GB2550426A - A metal decking sheet and composite slab and related methods - Google Patents

A metal decking sheet and composite slab and related methods Download PDF

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Publication number
GB2550426A
GB2550426A GB1608951.8A GB201608951A GB2550426A GB 2550426 A GB2550426 A GB 2550426A GB 201608951 A GB201608951 A GB 201608951A GB 2550426 A GB2550426 A GB 2550426A
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GB
United Kingdom
Prior art keywords
sheet
metal decking
decking sheet
metal
slab
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
GB1608951.8A
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GB201608951D0 (en
Inventor
Martin Thomas
Gibney Viv
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kingspan Holdings IRL Ltd
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Kingspan Holdings IRL Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kingspan Holdings IRL Ltd filed Critical Kingspan Holdings IRL Ltd
Priority to GB1608951.8A priority Critical patent/GB2550426A/en
Publication of GB201608951D0 publication Critical patent/GB201608951D0/en
Publication of GB2550426A publication Critical patent/GB2550426A/en
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • E04B5/38—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element
    • E04B5/40—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element with metal form-slabs
    • 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
    • E04C2/08—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 metal, e.g. sheet 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
    • E04C2/32—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/322—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with parallel corrugations
    • 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
    • E04C2/32—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/324—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with incisions or reliefs in the surface
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/24—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
    • E04D3/30—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like of metal
    • 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
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B2005/322—Floor structures wholly cast in situ with or without form units or reinforcements with permanent forms for the floor edges
    • 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
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B2005/324—Floor structures wholly cast in situ with or without form units or reinforcements with peripheral anchors or supports

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)

Abstract

The decking sheet 1 includes a number of raised projections 50 which are cut part way into a upper surface 4 of the sheet. The projections are located at discrete locations and separated from underlying metal while leaving an end of the discrete portions attached to the metal decking sheet. The projections are formed from a part thickness of the metal sheet and could be upto 50% of the thickness but possibly 30%. The metal decking sheet may be made from a series of corrugations including troughs and ridges. The decking may be used to make a slab (25, Figure 2) with concrete material reinforced with fibres. The projections may be formed by scoring or a die pressing.

Description

Title A Metal Decking Sheet and Composite Slab and Related Methods Field of the Invention [0001] The present invention relates to a metal decking sheet, a composite article comprising the metal decking sheet and a building slab; a method of manufacturing the metal decking sheet, a method of forming the composite article, and a building comprising the composite article.
[0002] It is known to provide a metal decking sheet as part of the structure of a building. For example the metal decking sheet may be part of a floor or a roof of a building.
Background to the Invention [0003] It is known to provide a metal decking sheet as part of the structure of a building. For example the metal decking sheet may be part of a floor or a roof of a building. Often times a series of metal decking sheets are laid out in a desired layout. They together form a support pan such as a floor or roof pan. They may overlap with each other. They are fixed in place, often times by being attached to a supporting framework for a building, for example a steel framework. They form a support surface onto which a slab forming material, such as concrete, can be applied, for example by pouring. The metal decking sheet and the material together form a composite structure for example a composite slab.
[0004] Material is applied to the metal decking sheets in order to form the composite slab. For example pourable slab forming material, such as concrete, may be applied, for example by pouring. It is then spread and/or levelled and/or compacted as desired. The material is then allowed to dry. For the purposes of the present invention allowing a material to dry includes not only drying in ambient conditions but also active drying.
[0005] Once dried, for example hardened or set, the slab forming material forms a slab which is attached to the metal decking sheets thus forming a composite slab. The composite slab would typically form a structural part of a building, for example a load-bearing surface such as part of an (entire) floor or part of an (entire) roof.
[0006] While such arrangements are useful, it is possible to improve the options available, including for example the load-bearing capacity of the composite slab. In particular, it would be useful to provide a composite slab which had greater load bearing ability. This would mean that similar load-bearing capacity could be provided with reduced amounts of materials, for example reduced amounts of the slab forming material. So for example the overall thickness of the composite slab could be reduced while maintaining a desired load-bearing strength.
Summary of the Invention [0007] In one aspect, the present invention provides a metal decking sheet for supporting a building slab wherein the sheet has a series of raised projections which are formed by cutting part way into an upper surface of the decking sheet at discrete locations so as to separate discrete portions of the metal decking sheet from underlying metal of the metal decking sheet while leaving an end of said discrete portions attached to the metal decking sheet and forming said discrete portions of the metal into raised projections.
[0008] This means that the raised projections are formed from a part thickness of the metal decking sheet. The remaining (underlying) thickness of the metal decking sheet is left in place. An island of metal is cut from the metal decking sheet and raised. This leaves a depression or well in the metal decking sheet. However, in a metal decking sheet of the invention, forming the raised projections does not create any apertures through the metal decking sheet. The depressions or wells in the metal decking sheet are areas of lesser thickness in the metal decking sheet that form the base to the depressions or wells and the depressions or wells are bounded by portions of the metal decking sheet which have the full thickness of the metal decking sheet.
[0009] A sliver of metal is raised from the metal decking sheet and is formed into a projection. While being raised it remains attached at one end to the metal decking sheet.
[0010] The projections raised form grips or keys for gripping or keying into a slab of material applied to the metal decking sheet. This means that the composite structure is stronger because the projections are embedded in the slab. The projections are keyed into the slab.
[0011] The metal decking sheet may have other engagement means for interlocking with the slab, for example interlocking with concrete poured onto it when the concrete has set. This forms a composite slab.
[0012] In order to ensure embedding of the projections in the slab of material, it is desirable that the slab of material is applied in a workable form, for example in a pourable form. This means that the slab material can be provided in, for example worked into, the spaces between the projections and thus increased the integrity of the engagement between the metal decking sheet and the slab of material in the resultant composite slab.
[0013] The composite slab thus formed has a greater strength than a corresponding composite slab which does not have the raised projections of the present invention.
[0014] In particular it is possible to achieve an at least 5% increase, for example an at least 10% increase, such as a 15% increase, in strength compared to a composite slab which does not have the raised projections of the present invention.
[0015] References to the strength of an object in the present invention relates to compressive strength, unless otherwise indicated.
[0016] This means that a composite slab of the present invention has greater load bearing capacity. This in turn means that similar strength or load-bearing capacity can be provided with reduced amounts of materials, for example reduced amounts of the slab forming material. So for example the overall thickness of the composite slab could be reduced while maintaining a desired load-bearing capacity or strength.
[0017] The projections are desirably shaped to grip the slab of material. For example they may have a catching edge that catches the slab of material and resists separation of the metal decking sheet from the slab of material.
[0018] For better gripping the projections may face in opposite directions. For example, series of projections may face in one direction and other series may face in an opposite direction.
[0019] Each of the series of raised projections has a base end attached to the metal decking sheet and a distal end spaced apart from the metal decking sheet.
[0020] So the metal of the (thickness of the) decking sheet is split and part is left in place and part is raised to form each projection. In particular one end of the piece of metal forming each projection is left attached to the metal while the other end is lifted free of the metal decking sheet. The base end is the end left attached to the metal decking sheet. The distal end is the end of the projection that is lifted free of the metal decking sheet [0021] Optionally at its base end the projection has a greater cross sectional area than it has at its distal end.
[0022] For example each of said series of raised projections may narrow in a direction from the base end toward the distal end. They may narrow in a tapering fashion or they may be stepped.
[0023] Desirably each of said series of raised projections has a pointed profile. For example the base end may be greater in cross-sectional area and the distal end may be pointed.
[0024] Suitably each of said series of raised projections has a hooked profile for example forming a hook. The hook provides a catching edge for catching/gripping/keying into the slab of material.
[0025] The metal decking sheet will typically have a substantially uniform thickness.
The metal decking sheet may have a thickness of from about 0.5 mm to about 2mm, such as from about 0.6 mm to about 1.5 mm, for example 0.7 mm to about 1.2 mm, including 0.7 mm to 1.1 mm. The metal decking sheet may have a thickness of from about 0.8 mm to about 1mm, for example the metal decking sheet may have a thickness of about 0.8 mm; about 0.9 mm or about 1 mm.
[0026] Each of said series of raised projections may be formed by raising a metal portion which has a thickness of up to 50%, for example up to 40%, such as up to 30% of the thickness of the metal decking sheet. Each of said raised portions may be formed by raising a metal portion which has a thickness of at least about 10% of the thickness of the metal decking sheet. Each of said series of raised projections may be formed by raising a metal portion which has a thickness of from about 0.07mm to about 0.6 mm, suitably 0.08 mm to 0.5 mm, more suitably from about 0.1 mm to about 0.4 mm.
[0027] Each of said series of raised projections may be formed from a piece of metal that has a height that is up to 5 times the thickness of the metal decking sheet. The metal decking sheet will typically have a substantially uniform thickness. To the extent that the thickness varies, then the raised projections may be formed with the height that is up to 5 times the height of the thickness of the metal decking sheet the place in which the projection is formed.
[0028] Each of said series of raised projections may have a height from the metal decking sheet (as measured perpendicularly from the part of the sheet to which it is attached) that is from about 0.5 mm to about 3 mm suitably from about 0.6 to about 2.7 mm, more suitably from about 0.7 mm to about 2.6 mm.
[0029] The metal decking sheet may be profiled. For example it may have defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second of the sheet.
[0030] The ridge may have embossed therein a raised reinforcing embossment running from a first end of the sheet to a second end of the sheet.
[0031] The trough may have embossed therein at least one and desirably at least two raised ribs running from a first end of the sheet to a second end of the sheet. The ribs key into the slab of material during formation of the composite slab.
[0032] As the decking sheet is formed from a continuous sheet of metal it will be appreciated that the troughs and the ridges are connected. Portions (for example sidewalls) of the metal decking sheet run from the ridges to the troughs. These portions may be inclined.
[0033] The portions of the metal decking sheet running from the ridges to the troughs may have embossed therein a series of shear keys which optionally run transverse to a longitudinal direction of a trough.
[0034] Desirably the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second of the sheet and the series of raised projections are formed in an upper surface of at least one trough and desirably formed in an upper surface of each trough.
[0035] The series of raised projections may be formed only in an upper surface of at least one trough and may be formed only in an upper surface of each trough. (Other parts of the metal decking sheet will not be provided with any raised projections.) [0036] The series of raised projections may be formed only in an upper surface of at least one trough and may be formed only in an upper surface of each trough.
[0037] A metal decking sheet according to the invention may be provided wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and the series of raised projections are only formed in an upper surface of at least one ridge and may be only formed in an upper surface of each ridge.
[0038] A metal decking sheet according to the invention may be provided wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and wherein the series of raised projections are formed in an upper surface of at least one of the portions of the metal decking sheet running from the ridges to the troughs and are desirably formed in an upper surface of each portion of the metal decking sheet running from the ridges to the troughs.
[0039] A metal decking sheet according to the invention may be provided wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and wherein the series of raised projections are only formed in an upper surface of at least one of the portions of the metal decking sheet running from the ridges to the troughs and are desirably only formed in an upper surface of each portion of the metal decking sheet running from the ridges to the troughs.
[0040] A metal decking sheet according to the invention may be provided wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second of the sheet and the series of raised projections are formed in an upper surface of at least one trough and in an upper surface of at least one ridge and are desirably formed in an upper surface of each trough and an upper surface of each ridge.
[0041] A metal decking sheet according to the invention may be provided wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second of the sheet and the series of raised projections are formed only in an upper surface of at least one trough and in an upper surface of at least one ridge and are desirably only formed in an upper surface of each trough and an upper surface of each ridge.
[0042] The invention also relates to a composite slab comprising a metal decking sheet according to the invention and a slab of material attached to each other, the slab of material may be formed by pouring a slab forming material onto the metal decking sheet and allowing the slab forming material to harden. The raised projections assist in attaching the slab to the metal decking sheet.
[0043] The slab of material may be a concrete material.
[0044] The slab of material is desirably a reinforced material.
[0045] The slab of material may be a reinforced material for example reinforced by bars and/or fibres.
[0046] Desirably the material is reinforced by fibres, for example metal fibres. Desirably the fibres are suitable for mixing with a workable material for example mixed with workable concrete. For example they may be added as a component that is mixed in during formation of the workable material.
[0047] Suitably the slab of material is fibre reinforced, for example is metal fibre, reinforced concrete.
[0048] The ridges and/or troughs may be substantially trapezoidal in shape for example forming three sides of a trapezoidal shape. The metal decking sheet may be cold formed.
[0049] The invention also relates to a method of forming a metal decking sheet for supporting a building slab wherein the sheet has a series of raised projections comprising: (i) cutting part way into an upper surface of the decking sheet at discrete locations so as to separate discrete portions of the metal decking sheet from underlying metal of the metal decking sheet while leaving an end of said discrete portions attached to the metal decking sheet; and (ii) forming said discrete portions of the metal into raised projections.
[0050] As above, while a portion of the thickness of the metal decking sheet is raised, no aperture through the metal decking sheet is formed. Accordingly the material for forming the slab cannot pass through the metal decking sheet.
[0051] Cutting partway into the metal decking sheet may be achieved by scoring. For example a rotary cutting head may be utilised.
[0052] Cutting part way into the metal decking sheet and forming said discrete portions may be achieved by die pressing.
[0053] The invention also relates to a method of forming a composite slab comprising: (i) providing a metal decking sheet according to the invention (and as set out above): (ii) pouring a slab forming material onto the metal decking sheet and allowing the slab forming material to harden; wherein the raised projections assist in attaching the slab to the metal decking sheet.
[0054] The invention also relates to a building comprising, as a structural element, a composite slab according to the present invention.
[0055] The invention extends to a metal decking sheet and also to a composite slab as described herein with reference to and as illustrated in the accompanying drawings.
Brief Description of the Drawings [0056] Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings (note: drawings are not to scale) in which: [0057] Figure 1 is a perspective view of a metal decking sheet of the invention (hatching indicates the surfaces on which raised projections are formed); [0058] Figure 2 is a perspective partial view of a building structure comprising a building framework structure, a composite slab comprising a metal decking sheet of the invention and a slab material (hatching indicates the surfaces on which raised projections are formed); [0059] Figure 3 is an end partial view of a building structure comprising a building framework structure, and a metal decking sheet of the invention; [0060] Figure 4 is an end partial view of a building structure comparable to that of Figure 3 where the metal decking sheet forms part of a composite slab (similar to Figure 1); [0061] Figure 5 is an enlarged perspective partial view of a metal decking sheet of the invention showing raised projections; [0062] Figure 6 is a side partial view of a metal decking sheet of the invention showing raised projections; [0063] Figure 7 is a side partial view of a composite slab of the invention showing a raised projection on a metal decking sheet of the invention embedded in a slab material; [0064] Figure 8 is a perspective view of a metal decking sheet of the invention (hatching indicates the surfaces on which raised projections are formed); and [0065] Figure 9 is a perspective view of a metal decking sheet of the invention (hatching indicates the surfaces on which raised projections are formed).
Detailed Description of the Drawings [0066] Figure 1 is a perspective view of a metal decking sheet 1 of the invention. The metal decking sheet is for supporting a building slab 20. The metal decking sheet 1 and the slab 20 together form part of the structure 30 of a building. For example the metal decking sheet 1 may be part of a floor or a roof of a building. It will be appreciated that to provide the desired structure a series of metal decking sheets may be laid out in a desired layout. For example they together form a support for a floor or roof. They may overlap with each other. Once in place a slab forming material can be applied across all the metal decking sheets. For ease of describing this invention however, a single metal decking sheet 1 will be referenced even though in practice a plurality of decking sheets such as an array of decking sheets will be employed.
[0067] The metal decking sheet 1 is fixed in place, being attached to a supporting framework for a building, for example a steel framework 31. It forms a support surface onto which a slab forming material, such as concrete, can be applied, for example by pouring to form a building slab 20. The metal decking sheet 1 and the material together form a composite structure for example a composite slab 25.
[0068] The material is applied to the metal decking sheet 1 in order to form the composite slab 25. For example workable slab forming material, such as concrete, may be applied, for example by pouring. It is then spread and/or levelled and/or compacted as desired, for example into a desired slab shape. The material is then allowed to dry by drying in ambient conditions or active drying.
[0069] Once dried, for example hardened or set, the slab forming material forms a slab 20 which is attached to the metal decking sheet 1 thus forming the composite slab 25.
The composite slab 25 would typically form a structural part of a building, for example a load-bearing surface 26 such as a floor or roof.
[0070] The metal decking sheet 1 is profiled. The profile is defined by alternating troughs 5 and ridges 6 running alongside each other from a first end 2 of the sheet to a second end 3 of the sheet. The opposing sides 7,8 of the metal decking sheet 1 have respective upstanding walls 9,10. A smaller trough 11 is formed between the respective walls 9 and 10 and the respective adjacent ridge 6. The wall 9 is formed by a folded over piece of the metal decking sheet 1.
[0071] Each ridge 6 forms three sides of a generally trapezoidal shape. In particular a ridge 6 has a crown part 15 and respective left and right inclined side walls 16,17.
[0072] Each ridge 6 has embossed therein a raised reinforcing embossment 18 running from a first end 2 of the sheet to a second end 3 of the sheet 1.
[0073] The respective bases of the troughs 5 are defined by respective base portions 2 running between respective wall 17 and 16 of the ridges 6. The respective bases of the troughs 11 are defined by respective base portions 2 running between respective walls 9 and 16, and 17 and 10.
[0074] The troughs 5 have embossed therein two raised ribs 23 running from a first end of the sheet 2 to a second end of the sheet 3. These provide strength to the metal decking sheet 1. The metal decking sheet 1 is formed from (for example cold pressed from) a continuous sheet of metal.
[0075] The portions of the metal decking sheet 1 running from the ridges to the troughs may have embossed therein a series of shear keys which optionally run transverse to a longitudinal direction of a trough. The shear keys may example be of a type described in GB 2 340 146 the entire contents of which, and in particular the contents relating to type and positioning of shear keys, are incorporated herein with reference.
[0076] Figure 2 is a perspective partial view of a building structure comprising a building framework structure 30, a composite slab 25 comprising a metal decking sheet 1 of the invention and a slab material 20. It will be appreciated that in Figure 2 the building slab 20 has, for the purposes of illustration, been shown cut back from the front end 2 of the metal decking sheet 1.
[0077] The metal decking sheet 1 has been put in place and attached by a series of fasteners 27 (only one fastener 27 is shown in Figure 2). Also provided is an upstand 35 which defines the outer border of the slab material 20. The upstand 35 is attached by a series of fasteners 39 (only one fastener 39 is shown in Figure 2) to the steel framework 31. A brace 36 braces the upstand 35 to the metal decking sheet 1. A fastener 37 fastens the brace 36 to the upstand 35. A further fastener 28 fastens the brace 36 to the metal decking sheet 1, and in particular to a ridge 6 thereof. It will be appreciated that a number of braces may be employed.
[0078] A series of pins 34 are provided in the steel framework 31 (only one pin 34 is shown in Figure 2). When the slab forming material forms the building slab 20 it will encase the pins 34 thus providing structural integrity between the slab 20 and the steel framework 31.
[0079] Figure 3 is an end partial view of a building structure comprising a building framework structure 30, and a metal decking sheet 1 of the invention and thus shows an alternative view to that of Figure 2 with the metal decking sheet 1 as shown in Figure 1 attached to the framework structure 30.
[0080] Figure 4 is an end partial view of a building structure comparable to that of Figure 3 where the slab 20 has been formed, for example by pouring concrete onto the metal decking sheet 1, and the slab 20 and the metal decking sheet are now a composite slab 25.
[0081] As best seen from Figures 5 to 7 the metal decking sheet 1 has a series of raised projections 50. The projections 50 are formed by cutting part way into an upper surface 4 of the metal decking sheet 1 at discrete locations so as to separate discrete portions of the metal decking sheet from underlying metal of the metal decking sheet while leaving an end of said discrete portions attached to the metal decking sheet. The discrete portions of the metal into raised projections.
[0082] With reference to Figures 5 and 6, each projection 50 is formed from a strip or sliver of metal 51. A first raised end 55 of the sliver of metal 51 has been lifted away from the upper surface 4 of the metal decking sheet 1. A lower or base end 56 of the sliver of metal 51 remains attached to the metal decking sheet 1. The metal decking sheet 1 has a thickness indicated as T. It will be noted that the raised projections 50 are in the form of hooks. Furthermore, as exemplified in Figures 5 and 6 hook shapes of the raised portions 50 may face in opposing directions. This may achieve better gripping/keying in the slab 20.
[0083] The raised projections 50 are formed from a partial thickness Tp of the metal decking sheet 1. The remaining (underlying) thickness Tu of the metal decking sheet is left in place. So T = Tu + Tp. In effect an island of metal is cut from the metal decking sheet 1 and raised. This leaves a corresponding depression or well 57 in the metal decking sheet 1. However, in a metal decking sheet 1 of the invention, forming the raised projections 50 does not create any apertures through the metal decking sheet.
This is important because the slab forming material, for example concrete, cannot then pass through the metal decking sheet 1.
[0084] Figure 7 is a side partial view of a composite slab 25 of the invention showing a raised projection 50 on a metal decking sheet 1 of the invention embedded in a slab material 20. It is clear then that the raised projection 50 forms a good grip/key in the slab material 20. This in turn means that the strength of the composite slab 25 is greater than that of a comparable slab which does not have the raised projections 50.
[0085] There is a choice as to where to place the raised projections 50 on the decking sheet 1. It would be desirable to provide them on all parts of the upper surface 4 of the metal decking sheet 1. However, for ease of production, and reasons of economy, it may be desirable to select certain areas and produce the raised projections 50 on those.
[0086] The hatch line areas 60 in the various figures illustrate areas on which the raised projections 50 may be formed. It may be desirable to only form raised projections 50 on those areas indicated.
[0087] For example as illustrated in Figures 1-4 by the hatch line areas 60 the series of raised projections 50 may (only) be formed in the upper surface of opposing side walls 16,17 of at least one ridge 6 and desirably (only) formed in an upper surface of opposing side walls 16,17 of each ridge 6.
[0088] For example as illustrated in Figure 8 by the hatch line areas 60 the series of raised projections 50 may (only) be formed in an upper surface of (the base portion 21 of) at least one trough 5,11 and desirably (only) formed in an upper surface (of the base portion 21) of each trough.
[0089] For example the series of raised projections 50 may (only) be formed in an upper surface of (a crown 15 of) at least one ridge 6 and desirably (only) formed in an upper surface (a crown 15 of) of each ridge 6. Where the upper surface of the ridge 6 has embossed therein a raised reinforcing embossment 18 running from a first end 2 of the sheet to a second end 3 of the sheet 1 the raised projections 50 may (only) be formed in an upper surface of (a crown 15 of) the ridge on either side of the raised reinforcing embossment 18. (See Figure 9 for an embodiment which has the raised projections 50 formed in an upper surface of (a crown 15 of) the ridge on both sides of the raised reinforcing embossment 18.
[0090] Where (the base portion 21 of) a trough 5 has embossed therein one or more raised ribs 23 the raised projections 50 may be formed in an upper surface of (the base portion 21 of) that trough 5 at a position non-coincident with the raised ribs 23. Figure 8 illustrates an embodiment where the raised projections 50 have been provided on an upper surface of (the base portions 21 of) the troughs 5 on either side of the raised ribs 23.
[0091] For example as illustrated in Figure 9 by the hatch line areas 60, the series of raised projections 50 may be formed in an upper surface of a trough and an upper surface of a ridge. The raised projections 50 may (only) be formed in an upper surface of at least one trough 5,11 and desirably (only) formed in an upper surface of each trough and raised projections 50 may (only) be formed in an upper surface of at least one ridge 6 and desirably (only) formed in an upper surface of each ridge.
[0092] The words “comprises/comprising” and the words “having/including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
[0093] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

Claims (35)

Claims
1. A metal decking sheet for supporting a building slab wherein the sheet has a series of raised projections which are formed by cutting part way into an upper surface of the decking sheet at discrete locations so as to separate discrete portions of the metal decking sheet from underlying metal of the metal decking sheet while leaving an end of said discrete portions attached to the metal decking sheet and forming said discrete portions of the metal into raised projections.
2. A metal decking sheet according to claim 1 wherein each of said series of raised projections has a base end attached to the metal decking sheet and a distal end spaced apart from the metal decking sheet and optionally wherein the base end has a greater cross sectional area than the distal end.
3. A metal decking sheet according to any preceding claim wherein each of said series of raised projections narrows in a direction from the base end toward the distal end.
4. A metal decking sheet according to any preceding claim wherein each of said series of raised projections has a pointed profile.
5. A metal decking sheet according to any preceding claim wherein each of said series of raised projections has a hooked profile.
6. A metal decking sheet according to any preceding claim wherein each of said series of raised projections is formed by raising a metal portion which has a thickness of up to 50%, for example up to 40%, such as up to 30% of the thickness of the metal decking sheet.
7. A metal decking sheet according to any preceding claim wherein each of said series of raised projections is formed by raising a metal portion which has a thickness of from about 0.07mm to about 0.6 mm, suitably 0.08 mm to 0.5 mm, more suitably from about 0.1 mm to about 0.4 mm.
8. A metal decking sheet according to any preceding claim wherein each of said series of raised projections has a height above the sheet (as measured perpendicularly to the sheet) that is at is up to 5 times the thickness of the metal decking sheet.
9. A metal decking sheet according to any preceding claim wherein the metal decking sheet has a thickness of from about 0.5 mm to about 2mm, such as from about 0.6 mm to about 1.5 mm, for example 0.7 mm to about 1.2 mm, including 0.7 mm to 1.1 mm.
10. A metal decking sheet according to any preceding claim wherein the metal decking sheet has a thickness of from about 0.8 mm to about 1mm, for example the metal decking sheet may have a thickness of about 0.8 mm; about 0.9 mm or about 1 mm.
11. A metal decking sheet according to any preceding claim wherein each of said series of raised projections has a height above the sheet (as measured perpendicularly to the sheet) that is from about 0.5 mm to about 3 mm suitably from about 0.6 to about 2.7 mm, more suitably from about 0.7 mm to about 2.6 mm.
12. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and at least one and desirably each ridge has embossed therein a raised reinforcing embossment running from a first end of the sheet to a second end of the sheet.
13. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and the trough has embossed therein at least one and desirably at least two raised ribs running from a first end of the sheet to a second end of the sheet.
14. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and the portions of the metal decking sheet running from the ridges to the troughs are inclined.
15. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and wherein the portions of the metal decking sheet running from the ridges to the troughs have embossed therein a series of shear keys.
16. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and wherein the portions of the metal decking sheet running from the ridges to the troughs have embossed therein a series of shear keys and optionally the shear keys run transverse to a longitudinal direction of a trough.
17. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second of the sheet and the series of raised projections are formed in an upper surface of at least one trough and desirably formed in an upper surface of each trough.
18. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second of the sheet and the series of raised projections are only formed in an upper surface of at least one trough and desirably only formed in an upper surface of each trough.
19. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and the series of raised projections are formed in an upper surface of at least one ridge and desirably formed in an upper surface of each ridge.
20. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and the series of raised projections are only formed in an upper surface of at least one ridge and desirably only formed in an upper surface of each ridge.
21. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and the series of raised projections are only formed in an upper surface of at least one ridge and desirably only formed in an upper surface of each ridge.
22. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and wherein the series of raised projections are formed in an upper surface of at least one of the portions of the metal decking sheet running from the ridges to the troughs and are desirably formed in an upper surface of each portion of the metal decking sheet running from the ridges to the troughs.
23. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and wherein the series of raised projections are only formed in an upper surface of at least one of the portions of the metal decking sheet running from the ridges to the troughs and are desirably only formed in an upper surface of each portion of the metal decking sheet running from the ridges to the troughs.
24. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second end of the sheet and the series of raised projections are formed in an upper surface of at least one trough and in an upper surface of at least one ridge and are desirably formed in an upper surface of each trough and an upper surface of each ridge.
25. A metal decking sheet according to any preceding claim wherein the decking sheet is profiled having defined therein alternating troughs and ridges running alongside each other from a first end of the sheet to a second of the sheet and the series of raised projections are formed only in an upper surface of at least one trough and in an upper surface of at least one ridge and are desirably only formed in an upper surface of each trough and an upper surface of each ridge.
26. A composite slab comprising a metal decking sheet according to any preceding claim and a slab of material attached to each other, the slab of material formed by providing a workable slab forming material on, for example pouring a slab forming material onto, the metal decking sheet and allowing the slab forming material to harden wherein the raised projections assist in attaching the slab to the metal decking sheet.
27. A composite slab according to Claim 26 wherein the slab of material is concrete material.
28. A composite slab according to any of claims 26 or 27 wherein the slab of material is a reinforced material.
29. A composite slab according to any one of claims 26 to 28 wherein the slab of material is a reinforced material being reinforced by bars and/or fibres.
30. A composite slab according to any one of claims 26 to 29 wherein the slab of material is fibre reinforced, for example is metal fibre, reinforced concrete.
31. A method of forming a metal decking sheet for supporting a building slab wherein the sheet has a series of raised projections comprising: (a) cutting part way into an upper surface of the decking sheet at discrete locations so as to separate discrete portions of the metal decking sheet from underlying metal of the metal decking sheet while leaving an end of said discrete portions attached to the metal decking sheet; and (b) forming said discrete portions of the metal into raised projections.
32. A method according to claim 31 wherein cutting partway into the metal decking sheet is achieved by scoring.
33. A method according to claim 31 or 32 wherein cutting part way into the metal decking sheet and forming said discrete portions is achieved by die pressing.
34. A method of forming a composite slab comprising: (a) providing a metal decking sheet according to any of claims 1 to 25 (b) pouring a slab forming material onto the metal decking sheet and allowing the slab forming material to harden; wherein the raised projections assist in attaching the slab to the metal decking sheet.
35. A building comprising as a structural element a composite slab according to any one of claims 26 to 30.
GB1608951.8A 2016-05-20 2016-05-20 A metal decking sheet and composite slab and related methods Withdrawn GB2550426A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3789553A1 (en) * 2019-09-06 2021-03-10 Lenz, Tankred Prefabricated construction element and prefabricated system

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3812636A (en) * 1971-05-26 1974-05-28 Robertson Co H H Sheet metal decking unit and composite floor construction utilizing the same
US4251970A (en) * 1978-05-30 1981-02-24 Home Matti P Thin sheet having punched-out adhesion projections for use in compound structures, and compound structures constructed therewith

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3812636A (en) * 1971-05-26 1974-05-28 Robertson Co H H Sheet metal decking unit and composite floor construction utilizing the same
US4251970A (en) * 1978-05-30 1981-02-24 Home Matti P Thin sheet having punched-out adhesion projections for use in compound structures, and compound structures constructed therewith

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3789553A1 (en) * 2019-09-06 2021-03-10 Lenz, Tankred Prefabricated construction element and prefabricated system

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