BAUER, Nicholaus, B. (3273 213th Street West, Farmington, MN, 55024, US)
HAYDEN, Michael, R. (6704 Parkwood Lane, Edina, MN, 55436, US)
BAUER, Nicholaus, B. (3273 213th Street West, Farmington, MN, 55024, US)
That which is claimed is:
1. A non-cementitious infill platform floor panel comprising: a gusset plate located at each corner of the panel; a tubular frame arranged over the gusset plates forming a base surface delineating the shape of the panel; an under skin arranged over the base surface in the shape and area of the panel; a layer of plywood arranged over the under skin; and a top skin surface of a high strength to weight metal arranged over the layer of plywood.
2. A floor panel as claimed in claim 1 wherein the under skin is formed of materials capable of meeting ASTM E 84 requirements for Class A flame spread.
3. A floor panel as claimed in claim 1 wherein the top skin surface is attached to the layer of plywood via fasteners that are countersunk providing a flush surface.
4. A floor panel as claimed in claim 1 wherein the top skin surface is laminated to the layer of plywood.
5. A floor panel as claimed in claim 4 wherein the layer of plywood is laminated to the under skin.
6. A floor panel as claimed in claim 1 wherein each of the gusset plates includes an aperture to interface with a support structure component.
7. A floor panel as claimed in claim 1 wherein the top skin surface is composed of a durable high strength to weight material.
8. A floor panel as claimed in claim 1 wherein the floor panel shape is a square measuring 48 inches (1219.2 mm) x 48 inches (1219.2 mm), is no more than 5 inches (127 mm) thick and can withstand a concentrated load of up to and including 5000 lbs. (2,268 kg) applied onto a seven inch square area of the panel without failure.
9. A floor panel as claimed in claim 1 wherein the floor panel is no more than five inches thick.
10. A floor panel as claimed in claim 1 wherein the floor panel is field workable to be modified to adhere to adverse site conditions.
11. A floor panel as claimed in claim 1 wherein the floor panel weighs no more than 275 lbs. (124.7 kg).
12. A non-cementitious infill platform floor system comprising: a plurality of non-cementitious infill platform floor panels including a gusset plate located at each corner of the panel wherein each gusset plate includes an aperture to interface with a pedestal, a tubular frame arranged over the gusset plates forming a base surface delineating the shape of the panel, an under skin arranged over the base surface in the shape and area of the panel, a layer of plywood arranged over the under skin, a top skin surface of a high strength to weight metal arranged over the layer of plywood; and a plurality of pedestals interfacing with the floor panels.
13. A platform floor system as claimed in claim 12 wherein each of the plurality of pedestals includes a pedestal head configured to interface with the apertures.
14. A platform floor system as claimed in claim 12 wherein the floor system has a system deadload of no more than 0.2 psi (1.2 kPa).
15. A platform floor system as claimed in claim 12 wherein the floor panels are interchangeable.
16. A platform floor system as claimed in claim 12 wherein the floor panel shapes are squares measuring 48 inches (1219.2 mm) x 48 inches (1219.2 mm), are no more than 5 inches (127 mm) thick and can withstand a rolling load of up to and including 5000 lbs. (2,268 kg) applied onto a seven inch square area of the panel without failure. |
NON-CEMENTITIOUS INFILL PLATFORM FLOOR SYSTEM
FIELD OF THE INVENTION
The present invention is directed to elevated non-cementitious platform floor systems. More particularly, the present invention relates to non-cementitious infill platform floor systems comprising assemblies of modular floor panels arranged on elevated supports capable of withstanding loads and stresses within desired limits.
BACKGROUND In order to create an environment in which spectators may each enjoy a largely unobstructed sightline of an event, staging is erected. Such staging may involve constructing a raised platform for conducting the event, raised or tiered seating for the spectators to view the location of the event, or a combination of both. Both staging approaches involve constructing raised platforms and such construction may be temporary or permanent. Typically, the raised platforms consist of modular flooring panels elevated on pedestals, or other type of understructure, to provide for optional platform configurations. As with most forms of construction, there are several guidelines and safety requirements that the materials and final product must satisfy. For example, both modular floor panels and pedestals of a platform modular floor system must meet certain structural performance requirements. More specifically, a floor system must be capable of withstanding loads and stresses within stated limits. Floor panels must be able to withstand a concentrated load and rolling load of a specified force applied using a square plate to a 7 x 7 square inch (177.8 mm x 177.8 mm) area of the panel at any location on the panel without failure. Failure is the point at which the panel will no longer accept the load. The floor panels must also not exceed a specified permanent deflection after the concentrated load is removed. Floor panels, along with their supporting understructure, must be capable of supporting an impact load dropped from a height of 36 inches (914.4 mm) onto a one square inch area (645.16 mm 2 ), using a round or square indentor, at any location on the panel without failure. A pedestal assembly must sustain an axial load without deforming permanently. Another test for a pedestal assembly is to determine the
average overturning moment without defection when the assembly is fastened to a clean, sound, uncoated concrete surface.
In addition, floor systems must satisfy other safety guidelines such as those directed to natural forces such as earthquakes and fires. With respect to earthquakes, access flooring systems must withstand specified lateral seismic forces. An example standard setting body for such requirements is the International Conference of Building Officials which publishes building codes, including codes for specific seismic zones. With respect to fire, floor system components with exposed finishes must meet flame spread and smoke development criteria. Other components, such as pedestals or support system components, may qualify as noncombustible. An example standard setting body for such requirements is ASTM International (originally known as the America Society for Testing and Materials), which is another international standards organization that develops and publishes voluntary consensus technical standards for a wide range of materials, products, systems, and services. Thus, to ensure the safety of the end users of an infill platform floor system several structural and safety performance requirements must be satisfied. These must be met while also providing a system that is durable and convenient to work with, e.g., modular, lightweight, and portable. These systems may be particularly useful with respect to sporting event venues, concerts, ceremonies, worship facilities, and performing arts venues.
SUMMARY
To satisfy the requirements for non-cementitious floor panels and floor systems described above, and to overcome other limitations that will become apparent upon reading and understanding the present specification, the present invention discloses a non-cementitious floor panel and floor system. In one embodiment of the invention, a non-cementitious infill platform floor panel includes a gusset plate located at each corner of the panel and a tubular frame arranged over the gusset plates forming a base surface that delineates the shape of the panel. Arranged over the base surface in the shape and area of the panel is an under skin, and a layer of plywood is arranged over the under skin. A top skin surface composed of a high strength to weight metal is arranged over the layer of plywood.
In another embodiment of the invention, a non-cementitious infill platform floor system includes a plurality of non-cementitious infill platform floor panels and a plurality of pedestals interfacing with the floor panels. Each of the floor panels includes a gusset plate located at each corner of the panel and a tubular frame arranged over the gusset plates forming a base surface that delineates the shape of the panel. Arranged over the base surface in the shape and area of the panel is an under skin, and a layer of plywood is arranged over the under skin. A top skin surface composed of a high strength to weight metal is arranged over the layer of plywood. These and various other advantages and features of novelty are pointed out with particularity in the claims annexed hereto and form a part hereof. However, for a better understanding of the invention and its advantages, reference should be made to the drawings which form a further part hereof, and to accompanying descriptive matter, in which there are illustrated and described representative examples of apparatuses and systems in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in connection with the embodiments illustrated in the following diagrams.
FIG. IA is a side view illustrating a panel according to embodiments of the invention;
FIG. IB is a side view illustrating a corner of a panel according to embodiments of the invention;
FIG. 1C is a perspective view illustrating a panel according to embodiments of the invention; FIG. ID is a bottom view illustrating a panel according to embodiments of the invention; and
FIGS. 2A-B are side views illustrating a pedestal according to embodiments of the invention.
DETAILED DESCRIPTION
In the following description of various exemplary embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by
way of illustration various embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized, as structural and operational changes may be made without departing from the scope of the present invention. In accordance with embodiments of the invention, a non-cementitious infill platform floor system includes assemblies of modular floor panels on elevated supports (understructures) forming accessible under floor cavities (air spaces) to accommodate electrical, mechanical and special effect services and comply with specified performance requirements. In various embodiments of the present invention, an infill floor system comprises modular and removable non-cementitious filled panels fastened onto, and supported by, adjustable height pedestal assemblies. The pedestal head and panel corner design provide a positive location and lateral engagement of the panel to the understructure support system, which allows the panels to be coupled to the support system without the use of fasteners.
Panels provided according to some embodiments are removable via the use of a lifting device, and when in their unmodified form, may be interchangeable. Where multiple panels are modified in the same manner, e.g., cut to the same size, such panels may be interchangeable with each other. In reference now to FIG. IA, a floor panel according to an exemplary embodiment is illustrated in side view. Floor panel 100 includes multiple layers which are further illustrated using a detail drawing of corner, A, in Fig. IB.
Exemplary floor panel 100 includes five layers. These layers, starting from the bottom, include 1) a gusset plate 110 at each panel corner, 2) a base surface 120 arranged over the gusset plates 110 at the panel corners, 3) a metal under skin 130 arranged over the base surface 120, 4) a plywood inner core 140 arranged over the metal under skin 130, and 5) a top skin surface 150 formed of a high strength to weight metal surface. The base surface 120 may be, for example, formed using a lightweight tubular frame. In a further embodiment the tubular frame may have an outer diameter of 3 inches (76.2 mm).
According to certain embodiments, the metal under skin 130 is formed of materials capable of meeting ASTM E 84 requirements for Class A flame spread. For
example, such materials may include aluminum or other suitable flame resistant material.
The top skin surface 150 may be a high strength to weight steel sheet where the higher the strength level, the greater the potential for downgauging and thus the greater the potential weight saving. Examples of such materials have a yield strength of 700 to about 1400 N/mm 2 and a tensile strength of 1000 to 1600 N/mm 2 while having a thickness of 0.5 to 2 mm and a width of up to 1500 mm. The durability of the top skin surface may be increased, for example, via electrogalvanization and/or by coating the top skin surface with zinc. The top skin surface may be fastened to the plywood inner core 140 with specialty fasteners 145 and/or high strength adhesive. In an example embodiment, the plywood inner core 140 is manufactured from Douglas fir or Western Larch. For example, the top skin surface 150 may be laminated to Struc-1 plywood using a suitable adhesive and/or may be fastened using screws that are countersunk providing a flush surface. The example embodiment illustrated in Fig. 1 C is a floor panel having the top skin surface attached using a plurality of such screws in an ordered pattern of a grid of six screws by six screws spaced so as to provide five equal spaces in both a horizontal and vertical direction on the panel. This pattern is not a requirement for the panel and it is recognized that a variety of screw patterns are possible. The assembly of the top skin surface 150 and plywood inner core 140 may be fastened and/or laminated to an under skin consisting of an aluminum plate frame 130 via fasteners 135.
In another exemplary embodiment, Fig. ID depicts a bottom view of panel 100 where the inner core 140 and under skin 130 are fastened via a plurality of fasteners 135 in an ordered pattern. This pattern is not a requirement for the panel and it is recognized that a variety of fastener patterns are possible. Each gusset plate 110 is arranged at each corner of panel 100. The gusset plates 110 may, for example, be square shaped having dimensions of 4 square inches. Also, each gusset plate 110 includes an aperture 111 for accepting a pedestal pin or other panel support protrusion. This aperture may be specifically shaped to receive a pedestal pin or other support structure in such a manner as to not require additional fasteners.
It should be recognized that panels may have varying sizes and shapes. In certain embodiments, the panel may be 48 x 48 inches (1220 x 1220 mm) square and may weigh up to about 275 lbs. (1.2 kN). In one embodiment, a 48 x 48 inch panel weighs about 220 lbs. However, it will be understood that various panel sizes and weights may be provided in accordance with the present invention. Where a series of panels are provided of the same size and shape, they may be interchangeable with each other while not disturbing adjacent panels or under structure. Panel corners may be configured with locating tabs and with an integrally formed structure, such as a recess, to interface with a support structure, e.g., a protrusion on a pedestal head, in order to provide positive lateral retention and positioning with or without fasteners. In some implementations, pedestal pins may be provided and the panel may have recesses at its bottom. These recesses may be at least 1 inch deep.
Panels may be fastened to pedestal heads by a machine screw designed to be self- capturing within the body of the panel. Providing such a fastening mechanism may prevent the loss of panel fastening screws when accessing the under- floor space and prevent potential damage to objects by screws extending beyond the depth of the panel.
Installation of panels of an infill floor system according to certain embodiments may be performed according to certain tolerances. For example, the fit between the pedestal head, panel, and screw may allow an installation with an average panel-to-panel gap of maximum 1/8 inch (3 mm). Another scenario may involve installation of an infill floor to be level within plus or minus 1/8 inch in 10 feet (3.2 mm in 3048 mm), and plus or minus 1/4 inch (6.35 mm) over the entire area. Panels may be installed level, such that panel-to-panel elevation does not exceed 1/16 inch (1.5 mm). In addition, the floor system may be rigid and free of vibration, rocking panels, rattles, or squeaks.
In various embodiments, panels may be machine workable after installation. For example, under certain circumstances cutouts may be necessary in the panels in order to accept flush mounted electrical floor pockets for lighting, automation, special effects fixtures and penetrations for acrobatic anchors. In addition, panels may accept typical woodscrew fasteners anywhere on the panel. Panel 100 may have a mill finish
and a finished floor surface may be subsequently installed. Alternatively, panel 100 may be provided with a finished floor surface.
Panels may be arranged on any suitable support structure in order to form the infill floor system. The pedestals described below provide one example of a support structure for supporting a floor system consisting of a plurality of panels such as panel 100.
An example pedestal as illustrated in Fig. 2A includes three main portions. For example, pedestal 200 includes: 1) a base assembly 202, 2) a column 203 designed to engage a head assembly 201, and 3) a pedestal head assembly 201. The base assembly 202 may be constructed of a formed steel plate, having, for example, no less than 49 square inches (316 cm 2 ) of bearing area. The column 203 may be, for example, a round steel tube column. In one embodiment, the column may made from drawn-over-mandrel (DOM) structural round carbon steel tubing that meets the ASTM A513 type 5 standard. Such material provides for outer diameter and inner diameter concentricity due to dimensional accuracy, dependable weld integrity, and a desirable surface finish. Also, the pedestal head assembly 201 may be made of steel. An example of a pedestal head is illustrated in the detail drawing of Fig. 2B. In certain embodiments a pedestal head may include: 1) locating tabs 210, 2) a plated steel pedestal head 220 welded to a threaded rod 230, 3) a specially designed adjusting nut 250, and 4) a double nut system 240. The locating tabs 210 are of an integral shape to interface with a panel for positive lateral retention and positioning without fasteners. The adjusting nut 250 allows for leveling the floor system. In one example, the adjusting nut 250 may have an adjustment range of plus or minus 3 inches (76.2 mm). The double nut system 240 may be used to lock the pedestal head at a selected height such that deliberate action is required to change the height setting. The double nut system 240 also may prevent vibration displacement.
This example pedestal head configuration allows a floor to be installed during the construction process without screws so that access by other related trades can be accomplished quickly and easily. It also enables the user to have a mixed installation of fastened and unfastened panels within the same installation.
Pedestals may be corrosive resistant, all steel welded construction with a hot dip galvanized or zinc plated finish.
Pedestal bases may be anchored to a sub-floor using expansion anchors, such as, torque-controlled expansion anchors, made from carbon-steel components zinc- plated to comply with ASTM B 633, Class Fe/Zn 6 (5 microns) for Class SC 1 service condition (mild), with the capability to sustain, without failure, a load equal to 1.5 time the loads imposed by pedestal overturning moment on fasteners, as determined by testing per ASTM E 488. Such testing is conducted by a qualified independent testing agency.
In order to be approved for public use, a floor system must meet several construction and safety requirements. The floor system of the present invention is constructed such that it exceeds the safety requirements of other non-cementitious platform floor systems.
For example, a floor system according to an example embodiment may have a system deadload that does not exceed 0.2 psi (1.2 kPa). In one scenario, a 6 inch (150 mm) thick reinforced concrete slab may be used to support the floor system, and due to the design and arrangement of the floor system, the support structure/panels will not cause a 6 inch (150 mm) concrete slab to be punctured.
Individual floor panels are configured to withstand a concentrated load and rolling load. The tests for determining whether a floor panel satisfies stated requirements are typically performed on a floor panel having approximate dimensions of 48 inches (1219.2 mm) x 48 inches (1219.2 mm) x 5 inch (127 mm). According to an example embodiment of the present invention, modular floor panels having these approximate dimensions are configured to be capable of withstanding a concentrated load and rolling load of about 4730 lbs. (2,145 kg) to about 5000 lbs. (2,268 kg) applied onto a 7 x 7 square inch (177.8 mm 2 ) area using a square plate at any location on the panel without failure. Failure is the point at which the panel will no longer accept the load. In a particular embodiment, a modular floor panel having the above- mentioned approximate dimensions can withstand a concentrated load and a rolling load of 4750 lbs. (2,154 kg) applied onto a 7 x 7 square inch (177.8 mm 2 ) area using a square plate at any location on the panel without failure. In addition, the modular floor panels are configured to not exceed a permanent deflection of 0.10 inch (2.5 mm) after the concentrated load is removed.
In use, a floor system comprising at least two 48 inch (1219.2 mm) x 48 inch (1219.2 mm) panels arranged side-by-side, is capable of supporting a forklift holding about a 9500 Ib. (4,290 kg) load at its front axle. In this application, each of the axle's front wheels rolls along on adjacent panels such that each panel supports a 4750 Ib. (2,145 kg) load. Accordingly, each wheel of a front axle of a forklift may roll along 48 inch (1219.2 mm) x 48 inch (1219.2 mm) panels provided according to the present invention for any distance, e.g., the length of a stadium. Other non-cementitious infill platform floor systems are not capable of supporting such rolling loads.
According to certain embodiments of the invention, modular floor panels having the above-described approximate dimensions, along with their supporting understructure, may be capable of supporting an impact load of about 120 lbs. to about 200 lbs. (54 to 90.8 kg) dropped from a height of 36 inches (914.4 mm) onto a one square inch area (645.16 mm ), using a round or square indentor, at any location on the panel without failure. In a particular embodiment, modular floor panels and supporting understructures are capable of supporting an impact load of 150 lbs. (68 kg) dropped from a height of 36 inches (914.4 mm) onto a one square inch area (645.16 mm 2 ), using a round or square indentor, at any location on the panel without failure.
According to certain embodiments, pedestals are used to provide an understructure to support modular floor panels a desired distance above a base surface. Pedestals may be configured according to a single column approach in which each pedestal is capable of supporting the corners of four panels, except at the perimeter of a floor system. Although the present invention is described in the context of pedestal support systems, any suitable support system may be used to support modular floor panels a desired height above a surface.
In an example embodiment, a pedestal assembly may be configured to sustain between about a 5000 to 6000 Ib. (2,268 to 2,721.5 kg) axial load without deforming permanently. In a particular embodiment, a pedestal assembly is configured to sustain a 5500 Ib. (2,494.8 kg) axial load without permanent deformation. In some implementations, a pedestal assembly has an average overturning moment of about 900 in-lbs to about 1200 in-lbs. without permanent deflection when fastened to a clean, sound, uncoated concrete surface. In a particular implementation,
a pedestal assembly has an average overturning moment of 1 100 in-lbs. (124 Nm) without permanent deflection when fastened to a clean, sound, uncoated concrete surface. The International Conference of Building Officials (ICBO) number for the specific system or structural calculations is required to attest to the lateral stability of a system under seismic conditions.
According to some embodiments of the invention, access flooring is capable of withstanding a lateral seismic force (Fp) in a seismic zone according to requirements of International Building Code 2003.
Floor system components of a floor system that have exposed finishes must meet Class A Flame Spread requirements for flame spread and smoke development. For example, a floor system of the present invention meets ASTM E 84, which is a standard test method for surface burning characteristics for building materials. Pedestals or other support system components that provide an infill platform floor system support structure must qualify as noncombustible by demonstrating compliance with requirements of ASTM E 136, which is a standard test method for behavior of materials in a vertical tube furnace at 1,382 °F (750 °C).
It is understood that the floor system of the present invention may be used with various accessories and devices. For example, panels may be lifted using portable lifting devices. In addition, supports and/or panels may be adjusted using standard or specialized tools. Railings, step units, and other accessories may be suitably arranged at any desirable location on the floor system.
The floor system of the present invention may be installed using conventional methods, for example, which may be according to a project's or manufacturer's specifications. The locations of the floor system supports, e.g., understructure, may be arranged such that uncut panels are interchangeable with each other. Supports may also be arranged so that mechanical and electrical work may be installed without interfering with the support structure's installation. In addition, a finished floor system may include various access points, which provide access to the support structure, wiring or mechanics and/or to the sub-floor. In some implementations, additional support structures such as pedestals may be installed as needed in order to support panels where a floor is disrupted by column, walls, and cutouts.
The foregoing description of the exemplary embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not with this detailed description, but rather determined by the claims appended hereto.