US20080053022A1 - Hollow core floor and deck element - Google Patents

Hollow core floor and deck element Download PDF

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Publication number
US20080053022A1
US20080053022A1 US11/485,823 US48582306A US2008053022A1 US 20080053022 A1 US20080053022 A1 US 20080053022A1 US 48582306 A US48582306 A US 48582306A US 2008053022 A1 US2008053022 A1 US 2008053022A1
Authority
US
United States
Prior art keywords
skins
deck
set forth
core element
concrete
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.)
Abandoned
Application number
US11/485,823
Other languages
English (en)
Inventor
Carl R. Marschke
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to US11/485,823 priority Critical patent/US20080053022A1/en
Priority to US11/777,002 priority patent/US7770342B2/en
Priority to PCT/US2007/073357 priority patent/WO2008008890A2/fr
Publication of US20080053022A1 publication Critical patent/US20080053022A1/en
Priority to US12/550,996 priority patent/US20100006626A1/en
Abandoned 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
    • E04B5/43—Floor structures of extraordinary design; Features relating to the elastic stability; Floor structures specially designed for resting on columns only, e.g. mushroom floors
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D19/00—Structural or constructional details of bridges
    • E01D19/12—Grating or flooring for bridges; Fastening railway sleepers or tracks to bridges
    • E01D19/125—Grating or flooring for bridges
    • 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
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/026—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of plastic
    • 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
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D2101/00—Material constitution of bridges
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D2101/00—Material constitution of bridges
    • E01D2101/20—Concrete, stone or stone-like material
    • E01D2101/24—Concrete
    • E01D2101/26—Concrete reinforced
    • E01D2101/268—Composite concrete-metal
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D2101/00—Material constitution of bridges
    • E01D2101/30—Metal
    • E01D2101/34—Metal non-ferrous, e.g. aluminium
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D2101/00—Material constitution of bridges
    • E01D2101/40—Plastics

Definitions

  • the present invention pertains to a lightweight hollow core structural building element which can be used as a beam or can be joined with other elements to form a floor or deck panel.
  • the use of such hollow core panels has been inhibited because of difficulties in fabricating the panels in an efficient and cost effective manner.
  • a structural support such as a floor or bridge deck, is fabricated from open core elements faced with upper and lower steel skins which are welded together and over which a layer of concrete is poured.
  • the invention encompasses the modules, the overall structural support, and the method of making the same.
  • a horizontal structural support in one aspect of the invention, includes an open core element that has a plurality of corrugated strips of a web material bonded together and having the flutes oriented vertically.
  • the open core element defines horizontal upper and lower surfaces to which steel skins are attached.
  • a layer of concrete is placed on the upper steel skin.
  • the structural support includes a plurality of upstanding steel projections that are attached to the upper steel skin and are embedded in the concrete layer.
  • a plurality of open core elements are provided, each having steel skins that are co-extensive with and attached to the core element and shaped to define modules of a generally rectangular shape.
  • the modules are connected edge-to-edge with welded joints along abutting edges of the upper and lower skins to form a deck.
  • the layer of concrete is placed over the entire deck. Close-out panels are placed to enclose portions of the assembled core elements that define the outer periphery of the deck.
  • the web material for making the open core elements is paper and, most preferably, resin-impregnated paper.
  • the invention also includes a method for making a load bearing deck or the like comprising the steps of: forming an open core element from a plurality of long and relatively narrow strips of a corrugated web material by bonding the strips together with the flutes extending between the long edges of the strips, and with the open core element defining parallel rectangular upper and lower surfaces perpendicular to the flutes; bonding rectangular steel skins to the upper and lower surfaces of the core element to form a deck module, the skins each having opposite long edges that correspond to the length of the strips; and, connecting adjacent modules by welding together the long edges of adjacent upper skins and lower skins.
  • the method further includes the step of pouring a layer of concrete over the interconnected upper skins to form the deck.
  • the method preferably includes, prior to the concrete pouring step, the step of attaching a plurality of upstanding steel projections to the exposed surfaces of the upper skins, and the pouring step includes embedding the projections in the concrete. Also prior to the pouring step, the method may include the step of placing utility connections on the exposed surface of the upper skins and embedding the connections in the concrete during the pouring step.
  • FIG. 1 is a perspective view of a structural deck or floor assembled from modules according to the present invention.
  • FIG. 2 is a perspective view, similar to FIG. 1 , showing a single open core module used in fabricating the deck of FIG. 1 .
  • FIG. 1 there is shown a portion of a deck 10 or floor useful, for example, in the construction of a bridge or a building, in which a series of long and relatively narrow modules 11 are joined together and covered with a poured concrete slab 12 .
  • Each of the modules 11 could be made of any desired dimensions, but for use in a floor deck, for example, module 11 could have a depth or thickness of 16 in., a width of 8 ft. and a length of 50 ft.
  • Each deck module 11 includes a hollow core element 13 of the type described and manufactured in accordance with the method disclosed in my above identified patent application.
  • the hollow core element 13 includes a stack of long, narrow corrugated paperboard strips 14 , each of which in the embodiment shown comprises a fluted web 15 and a smooth web 16 joined with a suitable adhesive.
  • the webs 15 and 16 may be made of many suitable materials, but resin-impregnated paper is presently preferred.
  • flutes are formed in the fluted web 15 of a substantially larger size than typically used for corrugated paperboard.
  • the flutes may have a height of about 1 ⁇ 2 in. and, in order to provide a stack of strips 14 to make a module 11 with an 8 ft. width, approximately 180 to 200 strips would be required.
  • the strips are 16 in. wide and 50 ft. long.
  • the method and apparatus of my above-identified application are capable of forming up hollow core elements of the required size.
  • Each of the rectangular hollow core elements 13 has plan dimensions of 8 ft. by 50 ft.
  • Steel sheets comprising an upper skin 17 and a lower skin 18 are attached to the respective upper and lower surfaces 20 and 21 of the hollow core element 13 .
  • the upper skin 17 may be, for example, 1 ⁇ 8 in. in thickness and the lower skin 18 may be 1 ⁇ 4 in. in thickness.
  • high modulus steel is preferred, other materials may be utilized, particularly for the upper skin where tensile strength and high modulus of elasticity are not major concerns.
  • the skins 17 and 18 may be secured to the hollow core element 13 with any of a number of suitable adhesives, including epoxies.
  • the resulting deck module 11 is attached to like modules to fabricate the deck 10 shown in FIG. 1 .
  • Modules 11 are positioned side-by-side, preferably in their final positions in the structure in which they are used, with the long edges 22 of the steel skins 17 and 18 abutting. In this position, each abutting pair of upper skins 17 and lower skins 18 are connected with welds 23 .
  • the upper surface of the upper skins 17 are provided with an array of upstanding projections 24 , preferably short steel posts 25 which are welded to the skin 17 .
  • the height of the posts 25 depends on the thickness of the concrete slab 12 , but for a 4 in. slab, posts having a height of about 3 in. are satisfactory.
  • the exposed core elements 13 along the outer periphery of the fabricated deck 10 , are closed with suitable close-out panels 26 .
  • the panels 26 may be made of any suitable material and glued, welded or otherwise secured to the exposed core elements 13 or the edges of the skins 17 and 18 .
  • the composite structural support of the present invention has been described with respect to the fabrication of a floor for a building or a deck for a bridge, the present invention lends itself well to the fabrication of structural supports of a wide variety of shapes and sizes. For example, a much narrower module, namely one using a much smaller number of strips 14 (say 16 strips stacked to form a hollow core element about 8 in. wide) can function as a beam.
  • a floor, deck or beam member made in accordance with the present invention could be provided with a camber as is sometimes done in long span beams.
  • the inherent flexibility of the fluted paper core element 13 will permit the necessary flexure to be imparted to provide a camber.
  • one of the skins 17 or 18 could be applied to the core element, the element then flexed to the desired camber and the other skin attached to the core in the bowed orientation.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Bridges Or Land Bridges (AREA)
  • Joining Of Building Structures In Genera (AREA)
US11/485,823 2006-07-13 2006-07-13 Hollow core floor and deck element Abandoned US20080053022A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US11/485,823 US20080053022A1 (en) 2006-07-13 2006-07-13 Hollow core floor and deck element
US11/777,002 US7770342B2 (en) 2006-07-13 2007-07-12 Hollow core floor and deck element
PCT/US2007/073357 WO2008008890A2 (fr) 2006-07-13 2007-07-12 plancher central creux et élément de PONT
US12/550,996 US20100006626A1 (en) 2006-07-13 2009-08-31 Method for Making a Hollow Core Floor and Deck Element

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/485,823 US20080053022A1 (en) 2006-07-13 2006-07-13 Hollow core floor and deck element

Related Child Applications (2)

Application Number Title Priority Date Filing Date
US11/777,002 Continuation-In-Part US7770342B2 (en) 2006-07-13 2007-07-12 Hollow core floor and deck element
US12/550,996 Division US20100006626A1 (en) 2006-07-13 2009-08-31 Method for Making a Hollow Core Floor and Deck Element

Publications (1)

Publication Number Publication Date
US20080053022A1 true US20080053022A1 (en) 2008-03-06

Family

ID=38663049

Family Applications (3)

Application Number Title Priority Date Filing Date
US11/485,823 Abandoned US20080053022A1 (en) 2006-07-13 2006-07-13 Hollow core floor and deck element
US11/777,002 Expired - Fee Related US7770342B2 (en) 2006-07-13 2007-07-12 Hollow core floor and deck element
US12/550,996 Abandoned US20100006626A1 (en) 2006-07-13 2009-08-31 Method for Making a Hollow Core Floor and Deck Element

Family Applications After (2)

Application Number Title Priority Date Filing Date
US11/777,002 Expired - Fee Related US7770342B2 (en) 2006-07-13 2007-07-12 Hollow core floor and deck element
US12/550,996 Abandoned US20100006626A1 (en) 2006-07-13 2009-08-31 Method for Making a Hollow Core Floor and Deck Element

Country Status (2)

Country Link
US (3) US20080053022A1 (fr)
WO (1) WO2008008890A2 (fr)

Cited By (2)

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US20120317914A1 (en) * 2011-06-20 2012-12-20 Mark Bomberg Continuous thermal insulation and fire protective composite placed on thermo-grid designed for wind load transfer
CN110468708A (zh) * 2019-07-31 2019-11-19 中铁大桥科学研究院有限公司 一种钢-uhpc预制板的组合桥面结构及其施工方法

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US8015771B2 (en) * 2008-02-11 2011-09-13 Leblang Dennis William Building form for concrete floors, walls and beams
US20090313924A1 (en) * 2008-06-18 2009-12-24 Gillespie Hubert R Concrete building structures
WO2010069994A2 (fr) * 2008-12-19 2010-06-24 Inter Ikea Systems B.V. [Nl] Modules de constructions pour meuble, et leur procédé de fabrication
WO2010078413A1 (fr) 2008-12-31 2010-07-08 Apinee, Inc. Conservation du bois, compositions et procédés correspondants
US8631848B2 (en) * 2009-09-14 2014-01-21 Michael B. Hladilek Apparatus and method for producing waterproof structural corrugated paperboard
US7998300B2 (en) * 2009-09-14 2011-08-16 Carl R. Marschke Apparatus and method for producing waterproof structural corrugated paperboard
US8245469B2 (en) * 2010-05-20 2012-08-21 Aditazz, Inc. Deck assembly module for a steel framed building
CN102322163B (zh) * 2010-06-18 2014-11-26 柳忠林 用作地下室顶板的大跨度大荷载预应力槽形叠合板
CN102758450A (zh) * 2011-04-26 2012-10-31 柳忠林 用作地下室顶板的大跨度大荷载预应力槽形叠合板
US9878464B1 (en) 2011-06-30 2018-01-30 Apinee, Inc. Preservation of cellulosic materials, compositions and methods thereof
DE102011109122A1 (de) * 2011-08-01 2013-02-07 B.T. Innovation Gmbh Mehrschichtiges Bauelement
US8833573B2 (en) * 2012-01-16 2014-09-16 Sonoco Development, Inc Dividerless packaging system for shipping and displaying palletized products
US9506266B2 (en) 2014-09-11 2016-11-29 Aditazz, Inc. Concrete deck with lateral force resisting system
CN104763141A (zh) * 2015-04-14 2015-07-08 许昌学院 一种建筑用快速拼接模板
CN104831629A (zh) * 2015-05-31 2015-08-12 长安大学 一种内置u型连接结构的scs钢板混凝土桥面板
US9797147B2 (en) * 2015-07-08 2017-10-24 Void Form Products, Inc. Water proof construction unit
KR20170093423A (ko) * 2016-02-05 2017-08-16 주식회사 대솔오시스 흡차음 성능을 가진 자동차용 러기지 보드
US10711409B2 (en) 2018-04-03 2020-07-14 Valery Tsimmerman Trestle mat construction panel configured for use with building equipment and a method of manufacture and/or use thereof
CN110439175B (zh) * 2019-08-19 2021-11-23 苏道远 具有蒙皮效应壳体结构的陶粒砼板及其加工方法
DE102019125885A1 (de) * 2019-09-26 2021-04-01 Li-Chun Chan Eine Kunststoffplattenstruktur für den Gebäudebau

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US20080010943A1 (en) 2008-01-17

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