CA2702575A1

CA2702575A1 - Composite deck system

Info

Publication number: CA2702575A1
Application number: CA2702575A
Authority: CA
Inventors: Harry Collins
Original assignee: Individual
Current assignee: New Millennium Building Systems LLC
Priority date: 2007-10-15
Filing date: 2007-10-15
Publication date: 2009-04-23
Anticipated expiration: 2027-10-15
Also published as: BRPI0722166A2; WO2009051589A1; CN101821463B; JP5230747B2; MX2010004070A; IL204999A; NZ585315A; JP2011501002A; EP2231939A1; IL204999A0; AU2007360171A1; CN101821463A; CA2702575C; EP2231939A4; KR20100057085A

Abstract

A composite deck system having a deck component and a concrete component. The deck component of the present invention includes deck sections, each having a longitudinally-extending rib with spaced apart sidewalls connected to a top wall. At the opposing ends of the sidewalls can be included side edges or webs having upturned flanges with an opening or openings along the flanges that are dimensioned to fa-cilitate composite action between the deck sections and the concrete. The system includes a first deck section, as described, adjacent to a second deck section, wherein the side edges of the first and second deck sec-tions are in juxtaposed relation. These deck sections can be combined with concrete to form a composite deck.

Description

TITLE
COMPOSITE DECK SYSTEM
BACKGROUND OF THE INVENTION
[0001] The present invention relates to composite decks.

[0002] The use of metal decks or sheets to act compositely with concrete slabs is known. These structures are commonly referred to as "composite decks,"
and are often used in the construction of floors. Composite decks are more efficient than non-composite decks because they make use of the strength of both the steel and the concrete components, resulting in lighter, more cost-effective floors.
Because composite decks are widely used in construction applications, there is a great demand that these components be both structurally sound and economical.
Thus, the functionality and durability of composite decks are of utmost significance.

[0003] In order to ensure that a composite deck will function properly and will have a long lifespan, the interaction between the concrete and the metal decks or sheets must remain in tact. The less separation that occurs between the metal sheet and the concrete interface, the more stable and stronger the composite deck will be.
Accordingly, the "co-action" or "composite action" between the metal deck and the concrete can determine the overall success of the composite deck.

[0004] Various means have been employed to enhance composite action between metal decks and concrete. For example, embossments along the metal sheets have been used. Altering the dimension and stiffness of the deck profile has also been used. Additionally, the use of steel wires welded to the web of decks has been used to enhance composite action. The gain of composite action produced by these means, however, is often negated by the loss of flexibility in construction design necessitated by these types of devices. Furthermore, composite action between the deck and the concrete of these devices is not ideal and can still be improved.

[0005] Accordingly, there exists a need for a composite deck system that can exhibit improved composite action between the metal deck component and concrete, and that can provide greater overall flexibility in construction applications.
SUMMARY OF THE INVENTION

[0006] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.

[0007] The present invention includes a compositedeck system having a deck component and a concrete component. The deck component of the present invention includes deck sections, each having a longitudinally-extending rib with spaced apart sidewalls connected to a top wall. At the opposing ends of the sidewalls can be included side edges or webs having upturned flanges with an opening or openings along the flanges that are dimensioned to facilitate composite action between the deck sections and the concrete. As used herein, "composite action" refers to the interaction between a deck and concrete. The system includes a first deck section, as described, adjacent to a second deck section, wherein the side edges of the first and second deck sections are in juxtaposed relation.
These deck sections can be combined with concrete to form a composite deck.

[0008] A feature of the present invention is the use of a composite deck system that employs deck sections having side edges with upturned flanges in juxtaposed relation, whereby the flanges have an opening or openings dimensioned to achieve composite interaction between the decks and poured-in place concrete.
In particular, the deck flanges can include a wide variety of openings, such as notches or perforations. These openings can act in concert with the side edges to achieve enhanced composite action between the decks and the concrete. When the concrete component is added to the deck sections, the openings can create both vertical and horizontal locking with the concrete in relation to the orientation of the decks. With improved compatibility between the decks and the concrete comes greater flexibility in the construction applications employing the composite decks.
For example, the composite deck system of the present invention can allow for longer and wider deck spans. Moreover, the strength provided by the composite deck system of the present invention can allow for other structural components, such as columns or beams, to be eliminated and/or spaced further apart. This additional flexibility, therefore, can offer different aesthetic environments.
Additionally, with fewer structural components needed, the costs and installation times of construction can be reduced.

[0009] Another feature of the present invention includes the use of a deck component having side edges with upturned flanges. This feature can further enhance the vertical locking between the deck sections and the concrete.
Furthermore, the upturned flanges can act as a pillar, thereby enhancing the load carrying capacity of the composite deck system. In particular, this feature can provide restraint to the vertical component of the strain differential between the decks and the concrete under the superimposed load condition.

[0010] Other features and advantages of the present invention will be apparent to those skilled in the art from a careful reading of the Detailed Disclosure of the Preferred Embodiments presented below and accompanied by the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,

[0011] FIG. 1A illustrates a plan view of deck sections including a concrete component according to a first embodiment of the composite deck system of the present invention;

[0012] FIG. 1 B illustrates a plan view of deck sections in combination with a concrete component according to a first embodiment of the composite deck system of the present invention;

[0013] FIG. 2 illustrates an end view of a deck section of a first embodiment of the composite deck system of the present invention;

[0014] FIG. 3A illustrates a perspective view of adjacent deck sections of a first embodiment of the composite deck system of the present invention;

[0015] FIG. 3B illustrates an end view of the adjacent deck sections of FIG.
3A of a first embodiment of the composite deck system of the present invention;

[0016] FIG. 4A illustrates a plan view of deck sections including a concrete component according to an alternative embodiment of the composite deck system of the present invention;

[0017] FIG. 4B illustrates a plan view of deck sections including a concrete component according to an alternative embodiment of the composite deck system of the present invention;

[0018] FIG. 5 illustrates a top plan view of adjacent deck sections according to a first embodiment of the composite deck system of the present invention;

[0019] FIG. 6A illustrates a cross-sectional view of adjacent deck sections taken at line 6A-6A of FIG. 5 of a first embodiment according to a first embodiment of the composite deck system of the present invention;

[0020] FIG. 6B illustrates a cross-sectional view of adjacent deck sections taken at line 6B-6B of FIG. 5 of a first embodiment according to a first embodiment of the composite deck system of the present invention;

[0021] FIG. 7A illustrates a perspective view of adjacent deck sections of an alternative embodiment of the composite deck system of the present invention;

[0022] FIG. 7B illustrates an end view of the adjacent deck sections of FIG.
4A of an alternative embodiment of the composite deck system of the present invention;

[0023] FIG. 8A illustrates a perspective view of adjacent deck sections of an alternative embodiment of the composite deck system of the present invention;

[0024] FIG. 8B illustrates an end view of the adjacent deck sections of FIG.
5A of an alternative embodiment of the composite deck system of the present invention;

[0025] FIG. 9 illustrates a perspective view of adjacent deck sections of an alternative embodiment of the composite deck system of the present invention;

[0026] FIG. 10 illustrates a perspective view of adjacent deck sections of an alternative embodiment of the composite deck system of the present invention;

[0027] FIG. 11 illustrates a perspective view of adjacent deck sections of an alternative embodiment of the composite deck system of the present invention;

[0028] FIG. 12 illustrates an end view of adjacent deck sections of an alternative embodiment of the composite deck system of the present invention;

[0029] FIG. 13 illustrates a perspective view of adjacent deck sections of an alternative embodiment of the composite deck system of the present invention;

[0030] FIG. 14 illustrates a perspective view of adjacent deck sections of an alternative embodiment of the composite deck systems of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] As illustrated in FIGS. 1A-1B, the present invention includes a composite deck system 10 including a deck component 12 and a concrete component 14. The deck component 12 can include a first deck section 16 and a second deck section 18 that are adjacent along their longitudinal axes.
Additional deck sections can be employed depending on the required width of the composite deck system and the dimensions of the deck sections. The decks employed can be made of metal, such as steel. If steel is used, the thickness of the steel will depend on the application of the resulting composite deck. Generally, the first deck section 16 and the second deck section 18 include longitudinally-extending, protruding ribs 50, as shown in FIG. 2. The illustration of the ribs 50 is made merely for completeness to place the deck sections into context; therefore, the shape of the ribs 50 can vary depending on structural and/or aesthetic preferences. Although alternative methods can be employed to construct the composite deck system 10 of the present invention, one method includes pouring the concrete in place after aligning and connecting the deck sections 16, 18 and securing the deck sections 16, 18 to a structure, such as load bearing element.

[0032] In a first embodiment, the first deck section 16 includes a first top surface 20 connected to a first side wall 22 and a first side edge 24, which is in a plane approximately parallel to the plane of the first top surface 20, and which has a first upturned flange 26 with a first opening 28. The second deck section 18 is approximately identical to the first deck section 16, and includes a second top surface 30 connected to a second side wall 32 and a second side edge 34, which is in a plane approximately parallel to the plane of the second top surface 30, and which has a second upturned flange 36 with a second opening 38 that is in juxtaposed relation to the first upturned flange 26. The concrete component includes a concrete layer 40 that is positioned on the first and second deck sections 16, 18, whereby the concrete layer 40 surrounds the deck sections, including the first and second upturned flanges 26, 36.

[0033] As discussed, a feature of the present invention includes the use of deck sections having side edges with flanges that include an opening or openings.
These openings can act in concert with the side edges to achieve enhanced composite action between the deck sections 16, 18 and concrete. Using the first embodiment as an example, when the concrete component 14 is added to the deck sections 16, 18, the openings 28, 38 can create both vertical and horizontal locking with the concrete 40 in relation to the orientation of the decks. In particular, the flanges can distribute the strain interaction in a regular and nearly continuous manner thereby minimizing the end slip phenomenon that is common to many composite deck systems. Further, when the flanges are confined within the concrete 40 thereby stiffening the deck at the point of the interaction, this feature enables the deck to resist the strain to near bearing type capacity.

[0034] With improved compatibility between the decks and the concrete 40 comes greater flexibility in the construction applications employing the composite deck system 10. For example, the composite deck system 10 of the present invention can allow for longer and wider deck spans. Moreover, the strength provided by the composite deck system 10 of the present invention can allow for other structural components, such as columns and beams, to be eliminated and/or spaced further apart. This additional flexibility, therefore, can offer different aesthetic environments. Additionally, with fewer structural components needed, the costs and installation times of construction can be reduced.

[0035] Another feature of the present invention includes the use of a deck component having side edges with upturned flanges. This feature can further enhance the vertical locking between the deck sections and the concrete.
Furthermore, the upturned flanges can act as a pillar, thereby enhancing the load carrying capacity of the composite deck system 10. In particular, this feature can provide restraint to the vertical component of the strain differential between the decks and the concrete 40 under the superimposed load condition.

[0036] The particular shapes and dimensions of the first and second upturned flanges 26, 36, as well as the openings along the flanges can vary.
In the first embodiment, shown in FIGS. 3A-3B, the first and second upturned flanges 26, 36, can be approximately perpendicular to the first and second side edges 24, 34 of the deck sections 16, 18. As further illustrated, the flanges 26, 36 can generally have an inverted L-shape with first and second base member 29, 39 connected to a first and second protruding rim 27, 37, respectively, and can extend longitudinally along the length of the deck sections 16, 18. The plane of the first and second rims 27, 37 is approximately parallel to the plane of the first and second side edges 24, 34. Additionally, the angle A between the first flange 26 and the first side edge 24 is about 900, and the angle B between the second flange 36 and the second side edge is about 90 . The second flange 36 can be dimensioned to overlap the first flange 26 so that the flanges are juxtaposed. When the composite deck is formed, the deck sections 16, 18 can be aligned so that the first and second flanges 26, 36 are engaged or nested.

[0037] Depending on the application of the composite deck system 10, each deck section can include a flange as presently described along one side edge or along both side edges. In the case that the deck section is being used as a central section and will include adjacent deck sections on either side, the deck section can include a flange on both of its side edges, as shown in FIG. 2. Further, if the flanges employ the shape of the first embodiment, the deck section will have a nesting flange 51 along one side edge, and an overlapping flange 53 along the opposing side edge.

[0038] In addition to the L-shape, the first and second flanges 26, 36 can also include an opening. As shown, each of the flanges includes an opening 28, 38.
In particular, the opening can be a notch that is roughly rectangular in shape and that is included along the edge of the flange rims 27, 37. If both the first and second flanges 26, 36 include an opening, the openings 28, 38 can be approximately the same size and be in approximately the same location, whereby when the first flange 26 and the second flange 36 are aligned, the openings 28, 38 are matched. As used herein, "matched openings" refers to openings that are of about the same shape and dimension and are positioned in about the same location along juxtaposed first and second flanges. Alternatively, there can be one opening along one or both of the first and second flange rims 27, 37, as well as one or both of the first and second base members 29, 39, or there can be a plurality of openings along one or both of the first and second flanges 26, 36, as well as one or both of the first and second base members 29, 39.

[0039] Alternative embodiments are also contemplated by the present invention. These embodiments are shown in FIGS. 4A-14. In the first alternative embodiment, shown in combination with a concrete component in FIGS. 4A-4B, and shown in detail in FIGS. 5A-6B, the first and second upturned flanges 26, 36, can be approximately perpendicular to the first and second side edges 24, 34 of the deck sections 16, 18. As further illustrated, the flanges 26, 36 can generally have an inverted L-shape with first and second base member 29', 39' connected to a first and second protruding rim 27', 37', respectively, and can extend longitudinally along the length of the deck sections 16, 18. In particular, the first flange 26 can include a first and second cut, 28', and the second flange 36 can include a third and fourth cut 38', respectively. Between the cuts 28', 38', the flanges 26, 36 include a first fold 21 and a second fold 23, respectively, along the longitudinal edges. As shown, second fold 23 covers the first fold 21, so that the folds are nested. The plane of the first and second rims 27', 37' is approximately parallel to the plane of the first and second side edges 24, 34. Additionally, the angle A between the first flange 26 and the first side edge 24 is about 900, and the angle B between the second flange 36 and the second side edge is about 90 . The second flange 36 can be dimensioned to overlap the first flange 26 so that the flanges are juxtaposed. When the composite deck is formed, the deck sections 16, 18 can be aligned so that the first and second flanges 26, 36 are engaged or nested.

[0040] In another alternative embodiment shown in FIGS. 7A-7B, the first and second flanges 26, 36 are shaped similarly to the flanges of the first embodiment, except that the first and second flanges 26, 36 are at different angles with relation to the side edges 24, 34. In particular, angle A between the first flange 26 and the first side edge 24 is greater than about 90 , and the angle B between the second flange 36 and the second side edge 34 is less than about 900. Additionally, because the angles of the flanges are distinct, the planes of the first and second rims 27, 37 are no longer parallel with the plane of the first and second side edges 24, 34, and are in stead an angle to the planes of the first and second side edges 24, 34.
Alternatively, there can be one opening along one or both of the first and second flange rims 27, 37, as well as one or both of the first and second base members 29, 39, or there can be a plurality of openings along one or both of the first and second flanges 26, 36, as well as one or both of the first and second base members 29, 39.

[0041] FIGS. 8A-8B illustrate another alternative embodiment. As shown, the flanges 26, 36 of this embodiment are similar to the embodiment of FIGS. 7A-7B, except that the openings 28, 38 are not notches along the edges of the flange rims 27, 37, but rather are openings within the flange rims 27, 37 that can be circular in shape. Again, angle A between the first flange 26 and the first side edge 24 is greater than about 90 , and the angle B between the second flange 36 and the second side edge is less than about 90 . Alternatively, there can be one opening along one or both of the first and second flange rims 27, 37, as well as one or both of the first and second base members 29, 39, or there can be a plurality of openings along one or both of the first and second flanges 26, 36, as well as one or both of the first and second base members 29, 39.

[0042] Yet another alternative embodiment is illustrated in FIG. 9. As shown, the flanges 26, 36 are similar to the embodiment described in FIGS. 8A-8B, except the shape of the openings 28, 38 can be rectangular. Alternatively, there can be one opening along one or both of the first and second flange rims 27, 37, as well as one or both of the first and second base members 29, 39, or there can be a plurality of openings along one or both of the first and second flanges 26, 36, as well as one or both of the first and second base members 29, 39.

[0043] FIG. 10 illustrates an alternative embodiment that is distinct from the embodiment previously described in that the flanges 26, 36 do not include a first and second flap 27, 37 along their respective top edges. Accordingly, there is no overlap of the second flange 34 onto the first flange 24, and each flange is generally upturned at about 90 , as shown in FIG. 12. Moreover, the openings 28, 38 can be included along what were previously referred to as base members 29, 39. In particular, the openings can be rectangular shaped. Alternatively, there can be one opening along one or both of the first and second base members 29, 39, or there can be a plurality of openings along one or both of the first and second base members 29, 39.

[0044] FIGS. 11 and 13 illustrate alternative embodiments that are similar to that of FIG. 10. In particular, the flanges 26, 36 shown in FIG. 11 are similar to those described and shown in FIG. 10, except the openings 28, 38 are notches along the respective top, longitudinal edges of the flanges 26, 36. Furthermore, this embodiment shows that the positioning of the openings 28 of the first flange 26 need not match the openings 38 of the second flange 36. As shown in FIG. 11, opening 38 is eclipsed by flange 26. FIG. 13 illustrates flanges 26, 36 similar to those described and shown in FIG. 10, except the openings 28, 38 are circular in shape.

[0045] Although particular shapes and positions have been described and shown with respect to the openings 28, 38, any geometric shape can be employed along any area of the flanges 26, 36. Furthermore, the frequency of openings along the flanges can also be varied. For example, the flanges 26, 36 can be perforated throughout so as to provide a polka-dot type pattern 70, as shown in FIG. 11.
Additionally, it should be understood that the deck section shown in FIG. 2 can include any of the alternative flange embodiment as described, and does not necessarily need to include a nesting flange and an overlapping flange.

[0046] Those skilled in the art of composite decks will recognize that many substitutions and modifications can be made in the foregoing preferred embodiment without departing from the spirit and scope of the present invention.

Claims

1. A composite deck, comprising:
a first deck section having a first top surface, a first side wall, and a first side edge having a first upturned flange;
a second deck section having a second top surface, a second side will, and a second side edge having a second upturned flange, wherein said first deck section and said second deck section are adjacent along their longitudinal axes, wherein said first upturned flange is in juxtaposed relation to said second upturned flange, and wherein said first upturned flange includes a first opening; and a concrete layer positioned on said first top surface and said second top surface and surrounding said first upturned flange and said second upturned flange.

2. The composite deck as recited in claim 1, wherein said second upturned flange includes a second opening.

3. The composite deck as recited in claim 2, wherein said second opening is matched with said first opening.

4. The composite deck as recited in claim 2, wherein said first opening and said second opening are circular.

5. The composite deck as recited in claim 2, wherein said first opening and said second opening are rectangular.

6. The composite deck as recited in claim 2, wherein said first opening and said second opening can be of any geometrical shape.

7. The composite deck as recited in claim 1, wherein said first upturned flange and said second upturned flange are perforated.

8. The composite deck as recited in claim 1, wherein said first upturned flange includes a first base member connected to a first rim, and wherein said second upturned flange includes a second base member connected to a second rim.

9. The composite deck as recited in claim 8, wherein the plane of said first rim and the plane of said second rim are each about parallel with the plane of said first side edge and the plane of said second side edge, respectively, wherein the angle A between said first base member and said first side edge is about 90°, and wherein the angle B between said second base member and said second side edge is about 90°.

10. The composite deck as recited in claim 8, wherein the plane of said first rim and the plane of said second rim are each at an angle with the plane of said first side edge and the plane of said second side edge, wherein the angle A between said first base member and said first side edge is greater than about 90°, and wherein the angle B between said second base member and said second side edge is less than about 90°.

11. A deck section for use in a composite deck system, comprising:
a longitudinally-extending rib formed by a first side wall and a second sidewall connected to a top surface, said first side wall including a first side edge having a first upturned flange, said second sidewall including a second side edge having a second upturned flange, wherein said first upturned flange includes an opening.

12. The deck section as recited in claim 11, wherein said second upturned flange includes a second opening.

13. The deck section as recited in claim 12, wherein said first opening and said second opening are circular.

14. The deck section as recited in claim 12, wherein said first opening and said second opening are rectangular.

15. The deck section as recited in claim 12, wherein said first opening and said second opening can be of any geometrical shape.

16. The deck section as recited in claim 11, wherein said first upturned flange and said second upturned flange are perforated.

17. The deck section as recited in claim 11, wherein said first upturned flange is a nesting flange, and wherein said second upturned flange is an overlapping flange.

18. The composite deck as recited in claim 17, wherein said first flange includes a first base member connected to a first rim, and wherein said second flange includes a second base member connected to a second rim.

19. The composite deck as recited in claim 18, wherein the plane of said first rim and the plane of said second rim are each about parallel with the plane of said first side edge and the plane of said second side edge, respectively, wherein the angle A between said first base member and said first side edge is about 90°, and wherein the angle B between said second base member and said second side edge is about 90°.

20. The composite deck as recited in claim 18, wherein the plane of said first rim and the plane of said second rim are each at an angle with the plane of said first side edge and the plane of said second side edge, respectively, wherein the angle A
between said first base member and said first side edge is greater than about 90°, and wherein the angle B between said second base member and said second side edge is less than about 90°.

21. A deck section for use in a composite deck system, comprising:
a first longitudinally-extending rib formed by a first side wall and a second sidewall connected to a first top surface, said first side wall including a first side edge having a first upturned flange, wherein said first upturned flange includes a first cut, a second cut, and a first fold between said first and second cut;
a second longitudinally-extending rib that is adjacent to said first longitudinally-extending rib, said second longitudinally-extending rib formed by a third side wall and a fourth sidewall connected to a second top surface, said third side wall including a second side edge having a second upturned flange, wherein said second upturned flange includes a third cut, a fourth cut, and a second fold between said third and fourth cut, and wherein said second fold covers said first fold so that said second fold and said first fold are nested.