Cross-Reference to Related Applications

The present application is a Non-Provisional application, which claims the priority and benefit of U.S. Provisional Application Ser. No. 62/195,677 filed on July 22, 2015 and entitled "METAL DECKING," which is incorporated herein by reference in its entirety.

Technical Field

Composite decking may be used as floor and/or ceiling components for single or multiple-story buildings. The composite decking is used to complete the structural diaphragm of the building. Composite decking includes a contiguous metal sheet having concrete formed thereon. Composite decking may include a mesh structure to give the concrete rigidity.

Summary

In one implementation, a metal deck is provided that includes a plurality of decking components formed in a contiguous metal sheet. Each of the deck components includes a plurality of folded ribs formed along the length of the metal deck. Each of the plurality of folded ribs is configured such that one or more trusses of a building may fit between the plurality of folded ribs.

Brief Descriptions of the Drawings

A further understanding of the nature and advantages of the present technology may be realized by reference to the figures, which are described in the remaining portion of the specification. In the figures, like reference numerals are used throughout several figures to refer to similar components. In some instances, a reference numeral may have an associated sub-label consisting of a lower-case letter to denote one of multiple similar components. When reference is made to a reference numeral without specification of a sub-label, the reference is intended to refer to all such multiple similar components.

FIG. 1 illustrates a three-dimensional view of an example metal deck disclosed herein.

FIG. 2A illustrates a side view of an example metal deck, and FIG. 2B illustrates a top view of an example metal deck.

FIG. 3 illustrates a cross-sectional view of an example metal deck.

FIG. 4 illustrates a three-dimensional view of an example metal deck disclosed herein on top of a truss structure.

FIG. 5 illustrates an alternative three-dimensional view of an example metal deck disclosed herein on top of a truss structure.

FIG. 6 illustrates an alternative top view of an example metal deck.

FIG. 7 illustrates a three-dimensional view of an example metal deck disclosed herein.

FIGS. 8A-8C illustrate example side views of an example metal deck disclosed herein.

FIG. 9 illustrates example operations for manufacturing and installing metal decking in a building.

FIG. 10 illustrates an example top view of the metal deck disclosed herein.

FIG. 11 illustrated an example top view of portions of the metal deck disclosed herein.

FIG. 12 discloses an alternative view of example metal deck disclosed herein. FIG. 13 illustrates yet another alternative view of example metal deck disclosed herein.

FIG. 14 illustrates a side view of the example metal deck disclosed herein.

FIG. 15 illustrates another alternative side view of the metal deck disclosed herein. Detailed Descriptions

When building single or multiple-story buildings, composite decking may be used for floors and/or ceilings. The composite decking with concrete is used to complete the structural diaphragm of the building. The structural diaphragm in a building ties the vertical and horizontal structural components and makes them perform together to transfer lateral and vertical forces. To place composite decking, a contiguous ribbed sheet of metal is installed, then concrete is poured on the top surface of the metal decking to form the composite deck. In some implementations mesh is placed before concrete is poured to give the concrete rigidity. In various implementations, the metal sheet of the composite decking is used as the mechanism to form the concrete thereon. The process of connecting the metal sheet to structural elements (e.g., I-beams), placing mesh, pouring concrete, and curing the concrete is time consuming and expensive.

In the implementations described herein, a metal decking is provided. The metal decking described herein uses a ribbed structure that has strength qualities such that the metal decking may be utilized as a floor and/or ceiling of a building without concrete. As such, the metal decking described herein provides the strength qualities to complete the structural diaphragm of the building without the expensive and time consuming process of pouring concrete. A size and shape of a panel of the metal decking may be standardized. The standardization of the metal decking allows for manufacturing of the metal decking using cold roll former machines. In the implementation disclosed herein, the lengths, depth, angles, etc. are standardized. Such standardization reduces the need for repeated engineer design and analysis of metal decking. Furthermore, the standardization also reduces the costs of manufacturing the metal decking. These standardized metal decks can be utilized with other standardized building components such as wall panels, trusses, etc.

In various implementations a layer of concrete may be poured on top of the metal decking described herein for noise dampening purposes. In these implementations, a sound mat may be placed on the metal decking before the concrete is poured.

FIG. 1 illustrates a three-dimensional view of an example metal deck 100 disclosed herein. Specifically, the metal deck 100 includes a plurality of decking components 102a, 102b, ... 102n (hereinafter referred to as decking components 102). The metal deck 100 may be formed as one contiguous manufactured product having the decking components 102 joined to each other. For example, the metal deck 100 may be formed from a metal sheet using a roll-former machines. Such roll formers may be communicatively connected to a machine that is configured to receive a macro file with instructions for cutting steel rolls at predetermined distances and predetermined angles so that it can be roll formed to generate the metal decking. Furthermore, such a roll former Machen is also configured to receive instructions from the macro file regarding placement, punching, etching or cutting of pilot holes for fasteners and other openings. The thickness of the sheet used to form the metal deck 100 may be, for example, 12-18 gauge (between 0.050 to 0.1 1 inches) for stainless steel sheets. However, alternate thickness of the metal sheet may also be used. Similarly, alternative materials used in building construction, such as galvanized steel, aluminum, etc., may also be used.

Each of the decking components 102 may be configured to have ribs 104 along its length 120. The ribs 104 have folded profile and the ribs face from the downward facing surface of the decking components 102. In other words, when the decking components 102 are used to form a metal deck, the folded ribs 104 face towards the ground, and a

substantially flat surface on the other side of the decking components opposite the ribs 104 faces away from the ground.

Furthermore, the decking components 102 are formed such that the ribs 104 include rib openings 106a, 106b, 106c etc. at predetermined intervals along the length 120. Such rib openings 106 in the ribs 104 are included across the width 130 of the metal deck 100. In other words, the ribs 104 are not continuous along the entire length 120 of the decking

components 102. Note that the rib opening 106c is illustrated to be at one end of the decking components 102. Similar rib openings 106 may also be provided at the other end of the decking components 102. The rib openings 106 are configured to receive a truss structure that supports the metal decking 100.

In one implementation, the ribs 104 between the rib openings 106 are ribbed flutes that are 21.80 inches in length. Note that in alternative implementations, other length of the ribbed flutes may be provided. In one implementation, each of the rib openings 106 between the ribbed flutes may be 2.20 inches. As a result, the distance between the beginnings of each of the rib openings 106 is 24 inches. The dimensions of the lengths of the ribbed flutes and the rib openings 106 may be selected based on the dimensions of other components of a construction system. For example, if the metal deck 100 is used with trusses that are 21.80 inches apart from each other, the ribbed flute length is selected to be 21.80 inches.

Furthermore, if the width of the trusses is 2.20 inches, the rib openings of 2.20 inches are provided. This allows fitting the metal deck 100 on top of a series of trusses.

FIG. 2A illustrates a side view of a metal deck 200 and FIG. 2B illustrates a top view of the metal deck 200. Referring to FIG. 2A, the metal deck 200 includes ribs 204 with a number of predetermined rib openings 206a to 206e. Each of the rib openings 206 is configured to receive a truss that may support the metal deck 200. The sides of the ribs openings 206 are at an angle such as to act as a guide to receive the trusses. For example, after the trusses in a structure are installed, a sheet of the metal deck 200 may be placed on top of the trusses, with the trusses being guided to the ribs openings 206 by the slanted angle of the rib openings 206. As such, a person placing the metal deck 200 does not have to force an exact fit over the trusses.

Referring now to FIG. 2B, the metal deck 200 includes a number of decking components 202a to 202e. The decking components 202 may be formed from one contiguous piece of metal. The ribs 204 extend beneath the metal deck 200 (e.g., in a z-direction), with the predetermined rib openings 206. The rib openings 206 on different ribs are aligned such that a number of parallel rib openings may receive a truss. For example, the rib openings 206 along line 208 may receive a truss.

FIG. 3 illustrates a cross-sectional view of an example metal deck 300. The metal deck 300 includes ribs 302a and 302b and top ribs 306a and 306b. As illustrated in an expanded view 304 of the rib 302a, the rib 302a has a folded profile. A height 310 of the rib 302a may be, for example, approximately 1.25 inches. The sides 312 and 314 are shown be perpendicular to the surface of the metal deck 300. In one implementation, the top end of the rib 302a may be pinched closed such that the top ends of the sides 312 and 314 are touching each other such as to give the top surface of the metal deck 300 a substantially flat surface. Furthermore, in the illustrated implementation, the top ends of each of the sides 312 and 314 are curved. The ribs 302 provide the deck 300 additional support and give the deck 300 a rigid structure.

The top ribs 306 may provide grip or traction for the metal deck 300. For example, the top of the metal deck 300 may be a working surface, the top ribs 306 may provide traction such that people may walk about the top without slipping. The top ribs 306 may be arranged in different patterns. FIG. 4 illustrates a three-dimensional view 400 of an example metal deck 402 disclosed herein on top of a truss structure 404. Specifically, the metal deck 402 including a plurality of ribs 410a, 410b, etc. having rib openings 408a, 408b, 406c etc. The metal deck 402 is illustrated as laid on top of the truss structure 404 that includes a plurality of trusses 406a, 406b, etc. The rib openings 408 are dimensioned to fit around the trusses 406 and the ribs 410 fit between the trusses 406.

FIG. 5 illustrates an alternative three-dimensional view 500 of an example metal deck 502 disclosed herein on top of a truss structure 504. Specifically, the metal deck 502 includes a plurality of deck components 506a, 506b, etc. that are laid on top of trusses 508a, 508b, etc. It should be understood that the metal deck 502 may include a greater or fewer number of deck components 506 than illustrated. It should also be understood that the truss structure 504 may include a greater or fewer number of trusses than illustrated. As such, ribs (not shown) of the metal deck may include a number of rib openings (not shown) to match the number of trusses 508.

FIG. 6 illustrates an alternative top view of an example metal deck 600. The metal deck 600 includes a plurality of decking components 602a, 602b, etc. A top surface 604 of the metal deck 600 includes a plurality of top ribs 604a, 604b, etc. Some of the top ribs 604, such as the top rib 604e, extend along a length 610 of the metal deck 600. Other top ribs, such as top ribs 604a, 604b, 604c are positioned in a diagonal pattern. It should be understood that the top ribs 604 may be positioned in other patterns. For example, the top rib 604d may be positioned perpendicular to top rib 604e. The top ribs 604 provide traction for the top surface 606. As such the top surface 604 may be a working surface.

FIG. 7 illustrates a three-dimensional view of an example metal deck 700 disclosed herein. Specifically, the metal deck 700 includes a plurality of decking components 702a, 702b, ... 702n (hereinafter referred to as decking components 702). The metal deck 700 may be formed as one contiguous manufactured product having the decking components 702 joined to each other. For example, the metal deck 700 may be formed from a metal sheet using a roll-forming machine. The thickness of the sheet used to form the metal deck 700 may be, for example, 16-18 gauge (between 0.0625 to 0.0500 inches) for stainless steel sheets. However, alternate thickness of the metal sheet may also be used. Similarly, alternative materials used in building construction, such as galvanized steel, aluminum, etc., may also be used. For example, if standard steel sheet is used to make the decking components 702, the thickness of the deck may be for example, 16-18 gauge standard steel, which equated to thickness of .00598 to 0.0478 inches. On the other hand, if galvanized steel sheet is used to make the decking components 702, the thickness of the deck may be for example, 16-18 gauge galvanized steel, which equated to thickness of 0 0635 to 0.0516 inches.

Each of the decking components 702 may be configured to have ribs 704 along its length 720. The ribs 704 are formed in the shape of dovetail and the ribs 704 face the downward facing surface of the decking components 702. In other words, when the decking components 702 are used to form a metal deck, the dovetailed ribs 704 face towards the ground and the flat surface on the other side of the decking components 702 opposite the ribs 704 faces away from the ground.

Furthermore, the decking components 702 are formed such that the ribs 704 are cut at predetermined intervals along the length 720. Such cuts in the ribs 704 are across the width 730 of the metal deck 700. In other words, the ribs 704 are not continuous along the entire length 720 of the decking components 702. Specifically, as illustrated in FIG. 7, each of the decking components 702 has rib openings 706a, 706b, 706c (hereinafter referred to as rib openings 706). Note that the rib opening 706c is illustrated to be at one end of the decking components 702. Similar rib opening 706 may also be provided on the other end of the decking components 702.

In one implementation, the ribs 704 are cut along its length 720 to form ribbed flutes that are 21.80 inches in length. Note that in alternative implementations, other lengths of the ribbed flutes may be provided. In one implementation, each of the rib openings 706 between the ribbed flutes may be 2.20 inches. As a result, the distance between the beginnings of each of the rib openings 706 is 24 inches. The dimensions of the lengths of the ribbed flutes and the rib openings 706 may be selected based on the dimensions of other components of a construction system. For example, if the metal deck 700 is used with trusses that are 21.80 inches apart from each other, the ribbed flute length is selected to be 21.80 inches.

Furthermore, if the width of the trusses is 2.20 inches, the rib openings 706 of 2.20 inches are provided. This allows fitting the metal deck 700 on top of a series of trusses.

FIGS. 8A-8C illustrate example side views of a partial metal decking disclosed herein. Specifically, FIG. 8A illustrates a side view of a metal deck 800 showing a plurality of dovetailed shaped ribs 802 that extend along the z-direction. In one implementation, the metal deck 800 also includes top ribs 804 on its surface such that the top ribs 804 are indented upwards in a direction opposite the ribs 802. The ribs 802 and the top ribs 804 provide bracing or strength to the metal decking system. Furthermore, the top ribs 804 provide traction for the top surface of the deck. Note that if the metal deck 800 was provided to have no ribs, it may deflect under smaller loads and therefore such metal deck 800 without ribs will not provide sufficient support as a working surface.

FIG. 8B illustrates an expanded view of a rib 810 with the rib 810 having two sides 812 and 814 and a bottom 816. The sides 812 and 814 are shown to have angles 808a and 808b with respect to the surface of the metal deck 800. Note that in this implementation, these angles 808a and 808b are approximately similar to each other, giving the rib 810 a symmetrical shape about the x-axis. However, in an alternative implementation, the angles 808a and 808b may be different from each other based on one or more load balancing requirements. In one implementation, the top end of the rib 810 may be pinched close such that the top ends of the sides 812 and 814 are touching each other. Furthermore, in the illustrated implementation, the top ends of each of the sides 812 and 814 are curved.

FIG. 8C illustrates an expanded view of a top rib 820. The top rib 820 may have a height of approximately 1.25 inches.

FIG. 9 illustrates example operations 900 for manufacturing and installing metal decking in a building. An operation 902 receives a macro file at a roll former machine used to generate various components of buildings. In one implementation, such a macro file may be received from a software application that generates the macro file based on an architectural drawing. At operation 904, steel rolls are positioned in the roll formers. At operation 906, the roll formers interpret the instructions from the macro file to roll form the metal decking. At operation 908, pilot holes are punched in the metal decking. At operation 910, the metal decking is positioned on previously installed trusses. The metal decking is attached to the trusses at operation 912. In operation 914, wall panels for the next floor of the building or installed on top of the metal decking. This process may be repeated for the number of stories in the building.

FIG. 10 illustrates example top view 1000 of the metal deck disclosed herein. The metal deck disclosed herein may include a number of ribs on the top of the deck. Specifically, these ribs may be at an angle to the length of the metal deck. In example implementations, the length of a sheet of metal deck may be between 2 feet to 20 feet. However, in alternative implementations, other lengths may be available.

FIG. 11 illustrated example top views 1100 of portions of the metal deck disclosed herein. Specifically, the top views 1100 show various example arrangement of the ribs located on top of the metal deck. For example, these ribs may be at an angler of 35 or 40 degrees to an axis along the length of the deck. Alternate arrangements may have alternate angles ranging from 20 to 60 degrees. In one implementation, the length of the top ribs may be between 3.25 to 5.00 inches. However, other lengths may be possible.

FIG. 12 discloses an alternative view 1200 of example metal deck disclosed herein.

As shown herein, in an example implementation, an edge of the folded rib may be cut at an angle of 75 degrees (1202) from the surface of the metal deck to accommodate a truss therein. Furthermore, in the illustrated implementation, the folded ribs may have openings at intervals of approximately two feet. The metal deck may have an open edge at each end of approximately 1.125 inches.

FIG. 13 illustrates yet another alternative view 1300 of example metal deck disclosed herein. Details of sections 1302 and 1304 are described in further detail below in FIGS. 14 and 15.

FIG. 14 illustrates a side view 1400 of the example metal deck disclosed herein. As shown herein, the side view 1400 illustrates the length of the folded rib 1402 being approximately 1.25 inches. The thickness of the folded rib 1402 may be approximately 0.13 inches.

FIG. 15 illustrates another alternative side view 1500 of the metal deck disclosed herein. As shown by 1502, the metal deck may bend at the edge to approximately 88 degrees (from 90 degrees) when loaded, thus giving flexibility to the edge of the metal deck. The top ribs may be placed approximately 0.57 inches away from the folded rib.

The above specification, examples, and data provide a complete description of the structure and use of exemplary embodiments of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Furthermore, structural features of the different embodiments may be combined in yet another embodiment without departing from the recited claims. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the invention. The implementations described above and other implementations are within the scope of the following claims.