Serial NO. 457,996, now U~S. Patènt 3,965,641, for use in both poured concrete , j rr O /!3-~

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deck structures, as illustrated in ~ig. 1 of that patent, or in prefabricated or precast roof structures as illustra;_ed in Fig. 2 of U.S. Patent 3,965,641.

The structural sheet metal shapes 13 and 33 of this invention may be used ~s sub-purlins and supported by any suitable structural members such as open web joists and I
beams spaced at proper intervals, making a suitable roo:~
support member system as shown in Figs. 6 and 7. Any roof support member system suitable for support of a poured roof is satisfactory. Gypsum formboard 112 having a desired thickness of synthetic organic polymeric foam 113 may be placed in contact with the upper side of the gypsum formboard, the g~-psum formboard resting upon the flanges 28 and 29 of adjacent structural sheet metal shapes of this inven~ion. It is des- :
ired that the polymeric foam have openings of more than about 5 percent of the area of the polymeric foam, preferably about 5 to 20 percent of the surface area of the polymeric foam providing communication between the volum~
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above the polymeric foam to the upper sur~ace of the gypsum formboa~d. Conven-tionally used wire reinforcin~ mesh~is placed above the /~
polymeric foam and concrete~poured eO a desired thickness above the polymeric foam, the concrete extending through the above mentioned openings in the polymeric foam to contaet the gypsum formboard and the poured concrete flowing -~7 both under and over the stiffening member~o~
the.sheet metal structural shape o~ this invention, thereby p~ovidi~g excellent upli~t resistance and a composite roof structure.
Any gypsum formboard providing a two hour ire rating when used with poured gypsum slabs is suitable. The least expensive of the gypsum formboards~
the rigid one-half inch thick gypsum form~oard i~
suitable for use in the roof structure of this inven-tion, however, various surfaced gypsum formboards having suitable ceiling surfaces may be utilized as long as the incombustibility and flame spread rating~
are satisfactory~ .
The synthetic organic polymer foa~ may be any substantially rigid organic polymer foam having good insulating properties and preferably a high . ' --' ' ' ~ ' ' ' ' -.
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temperature at which thermal decomposltion occurs.
Suitable foams include polystyrene, styrene-maleic anhydride, phenolic, such as phenol formaldehyde, polyurethane, vinyl, such as polyvinyl chloride and copolymers of polyvinyl chloride and polyvinyl acetate, epoxy~ polyethylene, urea formaldehyde, acrylic, polisocyanurate and the like. Preferred foams are selected from the group consisting o~
polystyrene and polyurethane. Particularly suitable foams are closed cell foams which provide high insulating properties and low internal permeability to moisture. Such organic polymsr foams are substan-tially rigid bodies o foam and are well known for thèir low density and outstanding thermal insulatî~g properties. Previously, use of organic polymer foam~
in roof structures has been limited due to the need . .
; for care and special attention in installation if they are used alone and due to their decomposition at higher temperatures perm;tting structural damage.
In accordance with this invention these disadvantages are overcome and polystyrene may be advantageously utilized.
; The organic polymeric foam and the gypsum formboard may be preassembled by fastening the foam ,'-.
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0 7 611Z~3 to the formboard by an~ suitable fastening means.
Suitable fastening means include synthetic and natural adhesives, wire staples, metal clips and the like.
Suitable synthetic adhesives include epoxy, polyure-than, polyamide and polyvinylacetate and its co- ~
polymers. Adhesives and wire staples are preferxed.
The polymer foam and gypsum formbnard may also be readily assembled at the construction site by first laying the formboard in place and placing the ~oam on top o it in a fashion to hold the foam the desired distance from the novel purlins. ~
Following installation o the gypsum form-board - polymer foam, standard reinforcing wire mesh used in poured gyps~m deck assemblies, shown asll4 i&
applied and gypsum concrete poured to a suitable . .
thickness of about 1-1/2 to about 3 inches over the surface of the polymer foam, about 2 inches being I -preferred. The poured gypsum concrete flows through openings in the polymer foam and adheres to the upper surface of the gypsu~ board 12. This structure provides an integral roofing structure having desired fireproof ana internal insulation properties.
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~078~L28 The gypsum concrete utili7Pd may be preferably standard gypsum concrete. However,modif~ed concretes contalning various fillers, such ~s perlite, aggregate for thermal insulation and lighter weight are suitable, or exploded mica in portland cement is suitable, but not necessary in the roof structure of this invention.
The gypsum concrete is especially desirable for use in roo~ structures not only because ït is incombustible but also because the gypsum sets within a ~ew minutes ___ to form a slab that is hard enough to walk upon there-by permitting, in many cases, a waterproof wearing surface to be laid the same day the slab is poured.
When any type of portland cement is used, the setting time is much slower and to prevent moisture from sagging the formboard, I have found it necessary to place a moisture permeable sheet between the cement and the top surface of the formboard. I have ound that moisture permeable paper, such as gypsum board paper, preferably placed on top of the foam is satisfacto~y.

A built up roofing membrane comprising alternate layers of roofing felt~and hot asphaltAmay be applied on top of the concrete with a waterproof wearing surfnce of tar and gravel. Any suitable waterproof wearing surfaee for flat type roofs i~

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. . . - . -~07~ 8 suitable ~or this roof structure of thls invention, or the gypsum concrete may be waterproofed with ', a plastic membrane, such as on d~me-type roof structures.
The drying of the concrete continues by removal of moisture from the concrete for several weeks a~ter pouring. I have ~ound that in using the roof structure of this inven,tion,the drying time of j' the concrete is not greatly increased. Thi~ results rom the concrete being,in communication throu~h hales .
in the polymer foam with the gypsum formboard which ;
i5 porous to water. The drying of the concrete after a built-up type roo~ing membrane is applied to it~ r exterior continues by the moisture esc~ping through .. , I
the formboard. ~,' , I
The roof structure of this in~ention provides properties ~hich are presently being called for by . ! ' newer building regulations. The first such propert~ -is fire ratings which~ following suitable AST~ testin~, result in two hour fire ratings for the roof structure.
The second important property is thermal insulation combined with the s'ati'sfactory fire rating. Present .. , j energy conservation eo~siderations result in a l'U'1 i value of 0.10 and less being desirable~ Calculations , , ~
show that roof structures of this invention utilizing , ~' the sheet metal shape as a purlin and using polystyrene , ' '. . ..

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and gypsum concrete result in "U" values of 0.06 and les~. When the sheet metal shape is utilized as ~
sub-purlin with 1/2 inch gyps-~ formboard, 1-1/2 inch polystyrene foam board and 2 inch gyp~um concrete the "U" value ~s 0.10. Thus, an inexpensive deck is provided having both a two hour fire rating for Class 1 fire rated construction and insulation properties resultin~ in "U" values of 0..10 and less.
Further, a range o~ desired insulating properties may be achieved by varying the thickness of the synthetic polymer foam.
Any suitable ceiling s~ructure may be installed beneath the roof structure of this invention as long as suitable ventilation is furnished. However, in contrast to prior roof structures, it is not necessary ~hat the ceiling provide the insulation or fireproofing .
~ualities. The roof structure of this inventio~
provides high insulation and fireproof properties with-ou~ any structure beneath it and may be left exposed.
Further, when the sheet metal shape of this inventio~ -is used directly as a purlin, about one foot of interior occupanoy space is gained over conventional constructio~
using exposed jois~s which mus~ als~ be fireprooed The sheet metal shapes of this invention may also be utilized in roof deck construction utilizing ' .`~

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' . : ' -- : ;, ~7~1Z~3 precast fireproof and insulating slabs such as fibrous materials bonded with hydraulic cement binders as shown in Fig. 7. The slabs may be laid on flanges 28 and 29, of the sheet metal shapes 33 and the space between the slabs and the sheet metal shapes is covered rom the top with grout 118. Any precast slab affording suitable fireproofing and insulating properties is suitable for use in the deck of this invention.

While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set ~orth for purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodi-ments and that certain of the details described here.in can be varied considerably without departing from the basic principles of the invention.

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Claims (24)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A sheet metal structural shape for use in building construction which is symmetrical about a bisecting plane through a central web having:
a central web;
two diagonal legs projecting downwardly from one end of said web forming an included angle of about 30° to about 90° between said legs and having its vertex at the bottom of the web, said diagonal legs having a vertical height of about 1-1/8 to about 10 inches, said vertical height being substantially greater than the length of said central web;
each diagonal leg having a leg projecting downward at its extremity in a plane substantially parallel to said web, said legs being substantially parallel;
each of said parallel legs having a flange extend-ing outwardly at their extremity;
a closure side extending between the extremities of said flanges enclosing the area formed by said diagonal sides, said parallel sides and said closure side; and a stiffening member at the other end of said web, said stiffening member being narrower than said flanges and substantially less height than the height of said diagonal legs.

2. The structural shape of Claim 1 wherein said central web is about 3/8 to about 5/8 inch.

3. The structural shape of Claim 1 wherein said included angle is about 40° to about 60°.

4. The structural shape of Claim 1 wherein said diagonal legs have a vertical depth of about 1-1/8 to about 4 inches.

5. The structural shape of Claim 1 wherein said parallel legs are about 3/8 to about 4 inches.

6. The structural shape of Claim 1 wherein said stiffening member is an inverted isosceles triangle.

7. The structural shape of Claim 1 wherein said stiffening member is a stiffener flange.

8. The structural shape of Claim 1 wherein said stiffening member is a box shape.

9. The structural shape of Claim 1 wherein said/closure side is spaced from said flanges by box sides extending from the extremity of each flange to each end of said closure side in a plane substantially parallel to said web.

10. The structural shape of Claim 9 wherein said box sides are about 1/2 to about 2 inches.

11. A building wall structure comprising:
a spaced series of parallel sheet metal structural shapes which are symmetrical about a bisecting plane through a central web having a central web, two diagonal legs projecting downwardly from one end of said web form-ing an included angle of about 30° to about 90° between said legs and having its vertex at the bottom of the web, said diagonal legs having a vertical height of about 1-1/8 to about 10 inches, each diagonal leg having a leg project-ing downward at its extremity in a plane substantially parallel to said web, said legs being substantially parallel, each of said parallel legs having flanges extending out-wardly at their extremity, a closure side extending between the extremities of said flanges enclosing the area formed by said diagonal sides, said parallel sides and said closure side, and a stiffening member at the other end of said web; said stiffening member being narrower than said flanges;
said structural shapes fastened to a holding structure at each end; and wall closure material fastened to said flanges of adjacent structural shapes.

12. The building wall structure of Claim 11 wherein a double wall structure is formed by fastening a second wall closure material to said stiffening member.

13. The building wall structure of Claim 11 wherein said closure side is spaced from said flanges by box sides extending from the extremity of each flange to each end of said closure side in a plane substantially parallel to said web.

14. A building deck structure comprising:
a spaced series of parallel sheet metal structural shapes which are symmetrical about a bisecting plane through a central web having a central web, two diagonal legs projecting downwardly from one end of said web forming an included angle of about 30° to about 90° between said legs and having its vertex at the bottom of the web, said diagonal legs having a vertical height of about 1-1/8 to about 10 inches, each diagonal leg having a leg projecting downward at its extremity in a plane substantially parallel to said web, said legs being substantially parallel, each of said parallel legs having flanges extending outwardly at their extremity, a closure side extending between the extremities of said flanges enclosing the area formed by said diagonal sides, said parallel sides and said closure side, and a stiffening member at the other end of said web; and decking assembly having its lower surface resting on said flanges and extending between adjacent structural shapes.

15. The building deck structure of Claim 14 wherein said building deck structures comprises:
gypsum formboard resting on said flanges and extending between adjacent structural shapes;
rigid synthetic polymer foam having an underside adjacent the upper side of said gypsum formboard and having spaces vertically communicating from the upper side of said formboard to the upper side of said foam, said spaces having an area of more than about 5 percent of the area of the upper, side of said formboard; and poured concrete adjacent the upper side of said foam and around said stiffener to prevent uplift and extending through said spaces contacting the upper side of said gypsum formboard, said concrete completing drying by escape of moisture through said gypsum formboard.

16. The building deck structure of Claim 14 wherein said structural shape central web is about 3/8 to about 5/8 inch.

17. The building deck structure of Claim 14 wherein said structural shape diagonal legs have a vertical depth of about 1-1/8 to about 4 inches.

18. The building deck structure of Claim 14 wherein said structural shape, diagonal legs have a vertical depth of about 4 to about 10 inches.

19. The building deck structure of Claim 14 wherein said structural shape parallel legs are about 3/8 to about 4 inches.

20. The building deck structure of Claim 14 wherein said structural shape stiffening member is an inverted isosceles triangle.

21. The building deck structure of Claim 14 wherein said structural shape stiffening member is a stiffener flange.

22. The building deck structure of Claim 14 wherein said structural shape closure side is spaced from said flanges by box sides extending from the extremity of each flange to each end of said closure side in a plane substantially parallel to said web.

23. The building deck structure of Claim 14 wherein said decking assembly comprises prefabricated deck structures.

24. The deck structure of Claim 23 having grouting between said prefabricated deck structures and surrounding said stiffening member providing uplift resistance.