US20070175141A1

US20070175141A1 - Apparatus and Method for Forming an Elevated Deck

Info

Publication number: US20070175141A1
Application number: US11/620,538
Authority: US
Inventors: Van Smith; Roman Brewka
Original assignee: Western Forms Inc
Current assignee: Western Forms Inc
Priority date: 2006-01-05
Filing date: 2007-01-05
Publication date: 2007-08-02
Also published as: WO2007082150A2; WO2007082150A3

Abstract

An system and method for forming an elevated deck and support beam within a structure enables the pouring of one or a succession of superposed decks above a surface such as a floor, the ground or other supporting surface. The system includes a plurality of profiles which alone or in combination define concrete-receiving reservoirs for forming poured in place support beams, with the elevated deck being poured contemporaneously therewith for support on the beams. The profiles include first and second preferably divergent sidewalls which are connected by middle member which serves as a base or bridge between the sidewalls. The profiles are complementally configured to nest with one another to provide a span across structural walls, and may be provided with complementally configured end caps.

Description

This application claims the benefit of U.S. Provisional Application No. 60/756,506 filed Jan. 5, 2006.

FIELD OF THE INVENTION

The present invention relates generally to the field of construction and, more specifically, to a method and apparatus for forming an elevated floor and support beams supporting the floor.

BACKGROUND OF THE INVENTION

Concrete is a cementatious material which is a versatile and commonly used building material and particularly useful in forming floors and walls of building structures. These structures can be of varied size and design thereby requiring concrete to be poured and shaped in different quantitites as well as in differing dimensions. Currently, in the concrete industry, a high demand for lumber has forced a shift to using concrete in order to reduce the number of trees being harvested for lumber. One barrier to continuing this trend to the use of concrete has been the lack of an elevated floor pouring system that does not depend on repetitive dimensions in order to be economical to manufacture.
Generally, an elevated deck is produced using a plurality of construction materials. A first manner of producing an elevated concrete deck uses pre-fabricated concrete slabs. However, the cost of producing, manipulating and setting these slabs is high. Using pre-fabricated slabs also requires heavy machinery to be employed for transporting and correctly positioning the slabs in order to produce the desired deck. Additionally, the use of slabs results in the need for further workmanship in order to create a single, level surface by covering the seams between each of the individual slabs. Devices exist which attempt to remedy some of the noted drawbacks such as the system described by Zambelli et al. in U.S. Pat. No. 6,457,288 which provides a self-supporting and walkable pre-fabricated panel. However, this system requires a long pre-order schedule and further requires a user to provide the manufacturer with precise dimensions associated with the panels.
Another method for producing a concrete deck is disclosed in U.S. Pat. No. 6,272,749 issued to Boeshart et al. Therein, a method for producing a single-use form panel insert from an extrudable material, such as plastics, is disclosed. The form panel is cut and positioned side-by-side and between each panel is a channel able to receive support beams. Concrete is subsequently poured over the panels to form a deck. However, this method uses form panels that are not re-useable. Additionally, the panels used in the Boeshart et al. system requires the order therefore to be placed far in advance of intended use and, similarly to the Zambelli et al. system, requires precise dimensions be provided at the time of order.
A further form system for poured concrete is described by Boeshart in U.S. Pat. No. 6,817,150. This system is similar to the system described in U.S. Pat. No. 6,272,749 and also includes a plurality of hat members able to be positioned on a top surface of the form in order to selectively increase the thickness thereof. The positioning of hat members provides a greater depth for the slots between the form panels in which the concrete will flow. Similarly to the device above described Boeshart et al. system, this system requires the order therefore to be placed far in advance of intended use and requires precise dimensions be provided at the time of order.
Therefore, a need exists for a method and system that allows for the creation of an elevated deck that is flexible with respect to the desired dimensions of the structure created therefrom and that is re-useable. The system according to the invention principles satisfies these needs and remedies the above-noted drawbacks.

SUMMARY OF THE INVENTION

These objects have largely been achieved by the apparatus and method for forming an elevated deck in accordance with the present invention. The present invention includes a profile form which is especially configured for receiving concrete on the generally upper surface thereof and alone, or in combination with other similar profiles, forming a deck and a support beam or beams which support the deck.
In one aspect of the present invention, each of the profile forms include first and second end sections connected by a midsection. The midsection includes first and second side walls extending from the first and second end sections, respectively, and connected by a base section to form a reservoir between the first and second end sections. Preferably, at least one of the first and second end sections includes a lip for receiving an end section of an adjacently positioned form profile when crating a planar elevated deck whereby the system may incorporate a plurality of form profiles overlapping longitudinally or laterally to thereby adjust or extend to provide an elevated of selected and desired length and width dimension. A support structure is provided for receipt within the reservoir of desired ones of the profile forms. The support structure includes a structure for forming a conduit therethrough, a nailing strip connected to the structure, and a plurality of support bars resting atop the structure wherein concrete poured atop the profile form hardens threrearound securing the support structure within the deck. The profile forms are selectively removeable after the concrete is set and the nailing strip is visible on an underside of the beam formed from the plurality of forms.
In the first aspect of the apparatus and system as broadly described above, the profile is configured in an elongated, generally U-shaped configuration whereby concrete poured between the side walls of the U cures to form a beam for supporting the elevated deck thereabove. In a second aspect of the apparatus and system of the present invention, the profile forms present a generally inverted U-shaped configuration. In this second aspect of the system hereof, the reservoirs for forming the beams are located between two adjacent, side-by-side profiles. The profiles may be overlapped longitudinally to lengthen the resulting beam and deck, and the number of profiles placed side-by-side in generally parallel relationship may be increased to provide the desired lateral dimension to the resulting deck. Advantageously, the profiles may be made of a standard configuration to provide nesting for storage and transport, and overlapping so that a wide variety of length of the constructed deck may be accomplished by overlapping the profiles. Moreover, the laterally adjacent profiles may be overlapped, butted with one side edge against another, or spaced laterally so that a gap is presented between adjacent profiles. While it would be expected that such lateral spacing would present a gap which concrete would pass through, advantageously boards may be placed atop the side edges of the profiles to provide a dual purpose. First, the boards prevent the flow of concrete between the profiles. Moreover, the boards also remain embedded in the cured concrete at the bottoms of the beams formed in the reservoirs defined between the profiles and provide a nailing surface for receiving fasteners for ceilings, hangers and the like. Advantageously, these boards may be merely placed in position covering the side edges of the profiles without the necessity of further attachment to the profiles.
The second aspect of the system and apparatus hereof also advantageously may include end caps which may be attached to the ends of a profile or the ends of two profiles in a plurality of longitudinally placed and aligned series of such profiles to inhibit the passage of flowable concrete into the space below the profiles. The second aspect also contemplates the possible use of brackets to support forms to provide a passage in the elevated deck so that the base of the forms is positioned substantially coplanar with the bottom of the beams formed by the profile. Another preferable component of the second aspect of the invention is the use of one or a plurality of jump rails extending transverse to the longitudinal axis of the profiles to interconnect the profiles in desired spaced relationship.
The invention also includes the methods of forming an elevated concrete deck and support beams corresponding to the first and second aspects of the invention summarized above. The method of the invention may include pouring the elevated concrete deck either continuously with the upright walls of the structure, or first forming the upright walls and then using the formed walls as supports for the systems outlined above.
One method for forming an elevated concrete deck according to the principles of the invention involving the first aspect of the invention described above includes the activities of placing shoring beams between opposing side walls along a length of a structure and positioning a plurality of beam holders at predetermined intervals along the length of a wall on opposing walls of the structure and aligned with each of the shoring beams. A first profile form is positioned within a respective one of the plurality of beam holders and further profile forms are positioned adjacent thereto and along the length of a respective shoring beam extending to the opposing beam holder on the opposing wall. An end section of a profile form positioned in an adjacent beam holder is received by a lip in the end section of the adjacent profile form. The end section of each profile form received within a beam holder is positioned within a lip of an end section of an adjacent profile form along the width of the wall. Once the profile forms are positioned to form a mold of the deck, concrete is poured and received within each of the reservoirs formed by the profiles and atop the profiles creating a level deck connected to and supported by the beams. Upon hardening, the shoring beams are removed and the profiles disengaged from the beams and floor.
In the method involving the first aspect as summarized herein, an insert is positioned within the reservoir of each desired profile and used for forming a concrete beam and elevated deck. The insert includes a structure for forming a conduit through each beam adapted for receiving at least one of pipes, wires and other infrastructural elements. The conduit extends through the beam and parallel to the side walls of the structure. The insert further includes a plurality of stabilizing parts connected to the support structure for providing additional stability to the support beam once formed. The stabilizing bars extend perpendicular to the conduits. A nailing strip is connected to the support structure on a side opposite the stabilizing bars. Upon hardening of the concrete and forming of the beam, the profile form is removed and the nailing strip is exposed, or substantially so, on an underside of the beam. The nailing strip provides means for connecting a panel such as sheetrock thereto.
The method involving the second aspect of the invention is similar to the foregoing in many respects. The profiles are placed so that they extend, alone or in butted or overlapping combination, to substantially span two opposing walls of the structure atop shoring posts and beams as described above. The profiles may be supported at their ends on the structural walls or by boards supported on shoring members or attached to the walls of the structure, to forming panels, or other supports. End caps are attached to the ends of the profiles proximate the side walls of the structure to prevent concrete from leaking into the space below, and a barrier of boards or panels is provided to define the outer surface of the elevated deck in a position so that a surrounding wall is formed of the poured concrete of substantially the same depth as of the beams formed in the reservoirs. Because the profiles are placed in an essentially inverted U-shaped configuration, the reservoirs for the beams are provided between adjacent profiles. Tubular members of synthetic resin, metal or other material which will retain its shape under the weight of the poured concrete may be placed in alignment in an orientation transverse to the longitudinal axis of the profiles to receive conduit, pipes or the like as described above. Reinforcing material such as steel bar or webs are placed in the reservoirs between the profiles, and boards are placed atop the side edges of the profiles as described above. Brackets for supporting forms for passages through the deck are affixed to the underside of some profiles when desired, and jump rails attached to ensure proper positioning of the forms. Pins and wedges connect the jump rail, brackets, and overlapping profiles and end caps. After the concrete is poured atop the system and cured to sufficient hardness, the shoring members are removed, and the wedges knocked from their slots in the pins, the profiles, jump rails, brackets and passage-forming forms may be removed from the bottom of the support beams and deck for reuse. Removal of the profiles is especially easy because of the flexibility of the profiles laterally at their radiused corners. The side walls are free to flex inwardly and the profile readily releases from the concrete above. Only tubular members for the conduit and other infrastructural members, and the boards placed atop the side edges of the profile for use as nailing strips remain with the cured concrete of the elevated deck and support beams.
The resulting elevated deck not only is supported adequately below and to the structure walls, but is economical to construct because the forming members may be reused. Moreover, it is a fillerless forming system in that no special “filler” members must be constructed. Because the profiles are constructed to overlap, the profiles essentially provide a telescoping arrangement longitudinally. The ability to use boards both as nailers and to inhibit the flow of concrete through the openings in the end walls along the sides of the profiles thus provides a great deal of flexibility in terms of the spacing between the profiles, again avoiding the necessity of special “filler” forms. Thus, the inventory of the concrete contractor is reduced, and because the forming members may be reused to a great extent, the resulting elevated deck is constructed not only with consistently sufficient supporting beams having at least a minimum height and width, but also more economically than with other forming methods.
These and other advantages will be readily apparent to those skilled in the art with reference to the detailed description and drawings hereof.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a profile form for use in producing an elevated deck and a beam for supporting the elevated deck according to the principles of the invention;
FIG. 2 is a cross-sectional side view of a profile form including a lip on each end section used in producing an elevated deck and beam for supporting an elevated deck according to the principles of the invention;
FIG. 3 is a side view of an extension leg according to the principles of the invention;
FIG. 4 is a plan view of a structure including beam holders for forming an elevated deck according to the principles of the invention;
FIG. 5 is a cross-sectional side view of a profile form including a support device within a beam holder according to the principles of the invention;
FIG. 6 is a cross-sectional view of the support device taken along line 6-6 of FIG. 5 according to the principles of the invention;
FIG. 7 is a cross-sectional view of the elevated deck and support beams of the structure according to the principles of the invention;
FIG. 8 is a flow diagram detailing a method of forming an elevated deck and beams for supporting the elevated deck according to the principles of the invention;
FIG. 9 is a perspective view of an alternate embodiment of a profile form according to the present invention showing its use in a system including end caps, attachment pins and wedges, jump rails and brackets used with the profile for forming an elevated concrete deck and beams for supporting the elevated deck according to the principles of the invention;
FIG. 10 is an upper perspective view of a system in FIG. 9 being arranged atop a floor and within upright walls of a structure under construction for forming an elevated concrete deck and beams for supporting the elevated deck according to the principles of the invention, with portions of two of the structural walls broken away for clarity;
FIG. 11 is a lower perspective view of the underside of the system shown in FIG. 10 with portions of the floor and upright walls broken away for clarity to show the positioning of the support posts, beams, jump rails and brackets below the profiles according to the principles of the invention;
FIG. 12 is an enlarged lower perspective view of the underside of the system as shown in FIG. 11 showing the profiles and end caps carried by an end support and the positioning of the brackets for use in creating an internal passage through the deck in accordance with the principles of the invention;
FIG. 13 is a fragmentary top plan view of the system of FIG. 9 to show the opening through the deck, the overlapping profiles, and the use steel reinforcements positioned in channels formed by adjacent profiles;
FIG. 14 is an enlarged, fragmentary vertical cross-sectional view taken along line 14-14 of FIG. 13 to show the positioning of the profiles and the form for creating the internal passage, and the location of boards extending along the channels;
FIG. 15 is an upper perspective view of the completed elevated deck including the internal passage provided by the system of FIG. 9;
FIG. 16 is an enlarged lower perspective view of the completed elevated deck shown in FIG. 15 showing the canals formed between the beams, the internal passage, and the provision of transverse openings through the beams.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description describes in detail preferred embodiments of the invention hereof. This discussion should not be construed, however, as limiting the invention to those particular embodiments discussed. Practitioners skilled in the art will recognize numerous other embodiments as well with reference to the drawings and the following description.
Referring now to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 8 illustrate a first embodiment 10 of the system for forming an elevated deck of the present invention, while FIGS. 9 through 16 illustrate a second embodiment 100 of the system of the present invention. In the context of the invention hereof, an elevated deck is to be understood as any substantially horizontal structure element formed by poured-in-place concrete or other cementations material and which is connected to upright walls and vertically spaced above a surface such as a lower floor or the ground, whereby the construction of the elevated deck presents a space between the elevated deck and the floor or ground. That space may be a crawl space, basement, lower floor area in a multilevel structure, porch or other accessible area where the elevated deck is located overhead and in spaced relationship to a surface such as the ground or a floor therebeneath.
FIG. 1 is a perspective view of a profile form 12 for use with the system 10. The profile form 12 includes a first end wall 22 and a second end wall 30. A first side wall 14 and a second side wall 16 each extend at an angle from the first end wall 22 and a second end wall 30 respectively. A base 18 connects the first side wall 14 with the second side wall 16 at a side opposite the connections to the first and second end walls, respectively. The base 18 extend substantially parallel to the first and second end walls 22, 30.
The first end wall 22 includes a first stepped lip 25. The first stepped lip 25 includes a first section 24 connected to the first side wall 14. A second section 28 extends from the first section 24 at an end opposite the connection to the first side wall 14 so as to form a step between the first section 24 and second section 28. Each of the first section 24 and the second section 28 extends substantially parallel to the base 18. The second end wall 30 forms a planar surface extending from the second side wall 16 at an end opposite the base 18. The second end wall 30 extends substantially parallel to the base 18 a predetermined distance from the second side wall 16. The second end wall 30 functions to space the profile form 12 from an adjacently positioned profile form 12. Additionally, when profile forms 12 are positioned adjacently to one another along a length of a structure, the second side wall 30 is received by the second section 28 and against the lip 25 of the first end wall 22 thereby creating a level surface between the second end wall 30 and the first section 24 as shown in FIG. 6. The connection between the first and second side walls 14, 16 and the base 18 form a reservoir 20 for selectively receiving concrete therein and forming a beam as will be discussed hereinafter with respect to FIGS. 5 and 6. Concrete is also poured over the surface formed by the first end wall 22 and the second end wall 30 thereby forming a level surface of an elevated deck. Upon hardening of the cement placed thereon thereby creating the deck and support beams, the profile forms 12 are able to be removed from the beam and deck for re-use at a later date. The profile forms 12 are preferably made from aluminum thereby allowing the forms 12 to be lightweight an easily positionable by hand. However, use of aluminum to form the profile forms 12 is described for purpose of example only and the profiles 12 may be formed from any material that is lightweight and able to retain concrete therein as well as able to be removed from the deck after the concrete hardens. Additionally, the shape of the profile forms 12 provides for the profiles to be stackable. This provides for the forms to be easily transported and/or stored.
FIG. 2 illustrates a profile form 12 for use with the system 10. The profile 12 shown herein is similar to the profile discussed above with respect to FIG. 1. The profile includes the first side wall 14 and the second side wall 16 connected to one another via the base 18. Extending from the first side wall 14 is the first end wall 22. The first end wall 22 includes the first section 24 connected to the first side wall 14 and the second section 28 extends from the first section 24 at an end opposite the connection to the first side wall 14 so as to form a step or lip 25 between the first section 24 and the second section 28. Similarly the profile form 12 shown in FIG. 1, a second end wall 23 extends from an end of the second side wall 16 opposite the base 18. A first section 24 of the second end wall 23 is connected to the second side wall 16 and a second section 28 extends from the first section at an opposite the connection with the second side wall 16 so as to form a step or lip 27 between the first section 24 and the second section 28. The profile form 12 shown herein allows for a user to define a space to remain open in the elevated deck formed using the system 10. This is particularly useful when a user requires an opening for at least one of a stairway or elevator shaft to be included within the structure. Additionally, this profile form 12 allows for use of an extension leg 29 shown in FIG. 3 of a predetermined size to be used to separate adjacent profile forms 12 thereby creating the elevated deck with the concrete beams separated by a distance equal to the length of the extension leg 29. The extension leg 29 may be formed in any desired length and width providing further flexibility to the system 10. The extension leg 29 has a thickness substantially the same as the thickness of the lips 25, 27 thereby providing level surface on which the poured concrete will rest when creating the elevated deck.
A top plan view of a structure 42 within which an elevated deck will be formed is shown in FIG. 4. The structure 42 includes a first wall 43 and a second wall 45 forming a first pair of opposing structural walls 44. A third wall 47 and a fourth wall 49 form a second pair of opposing structural walls 46 and are connected between the first pair of structural walls 44. The second pair of opposing structural walls 46 connect the first pair of walls 44 to one another. The first pair of walls 44 define the length of the structure 42 while the second pair 46 define the width the structure 42. Pairs of beam holders 26 are positioned on opposing sides of the first pair of opposing structural walls 44. While the structure 42 shown herein is rectangular in shape, this is for purposes of example only and the structure may be formed in any geometric shape or design. Additionally, the structure 42 may include any number of walls defining the boundary of the structure 42.
The respective pairs of beam holders 26 are spaced along the length of opposing structural walls 44 and each beam holder 26 secures a respective profile form 12. The reservoirs 20 of the profile forms 12 are positioned within and extend between the pair of beam holders 26 to define a support beam 48 which extends between the first pair opposing structural walls 44. Furthermore, when positioning the profile forms 12, the second end wall 30 of a first profile form 12 is received by and rests on the second section 28 of the first end wall 22 of a profile form 12 is received by and rests on the second section 28 of the first end wall 22 of a profile form 12 positioned adjacent along the length of the wall 44 thereby forming a level surface between the adjacent profile forms 12. When it is desired to have a space within he deck to be formed, the profile form illustrated in FIG. 2 is used leaving a space between adjacent rows of profile forms. The positioning of the profile forms 12 is performed until the area defined by the structural walls is covered by the profile forms 12 in a pattern defining the desired deck to be formed. An exemplary elevated deck including support beams 48 as shown in FIG. 7, is formed by pouring concrete over the plurality of profile forms 12 positioned within the area defined by the structural walls shown in FIG. 4 and allowing the concrete to harden. The beam 48 is formed when concrete is received within the reservoirs 20 of the profile forms 12 and the deck 50 is formed by pouring concrete over the surface formed by the end walls 22, 30 once the plurality of aligned reservoirs 20 are filled with concrete and allowed to harden. The support beams 48 further connect the first wall 43 with the second wall 45. Each beam 48 extends parallel to the third wall 47 and the fourth wall 49. Upon hardening of the concrete, the plurality of the profile forms 12 are selectively removable from the beams 48 and deck 50 to be used again at a later date. The system provides for flexibility with respect to the size and shape of the beams and deck formed within a structure because the profiles 12 overlap with one another and prevent the need for cutting to obtain a desired size or shape. Once the profile forms 12 are removed, they may be easily stacked for compact storage.
FIG. 5 shows a cross-sectional view of the profile form 12 positioned within a respective beam holder 26 and further including a structural support insert 31 positioned within a desired reservoir prior to concrete being received within the reservoir 20 thereof. The beam holder 26 has a shape substantially similar to the profile form 12 and receives the profile form 12 therein. The beam holder 26 includes a first support 15 and a second support 17. The first end wall 22 of the profile form 12 rests atop the first support 15 and the second end wall 30 rests atop the second support 17 thereby retaining the form profile within the beam holder 26.
The insert 31 is selectively received within the reservoir 20. The insert 31 sits on the base 18 of the reservoir 20. The insert 31 includes a support structure 33 defining a conduit 32 able to extend between the first wall 14 and the second wall 16 of the profile form 12 when positioned within the reservoir. The conduit 32 provides a channel that is able to selectively receive at least one of electrical wires and plumbing needed within the structure. Additionally, the conduit 32 may allow security and alarm wiring to pass therethrough. Furthermore, the beam profiles will permit heating ducts, air-conditioning ducts and other ducts to pass therethrough as well as allow for recessed lightening to be included therein. A post 36 extends from one side of the support structure 33. An attachment or nailing strip 38 is connected to the post 36 at an end opposite the support structure 33. When the insert is positioned within the reservoir, the attachment strip 38 is positioned atop the base 18 of profile form 12 and will remain exposed when the profile form 12 is removed from beam 48. The attachment strip 38 is accessible and allows for additional objects such as sheet rock to be selectively attached thereto. The insert 31 further includes a plurality of reinforcement beams 40 positioned on a side of the support structure 33 opposite the post 36 and extending perpendicular to the support structure 33. The reinforcement bars 40 extend parallel to the reservoir 20 when positioned therein and traverse the entire length of the profile form 12 as discussed above with respect to FIG. 3. The reinforcement bars 40 provide additional structural support for the beams 48 supporting the deck 50. The top portion of the insert 31, as shown in FIG. 5, has a width less than the width of the base 20 of the profile form 12 thereby allowing concrete received within the reservoir 20 to form and harden around the insert 31 thereby securing the insert 31 within the beam.
Once the concrete has cured, the plurality of profile forms 12 can begin to be selectively removed from the beam 48 beginning at substantially a midpoint of the beam 48. The final profile forms 12 removed are the ones supported by the beam holder 26. Those profile forms are loosened and slid out from the beam holder 26 and removed therefrom and are able to be used at a later date. Once the profile form is removed, the attachment strips 38 are visible through a base of the beams formed by the concrete and are useable to secure items such as sheet rock to the beams.
FIG. 6 shows a cross-sectional view of the insert 31 resting on the base 18 of the reservoir 20 taken along the line labeled 6-6 in FIG. 5. The insert 31 includes the support structure 33 forming the conduit 32 extending between the first side wall 14 and the second side wall 16 shown in FIG. 5. The post 36 extends from the support structure 33 in a direction towards the base 18 and includes the attachment strip 38 connected thereto at an end opposite the support structure 33. The insert 31 further includes a first support post 35 and a second support post 37. The first support post 35 and the second support post 37 extend angularly between an end of the post 36 adjacent the connection to the support structure 33 and the attachment strip 38. Each of the post 36, the first support post 35 and the second support post 37 have a width substantially the same as one another and substantially less than the width of the reservoir 20. This allows for concrete received within the reservoir 20 to flow therearound. Additionally, each of the post 36, the first support post 35 and the second support post 37 are formed from a material that provides sufficient support for a plurality of reinforcement bars 40 that may be selectively positioned atop the support structure 33. The support structure is preferably formed from at least one of metal and plastic or a combination thereof. Optionally, a dividing insert 39 for separating the inserts and for providing a channel 41 in the formed beam 48 for receiving plumbing or other piping or wires. The dividing insert 39 is shown herein resting atop the base 18 of the reservoir 20 of the profile form 12. Similarly to the support structure 33 forming the conduit 32, the dividing insert 39 extends between the first side wall 14 and the second side wall 16 of the profile 12. The concrete received within the reservoir 20 further flows over the dividing insert 39 thereby defining the position of the channel 41 in the resulting beam 48 formed therefrom. By positioning the dividing insert 39 in substantially the same position within the reservoir 20 of each respective profile forms 12, the channels 41 resulting from the dividing insert 39 will be substantially aligned with one another to further aid in the construction process.
FIG. 7 is a cross-sectional view of the structure 42 from FIG. 4 showing the mechanism by which the elevated deck 50 and beams 48 for supporting the deck 50 is formed. Shown herein is the second pair of opposing structural walls 46 including the third wall 47 and the fourth wall 49. Each of the third wall 47 and the fourth wall 49 includes a base 51 between which floor 56 extends. The floor 56 connects the second pair of structural walls 46 to one another and provide support for the structure 42. As shown herein the deck 50 extends atop the third wall 47 and the fourth wall 49. The deck 50 is also positioned atop the first pair of structural walls 44 shown in FIG. 4. At least one shoring beam 52 is erected and supported by a plurality of adjustable shores 54. The shoring beam 52 extends along the length of the structure and is positioned between the second pair of structure walls 46. The shoring beam 52 provides support for the plurality of profile forms 12 connected to one another along the length of the structure 42.
Shown herein are three profile forms 12 a, 12 b, 12 c. Each of the profile forms 12 a, 12 b, 12 c are received within a respective beam support 26. Additionally, a deck support 53 is positioned on an inner top surface of each of the third wall 47 and the fourth wall 49. The deck support 53 extends on the third wall 47 and fourth wall 49 along width of the structure 42.
As shown herein, as first end wall 22 a of the first profile form 12 a receives the extension leg 29. The extension leg 29 is further supported by the deck support 47 on the third wall 47. The second end wall 30 a of the first profile form 12 a extends and is received by the first end wall 22 b of the second profile form 12 b. The second end wall 30 b of the second profile form 12 b extends and is received by the first end wall 22 c of the third profile form 12 c. The second end wall 30 c of the third profile form 12 c extends therefrom and is positioned atop the deck support 47 on the fourth wall 49. The manner by which the profiles 12 a-c are connected provide supported for one another when adjacently positioned between the third wall 47 and the fourth wall 49. Additionally, the connection between the profiles 12 a-c provide a solid flat surface over which the concrete will be poured.
Each representative profile form 12 a-c includes a respective insert 31 in the reservoir 20 thereof. The insert 31 is described above with respect to FIGS. 5 and 6. Additionally, a plurality of reinforcement bars 40 are positioned atop the support structure 33 forming the conduit 32 of the insert 31 for providing additional strength to the beam 48 and deck 50 supported thereby.
The shoring beam 52 is positioned directly under the base 18 of each of the profiles 12 a-c and provides further support for the profiles 12 a-c until the cement poured thereon hardens. The beams 48 and deck 50 are formed when concrete is poured over the surface created by the connection of the profile forms 12 a-c to one another. The concrete is received within the reservoir 20 is filled, the concrete flows atop the end walls and extension legs 29 of the profile forms 12 a-c. The concrete is added until a deck of predetermined thickness is reached. Upon hardening, the concrete within the reservoir 20 and around the inserts 31 form the beams 48 a-c shown herein in the area below the dotted lines. Furthermore, the concrete atop the profile forms 12 and the beams 48 form the elevated deck 50. The beams 48 technically are formed integral with the deck 50 but are described as a separate object for ease of explaining the structure formed using the system 10. Once the concrete has hardened and cured such that the beams 48 can support the load of the deck 50 and anything positioned thereon, the at least one shoring beam 52 can be removed. Once removed, the profile forms 12 a-c can also be removed thereby leaving an elevated deck 50 and support beams 48. When the profile forms 12 a-c are removed, the conduits 32 extending through each respective beam 48 a-c accessible. Furthermore, the conduits 32 are aligned with one another along the length of the structure 42. The aligned conduits allow an object such as electrical wiring and/or plumbing pipes to pass therethrough and extend along the length of the structure 42. The object may pass through an opening proximate at least one of the conduit 32 in the first beam 48 a to the conduit 32 in the second beam 48 b and further through the conduit 32 of the third beam 48 c. Thus, the object can extend parallel to the first pair of opposing walls 44 and along the length of the structure 42.
While only a single shoring beam 52 and a single line of profile forms 12 a-c are shown in FIG. 6, the beams 48 and deck 50 cover the entire area defined by the first pair of opposing walls 44 and the second pair of opposing walls 46. This is accomplished by positioning a plurality of profile forms 12 adjacent one another along each of the width of the structure 42 and the length of the structure 42. When the profile forms 12 are positioned adjacently along the width of the structure, the reservoirs 20 of each respective profile form are aligned with one another thereby allowing the plurality of reinforcement bars 40 to rest atop the support structure 33 forming the conduits 32 of the inserts 31. Additionally, a plurality of shoring beams 52 supported by adjustable shores 54 are positioned parallel to one another and extend in parallel with the first pair of opposing wall 44 and alone the width of the structure for supporting each of the profiles 12. The shoring beams and shores are removed once the cement hardens thereby also allowing for removal of the profile forms. The positioning of the profiles 12 adjacent to one another along the length of the structure is described hereinabove with respect to FIG. 6 and will not be repeated.
When the area within the walls 44, 46 as shown in FIG. 3 are filled with adjacently positioned profiles along each of the length and width of the structure 42, the solid surface is formed and concrete is poured thereon to form the beams 48 and he elevated deck 50.
FIG. 8 is a flow diagram detailing the operation of the system 10. As discussed in step S800, shores are selectively and strategically positioned atop a base floor and shoring beams are placed atop the shores and between opposing side walls along a length of a structure. A plurality of beam holders are positioned at predetermined intervals along the length of opposing walls of the structure as described in step S802. A first profile form is positioned within a respective one of the plurality of beam holders as stated in step S804. Step S806 shows further profiles being positioned adjacent to the first profile form and that the further profiles are further positioned along the length of a respective shoring beam. The plurality of profiles connect to one another vertically along the length of the walls as in step S808. In step S809, additional profiles are positioned adjacent one another along a width of the structure extending towards the corresponding beam holder on the opposing wall such that the respective reservoir of the widthwise profiles are aligned. Concrete is poured and received within each of the profiles creating concrete beams and is further received atop the profiles creating level deck connected to and supported by the beams in step S810. Upon hardening, the shoring beams are removed and the profiles are disengaged from the beams and floor as in step S8l2.
FIGS. 9 through 16 illustrate an alternate embodiment of the profile form 12 as described above and an alternative system 100 for forming an elevated concrete deck 50. The system 100 includes a profile 102, and may include a complementally configured end cap 106, jump rail 108, brackets 110, pins 112 and wedges 114, as well as the use of various boards, beams, posts and ports as will be described hereinafter.
The profile 102 as shown in FIGS. 9 through 14 is an elongated member preferably formed of aluminum sheets having longitudinally extending first side wall 116 and second side wall 118 which are generally upright, spaced from one another, and preferably divergent in a transverse direction and not parallel to one another, being connected in a transverse direction by a panel member similar to base 18 as described above. However, in the profile 102 hereof, the panel member is provided as a longitudinally extending bridge 120 extending generally between the upper portions of the first and second side walls 116 and 118. That is to say, preferably the first side wall 116 and the second side wall 118, which viewed in cross-section, lie in a plane which is obtusely angled relative to the bridge and thus angled with respect to the plane in which the bridge 120 lies. The first side wall 116 is connected to the bridge 120 by a first corner 122, while the second side wall 118 is connected to the bridge 120 by a second corner 124. The first corner and the second corner are each rounded when viewed in cross-section, as seen in FIG. 14, which avoids a concentration of stress and permits the first side wall 116 and the second side wall 118 to flex at their respective corners 122 and 124 over repeated cycles of use. One preferable material which provides a good combination of strength for supporting poured concrete and flexibility for placement and removal of the profile 102 is 5054 H38 aluminum sheets having a thickness of between 0.1 and point 0.15 inch, and most preferably about 0.120 inch. The first side wall 116 has a first end wall 126 which extends from the first side wall 116 in a direction away from the bridge 120 and the second side wall 118, and is located in a plane substantially parallel to the bridge 120. The second side wall has a second end wall 128 which extends from the first side wall 118 in a direction away from the bridge 120 and the first side wall 116, and is located in a plane substantially parallel to the bridge 120. The first end wall 126 and the second end wall 128 are preferably substantially co-planar and preferably lie in a common plane which is substantially parallel to the plane in which the bridge 120 lies. Each of the first and second end walls is preferably provided with a plurality of mounting holes 130 which are longitudinally spaced along the end walls as shown generally in FIG. 9. The mounting holes 130 may be spaced according to the desired type of construction and environment of use; for example, the mounting holes 130 may be more closely spaced adjacent the first end 132 and the second end 134 of the profile 102, and have greater spacing in the area of the end wall intermediate the ends 132 and 134 as illustrated in FIG. 9.
The profiles 102 are elongated and extend longitudinally along an axis A. The profiles 102 may be constructed of various desired lengths but are preferably configured with a common cross-sectional profile for nesting during transport and for mounting in overlapping relationship, as illustrated by profile 102B having a first end 132 which overlaps the second end 134 of the profile 102A as illustrated in FIG. 9. In this overlapping relationship, a pin 112, such as a flathead pin having a shank 136 with a transverse slot, is inserted through the holes 130 which are aligned in registry and the pins 112 are secured by driving a wedge 114 through the slot as may be seen in FIG. 12. As may be seen in FIGS. 9 through 14, the profiles 102 are thus oriented in system 100 with the side walls 116 and 118 depending downwardly from the bridge 120. Because of their ability to overlap, a concrete contractor or other user of the system 100 need not maintain a large number of different lengths of profiles 102, as by simply overlapping the profiles as desired, the system 100 adjusts to a variety of different lengths of span.
The end cap 106 is also configured to nest with profile 102 and is also preferably formed of sheet aluminum, and thus has a cross-sectional configuration substantially the same as that of the profile 102. The end caps 106 are typically much shorter longitudinally than the profiles 102, as seen in FIG. 9, but instead of being open at both ends such as is the case with ends 132 and 134 of the profiles 102, the end caps 106 have a closed end 138 with an end panel 140 connecting and enclosing a first side wall 142, a second side wall 144, and a bridge 146, and an open end 148 opposite the closed end 138. Both the first side wall 142 and the second side wall 144 are provided with respective first end wall 150 and second end wall 152 each having mounting holes 154 which are spaced and arranged to be aligned in registry with the mounting holes 130 of the profiles 102, as may be seen in FIG. 9.
The system 100 further includes a jump rail 108 which facilitates temporary support and positioning of the profiles 102. The jump rail 108 includes an elongated member 156 preferably forged or cast of aluminum or steel which is provided with a plurality of holes 158 arrayed along the length of the jump rail 108 at close intervals, typically about 1 to 4 holes per inch. As can be seen in the drawings, the jump rail 108 is intended to be positioned below the end walls 126 and 128 of a profile (or end walls 150 and 152 of an end cap) and oriented transverse to the longitudinal axis of the profile, to thereby receive the pins 112 extending through the mounting holes 130 and the holes 158 of the jump rails. The close spacing of the holes 158 permits the profiles 102 to be positioned at desired widths, either with their end walls overlapping, butted, or spaced apart, depending on the desired spacing between the joists formed between the side walls of adjacent profiles 102. When the side edges of the end walls 126 and 128 of adjacent profiles 102 are spaced apart, as seen in FIG. 12, longitudinally extending boards 160 provide a dual function. First, the boards, which are laid without the need for fastening to or between adjacent profiles 102, serve to inhibit the flow of concrete during the pour through gaps between the end walls, and also cover the mounting holes 130. The boards 160 also serve an additional function as nailers to receive nails, screws, or similar fasteners for attaching a ceiling to the underside of the elevated deck 50 once embedded within the cured concrete.
The system 100 further facilitates the formation of an internal passage 162. As used herein, a passage is any opening in the deck 50, and may include ventilation passages, plumbing or fireplace chases, or larger openings such as for atriums or stairway passages, the latter being illustrated in FIGS. 15 and 16 and the system 100 structures for enabling its creation in FIGS. 10 through 14. As illustrated in FIGS. 10 through 14, a stairway passage is provided internal to the surrounding structural walls 44 and 46 of upright walls 43, 45, 47 and 49 by framing elements such as wooden or metal barrier walls 164, 166, 168, and 170, having braces 172, 174 and 176 and base 178, and which may be provided of, for example, wood boards, oriented strand board, plywood, or other members which are preferably held by bolts, nails, screws or other fasteners. Concrete is not poured internal to the barrier walls 164, 166, 168 and 170, but rather they form barriers against the intrusion of poured concrete to the area therewithin and which will constitute the passage 162. The base 178 is desired to lie just below the end walls 126 and 128 of the profiles, and thus to properly position the base 178, brackets 110 are provided for attaching the base to the profiles. The brackets 110 are preferably formed of a unitary step-shaped connector member 180 of metal such as aluminum or steel, and have an offset section 182 which spaces a substantially planar upper section 184 from a substantially planar lower section 186 about the width of the base. Thus, if the base 178 is to be about ¾ inch in thickness, the offset section 182 is configured to position the lower section to lie in a plane about ¾ inch below the upper section. The upper section 184 and the lower section 186 are constructed with a plurality of fastener holes 188 therethrough, as shown in FIG. 9, to facilitate attachment of the brackets 110 to the profiles 102 and to the base 178.
Also, in order to facilitate other trades in the installation of plumbing, electrical wires or conduit, or other useful utilities, the system 100 contemplates that ports 190 as shown in FIG. 16 may be provided through the beams 48 to be formed by the use of tubular members 192 which are placed transverse to the orientation of the profiles and secured against movement by tape 194, adhesive or other securement devices. The tubular members 192 should be secured at their ends to the side walls 116 and 118 of adjacent profiles 102 preferably at about the vertical midway point between the bridge and the end wall by tape 194 and to span the concrete-receiving reservoir 204 formed by the adjacent side walls 116 and 118. The use of tape 194 to inhibit the movement of the tubular members during the pour helps to ensure that the ports 190 are aligned and also to inhibit the concrete from entering either end to block the port 190. Unlike the profiles, end caps, jump rail and brackets, but like the boards 160, the tubular members 192 remain with the structure 42 after the concrete cures.
The use of the system 100 is in many ways similar to the use of the system 10. After the walls 43, 45, 47 and 49 and the 56 is poured, the system 100 is initially positioned. In pouring the walls 43, 45, 47 and 49, it may be desirable to pour the walls to include an elevated ledge 196 proximate to the upper end 198 of the walls 43, 45, 47 and 49. This ledge may 196 be used as a temporary support but more advantageously, may receive a portion of the poured concrete for the deck thereon to provide greater structural integrity. Also, the deck support 53 is positioned along the inside surface of the walls as desired, such as the third wall 47 and the fourth wall 49 which also provides a member to receive nails and other fasteners as desired. Deck barriers 200 are also preferably placed outside the perimeter on the outer surface of the walls 43, 45, 47 and 49 to contain the flowable concrete during the pour and during curing. The foundation floor 56 is poured within the walls 43, 45, 47 and 49, and after curing, the shoring structures are placed. These include preferably adjustable shoring posts 54 and shoring beams 52. As may be seen in FIGS. 11, 12 and 14, these shoring posts 54 are preferably placed below the shoring beams 52, which may be at different elevations above the foundation floor 56 so that supports 202 may be positioned below the base 178 and to permit its later removal without interfering with the other shoring beams 52 which support the profiles 102. Thus, primary shoring beams 52A typically extend in a spaced-apart, parallel orientation as shown in FIG. 10, while as shown in FIG. 14, secondary shoring beams 52B may be provided to extend either parallel to the primary shoring beams 52A or perpendicular or in another direction transverse to the primary shoring beams 52A so as to provide internal support for certain supports or, for example, the framing elements of the internal passage.
The profiles 102 are then laid atop the shoring beams 52 and for typical applications will lie in a substantially common, horizontal plane so that the deck to be formed is flat and level. The profiles 102 are typically laid parallel to one another and transverse, and most preferably perpendicular, to the primary shoring beams 52, and the concrete-receiving surface of the side walls, end walls and bridge thereof may be coated with oil or other release coating to facilitate removal of the profiles after the concrete cures. The profiles 102 are advantageously configured with one another to overlap at their ends as desired, so as to provide a fillerless system 100 such that profiles 102 can be provided, for the most part except for the creation of internal passages, of a common length. The ability to overlap allows the profiles 102 to be combined to extend substantially the entire width of the structure 42 (that is, between walls 43 and 45). In addition, the profiles 102 need not lie in abutment to one another, but may be spaced apart in parallel alignment to thicken the width of the beams 48 and to allow for structures having a variety of different lengths (that is, between walls 47 and 49).
After the profiles are positioned as desired, the jump rails 108 may be placed on the underside of the end walls of the profiles 102 and the end caps 106. In addition, the framing for the passage is constructed and positioned, supported by the brackets 110 and the shoring beams 52B and other supports as shown in FIG. 14. Thereafter, the boards 160 are placed along the length of the reservoirs 204 which in the system 100 lie between the side walls of adjacent profiles 102 and into which the concrete will flow to form the beams 48. Reinforcing members 206 such as steel reinforcing bar, welded wire mesh or other reinforcing grids acceptable for the type of construction are placed into the reservoirs 204 between the profiles and the tubular members 192 are taped into position at selected positions as dictated by the design of the structure. The system 100 is then ready to receive the poured concrete.
The concrete is then poured to fill between the profiles, around the end caps, and over the bridges to create the beams 48 and deck 50. After the concrete cures to a sufficient self-sustaining condition as determined by the contractor, the shoring posts 54 and shoring beams 52, as well as other supports not remaining with the completed structure, are removed. The wedges 114 are driven from the slots of the pins 112, and the jump rails 108 and brackets 110 are removed from the underside of the profiles 102 and end caps 106. The profiles 102 and end caps 106, whose divergent sidewalls are able to flex inwardly toward each other, are readily released from the deck 50 and beams 48 by tapping on the end walls. This causes the first side wall 116 to move toward the other divergent side wall 118 of the profile 102 (or end cap 106), and thus away from the opposing side wall of the adjacent profile which cooperatively formed the reservoir and thus the beam therebetween, and to release the profile 102 from the concrete thereabove. On the other hand, with respect to the profile 12, the first and second side walls 14 and 16 diverge from one another and form the reservoir and support beam for the deck in the system 10, and thus to remove the profile 12 from the deck 50 and support beam 48 in system 10, the side walls 14 and 16 are moved away from one another along their respective connections to the base as indicated by the letters A in FIG. 1. In each instance, the profile 12 or 102 may then fall downwardly or be readily removed by the worker. If necessary, a wedge such as a pry bar or wedge 114 may be inserted between the profile and the beam or deck formed thereabove. Similarly, the framing for the passage 162, which has also been provided with a release coating, may be pulled from the concrete and removed, leaving the passage 162 as shown in FIGS. 15 and 16. The use of the profiles and brackets allows concrete to fill around the passage 162 to a full depth, thus providing substantial structural walls 208 having sufficient strength to “box-in” the passage 162. The boards 160 remain embedded in the concrete and now perform a permanent function as nailers to receive nails, screws or other threaded fasteners for supporting ceiling or ventilation hangers without the necessity of driving into the concrete deck 50 or concrete beams 48. Also, the tubular members 192 remain in the concrete beams 48 formed in the reservoirs 204 to provide the desired ports 190 as seen in FIG. 16.
It may be appreciated by those skilled in the art that the description and drawings show the use of the system of the present invention in the context of forming an elevated deck above a foundation floor. It is to be understood that the system and its method of use may be repeated, for example, on the elevated deck as completed, in use on subsequent superposed floors, such that elevated concrete decks may be successively formed one above another in accordance with the invention as described, and is not limited to a single story above, for example, a basement.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, the invention is not intended to be limited to the detailed description set forth above, since it will be understood by those skilled in the art that various omissions, modifications, substitutions and changes in the form and details of the system and its components and the methods of forming the elevated concrete deck can be made by those skilled in the art without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of the prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.

Claims

1. A profile for use in forming an elevated deck and support beam structure, the profile comprising:

a. a first end wall;

b. a second end wall; and

c. a middle section including:

i. a first side wall connected to said first end wall;

ii. a second side wall connected to said second end wall; and

iii. a substantially planar wall connecting said first and second side walls, said substantially planar wall and said side walls forming a reservoir between said first and second end walls.

2. The profile as recited in claim 1, wherein said planar wall extends parallel to said first and second end walls.

3. The profile as recited in claim 1, wherein said first end wall includes:

a. a first section; and

b. a second section connected to said first section and forming a step or lip therebetween.

4. The profile as recited in claim 3, wherein said second end wall is a substantially flat planar member.

5. The profile as recited in claim 4, wherein said flat planar member has a thickness substantially equal to a thickness of said first section thereby forming a level surface when placed adjacent thereto.

6. The profile as recited in claim 3, wherein said second end wall includes:

a. a first section; and

7. The profile as recited in claim 1, wherein said reservoir is able to receive a reservoir of a further profile for storage thereof.

8. The profile as recited in claim 1, wherein said profile is re-useable.

9. An insert for providing structural support to an elevated deck and support beam of a structure, said insert comprising:

a. a support structure extending a width of the support beam and defining a conduit therethrough;

b. a support post extending from said support structure; and

c. an attachment strip connected to an end of said support post opposite said support structure and positioned at a base of the support beam for securing at least one of boards and panels to said support beam.

10. The insert as recited in claim 9, wherein said conduit is able to receive at least one of wires, pipes and plumbing therethrough.

11. The insert as recited in claim 9, wherein said support post extends substantially from a mid-point of said support structure.

12. The insert as recited in claim 9, wherein said insert comprises a first angled support post extending on a first side of said support post between said support structure and said attachment strip and a second angled support post extending on a second side of said support post opposite said first side between said support structure and said attachment strip.

13. The insert as recited in claim 9, further comprising at least one stabilizing bar extending perpendicular to said structural support and along a length of the support beam.

14. The insert as recited in claim 13, wherein said at least one stabilizing bar extends parallel to said attachment strip.

15. The insert as recited in claim 13, wherein said at least one stabilizing bar is positioned adjacent said structural support on a side of said insert opposite said attachment strip.

16. A method for forming an elevated deck and support beams of a structure including the activities of:

a. placing shoring beams between a first pair of opposing side walls along a length of a structure;

b. positioning a plurality of beam holders at predetermined intervals aligned along the length of a second pair of opposing walls of the structure;

c. positioning a reservoir presented by a plurality of profiles including a first end wall and a second end wall connected via a middle section forming the reservoir within respective ones of the plurality of beam holders, the first end wall of each profile being received by a stepped section of the second end wall of an adjacent profile to form a level surface therebetween;

d. further positioning a plurality of form profiles adjacent on another along the width of the structure and aligned with a further shoring beams creating a further row of form profiles;

e. aligning the reservoirs of adjacent profiles to provide respective reservoirs extending the width of the structure;

f. pouring concrete within each of the reservoirs and atop the profiles creating a level deck;

g. removing each of the shoring beams; and

h. disengaging the profiles from the beams and deck.

17. The method as recited in claim 16, wherein prior to said activity of pouring concrete, further comprising the activity of positioning a structural insert within the respective one of the aligned reservoirs along the width of the structure, the structural insert including at least one structural support defining a conduit extending between the walls of the reservoir, a support post extending from the structural support and an attachment strip connected to the support post at an end opposite the structural support.

18. The method as recited in claim 17, wherein said activity of disengaging the profiles further revealing the attachment strip extending alone the base of the beam.

19. The method as recited in claim 18, further comprising the activity of securing at least one of panels and boards to the securing strip thereby covering.

20. The method as recited in claim 16, further comprising the activity of stacking a profile within the reservoir of a further profile.

21. The method as recited in claim 17, further comprising the activity of positioning at least one framing member atop at least one of said shoring beams, and said step of positioning said form profiles includes positioning and connecting the plurality of form profiles around said framing member and to said framing member and said step of pouring concrete includes pouring concrete around the at least one framing member.

22. The method as recited in claim 21, further comprising the activity of inserting at least one of wiring, piping and plumbing through the aligned conduits along the length of the structure.

23. The method as recited in claim 16, wherein the form profiles include a first end wall extending from an edge of a first divergent side wall and a second end wall extending from an edge of a second divergent side wall opposite said first divergent side wall, said first and second end walls extending parallel to said connecting member, said first and second end walls including a plurality of apertures along the length of at least some of said form profiles, and further comprising the activities of at least one of:

connecting longitudinally adjacent form profiles to one another between their respective first and second ends via fasteners received through aligned apertures, and

connecting at least one jump rail to adjacent form profiles for supporting said rows of profiles, the jump rail being formed as a substantially planar member having a plurality of spaced apertures extending along a length of the jump rail.

24. The method as recited in claim 16, wherein prior to said activity of positioning profiles, the method comprises the activity of positioning an end cap in spanning relationship across the opposing side walls, the end cap including a pair of opposed, divergent side walls and having a connecting member connecting the side walls and an end panel enclosing at least one end of the end cap, and wherein said activity of positioning profiles includes positioning at least one of the profiles atop the end cap.

25. The method as recited in claim 16, wherein the profile is modified and includes first end wall and the second end wall each having stepped sections and further comprising the activity of positioning modified profiles adjacent one another thereby leaving an opening the formed deck.

26. A system for use in forming a deck and beam support structure of cementatious materials elevated above a supporting surface, said system comprising:

a plurality of elongated profiles having a longitudinal axis extending longitudinally from a first end to a second end, one of said plurality of profiles being oriented in substantially parallel alignment to another of said plurality of profiles, the profiles each including a pair of opposed, divergent side walls and a connecting member, the profiles each having a normally lower surface and a cementatious material receiving surface, the side walls of the aligned profiles presenting at least one reservoir for receiving flowable cementatious material for forming a beam;

a shoring member for supporting the profiles in an elevated condition above a supporting surface.

27. The system as recited in claim 26, wherein said reservoir is positioned between the side walls of at least one of said plurality of profiles.

28. The system as recited in claim 26, wherein said reservoir is positioned between two opposing side walls of two adjacent profiles of said plurality of profiles.

29. The system as recited in claim 26, wherein said profiles further comprise:

a first end wall extending from an edge of a first divergent side wall; and

a second end wall extending from an edge of a second divergent side wall opposite said first divergent side wall, said first and second end walls extending parallel to said connecting member.

30. The system as recited in claim 28, wherein said first and second end walls include at least one aperture extending therethrough.

31. The system as recited in claim 31, further comprising:

at least one jump rail having a plurality of apertures spaced along a length of the jump rail; and

a plurality of fasteners for releaseably securing said at least one jump rail to said plurality of adjacent profiles oriented in substantially parallel relationship to one another, wherein a respective aperture of said at least one jump rail is aligned with said apertures in said first and second end walls, and wherein said fasteners are selectively received through the aligned apertures of said jump rail and a respective one of said first and second end walls for releaseably securing said at least one jump rail to a plurality of profiles to provide support therefore.

32. The system as recited in claim 26, further comprising a framing member for defining an area of the deck to remain unfilled with cementations material, and wherein said plurality of profiles are selectively positionable around said framing member.

33. The system as recited in claim 32, further comprising step-shaped connectors having an offset section connecting first and second connector sections, and further including at least one connection aperture extending through each of said first and second connector sections for releaseably securing said profiles to said framing member.

34. The system as recited in claim 26, further comprising a plurality of support bars selectively positioned within a conduit between parallel adjacent profiles.

35. The system as recited in claim 28, further comprising an insert selectively receivable within said reservoirs extending between said first end and said second end for providing structural support to the deck and beam.

36. The system as recited in claim 35, wherein said insert comprises:

a. a support structure extending a width of the support beam and defining a conduit therethrough; and

b. at least one support bar extending along longitudinally between said first and second end.

37. The system as recited in claim 36, wherein said channel is adapted to receive at least one of wires, pipes and plumbing therethrough.

38. The system as recited in claim 26, further comprising at least one board positioned at a base of said reservoir and between opposing side walls of adjacent profiles.

39. The system as recited in claim 37, wherein said at least one board is adapted for connection to at least one of boards and panels thereto.

40. The system as recited in claim 29, further comprising at least one extension board selectively positioned to rest atop said first end wall of a first profile and said second end wall of an adjacent profile.

41. The system as recited in claim 29, further comprising mounting apertures extending through said first and second end walls and positioned at opposing distal ends of at least some of said profiles, said mounting apertures being sized and positioned to receive fasteners therethrough for mounting said profiles to additional, complementally configured profiles.

42. The system as recited in claim 26, further comprising an end cap including a pair of opposed, divergent side walls and having a connecting member connecting the side walls and an end panel enclosing at least one end of the end cap, said end cap being complementally configured to at least one of said profiles for mounting to and enclosing a first end of said at least one of said profiles.

43. The system as recited in claim 26, further comprising a wedge configured for selective positioning between a respective profile and a deck or support beam formed thereby and for releasing said profile from the formed deck upon hardening of the cementatious material.

44. The system as recited in claim 26, wherein one of said plurality of profiles complementally configured with another of said plurality of profiles for positioning in longitudinally overlapping relationship wherein said divergent first and second side walls of said one profile engage the corresponding divergent first and second side walls of the another profile when arranged in overlapping or nested relationship.

46. A system as recited in claim 26, wherein said plurality of profiles each include a pair of open ends for permitting nesting or overlapping of two similarly configured profiles.

47. A system as recited in claim 46, including at least one end cap having a pair of side walls and a bridge presenting a cross-sectional configuration complemental to at least one of said plurality of profiles, said end cap further including at least one closed end having an end panel substantially extending between said pair of side walls.

48. A system as recited in claim 26, including at least one elongated member extending beneath said plurality of profiles, connected thereto, and oriented transverse to the longitudinal axis of said plurality of profiles.

49. A system as recited in claim 48, wherein said elongated member includes a plurality of aligned openings, and further including respective pins extending through at least said one and said other of said profiles and through said openings in said elongated member for connecting said profiles to said elongated member.

50. A system as recited in claim 26, including further respective complementally configured profiles aligned with each of said plurality of profiles and positioned along said longitudinal axis in overlapping relationship to respective ones of said plurality of profiles.

51. A system as set forth in claim 26, including a tubular member extending across said reservoir.

52. A system as set forth in claim 26, including an elongated reinforcing member positioned in said reservoir to extend substantially parallel to said longitudinal axis of said profile.

53. A system as set forth in claim 26, including a plurality of brackets connecting respective ones of said plurality of profiles to a framing member extending upwardly from said brackets and between two laterally spaced profiles, said framing member defining a barrier to the entry of concrete in order to provide a passage through the deck and beam support structure to be formed of cementatious material.

54. A system as set forth in claim 27, further including a board positioned in said reservoir between said reservoir-defining side walls of adjacent profiles and atop said profiles, said board being oriented and configured to inhibit the passage of cementations material between said adjacent profiles.

55. A system for forming an elevated deck and support beam within a structure comprising a plurality of profiles, said plurality of profiles each including a first end wall, a second end wall and a middle section connecting said first end wall and said second end wall forming a reservoir therein, said plurality of profiles are aligned and positioned adjacent one another along each of a length of the structure and a width of the structure, wherein respective first end walls of ones of said plurality of lengthwise aligned profiles are received by second end walls of lengthwise adjacent profiles to form a level surface and reservoirs of widthwise aligned profiles are aligned to form a reservoir extending across the width of the structure for forming support beams.

56. The system as recited in claim 55, wherein said first end wall is a stepped section and said second end wall is a substantially planar member.

57. The system as recited in claim 56, wherein said substantial planar member is receivable in said stepped section thereby creating a level surface therebetween.

58. The system as recited in claim 55, further comprising an extension leg for receipt by either of said first end wall and said second end wall for extending a distance between adjacent profiles to equal to a length of said extension leg.

59. The system as recited in claim 58, wherein said extension leg has a thickness substantially equal to a thickness of each of said first end wall and said second end wall.

60. The system as recited in claim 55, further comprising a plurality of inserts selectively receivable within reservoirs and extending a width of the support beam and defining a conduit therethrough.

61. The system as recited in claim 60, wherein said conduit is able to receive at least one of wires, pipes and plumbing therethrough.

62. The system as recited in claim 55, further comprising a plurality of beam holders positioned at predetermined intervals along a length of opposing structural walls for receiving respective reservoirs of said profiles therein.

63. The system as recited in claim 55, further comprising a plurality of shoring beams supported by a plurality of adjustable shores extending along the length of the structure and parallel with opposing structural walls for supporting said plurality of profiles within the structure.

64. The system as recited in claim 55, wherein upon hardening of the concrete, said profile is selectively removable from said structure for later re-use.

65. A method of forming an elevated deck and beam support structure above a surface and extending between at least two spaced, opposing upright walls of a structure, said method comprising the steps of:

providing a plurality of shoring members extending upwardly from said surface;

providing a plurality of elongated profiles each having generally divergent side walls and a panel member connecting the side walls to each other;

orienting said plurality of profiles to be supported by said shoring members whereby at least one of said plurality of profiles is substantially parallel to another of said profiles and substantially in a common horizontal plane;

flowing cementations material into at least one beam-defining reservoir defined by the side walls of one or more of said plurality of profiles and atop said panel members to form a generally unitary deck and beam support structure located in elevated relationship to said surface;

allowing said cementatious material to cure to a self-sustaining condition; and

removing said shoring members and said plurality of profiles from an underside of said deck and beam support structure.

66. A method as set forth in claim 65, wherein said step of removing said plurality of profiles includes the step of moving one of said divergent side walls of a profile away from the other of said divergent side walls of the profile.

67. A method as set forth in claim 65, wherein said step of removing said plurality of profiles includes the step of moving one of said divergent side walls of a profile toward the other divergent side wall of the panel.