CA2671647A1 - Composite panel and stud and dual slab panel and method - Google Patents
Composite panel and stud and dual slab panel and method Download PDFInfo
- Publication number
- CA2671647A1 CA2671647A1 CA 2671647 CA2671647A CA2671647A1 CA 2671647 A1 CA2671647 A1 CA 2671647A1 CA 2671647 CA2671647 CA 2671647 CA 2671647 A CA2671647 A CA 2671647A CA 2671647 A1 CA2671647 A1 CA 2671647A1
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- web
- concrete
- embedment
- sheet metal
- openings
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
- E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
- E04B5/17—Floor structures partly formed in situ
- E04B5/23—Floor structures partly formed in situ with stiffening ribs or other beam-like formations wholly or partly prefabricated
- E04B5/29—Floor structures partly formed in situ with stiffening ribs or other beam-like formations wholly or partly prefabricated the prefabricated parts of the beams consisting wholly of metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C3/08—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with apertured web, e.g. with a web consisting of bar-like components; Honeycomb girders
- E04C3/09—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with apertured web, e.g. with a web consisting of bar-like components; Honeycomb girders at least partly of bent or otherwise deformed strip- or sheet-like material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0426—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section
- E04C2003/0434—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section the open cross-section free of enclosed cavities
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
- E04C2003/0452—H- or I-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
- E04C2003/0473—U- or C-shaped
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Panels For Use In Building Construction (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
Abstract
A thin shell composite panel having a concrete slab , and sheet metal reinforcing studs, partly embedded in the slab at spaced apart locations , each sheet metal reinforcing stud having a sheet metal web, a plurality of web main openings formed at spaced intervals and ribs and rib openings at the ends of each rib, rib flanges around the rib openings, web flanges formed around each main web opening , reinforcing channels formed along opposite sides of the web main openings, side flanges formed along each side of the web, an embedment strip formed along one side flange, concrete flow openings in the embedment strip.
Description
FIELD OF THE INVENTION
The invention relates to a composite panel formed of a concrete slab and sheet metal studs, and to a stud for such a panel, and to dual spaced apart concrete slabs bonded integrally with such studs in spaced apart relation , and a method of manufacture.
BACKGROUND OF THE INVENTION
Construction panels known as "thin shell " panels have been known for some time.
Such panels consist of a frame work of sheet metal reinforcing studs, and a slab of thin concrete. The studs have side edges which are partially embedded in the concrete.
This provides an advantageous construction member. The concrete provides a light weight economical wall and the sheet metal studs provide reinforcement. In addition the sheet metal studs enable interior dry wall to be attached , without the need for additional wall framing on the interior. However heating losses caused by thermal transmission through the studs, prevent some thin shell slab systems from achieving wide acceptance . In addition some of these simpler thin shell systems incorporated sheet metal studs which did not meet fire safety standards, and tended to buckle when subjected to prolonged high temperatures.
An improved example of such a composite panel is shown in US Patent 4,909,007, Inventor E R Bodnar.
This composite panel employed studs of an unusual design , having spaced apart openings. This form of stud had reduced thermal transmission compared to plain solid web studs.
Studs of this type have a better fire rating than plain studs, which was another advantage.
Another form of construction member is shown in US Patent 6,708,459 Inventor E
R
Bodnar.
This form of construction member provided dual slabs of thin shell concrete.
Both slabs were reinforced by sheet metal studs, extending between the two slabs.
This form of construction had greater strength , which was advantageous for forming , for example , floors or walls , of greater strength. In addition thermal insulation could be incorporated as a sandwich between the two slabs.
However this form of construction required the use of relatively complex additional attachments to be connected to the sheet metal studs. These attachments were in the form of embedment devices , screwed or fastened to the studs. The devices were required to provide for some form of embedment in the second concrete slab.
This increased the cost of the thin shell panel with two slabs and slowed down production.
Clearly it is desirable to provide an improved form of stud, having improved thermal efficiency, an improved fire rating, and capable of being made from thinner gauge metal.
Such a stud should be capable to being made with a single embedment edge for use with a single concrete slab, leaving a side flange on the other edge of the stud, for attachment of interior wall finishes, eg. Dry wall.
Thermal insulation may be placed between the studs in exterior walls.
It is also desirable to make such an improved stud with two embedment edges, for use with dual concrete slabs.
The invention relates to a composite panel formed of a concrete slab and sheet metal studs, and to a stud for such a panel, and to dual spaced apart concrete slabs bonded integrally with such studs in spaced apart relation , and a method of manufacture.
BACKGROUND OF THE INVENTION
Construction panels known as "thin shell " panels have been known for some time.
Such panels consist of a frame work of sheet metal reinforcing studs, and a slab of thin concrete. The studs have side edges which are partially embedded in the concrete.
This provides an advantageous construction member. The concrete provides a light weight economical wall and the sheet metal studs provide reinforcement. In addition the sheet metal studs enable interior dry wall to be attached , without the need for additional wall framing on the interior. However heating losses caused by thermal transmission through the studs, prevent some thin shell slab systems from achieving wide acceptance . In addition some of these simpler thin shell systems incorporated sheet metal studs which did not meet fire safety standards, and tended to buckle when subjected to prolonged high temperatures.
An improved example of such a composite panel is shown in US Patent 4,909,007, Inventor E R Bodnar.
This composite panel employed studs of an unusual design , having spaced apart openings. This form of stud had reduced thermal transmission compared to plain solid web studs.
Studs of this type have a better fire rating than plain studs, which was another advantage.
Another form of construction member is shown in US Patent 6,708,459 Inventor E
R
Bodnar.
This form of construction member provided dual slabs of thin shell concrete.
Both slabs were reinforced by sheet metal studs, extending between the two slabs.
This form of construction had greater strength , which was advantageous for forming , for example , floors or walls , of greater strength. In addition thermal insulation could be incorporated as a sandwich between the two slabs.
However this form of construction required the use of relatively complex additional attachments to be connected to the sheet metal studs. These attachments were in the form of embedment devices , screwed or fastened to the studs. The devices were required to provide for some form of embedment in the second concrete slab.
This increased the cost of the thin shell panel with two slabs and slowed down production.
Clearly it is desirable to provide an improved form of stud, having improved thermal efficiency, an improved fire rating, and capable of being made from thinner gauge metal.
Such a stud should be capable to being made with a single embedment edge for use with a single concrete slab, leaving a side flange on the other edge of the stud, for attachment of interior wall finishes, eg. Dry wall.
Thermal insulation may be placed between the studs in exterior walls.
It is also desirable to make such an improved stud with two embedment edges, for use with dual concrete slabs.
2 Preferably there will be provided an advanced method of making such a dual slab composite panel.
BRIEF SUMMARY OF THE INVENTION
With a view to providing an improved thin shell composite panel member, having at least one thin concrete slab and a plurality of sheet metal studs partly embedded in the slab, and providing reinforcing for the slab, the invention comprises a thin shell composite panel member having a concrete slab , and sheet metal reinforcing studs, partly embedded in said slab at spaced apart locations , and wherein each said sheet metal reinforcing stud comprises, a sheet metal web, a plurality of main web openings formed at spaced intervals and defining ribs between said main web openings, rib openings at the ends of each rib , rib flanges around the rib openings, web flanges formed around each said main web opening substantially normal to the plane of said web, reinforcing channels formed by additional bends in some said web flanges , extending along opposite sides of said web main openings, side flanges formed along each side of said web , an embedment strip formed along one said side flange , concrete flow openings in said embedment strip at spaced intervals, and a lock strip formed on said embedment strip.
Preferably the stud will have embedment strips along both said sides of said web, and concrete flow openings therein, and lock strips along both such embedment strips.
BRIEF SUMMARY OF THE INVENTION
With a view to providing an improved thin shell composite panel member, having at least one thin concrete slab and a plurality of sheet metal studs partly embedded in the slab, and providing reinforcing for the slab, the invention comprises a thin shell composite panel member having a concrete slab , and sheet metal reinforcing studs, partly embedded in said slab at spaced apart locations , and wherein each said sheet metal reinforcing stud comprises, a sheet metal web, a plurality of main web openings formed at spaced intervals and defining ribs between said main web openings, rib openings at the ends of each rib , rib flanges around the rib openings, web flanges formed around each said main web opening substantially normal to the plane of said web, reinforcing channels formed by additional bends in some said web flanges , extending along opposite sides of said web main openings, side flanges formed along each side of said web , an embedment strip formed along one said side flange , concrete flow openings in said embedment strip at spaced intervals, and a lock strip formed on said embedment strip.
Preferably the stud will have embedment strips along both said sides of said web, and concrete flow openings therein, and lock strips along both such embedment strips.
3 Preferably the main web openings are formed with four radiussed corners, and with four linear sides extending between the corners.
Preferably two of the linear sides will be spaced apart and parallel to each other and parallel to the side edges of the web, and including inner flanges formed on said linear sides, and bends in said inner flanges forming the same into generally three-sided reinforcing channels.
Preferably the other two linear sides will be provided with generally triangular flange portions .
Preferably the web is formed with lengthwise indentations, running between the web main openings and the web side flanges.
Preferably the side flanges are also provided with lengthwise indentations .
In a further embodiment the web is formed with said side flanges extending out to a first side of said web and with concrete flow openings in said web adjacent to said side flanges , and said concrete flow openings being formed by punching out portions of said web so as to deflect locking tab portions extending outwardly to a second side of said web, in a plane generally co planar with said side flanges, for embedment in said concrete.
The invention also provides a method of making a dual slab composite panel, by pouring a first panel, and embedding a grid of studs having first and second embedment edges , with their first embedment edges in the first panel, and then placing thermal insulation material between the studs, leaving the second embedment edges exposed above the insulation material, and then pouring a second slab onto the
Preferably two of the linear sides will be spaced apart and parallel to each other and parallel to the side edges of the web, and including inner flanges formed on said linear sides, and bends in said inner flanges forming the same into generally three-sided reinforcing channels.
Preferably the other two linear sides will be provided with generally triangular flange portions .
Preferably the web is formed with lengthwise indentations, running between the web main openings and the web side flanges.
Preferably the side flanges are also provided with lengthwise indentations .
In a further embodiment the web is formed with said side flanges extending out to a first side of said web and with concrete flow openings in said web adjacent to said side flanges , and said concrete flow openings being formed by punching out portions of said web so as to deflect locking tab portions extending outwardly to a second side of said web, in a plane generally co planar with said side flanges, for embedment in said concrete.
The invention also provides a method of making a dual slab composite panel, by pouring a first panel, and embedding a grid of studs having first and second embedment edges , with their first embedment edges in the first panel, and then placing thermal insulation material between the studs, leaving the second embedment edges exposed above the insulation material, and then pouring a second slab onto the
4 insulation material, the material of the second slab flowing around the exposed second embedment edges of the studs and embedding them in the second slab, and allowing the two slabs to cure The various features of novelty which characterize the invention are pointed out with more particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
IN THE DRAWINGS
Figure 1 is a schematic perspective of a composite construction panel, showing a single concrete slab, and a plurality of steel reinforcing studs;
Figure 2 is a perspective of a stud for reinforcing a single slab;
Figure 3 is a cut away side elevation of slab and single stud , of Fig 2;
Figure 4 is a side elevation of a stud for reinforcing a dual slab composite panel;
Figure 5 is a section along line 5-5 of Fig 4;
Figure 6 is a perspective of a dual slab composite panel;
Figure 7 is a section along line 7-7 of Fig 6;
IN THE DRAWINGS
Figure 1 is a schematic perspective of a composite construction panel, showing a single concrete slab, and a plurality of steel reinforcing studs;
Figure 2 is a perspective of a stud for reinforcing a single slab;
Figure 3 is a cut away side elevation of slab and single stud , of Fig 2;
Figure 4 is a side elevation of a stud for reinforcing a dual slab composite panel;
Figure 5 is a section along line 5-5 of Fig 4;
Figure 6 is a perspective of a dual slab composite panel;
Figure 7 is a section along line 7-7 of Fig 6;
5 Figure 8 is a perspective of a further embodiment of stud for a dual slab composite panel; and, Figure 9 is a section along 9 - 9 of Fig 8.
DESCRIPTION OF A SPECIFIC EMBODIMENT
Referring to Fig 1 it will be appreciated that this is a schematic illustration of a typical thin shell composite panel (P) to which the invention relates. It comprises a concrete slab (C ) and a plurality of sheet metal reinforcing studs (S ), arranged in parallel spaced apart relation. Portions of the sheet metal reinforcing studs (S ) are embedded in the concrete slab (C) . Typically top (and bottom) members (M) are attached to the top and bottom ends of the sheet metal reinforcing studs (S) , so as to hold the sheet metal reinforcing studs (S) in a predetermined parallel relation prior to embedment in the concrete slab (C) . The top and bottom members (M ) will typically be simple sheet metal C-sections , with the ends of the sheet metal reinforcing studs (S) being received within in the C-section shapes.
From this brief explanation, it will be understood that the invention relates to an improved thin shell composite panel member using an improved sheet metal reinforcing stud having advanced features. The invention further relates to providing a thin shell composite panel member which has dual concrete slabs (Fig 6 and 7, described below, and to a stud extending between the two slabs..
The sheet metal reinforcing studs (10) are shown in Fig 2 and 3.
Stud (10) has a sheet metal web (12 of planar sheet metal. Main web openings (14 ) are punched out of sheet metal web (12 ) at spaced intervals. Each main web opening
DESCRIPTION OF A SPECIFIC EMBODIMENT
Referring to Fig 1 it will be appreciated that this is a schematic illustration of a typical thin shell composite panel (P) to which the invention relates. It comprises a concrete slab (C ) and a plurality of sheet metal reinforcing studs (S ), arranged in parallel spaced apart relation. Portions of the sheet metal reinforcing studs (S ) are embedded in the concrete slab (C) . Typically top (and bottom) members (M) are attached to the top and bottom ends of the sheet metal reinforcing studs (S) , so as to hold the sheet metal reinforcing studs (S) in a predetermined parallel relation prior to embedment in the concrete slab (C) . The top and bottom members (M ) will typically be simple sheet metal C-sections , with the ends of the sheet metal reinforcing studs (S) being received within in the C-section shapes.
From this brief explanation, it will be understood that the invention relates to an improved thin shell composite panel member using an improved sheet metal reinforcing stud having advanced features. The invention further relates to providing a thin shell composite panel member which has dual concrete slabs (Fig 6 and 7, described below, and to a stud extending between the two slabs..
The sheet metal reinforcing studs (10) are shown in Fig 2 and 3.
Stud (10) has a sheet metal web (12 of planar sheet metal. Main web openings (14 ) are punched out of sheet metal web (12 ) at spaced intervals. Each main web opening
6 (14) , in this embodiment is of generally four sided quadrilateral shape. It has two linear parallel sides (16 and 18), one being shorter and the other longer, and spaced apart and parallel with one another, and aligned with the longitudinal axis (20 ) of the sheet metal web (12). The main web openings (14) have two non parallel linear sides (22 and 24) , extending diagonally from side to side of the sheet metal web (12) .
The four sides are joined by radiussed corners (26) . Along the two parallel linear sides (16 and 18) there are formed web flanges (28) , integral with the metal of the sheet metal web (12) . The web flanges (28) are formed with a first bend (30) normal to the plane of the sheet metal web (18) , and with a second bend (32 ) bending that portion into a plane parallel to the plane of sheet metal web (18) . This two bends form the web flanges (28) into axial reinforcing channels extending along the longitudinal axis (20) of the sheet metal web (12) .
The two non-parallel linear sides (22 and 24 ) of two adjacent main web openings (14 ) form ribs (36 ) extending diagonally from side to side on the sheet metal web (12) .
Rib flanges (38 ) extend along each side edge of each of ribs (36) being bent substantially normal to the plane of sheet metal web (12) . Triangular flange portions (40 ) are formed on rib flanges (38) intermediate their ends, for additional reinforcement, being highest at a mid point, and tapering down at each end.
It will be appreciated that , while the general thinking would suggest that, in order to reduce thermal transmission across sheet metal web (12) , it would be desirable to remove as much metal as possible, it has been found, contrary to such thinking , that it
The four sides are joined by radiussed corners (26) . Along the two parallel linear sides (16 and 18) there are formed web flanges (28) , integral with the metal of the sheet metal web (12) . The web flanges (28) are formed with a first bend (30) normal to the plane of the sheet metal web (18) , and with a second bend (32 ) bending that portion into a plane parallel to the plane of sheet metal web (18) . This two bends form the web flanges (28) into axial reinforcing channels extending along the longitudinal axis (20) of the sheet metal web (12) .
The two non-parallel linear sides (22 and 24 ) of two adjacent main web openings (14 ) form ribs (36 ) extending diagonally from side to side on the sheet metal web (12) .
Rib flanges (38 ) extend along each side edge of each of ribs (36) being bent substantially normal to the plane of sheet metal web (12) . Triangular flange portions (40 ) are formed on rib flanges (38) intermediate their ends, for additional reinforcement, being highest at a mid point, and tapering down at each end.
It will be appreciated that , while the general thinking would suggest that, in order to reduce thermal transmission across sheet metal web (12) , it would be desirable to remove as much metal as possible, it has been found, contrary to such thinking , that it
7 is in fact advantageous to remove somewhat less metal than would normally be thought to be desirable . According to the invention it is found that this can be achieved without any sacrifice in low thermal conductivity, and results in a surprising increase in strength.
The main openings (14) are formed through the sheet metal web (12 ) of the sheet metal reinforcing stud (10) , according to the invention, are specifically placed so as to reduce thermal transmission at various locations across the sheet metal web (12) .
The sheet metal that is deliberately left in the sheet metal reinforcing stud (10) , such as the ribs (36) , the linear parallel sides (22 ) and the non parallel linear sides (24) , and the channels formed by web flanges (28) all contribute to giving the sheet metal reinforcing stud (10 ) greater strength to accommodate the stresses in use, while contributing little or nothing to increasing thermal transmissions across the sheet metal reinforcing stud (14 ) In order to still further inhibit thermal transmission across the sheet metal reinforcing stud (10) is formed with rib openings (42) punched through the sheet metal web (12 ) at each end of each of ribs (36) . These rib openings (42 ) are formed with annular flanges (44 ) around each rib opening (42) , for greater strength.
In the embodiment of Fig 2 there is a side flange (46 ) formed normal to the plane of sheet metal web (18) , and a lip (48) is formed on the free edge of side flange (46 ) for reinforcement.
Such a side flange may be used for attachment of interior wall finishing material, typically dray wall panels, or the like (not shown).
Lengthwise flange indentations (50 are formed in side flanges (46 ) to provide greater
The main openings (14) are formed through the sheet metal web (12 ) of the sheet metal reinforcing stud (10) , according to the invention, are specifically placed so as to reduce thermal transmission at various locations across the sheet metal web (12) .
The sheet metal that is deliberately left in the sheet metal reinforcing stud (10) , such as the ribs (36) , the linear parallel sides (22 ) and the non parallel linear sides (24) , and the channels formed by web flanges (28) all contribute to giving the sheet metal reinforcing stud (10 ) greater strength to accommodate the stresses in use, while contributing little or nothing to increasing thermal transmissions across the sheet metal reinforcing stud (14 ) In order to still further inhibit thermal transmission across the sheet metal reinforcing stud (10) is formed with rib openings (42) punched through the sheet metal web (12 ) at each end of each of ribs (36) . These rib openings (42 ) are formed with annular flanges (44 ) around each rib opening (42) , for greater strength.
In the embodiment of Fig 2 there is a side flange (46 ) formed normal to the plane of sheet metal web (18) , and a lip (48) is formed on the free edge of side flange (46 ) for reinforcement.
Such a side flange may be used for attachment of interior wall finishing material, typically dray wall panels, or the like (not shown).
Lengthwise flange indentations (50 are formed in side flanges (46 ) to provide greater
8 strength. Such indentations also assist in the fastening of wall finishing panels. The indentations serve the additional function of guiding dry wall screws (not shown), if such are used.
A partial flange (52) is formed along the other side edge of sheet metal web (12) .
Partial flange (52) has an embedment wall (54 ) formed on its free edge.
Embedment wall (54) is bent outwardly at a non-right angle. Along the embedment wall (54) at spaced apart intervals there are a plurality of concrete flow openings (56) punched out of the sheet metal at spaced intervals . A locking strip (58) is formed along the free edge of embedment wall (54) .
The locking strip (58) is bent at an angle to the embedment wall (54) . In this way the entire locking strip (58) can be immersed in the concrete material of slab (60) , and the embedment wall (54) can be at least partially embedded, with concrete flowing through the concrete flow openings (56) .
With studs spaced at for example 24 inch centres, the entire concrete slab (60 ) and studs, forming the composite panel , can be reinforced, and the composite panel can then be securely fastened in position, typically forming an exterior wall of a building.
Lengthwise web indentations (62 ) are formed along the sheet metal web (12 ), for still greater strength The sheet metal reinforcing studs (10 ) also provide load bearing support for upper floors, at least up to a certain predetermined number of floors. The various flanges (30) forming reinforcing channels and the lengthwise indentations (50) and (62) all contribute to provide excellent load bearing properties.
A partial flange (52) is formed along the other side edge of sheet metal web (12) .
Partial flange (52) has an embedment wall (54 ) formed on its free edge.
Embedment wall (54) is bent outwardly at a non-right angle. Along the embedment wall (54) at spaced apart intervals there are a plurality of concrete flow openings (56) punched out of the sheet metal at spaced intervals . A locking strip (58) is formed along the free edge of embedment wall (54) .
The locking strip (58) is bent at an angle to the embedment wall (54) . In this way the entire locking strip (58) can be immersed in the concrete material of slab (60) , and the embedment wall (54) can be at least partially embedded, with concrete flowing through the concrete flow openings (56) .
With studs spaced at for example 24 inch centres, the entire concrete slab (60 ) and studs, forming the composite panel , can be reinforced, and the composite panel can then be securely fastened in position, typically forming an exterior wall of a building.
Lengthwise web indentations (62 ) are formed along the sheet metal web (12 ), for still greater strength The sheet metal reinforcing studs (10 ) also provide load bearing support for upper floors, at least up to a certain predetermined number of floors. The various flanges (30) forming reinforcing channels and the lengthwise indentations (50) and (62) all contribute to provide excellent load bearing properties.
9 The provision of main web opening (14 ) and rib openings (42 ) ensure that the sheet metal reinforcing studs (10) have a low thermal conductivity across their width, thus preventing the development of cold spots , known as ghosting , on the interior walls.
In accordance with a further embodiment, shown in Figs 4 and 5, there may be provided a sheet metal reinforcing stud (70) having two partial flanges(72-74) , one along each side of the sheet metal reinforcing stud (70) , and having two embedment walls (76-78 ), and two lock strips (80-82) ,on respective embedment walls (76-78).
The sheet metal reinforcing stud (70) has a similar sheet metal web (84) and main web openings (86 ) as the Fig 2 embodiment.
It further has reinforcing flanges forming channels (88 ) and ribs, and rib flanges , and rib openings (90) , as in the Fig 2 embodiment.
However this embodiment is designed for use with dual slabs of concrete, and for that reason both embedment walls (76-78) have flow openings (92-94) and lock strips (80-82).
This embodiment of sheet metal reinforcing stud (70 ) can then be used to fabricate a thin shell composite panel member (104 ) with two concrete slabs (106-108 ), as shown in Figs 6 and 7. The two concrete slabs (106-108 ) are spaced apart, being connected to the respective embedment strip (76-78 ) and lock strip (80-82 ) on opposite side edges of the same sheet metal reinforcing stud (70) .
The reinforcement and increased strength of this dual slab thin shell composite panel member comes in part from the embedment of each of the embedment strip and lock strip in its respective concrete slab (106-108) . The concrete slabs (106-108 ) are effectively joined together, although separate, and are both reinforced by the same sheet metal reinforcing stud (70) .
This embodiment can be used for much heavier duty applications such as flooring , roofing , and for erecting walls where much greater strength is required than can be achieved in a thin shell composite panel member (10 ) with only a single concrete slab (12) .
The manufacture of the thin shell composite panel member (104) with dual concrete slabs (106-108 ) can be achieved in two ways.
The first method is simply to pour a first concrete slab (106 ) and then lower a grid of sheet metal reinforcing studs (70 ) down onto the concrete slab (106 ), so that the first lock strip (80) and embedment wall (76) become immersed in the concrete slab (106).
After the concrete slab (106) has cured and set, then the entire assembly could then be lifted and rotated over. The second concrete slab (108) can then be poured, and the second lock strip (82 and embedment wall (78 ) can then be immersed in the second concrete slab (108) .
However this may take time, and involve complex handling .It is preferred that the dual slab thin shell composite panel member (104) be formed by simply pouring the first concrete slab (106) . Then the first embedment walls (76) of the sheet metal reinforcing studs (70) are immersed in the first slab (106).
Then thermal insulation blocks (110) are inserted between the sheet metal reinforcing studs (70 ), leaving the second embedment walls (78) exposed above the insulation blocks.
Then the second concrete slab (108) can be poured directly over the thermal insulation blocks (110) , covering and immersing the second embedment walls (78 ) and second lock strips (82) .
The entire assembly can then be allowed to cure , with both slabs curing substantially at the same time.
This second method reduces handling and repositioning of the product, and also provide the interior of the thin shell composite panel member (104 ) with thermal insulation incorporated directly into it as part of the manufacturing process.
A further embodiment of reinforcing stud (120) is shown in Figs 8 and 9.
In this embodiment the stud has a sheet metal web (122) , with main openings (124 ) and channels ( 126) along opposed linear sides of the openings. Diagonal ribs (128 ) extend between openings (124) . Rib openings (130) are formed at each end on each rib(128).
Lengthwise indentations (132) extend along web (122) . All of these features are similar to the same features in the Fig 4 and 5 embodiment.
Web (122) is somewhat wider than the web of the stud in Figs 4 and 5, for reasons explained below.
The embodiment differs from the Fig 4 and 5 embodiment in that there are two web flanges (134 ) and (136 ) formed along opposite side edges of the web (122 ) Web flanges (134-136 ) are bent normal to the plane of web (120). Lengthwise indentations (138 ) are formed along web flanges (134-136) .
Concrete flow openings (140 and (142) are formed through web (122) along the junction with web flanges'(134-136) . The concrete flow openings are formed by punching out generally trapezoidal locking tabs (144) . Locking tabs (144 ) are bent out normal to the plane of web (122) , and extend in a direction opposite to the direction of web flanges (134-136 ), but lie in a common plane with web flanges (134-136) .
The embodiment of stud may be used in forming dual slab composite panels, similar to panels shown in Fig 6 and 7.
The entire web flange and locking tabs along each edge of the stud may be immersed and embedded in respective slabs of concrete. The extra width of the web provides a sufficient depth of the web along each edge to accommodate the thickness of the concrete slab on each side.
However it will also be apparent that this stud can also be used, for reinforcing a single slab The fact that the stud has web flanges and locking tabs , bent normal to the plane of the web, and both lying in a common plane, would make it suitable for attachment of wall finishing panels, if desired.
The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.
In accordance with a further embodiment, shown in Figs 4 and 5, there may be provided a sheet metal reinforcing stud (70) having two partial flanges(72-74) , one along each side of the sheet metal reinforcing stud (70) , and having two embedment walls (76-78 ), and two lock strips (80-82) ,on respective embedment walls (76-78).
The sheet metal reinforcing stud (70) has a similar sheet metal web (84) and main web openings (86 ) as the Fig 2 embodiment.
It further has reinforcing flanges forming channels (88 ) and ribs, and rib flanges , and rib openings (90) , as in the Fig 2 embodiment.
However this embodiment is designed for use with dual slabs of concrete, and for that reason both embedment walls (76-78) have flow openings (92-94) and lock strips (80-82).
This embodiment of sheet metal reinforcing stud (70 ) can then be used to fabricate a thin shell composite panel member (104 ) with two concrete slabs (106-108 ), as shown in Figs 6 and 7. The two concrete slabs (106-108 ) are spaced apart, being connected to the respective embedment strip (76-78 ) and lock strip (80-82 ) on opposite side edges of the same sheet metal reinforcing stud (70) .
The reinforcement and increased strength of this dual slab thin shell composite panel member comes in part from the embedment of each of the embedment strip and lock strip in its respective concrete slab (106-108) . The concrete slabs (106-108 ) are effectively joined together, although separate, and are both reinforced by the same sheet metal reinforcing stud (70) .
This embodiment can be used for much heavier duty applications such as flooring , roofing , and for erecting walls where much greater strength is required than can be achieved in a thin shell composite panel member (10 ) with only a single concrete slab (12) .
The manufacture of the thin shell composite panel member (104) with dual concrete slabs (106-108 ) can be achieved in two ways.
The first method is simply to pour a first concrete slab (106 ) and then lower a grid of sheet metal reinforcing studs (70 ) down onto the concrete slab (106 ), so that the first lock strip (80) and embedment wall (76) become immersed in the concrete slab (106).
After the concrete slab (106) has cured and set, then the entire assembly could then be lifted and rotated over. The second concrete slab (108) can then be poured, and the second lock strip (82 and embedment wall (78 ) can then be immersed in the second concrete slab (108) .
However this may take time, and involve complex handling .It is preferred that the dual slab thin shell composite panel member (104) be formed by simply pouring the first concrete slab (106) . Then the first embedment walls (76) of the sheet metal reinforcing studs (70) are immersed in the first slab (106).
Then thermal insulation blocks (110) are inserted between the sheet metal reinforcing studs (70 ), leaving the second embedment walls (78) exposed above the insulation blocks.
Then the second concrete slab (108) can be poured directly over the thermal insulation blocks (110) , covering and immersing the second embedment walls (78 ) and second lock strips (82) .
The entire assembly can then be allowed to cure , with both slabs curing substantially at the same time.
This second method reduces handling and repositioning of the product, and also provide the interior of the thin shell composite panel member (104 ) with thermal insulation incorporated directly into it as part of the manufacturing process.
A further embodiment of reinforcing stud (120) is shown in Figs 8 and 9.
In this embodiment the stud has a sheet metal web (122) , with main openings (124 ) and channels ( 126) along opposed linear sides of the openings. Diagonal ribs (128 ) extend between openings (124) . Rib openings (130) are formed at each end on each rib(128).
Lengthwise indentations (132) extend along web (122) . All of these features are similar to the same features in the Fig 4 and 5 embodiment.
Web (122) is somewhat wider than the web of the stud in Figs 4 and 5, for reasons explained below.
The embodiment differs from the Fig 4 and 5 embodiment in that there are two web flanges (134 ) and (136 ) formed along opposite side edges of the web (122 ) Web flanges (134-136 ) are bent normal to the plane of web (120). Lengthwise indentations (138 ) are formed along web flanges (134-136) .
Concrete flow openings (140 and (142) are formed through web (122) along the junction with web flanges'(134-136) . The concrete flow openings are formed by punching out generally trapezoidal locking tabs (144) . Locking tabs (144 ) are bent out normal to the plane of web (122) , and extend in a direction opposite to the direction of web flanges (134-136 ), but lie in a common plane with web flanges (134-136) .
The embodiment of stud may be used in forming dual slab composite panels, similar to panels shown in Fig 6 and 7.
The entire web flange and locking tabs along each edge of the stud may be immersed and embedded in respective slabs of concrete. The extra width of the web provides a sufficient depth of the web along each edge to accommodate the thickness of the concrete slab on each side.
However it will also be apparent that this stud can also be used, for reinforcing a single slab The fact that the stud has web flanges and locking tabs , bent normal to the plane of the web, and both lying in a common plane, would make it suitable for attachment of wall finishing panels, if desired.
The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.
Claims (10)
OR PRIVILEGE IS CLAIMED AR DEFINED AS FOLLOWS;
1. A thin shell composite panel member having a concrete slab , and sheet metal reinforcing studs, partly embedded in said slab at spaced apart locations, and wherein each said sheet metal reinforcing stud comprises;
a sheet metal web;
a plurality of web main openings formed at spaced intervals and defining ribs between said main web openings;
rib openings at the ends of each rib;
rib flanges around the rib openings;
web flanges formed around each said main web opening substantially normal to the plane of said web;
reinforcing channels formed by additional bends in some said web flanges, extending along opposite sides of said web main openings;
side flanges formed along each side of said web;
an embedment strip formed along one said side flange;
concrete flow openings in said embedment strip at spaced intervals, and, a lock strip formed on said embedment strip.
a sheet metal web;
a plurality of web main openings formed at spaced intervals and defining ribs between said main web openings;
rib openings at the ends of each rib;
rib flanges around the rib openings;
web flanges formed around each said main web opening substantially normal to the plane of said web;
reinforcing channels formed by additional bends in some said web flanges, extending along opposite sides of said web main openings;
side flanges formed along each side of said web;
an embedment strip formed along one said side flange;
concrete flow openings in said embedment strip at spaced intervals, and, a lock strip formed on said embedment strip.
2. A thin shell composite construction panel as claimed in Claim 1 wherein each said stud has embedment formations along both said sides of said web, and concrete flow openings therein, and locking strips along both such embedment formations.
3 A thin shell composite construction panel as claimed in Claim 1 wherein the web main openings are formed with four radiussed corners, and with four linear sides extending between the corners.
4 A thin shell composite construction panel as claimed in Claim 1 wherein each said main web opening has two linear sides spaced apart and parallel to each other and parallel to the side edges of the web and including inner flanges formed on said two linear sides, and bends in said inner flanges forming the same into generally three-sided reinforcing channels, parallel to one another on opposite sides of said web main opening.
A thin shell composite construction panel as claimed in Claim 4 wherein said main web opening has two further linear sides provided with generally triangular flange portions .
6 A thin shell composite construction panel as claimed in Claim 1 wherein the web is formed with lengthwise indentations, running between the web main openings and the web side flanges .
7 A thin shell composite construction panel as claimed in Claim 6 wherein said side flanges are also provided with lengthwise indentations.
8 A thin shell composite construction panel as claimed in Claim 1 wherein said web is formed with said side flanges extending out to a first side of said web and with concrete flow openings in said web adjacent to said side flanges, and said concrete flow openings being formed by punching out portions of said web so as to deflect locking tab portions extending outwardly to a second side of said web, in a plane generally coplanar with said side flanges, for embedment in said concrete.
9. A method of making a thin shell composite panel member having two concrete slabs spaced apart in parallel planes , and sheet metal reinforcing studs, partly embedded in each said slab at spaced apart locations, and wherein each said sheet metal reinforcing stud has first and second edges and first and second concrete embedment strips, formed along respective said edges , and concrete flow openings in said embedment strips at spaced intervals, and, comprising the steps of;
pouring a first quantity of concrete into a form to form a first said slab;
assembling a reinforcing stud assembly of a plurality of said studs in side by side spaced apart parallel relation;
embedding said first embedment strips in said first quantity of concrete and allowing said concrete to cure;
removing said cured concrete and said reinforcing stud assembly from said form;
pouring a second quantity of concrete into said form;
inverting said cured concrete and reinforcing stud assembly;
embedding said second embedment strip in said second quantity of concrete, and allowing said concrete to cure, and, removing said composite panel member from said form.
pouring a first quantity of concrete into a form to form a first said slab;
assembling a reinforcing stud assembly of a plurality of said studs in side by side spaced apart parallel relation;
embedding said first embedment strips in said first quantity of concrete and allowing said concrete to cure;
removing said cured concrete and said reinforcing stud assembly from said form;
pouring a second quantity of concrete into said form;
inverting said cured concrete and reinforcing stud assembly;
embedding said second embedment strip in said second quantity of concrete, and allowing said concrete to cure, and, removing said composite panel member from said form.
10. A method of making a thin shell composite panel member having two concrete slabs spaced apart in parallel planes , and sheet metal reinforcing studs, partly embedded in each said slab at spaced apart locations , and insulation materials between said studs and said panels, and wherein each said sheet metal reinforcing stud has first and second edges and first and second concrete embedment strips, formed along respective said edges, and concrete flow openings in said embedment strips at spaced intervals, and, comprising the steps of;
pouring a first quantity of concrete into a form to form a first said slab;
assembling a reinforcing stud assembly of a plurality of said studs in side by side spaced apart parallel relation;
embedding said first embedment strips in said first quantity of concrete;
placing insulation material between said studs, said insulation material leaving said second embedment strips of said studs extending upwardly above said insulation material;
pouring a second quantity of concrete into said form over said insulation material, and embedding said second embedment strips of said studs in said second quantity of concrete, and allowing said concrete to cure, and, removing said composite panel member from said form.
pouring a first quantity of concrete into a form to form a first said slab;
assembling a reinforcing stud assembly of a plurality of said studs in side by side spaced apart parallel relation;
embedding said first embedment strips in said first quantity of concrete;
placing insulation material between said studs, said insulation material leaving said second embedment strips of said studs extending upwardly above said insulation material;
pouring a second quantity of concrete into said form over said insulation material, and embedding said second embedment strips of said studs in said second quantity of concrete, and allowing said concrete to cure, and, removing said composite panel member from said form.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2671647 CA2671647A1 (en) | 2009-07-10 | 2009-07-10 | Composite panel and stud and dual slab panel and method |
| ARP100102503 AR077560A1 (en) | 2009-07-10 | 2010-07-08 | A thin shell composite panel that has a concrete slab and reinforcement of laminated metal and methods to manufacture a thin shell composite panel that has two concrete slabs spaced apart in parallel plans and uplift units. |
| PCT/CA2010/001072 WO2011003198A1 (en) | 2009-07-10 | 2010-07-09 | Composite panel and stud and dual slab panel and method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2671647 CA2671647A1 (en) | 2009-07-10 | 2009-07-10 | Composite panel and stud and dual slab panel and method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2671647A1 true CA2671647A1 (en) | 2011-01-10 |
Family
ID=43428714
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2671647 Abandoned CA2671647A1 (en) | 2009-07-10 | 2009-07-10 | Composite panel and stud and dual slab panel and method |
Country Status (3)
| Country | Link |
|---|---|
| AR (1) | AR077560A1 (en) |
| CA (1) | CA2671647A1 (en) |
| WO (1) | WO2011003198A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105881698A (en) * | 2015-01-26 | 2016-08-24 | 任丘市永基建筑安装工程有限公司 | Prefabricating technology for double-layer heat preservation roof plate |
| US11028573B1 (en) * | 2020-01-16 | 2021-06-08 | Novel Structures, LLC | Serrated beam |
| US11725386B2 (en) | 2020-01-16 | 2023-08-15 | Simpson Strong-Tie Company Inc. | Serrated beam |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ATE87056T1 (en) * | 1988-12-21 | 1993-04-15 | Ernest R Bodnar | METAL SUPPORT. |
| US20030014935A1 (en) * | 2001-07-18 | 2003-01-23 | Bodnar Ernest R. | Sheet metal stud and composite construction panel and method |
| US20060150548A1 (en) * | 2004-12-27 | 2006-07-13 | Gcg Holdings Ltd | Floor system with stell joists having openings with edge reinforcements and method |
-
2009
- 2009-07-10 CA CA 2671647 patent/CA2671647A1/en not_active Abandoned
-
2010
- 2010-07-08 AR ARP100102503 patent/AR077560A1/en unknown
- 2010-07-09 WO PCT/CA2010/001072 patent/WO2011003198A1/en active Application Filing
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105881698A (en) * | 2015-01-26 | 2016-08-24 | 任丘市永基建筑安装工程有限公司 | Prefabricating technology for double-layer heat preservation roof plate |
| US11028573B1 (en) * | 2020-01-16 | 2021-06-08 | Novel Structures, LLC | Serrated beam |
| US11725386B2 (en) | 2020-01-16 | 2023-08-15 | Simpson Strong-Tie Company Inc. | Serrated beam |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2011003198A1 (en) | 2011-01-13 |
| AR077560A1 (en) | 2011-09-07 |
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