US20140311077A1 - Structural Component System - Google Patents
Structural Component System Download PDFInfo
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- US20140311077A1 US20140311077A1 US14/210,264 US201414210264A US2014311077A1 US 20140311077 A1 US20140311077 A1 US 20140311077A1 US 201414210264 A US201414210264 A US 201414210264A US 2014311077 A1 US2014311077 A1 US 2014311077A1
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- assemblies
- assembly
- primary
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- components
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- 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
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
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- 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
- E04B5/10—Load-carrying floor structures formed substantially of prefabricated units with metal beams or girders, e.g. with steel lattice girders
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
- E04C2/322—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with parallel corrugations
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/30—Columns; Pillars; Struts
- E04C3/32—Columns; Pillars; Struts of metal
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/30—Columns; Pillars; Struts
- E04C3/36—Columns; Pillars; Struts of materials not covered by groups E04C3/32 or E04C3/34; of a combination of two or more materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/38—Arched girders or portal frames
- E04C3/40—Arched girders or portal frames of metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/38—Arched girders or portal frames
- E04C3/46—Arched girders or portal frames of materials not covered by groups E04C3/40 - E04C3/44; of a combination of two or more materials
Abstract
A structural component system which in some embodiments comprises at least one substantially planar component having a corrugated cross-section, a surface with substantially parallel channels, and a length measured substantially parallel to said channels, a first component coupled in layers with a second component to create a primary system assembly, and a primary system assembly coupled in layers with other primary system assemblies and components.
Description
- This application claims priority under 35 U.S.C. §119(e) from earlier filed U.S. Provisional Application Ser. No. 61/783,581, filed Mar. 14, 2013, the entirety of which is incorporated herein by reference.
- 1. Technical Field
- The present system relates to the field of construction materials, particularly prefabricated or site-assembled decking sections.
- 2. Background
- Conventional metal decks are capable of covering spans in the range of 10 to 15 feet, while specialized deep metal decks can cover spans in the 20 to 30-foot range. Slabs can offer greater spanning capability. For example, pre-stressed hollow concrete core slabs can typically span 20 to 40 feet. Typical waffle slabs can span 20 to 30 feet, but those with added depth and weight can span approximately 50 feet.
- “Voided biaxial decks” (e.g., Bubbledeck or Cobiax) can span up to approximately 50 feet (60-feet if post-tensioned). Non-composite, one-way action, constant cross-section, prefabricated roof decks (e.g., Super Versa-Dek), which are comprised of two specific deck types that are mechanically connected to each other between node points, can span approximately 30 feet for roof loading.
- However, these existing systems present several drawbacks. First, they offer limited control on cross-section variation along the span and therefore cannot be optimized for longer spans. Next, they require that utilities are located outside of the deck (typically below the deck), thus resulting in the necessity of providing a separate ceiling space and enclosure. Third, these existing systems result in basically flat top and bottom surfaces and cannot produce articulated surfaces or curved surfaces.
- In addition some methods require additional shoring. Standard metal decking requires construction shoring for longer spans, while waffle-slab construction can require extensive formwork and shoring. Voided biaxial decks can demand extensive field labor for rebar placement, as well as additional shoring.
- With a conventional metal deck, span length is a limiting factor. Moreover, since thin sheet metals are susceptible to plate buckling and reduced capacity, the sections must be thickened and deepened to achieve longer spans. Therefore, manufacturers would need to produce and build an inventory of decking with multiple section depths and of varying gages. Contractors have to bear the additional expense of transporting heavier materials to construction sites.
- Although capable of greater spans than conventional metal decking, pre-stressed hollow concrete core slabs require a specialized fabrication facility and process, which can be time-consuming. Transporting these slabs to a job site also presents a challenge due to their weight and bulk. Once on-site, they are difficult to modify to accommodate building use or support utilities.
- Typical naval and outer space structures are constructed by welding solid-plate elements together to form a surface skin. The weight of these elements requires reinforcement with frequent internal compression framing and/or external tension rings. In addition, these structures often require structural redundancy (e.g., double-hulled construction) and ductility to withstand unexpected collision forces. In such applications, there are clear advantages to using limited basic shapes that can be easily transported, assembled, and modified in the field.
- What is needed is a simple system for creating custom metal decking on-site and on-demand.
- The present system provides a system of components that can be efficiently combined to create desired structural members, including supporting beams.
- Further details of the present system are explained with the help of the attached drawings in which:
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FIG. 1 depicts a perspective view of one embodiment of the basic system component of the present system. -
FIG. 2 a depicts a perspective view of one embodiment of a primary assembly of the present system. -
FIG. 2 b depicts a side cross-sectional view of the embodiment shown inFIG. 2 a used in conjunction with flooring or other board. -
FIG. 2 c depicts a side elevation view of the embodiment shown inFIG. 2 a used in conjunction with flooring or other board. -
FIG. 2 d depicts a side cross-sectional view of the embodiment shown inFIG. 2 a used in conjunction with a concrete surface. -
FIG. 2 e depicts a side elevation view of the embodiment shown inFIG. 2 a used in conjunction with a concrete surface. -
FIG. 3 a depicts a perspective view of one embodiment of a secondary assembly of the present system. -
FIG. 3 b depicts a perspective view of another embodiment of a secondary assembly of the present system in which the base components and/or primary assemblies are in a staggered formation. -
FIG. 3 c depicts a side cross-sectional view of the embodiment shown inFIG. 3 a or 3 b used in conjunction with flooring or other board. -
FIG. 3 d depicts a side elevation view of the embodiment shown inFIG. 3 c used in conjunction with flooring or other board. -
FIG. 3 e depicts a side cross-sectional view of the embodiment shown inFIG. 3 a or 3 b used in conjunction with a concrete surface. -
FIG. 3 f depicts a side elevation view of the embodiment shown inFIG. 3 e used in conjunction with a concrete surface. -
FIG. 3 g depicts a side cross-sectional view of the embodiment shown inFIG. 3 a or 3 b used in conjunction with concrete on the top and bottom surfaces. -
FIG. 3 h depicts a side elevation view of the embodiment shown inFIG. 3 g used in conjunction with concrete on the top and bottom surfaces. -
FIG. 3 i depicts a side cross-sectional view of the embodiment shown inFIG. 3 a or 3 b used in conjunction with flooring or other board and a staggered configuration of secondary assemblies. -
FIG. 3 j depicts a side elevation view of the embodiment shown inFIG. 3 i used in conjunction with flooring or other board and a staggered configuration of secondary assemblies. -
FIG. 4 a depicts a perspective view of one embodiment of a secondary assembly of the present system used in conjunction with cellular decking on the bottom surface. -
FIG. 4 b depicts a perspective view of one embodiment of a secondary assembly of the present system used with varying lengths of basic system components in conjunction with cellular decking on the bottom surface. -
FIG. 4 c depicts a side cross-sectional view of the embodiment shown inFIG. 4 a or 4 b used in conjunction with flooring or other board and cellular decking. -
FIG. 4 d depicts a side elevation view of the embodiment shown inFIG. 4 c used in conjunction with flooring or other board and cellular decking. -
FIG. 4 e depicts a side cross-sectional view of the embodiment shown inFIG. 4 a or 4 b used in conjunction with concrete and cellular decking. -
FIG. 4 f depicts a side elevation view of the embodiment shown inFIG. 4 e-used in conjunction with concrete and cellular decking. -
FIG. 5 a depicts a perspective view of one embodiment of a secondary assembly of the present system having webs placed in between the basic components of the present system. -
FIG. 5 b depicts a perspective view of one embodiment of a secondary assembly of the present system having webs placed in between the basic components of the present system with varying length of basic system components. -
FIG. 5 c depicts a side cross-sectional view of the embodiment shown inFIG. 5 a or 5 b at full length component region used in conjunction with flooring. -
FIG. 5 d depicts a side elevation view of the embodiment shown inFIG. 5 c-used in conjunction with flooring. -
FIG. 5 e depicts a side cross-sectional view of the embodiment shown inFIG. 5 a or 5 b at full length component region used in conjunction with a concrete surface. -
FIG. 5 f depicts a side elevation view of the embodiment shown inFIG. 5 e used in conjunction with a concrete surface. -
FIG. 5 g depicts a side cross-sectional view of the embodiment shown inFIG. 5 a or 5 b at full length component region used in conjunction with a concrete surface and concrete soffit. -
FIG. 5 h depicts a side elevation view of the embodiment shown inFIG. 5 g used in conjunction with a concrete surface and concrete soffit. -
FIG. 6 a depicts a perspective view of one embodiment of a secondary assembly of the present system in which the basic components of the present system can be arranged orthogonally. -
FIG. 6 b depicts a side cross-sectional view of the embodiment shown inFIG. 6 a used in conjunction with flooring and cellular decking. -
FIG. 6 c depicts a side elevation view of the embodiment shown inFIG. 6 a used in conjunction with flooring and cellular decking. -
FIG. 6 d depicts a side cross-sectional view of the embodiment shown inFIG. 6 a used in conjunction with a concrete surface and cellular decking. -
FIG. 6 e depicts a side elevation view of the embodiment shown inFIG. 6 a used in conjunction with a concrete surface and cellular decking. -
FIG. 7 a depicts a perspective view of one embodiment of a secondary assembly of the present system in which the basic components of the present system can be arranged orthogonally and with spaces in between. -
FIG. 7 b depicts a side cross-sectional view of the embodiment shown inFIG. 7 a used in conjunction with flooring and cellular decking. -
FIG. 7 c depicts a side elevation view of the embodiment shown inFIG. 7 a used in conjunction with flooring and cellular decking. -
FIG. 8 a depicts a perspective view of another embodiment of a secondary assembly of the present system. -
FIG. 8 b depicts a side cross-sectional view of the embodiment shown inFIG. 8 a used in conjunction with flooring or other board and cellular decking. -
FIG. 8 c depicts a side elevation view of the embodiment shown inFIG. 8 a used in conjunction with flooring or other board and cellular decking. -
FIG. 8 d depicts a side cross-sectional view of the embodiment shown inFIG. 8 a used in conjunction with a concrete surface or other board and cellular decking. -
FIG. 8 e depicts a side elevation view of the embodiment shown inFIG. 8 a used in conjunction with a concrete surface or other board and cellular decking. -
FIG. 8 f depicts a side cross-sectional view of the embodiment shown inFIG. 8 a used in conjunction with a concrete surface and concrete soffit. -
FIG. 8 g depicts a side elevation view of the embodiment shown inFIG. 8 a used in conjunction with a concrete surface and concrete soffit. -
FIG. 8 h depicts a side cross-sectional view of the embodiment shown inFIG. 8 a used in conjunction with a concrete surface and concrete soffit to create a cambered member. -
FIG. 8 i depicts a side elevation view of the embodiment shown inFIG. 8 a used in conjunction with a concrete surface and concrete soffit to create a cambered member. -
FIG. 9 a depicts a perspective view of another embodiment of a secondary assembly of the present system. -
FIG. 9 b depicts a side cross-sectional view of the embodiment shown inFIG. 9 a used in conjunction with flooring or other board and cellular decking. -
FIG. 9 c depicts a side elevation view of the embodiment shown inFIG. 9 a used in conjunction with flooring or other board and cellular decking. -
FIG. 9 d depicts a side cross-sectional view of the embodiment shown inFIG. 9 a used in conjunction with a concrete surface and concrete soffit. -
FIG. 9 e depicts a side elevation view of the embodiment shown inFIG. 9 a used in conjunction with a concrete surface and concrete soffit. -
FIG. 10 a depicts a perspective view of another embodiment of a secondary assembly of the present system in which primary assemblies of the present system can be arranged orthogonally and with spaces in between. -
FIG. 10 b depicts a side cross-sectional view of the embodiment shown inFIG. 10 a used in conjunction with solar panels. -
FIG. 10 c depicts a side elevation view of the embodiment shown inFIG. 10 a used in conjunction with solar panels -
FIG. 11 a depicts a perspective view of an embodiment of the present system used in conjunction with frame supports to create curved structures. -
FIG. 11 b depicts a side cross-sectional view of the embodiment shown inFIG. 11 a. -
FIG. 11 c depicts a side elevation view of the embodiment shown inFIG. 11 a. -
FIG. 12 a depicts a perspective view of an embodiment of the present system used in conjunction with frame supports to create tubular structures. -
FIG. 12 b depicts a side cross-sectional view of the embodiment shown inFIG. 12 a. -
FIG. 12 c depicts a side elevation view of the embodiment shown inFIG. 12 a. -
FIG. 13 a depicts a perspective view of an embodiment of the present system used in conjunction with frame supports to create tubular structures. -
FIG. 13 b depicts a side cross-sectional view of the embodiment shown inFIG. 13 a. -
FIG. 13 c depicts a side elevation view of the embodiment shown inFIG. 13 a. -
FIG. 14 a depicts a front view of an embodiment of the present system in use as a wall member having varied cross-sectional and side elevation profiles. -
FIG. 14 b depicts a top cross-sectional view of the embodiment shown inFIG. 14 a with interior cells filled with an additional material. -
FIG. 14 c depicts a top cross-sectional view of another embodiment of the present system. -
FIG. 14 d depicts a side elevation view of the embodiment shown inFIG. 14 c. -
FIG. 14 e depicts a top cross-sectional view of an embodiment of the present system used in conjunction with a concrete surface in use as a wall member. -
FIG. 14 f depicts a side elevation view of the embodiment shown inFIG. 14 e. -
FIG. 14 g depicts a top cross-sectional view of an embodiment of the present system used in conjunction with concrete surfaces in use as a wall member. -
FIG. 14 h depicts a side elevation view of the embodiment shown inFIG. 14 g. -
FIG. 14 i depicts a top cross-sectional view of an embodiment of a secondary assembly of the present system having web members in use as a wall member. -
FIG. 14 j depicts a side elevation view of the embodiment shown inFIG. 14 i. -
FIG. 15 a-i depict various types of shear stiffener members that can be used in conjunction with embodiments of the present system. -
FIG. 1 depicts a perspective view of one embodiment of abasic system component 102. As shown inFIG. 1 , abasic system component 102 can be a substantially planar member with a corrugated cross-section, having a series of substantially parallel bends 104. In some embodiments, substantiallyparallel bends 104 can alternate between approximately 60-degrees and approximately 120-degrees to form a series ofadjacent channels 106 having substantially semi-hexagonal cross-sections for abasic system component 102. However, in other embodiments, substantiallyparallel bends 104 can formchannels 106 having substantially semicircular, sinusoidal, triangular, rectangular, or any other known and/or convenient cross-sectional geometry. In some embodiments, abasic system component 102 can be fabricated from steel, but in other embodiments can be made from aluminum, alloy, composite, or any other known and/or convenient material. In the embodiment shown inFIG. 1 , abasic system component 102 can have a substantially rectangular geometry having a length l and a width w, where l denotes the dimension substantially parallel tobends 104 andchannels 106 of abasic system component 102, and w denotes the dimension substantially perpendicular tobends 104 andchannels 106 of abasic system component 102. However, in other embodiments, abasic system component 102 can have any other known and/or convenient geometry or dimensions. -
FIG. 2 a depicts a perspective view of one embodiment of aprimary assembly 202. As shown inFIG. 2 a, at least twobasic system components 102 can be stacked and oriented with substantiallyparallel bends 104 andchannels 106 aligned to formtube sections 203 having substantially hexagonal cross-sections. In such embodiments,basic system components 102 can be connected at adjacent surfaces withfasteners 204, which can be screws, bolts, rivets, locking tabs, or any other known and/or convenient system. As shown inFIG. 2 a, a group offasteners 204 can be aligned substantially parallel totube sections 203, but in other embodiments can be arranged in any other known and/or convenient configuration. In other embodiments,basic components 102 can be joined via welding, adhesive, or any other known and/or convenient method. - In some embodiments, as shown in
FIGS. 2 b and 2 c, at least oneprimary assembly 202 can be used in conjunction withflooring 206 placed on the top surface of aprimary assembly 202, wherein at least oneprimary assembly 202 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of aprimary assembly 202 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In some embodiments, as shown inFIG. 2 c, at least onesupport member 208 can be located on the bottom surface of and substantially along an edge of aprimary assembly 202, and substantially perpendicular to the longitudinal axis oftube sections 203. In some embodiments, asupport member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry. - In some embodiments, as shown in
FIGS. 2 d and 2 e, at least oneprimary assembly 202 can be used in conjunction with aconcrete surface 210 adjacent to the top surface of aprimary assembly 202, wherein at least oneprimary assembly 202 can support aconcrete surface 210. In some embodiments of the present system, a “poured” material can also be considered “cast.” In some embodiments, aconcrete surface 210 can be poured or cast in place directly onto at least oneprimary assembly 202. In some embodiments, as shown inFIG. 2 e, at least onesupport member 208 can be located on the bottom surface of and substantially along an edge of aprimary assembly 202, and substantially perpendicular totube sections 203. In some embodiments, asupport member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry. -
FIG. 3 a depicts a perspective view of an embodiment of asecondary system assembly 302, wherein at least twoprimary assemblies 202 can be connected such that theirbends 104 andchannels 106 are substantially parallel. As shown inFIG. 3 a, at least a pair ofsecondary system assemblies 202 can be stacked and oriented with substantiallyparallel bends 104 andchannels 106 aligned to formadditional tube sections 203 having substantially hexagonal cross-sections betweensecondary system assemblies 302. In such embodiments,secondary system assemblies 302 can be connected at adjacent surfaces withfasteners 204, which can be screws, bolts, rivets, locking tabs, or any other known and/or convenient system. As shown inFIG. 3 a, a group offasteners 204 can be aligned substantially parallel totube sections 203, but in other embodiments can be arranged in any other known and/or convenient configuration. In other embodiments,secondary system assemblies 202 can be joined via welding, adhesive, or any other known and/or convenient method. - In some embodiments, as shown in
FIG. 3 b,basic system components 102 and/orprimary assemblies 202 can be of varied lengths to create various staggered-profilesecondary assemblies 302. In such embodiments, the length of asecondary system assembly 302 can vary with the depth of asecondary system assembly 302. In some embodiments, at least twoprimary assemblies 202 of the same width can be connected such that asecondary assembly 302 has a uniform width, as seen in the frontal view ofFIG. 3 c.FIG. 3 d depicts the embodiment ofFIG. 3 c in profile view. In this embodiment,basic system components 102 can be of varying lengths and arranged from longest length to shortest length from top to bottom. As shown inFIG. 3 b, eachbasic system component 102 can also be beveled at its ends to any known and or convenient taper. As shown inFIG. 3 d, length can decrease substantially symmetrically with respect to the midpoint of the length ofbasic system components 102. - As shown in
FIG. 3 c andFIG. 3 d, flooring 206 can be placed on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can supportflooring 206. In some embodiments, as shown inFIGS. 3 c and 3 e, asecondary assembly 302 can have a maximum depth substantially equal to the depth of twoprimary assemblies 202, but in other embodiments can have any other known and/or convenient depth. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of asecondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In other embodiments, as shown inFIGS. 3 e and 3 f, at least onesecondary assembly 302 can be used in conjunction with aconcrete surface 210 adjacent to the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can support aconcrete surface 210. In some embodiments, aconcrete surface 210 can be poured in place directly onto the top surface of asecondary assembly 202. - In some embodiments, as shown in
FIGS. 3 d and 3 f, at least onesupport member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longestbasic system component 102 in the embodiment shown), and substantially perpendicular totube sections 203. In some embodiments, asupport member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry. - In some embodiments, as shown in
FIG. 3 g, at least threeprimary assemblies 202 of the same width can be connected such that asecondary assembly 302 has a uniform width, as seen in the frontal view ofFIG. 3 g. In some embodiments, asecondary assembly 302 can have a maximum depth substantially equal to that of threeprimary assemblies 202, but in other embodiments can have any other known and/or convenient depth.FIG. 3 h depicts the embodiment ofFIG. 3 g in profile view. In this embodiment,basic system components 102 can be of varying lengths and arranged from longest length to shortest length from top surface of asecondary assembly 302 to the center line, and then shortest to longest from the center to the bottom surface of asecondary assembly 302. As shown inFIG. 3 h,basic system component 102 length can change substantially symmetrically with respect to the midpoint of the length ofbasic system components 102. - In some embodiments, as shown in
FIGS. 3 g and 3 h, asecondary assembly 302 can be used in conjunction with aconcrete surface 210 on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can support aconcrete surface 210, and aconcrete soffit 304 on the bottom surface of asecondary assembly 302. In some embodiments, aconcrete surface 210 or aconcrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces of asecondary assembly 302. - In some embodiments, as shown in
FIG. 3 h, the top edge of asupport member 208 can be located substantially along an edge of asecondary assembly 302, while the bottom edge can be attached to and/or anchored in aconcrete soffit 304. - In some embodiments, at least two
primary assemblies 202 of varying width can be connected such that asecondary assembly 302 has cross sections of varying width, as seen in the frontal view ofFIG. 3 i. In some embodiments, each section of varying width can decrease in width from the top to the bottom and be configured in a symmetrical and/or regular pattern. However, in other embodiments, sections of varying width can be arranged in any known and/or convenient geometry or pattern. In some embodiments, asecondary assembly 302 can have a maximum depth substantially equal to the depth of 2.5primary assemblies 202, but in other embodiments can have any other known and/or convenient depth.FIG. 3 j depicts the embodiment ofFIG. 3 i in profile view. In this embodiment,basic system components 102 can be of varying lengths and arranged from longest length to shortest length from top to bottom. As shown inFIG. 3 i, length can decrease substantially symmetrically with respect to the midpoint of the length ofbasic system components 102. - As shown in
FIG. 3 i andFIG. 3 j, flooring 206 can be placed on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of asecondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. - In some embodiments, as shown in
FIG. 3 j, at least onesupport member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longestbasic system component 102 in the embodiment shown), and substantially perpendicular totube sections 203. In some embodiments, asupport member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry. -
FIG. 4 a depicts a perspective view of an embodiment of asecondary system assembly 302, such as that depicted inFIG. 3 a, used in conjunction withcellular decking 402 on the bottom surface of asecondary system assembly 302. In some embodiments, as shown inFIG. 4 b,basic system components 102 and/orprimary assemblies 202 can be of varied lengths to create various staggered profilesecondary assemblies 302. In some embodiments, at least twoprimary assemblies 202 of the same width can be connected such that asecondary assembly 302 has a uniform width, as seen in the frontal view ofFIG. 4 c.FIG. 4 d depicts the embodiment ofFIG. 4 c in profile view. In this embodiment,basic system components 102 can decrease in length from top to bottom, and then can have a bottommostbasic system component 102 with a length less than or substantially equal to that of a topmostbasic component 102, but greater than the length of the intermediatebasic components 102. As shown inFIG. 4 d, length can decrease or increase substantially symmetrically with respect to the midpoint of the length ofbasic system components 102. - As shown in
FIG. 4 c andFIG. 4 d, flooring 206 can be placed on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of asecondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. As shown inFIG. 4 c, the embodiment ofFIG. 4 b can be used in conjunction withcellular decking 402 on the bottom surface of asecondary system assembly 302. In some embodiments, asecondary assembly 302 can be used to construct a fully decked region. - In some embodiments, as shown in
FIG. 4 d, at least onesupport member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longestbasic system component 102 in the embodiment shown), and substantially perpendicular totube sections 203. In some embodiments, asupport member 208 can be an I-beam, but in other embodiments, can be a hollow structural tube, channel, angle, or beam with any other known and/or convenient cross-sectional geometry. In other embodiments, asupport member 208 can be a metallic plate, such as a steel plate cast in a concrete beam. In some embodiments,cellular decking 402 can be connected to asupport member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. - In other embodiments, as shown in
FIGS. 4 e and 4 f, at least onesecondary assembly 302 can be used in conjunction with aconcrete surface 210 adjacent to the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can support aconcrete surface 210. In some embodiments, aconcrete surface 210 can be poured in place directly onto the top surface of asecondary assembly 202. Such embodiments can also be used in conjunction withcellular decking 402 on the bottom surface of asecondary system assembly 302. - In some embodiments, as shown in
FIG. 4 f, at least onesupport member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longestbasic system component 102 in the embodiment shown), and substantially perpendicular totube sections 203. In some embodiments, asupport member 208 can be an I-beam, but in other embodiments, can be a hollow structural section, channel, angle, top or bottom chord of a truss, a straight or bent plate cast in a concrete beam or on a top face of a concrete walls, or a beam with any other known and/or convenient cross-sectional geometry. -
FIG. 5 a depicts a perspective view of an embodiment of aprimary system assembly 202, wherein aweb member 502 can be placed at any known and/or convenient intervals betweenbasic system components 102. As shown inFIG. 5 a, a pair ofbasic system components 102 can be stacked and oriented with substantiallyparallel bends 104 andchannels 106 aligned such that the spacing betweenbasic system components 102 can alternate substantially regularly between a maximum and minimum spacing, wherein a minimum spacing can be determined by the thickness of aweb member 502. In some embodiments, a plurality ofweb members 502 can provide support and spacing in betweenbasic system components 102. As shown inFIGS. 5 a, 5 b, 5 c, and 5 d, in such embodiments, atubular conduit region 504 can be created betweenbasic system components 102. In some embodiments, atubular conduit region 504 can have dimensions of approximately 16 inches high and approximately 24 inches wide, and can have a maximum height in the range of approximately 10 inches to approximately at least 22 inches and a maximum width in the range of approximately 12 inches to approximately at least 36 inches. In some embodiments, larger widths may require intermediate support in in thetubular conduit region 504, depending on the loading and section properties of the deck. - In some embodiments, a
web member 502 can be comprised of a pair ofchannel members 506. A pair ofchannel members 506 can be placed concave-out and substantially along the longitudinal edges of and betweenbasic system components 102 to create aprimary system assembly 202 having atubular conduit region 504 between the first and second basic system components. - In such embodiments,
basic system components 102 can be connected toweb members 502 withfasteners 204, which can be screws, bolts, rivets, locking tabs, or any other known and/or convenient system. In other embodiments,basic components 102 can be joined toweb members 502 via welding, adhesive, or any other known and/or convenient method. As shown inFIGS. 5 c, 5 e, and 5 f, access hatches 516 can be placed in abasic component 102 to facilitate placement of utilities in aconduit region 504. - As shown in the embodiment of
FIG. 5 b, thebasic components 102 can be of different lengths, with the upperbasic component 102 being longer than thelower component 102. In other embodiments, this configuration can be reversed. - As shown in
FIG. 5 c, the embodiment of aprimary assembly 202 withweb members 502 as shown inFIGS. 5 a and 5 b can be used in conjunction withflooring 206. Flooring 206 can be placed on the top surface of aprimary assembly 202, wherein at least oneprimary assembly 202 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of aprimary assembly 202 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. - In other embodiments, as shown in
FIGS. 5 e and 5 f, at least oneprimary assembly 202 withweb members 502 can be used in conjunction with aconcrete surface 210 adjacent to the top surface of aprimary assembly 202, wherein at least oneprimary assembly 202 can support aconcrete surface 210. In some embodiments, aconcrete surface 210 can be poured in place directly onto the top surface of aprimary assembly 202. - In some embodiments, as shown in
FIGS. 5 d and 5 f, at least onesupport member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longer of the twobasic system components 102 in the embodiment shown), and substantially perpendicular toconduit regions 504. In some embodiments, asupport member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry. - In some embodiments, as shown in
FIGS. 5 g and 5 h, aprimary assembly 202 withweb members 502 can be used in conjunction with aconcrete surface 210 on the top surface of aprimary assembly 202, wherein at least oneprimary assembly 202 can support aconcrete surface 210, and aconcrete soffit 304 on the bottom surface of aprimary assembly 202. In some embodiments, aconcrete surface 210 or aconcrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces of aprimary assembly 202. - In some embodiments having a
concrete soffit 304, as shown inFIG. 5 h, the top edge of asupport member 208 can be located substantially along an edge of aprimary assembly 202, while the bottom edge can be anchored in aconcrete soffit 304. In some embodiments, a support member can be an end support beam comprised of bent plates (angles) that can be embedded in a concrete fill that can be poured at the same time as aconcrete surface 210 top of a metal deck. - In some embodiments, as shown in
FIG. 5 g, aconcrete soffit 304 or any other known and or convenient substrate comprised of a liquid material that subsequently hardens into a solid state can be poured into any known and/or convenient form. A plurality ofprimary system assemblies 202 can be aligned substantially laterally adjacent to each other and substantially horizontally on the substrate such that there can be a gap betweenchannel members 506 along the lateral sides of eachprimary system assembly 202 to create an interstitiallongitudinal void 508 betweenchannel members 506. In some embodiments, an interstitiallongitudinal void 508 can have dimensions of approximately 16 inches high and approximately 24 inches wide, and can have a maximum height in the range of approximately 10 inches to approximately at least 22 inches and a maximum width in the range of approximately 12 inches to approximately at least 36 inches, and in some embodiments can have a width of approximately 25 inches. A top surface comprised of a pourable and subsequently hardening medium, such as aconcrete surface 210, can be poured and can flow through the gaps to fill interstitiallongitudinal voids 508 to form a continuous solid member connecting a top surface (concrete surface 210) and a substrate (concrete soffit 304). - In some embodiments, as shown in
FIG. 5 g, and other embodiments, a plurality oflateral supports 512 and/orvertical supports 514 can be placed withinconduit regions 504. In some embodiments, as shown inFIG. 5 g, if concrete topping is poured separately in each deck segment, there can be a cold joint 510 between segments when these are turned over and placed in position. - In some embodiments, a
concrete surface 210 can be poured on top of a form, which can be on the ground, on shoring, or suspended from the bottom layer of a deck bottom layer. However, in other embodiments, the use of temporary formwork can be eliminated, which can result in a significant savings in time and material. In some embodiments, aconcrete surface 210 can be poured as a topping on a deck, with deck acting as formwork, thus eliminating the need to use a temporary plywood formwork except for minimal formwork at the edges. In such embodiments, after a concrete surface has hardened, a deck with aconcrete surface 210 can be turned over such that aconcrete surface 210 can now be at thesoffit 304 and the deck is exposed at the top surface. In such embodiments, a new layer of concrete can be poured on top to create a deck with a concrete surface adjacent to the top and bottom surfaces of decking, which can be constructed without any use of additional plywood temporary formwork. - Wall construction will be also similar and though plywood formwork may be used, it is advantageous to construct the wall horizontally on the ground as described above without any use of plywood formwork and then tilt it up into vertical position, similar to a tilt up concrete wall construction.
-
FIG. 6 a depicts a perspective view of an alternative embodiment of asecondary system assembly 302 comprised of substantially orthogonally stackedbasic system components 102. In such embodiments, aprimary assembly 202 can have a pair ofbasic system components 102 that can be stacked or layered such that thebends 104 andchannels 106 of abasic component 102 can be oriented substantially orthogonally to thebends 104 andchannels 106 of anotherbasic component 102. In embodiments such as those shown inFIGS. 6 a, 6 b, 6 c, 6 d, and 6 e, eachbasic component 102 of aprimary assembly 202, and, therefore, of asecondary assembly 302, can be of substantially equal dimensions and/or substantially congruent geometry. However, in other embodiments, eachbasic component 102 can be of different dimensions and/or geometries to create various configurations ofsecondary assemblies 302. - As shown in
FIGS. 6 b-6 e, this embodiment can also be used in conjunction withflooring 206,cellular decking 402, and concrete 210 in any known and/or convenient combination. For example, as shown inFIG. 6 b andFIG. 6 c,flooring 206 can be placed on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of asecondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. As shown inFIGS. 6 a and 6 b, the embodiment ofFIG. 6 b can be used in conjunction withcellular decking 402 on the bottom surface of asecondary system assembly 302 In some embodiments,cellular decking 402 can be connected to asupport member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. - In some embodiments, as shown in
FIGS. 6 d and 6 e, asecondary assembly 302 can be used in conjunction with aconcrete surface 210 on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can support aconcrete surface 210, andcellular decking 402 on the bottom surface of asecondary assembly 302. In some embodiments,cellular decking 402 can be connected to asupport member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. In other embodiments, aconcrete soffit 304 can be used on the bottom surface of asecondary assembly 302. Aconcrete surface 210 or aconcrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces, respectively, of asecondary assembly 302. -
FIG. 7 a depicts a perspective view of another alternative embodiment of asecondary system assembly 302 comprised of substantially orthogonally stackedbasic system components 102. In the embodiment shown inFIG. 7 a, asecondary assembly 302 can have a substantially rectangular geometry having a length l and a width w, where l denotes the dimension substantially parallel tobends 104 andchannels 106 of abasic system component 102, and w denotes the dimension substantially perpendicular tobends 104 andchannels 106 of abasic system component 102. However, in other embodiments, asecondary assembly 302 can have any other known and/or convenient geometry or dimensions. In some embodiments, as shown inFIG. 7 a, aprimary assembly 202 can have onebasic system component 102 that can be stacked or layered such that thebends 104 andchannels 106 of abasic component 102 having a length l and a width w, Thisbasic component 102 can be oriented substantially orthogonally to thebends 104 andchannels 106 of at least one otherbasic component 102 that can have a length less than w and a width less than l. In such embodiments,basic system components 102 can be connected at adjacent surfaces withfasteners 204, which can be screws, bolts, rivets, locking tabs, or any other known and/or convenient system. In other embodiments,basic components 102 can be joined via welding, adhesive, or any other known and/or convenient method. - When connected to the
basic component 102, these narrowerbasic components 102 can be spaced at any known and/or convenient interval, regular or irregular, such that whenprimary assemblies 202 are connected,conduit spaces 504 can be created between layers ofprimary assemblies 202. For example, inFIG. 7 a, narrowerbasic components 102 can have a width such that a plurality can fit within the length l of a largerbasic component 102 and createmultiple conduit spaces 504. - As shown in
FIGS. 7 b and 7 c, this embodiment of asecondary assembly 302 can also be used in conjunction withflooring 206,cellular decking 402 in any known and/or convenient combination. For example, as shown inFIG. 7 b andFIG. 7 c,flooring 206 can be placed on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of asecondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. As shown inFIGS. 7 b and 7 c, the embodiment ofFIG. 7 a can be used in conjunction withcellular decking 402 on the bottom surface of asecondary system assembly 302. In some embodiments,cellular decking 402 can be connected to asupport member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. -
FIGS. 8-14 depict various other embodiments of the present system. In these embodiments, various widths and lengths ofbasic system components 102 can be combined to form a variety of cross-sections and support geometries. In some of these embodiments, additional features can be added for functional or aesthetic purposes. -
FIG. 8 a depicts a perspective view of another embodiment of the present system. As shown inFIG. 8 b,primary assemblies 202 of varying width (as seen inFIG. 3 i) can be coupled to create asecondary assembly 302 having cross sections of varying width, as seen in the frontal view ofFIG. 3 i. In some embodiments, each section of varying width can decrease and then increase in width from the top to the bottom to createlongitudinal voids 802 substantially parallel to and oriented with substantiallyparallel bends 104 andchannels 106. In some embodiments,primary assemblies 202 can be configured in a symmetrical and/or regular pattern, but in other embodiments can be arranged in any other known and/or convenient geometry. - As shown in
FIG. 8 c, a side elevation view of the embodiment shown inFIG. 8 b, a plurality ofsecondary assemblies 202 can be placed at intervals between a pair ofprimary system components 102, creating atertiary system assembly 804 havingtubular voids 806 running substantially orthogonally to thelongitudinal voids 802. In some embodiments,tubular voids 806 can have a substantially rectangular cross-section, but in other embodiments (i.e., those havingprimary assemblies 202 of varying length comprising secondary assemblies 302) can have any other known and/or convenient cross-sectional geometry. -
FIGS. 8 b and 8 c also show this embodiment used in conjunction withflooring 206 andcellular decking 402. Flooring 206 can be placed on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of asecondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In some embodiments,cellular decking 402 can be connected to asupport member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. -
FIGS. 8 d and 8 e show this embodiment where at least onesecondary assembly 302 can be used in conjunction with aconcrete surface 210 adjacent to the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can support aconcrete surface 210. In some embodiments, aconcrete surface 210 can be poured in place directly onto the top surface of asecondary assembly 202. Such embodiments can also be used in conjunction withcellular decking 402 on the bottom surface of asecondary system assembly 302. - In
FIGS. 8 f and 8 g, this embodiment can be used in with aconcrete surface 210 on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can support aconcrete surface 210, and aconcrete soffit 304 on the bottom surface of asecondary assembly 302. In some embodiments, aconcrete surface 210 or aconcrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces of asecondary assembly 302. -
FIGS. 8 h and 8 i also show the embodiment ofFIGS. 8 f and 8 g used in conjunction with aconcrete surface 210 andconcrete soffit 304, but in which atertiary system assembly 804 can be cambered. -
FIG. 9 a depicts a perspective view of atertiary system assembly 804. In some embodiments, atertiary system assembly 804 can have a transverse void 902. In some embodiments, a transverse void 902 can have a width approximately less than one-third of the length oftertiary assembly 804, but in other embodiments can have any other known and/or convenient dimensions. -
FIGS. 9 b and 9 c also show this embodiment used in conjunction withflooring 206 andcellular decking 402. Flooring 206 can be placed on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of asecondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In some embodiments,cellular decking 402 can be connected to asupport member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. In some embodiments, as shown inFIG. 9 c, atertiary system assembly 804 can be supported by bearing on the bottom surface, but in other embodiments can be used in conjunction with any known and/or convenient support method. -
FIGS. 9 d and 9 e show this embodiment in use with aconcrete surface 210 on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can support aconcrete surface 210, and aconcrete soffit 304 on the bottom surface of asecondary assembly 302. In some embodiments, aconcrete surface 210 or aconcrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces of asecondary assembly 302. - As shown in
FIG. 10 a, in some embodiments, configurations of the present system can be formed intoedge beams 1002 that can supportsolar panels 1004, or any other known and/or convenient panel. In the embodiment shown inFIG. 10 a,primary assemblies 202 can have a substantially rectangular geometry with a length measured in a direction substantially parallel to and a width measured in a direction substantially perpendicular tochannels 106. Toform edge beams 1002, firstprimary assemblies 202 having a given length and width can be substantially orthogonally stacked and coupled with othersecondary assemblies 202 having a length substantially equal to the width of firstprimary assemblies 202 and a width less than half of the measure of the length of firstprimary assemblies 202. As shown inFIGS. 10 a and 10 b, in some embodiments, secondprimary assemblies 202 can have a width less than one-third of the measure of the length of firstprimary assemblies 202 and be placed along the edges of a firstprimary assembly 202 to formedge beams 1002, but in other embodiments can have any other known and/or convenient geometry and/or dimensions. - As shown in
FIG. 11 a, in some embodiments, the present system can be configured into arches or other types of curved geometries.FIG. 11 a depicts a perspective view of such an embodiment where a plurality ofsecondary assemblies 302 can be arranged and coupled along their longitudinal edges to create a curved construction. Such embodiments can be used in conjunction withcellular decking 402 as described in previous embodiments. Such embodiments can also be used in conjunction withflooring 206 as described in previous embodiments. Such embodiments can also be used in conjunction withconcrete surfaces 210,flooring 206, and any other known and/or convenient materials.Framing 1102 can be added to provide additional support. In this and other embodiments, afoam polymer material 1104 can be added to the spaces within a structure to provide thermal or sound insulation, or, in applications where an embodiment is used against water, to protect against water infiltration and enhance flotation. -
FIG. 11 b depicts a cross-sectional view of the embodiment inFIG. 11 a. -
FIG. 11 c depicts a side elevation view of the embodiment inFIG. 11 b. -
FIG. 12 a depicts another embodiment of the present system where a plurality ofsecondary assemblies 302 can be used to fabricate structures with a substantially closed polygonal cross-section. In the embodiment shown inFIG. 12 a, such structures can have a substantially hexagonal cross-sectional geometry, but in other embodiments can have any other known and/or convenient geometry. In such embodiments, anexternal tension ring 1202 can be added to provide further structural support. Such embodiments can also be used in conjunction withflooring 206 as described in previous embodiments. Such embodiments can also be used in conjunction withconcrete surfaces 210,cellular decking 402, and any other known and/or convenient materials. -
FIG. 12 b depicts a cross-sectional view of the embodiment inFIG. 12 a. -
FIG. 12 c depicts a side elevation view of the embodiment inFIG. 12 b. -
FIG. 13 a depicts an embodiment of the present system where a plurality ofprimary assemblies 202 can be configured to form anedge beam 1302. In the embodiment shown inFIG. 13 a, a first set ofprimary assemblies 202 can have a substantially rectangular geometry with a length measured in a direction substantially parallel to and a width measured in a direction substantially perpendicular tochannels 106. Toform edge beams 1302, a first setprimary assemblies 202 having a given length and width can be stacked and coupled such that theirchannels 106 are substantially parallel and their edges are substantially flush with each other. These firstprimary assemblies 202 can be coupled with secondprimary assemblies 202 having a length substantially equal to the width of firstprimary assemblies 202 and a width less than half of the measure of the length of firstprimary assemblies 202. As shown inFIGS. 13 a and 13 b, in some embodiments, secondprimary assemblies 202 can have a width less than one-fifth of the measure of the length of firstprimary assemblies 202 and be placed along the edges of a set of firstprimary assemblies 202 to formedge beams 1302, but in other embodiments can have any other known and/or convenient geometry and/or dimensions. In this and other embodiments, afoam polymer material 1104 can be added to the spaces within a structure to provide thermal or sound insulation, or, in applications where an embodiment is used against water, to protect against water infiltration and enhance flotation. -
FIGS. 13 b and 13 c also show this embodiment used in conjunction withflooring 206 andcellular decking 402. Flooring 206 can be placed on the top surface of asecondary assembly 302, wherein at least onesecondary assembly 302 can supportflooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of asecondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In some embodiments,cellular decking 402 can be connected to asupport member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. - In addition, in this and other embodiments, larger sections of
secondary assemblies 302 can be connected with asegment connector 1304. -
FIG. 13 b depicts a cross-sectional view of the embodiment inFIG. 13 a. -
FIG. 13 c depicts a side elevation view of the embodiment inFIG. 13 b. -
FIG. 14 a depicts a front view of an embodiment of the present system in use as a wall member having varied cross-sectional and side elevation profiles. Some embodiments of the present system in use as a wall member can support axial loads, but in other embodiments can be non-load-bearing. As shown inFIG. 14 a, asecondary assembly 302 can be positioned such that substantiallyparallel channels 106 can be oriented substantially vertically to create a wall member. In some embodiments, fenestrations 1402 can be cut through asecondary assembly 302 to accommodate windows or any other know and/or convenient portal. As shown inFIG. 14 a, fenestrations 1402 can have a substantially square or rectangular geometry, but in other embodiments can have any other known and/or convenient geometry. -
FIG. 14 b depicts a top view of the embodiment shown inFIG. 14 a. As shown inFIG. 14 b,primary assemblies 202 of varying width (as previously described inFIG. 3 i) can be coupled to create asecondary assembly 302 having cross sections of varying width. In some embodiments, each section of varying width can decrease and then increase in width from the top to the bottom to createlongitudinal voids 802 substantially parallel to and oriented with substantiallyparallel bends 104 andchannels 106. In some embodiments,primary assemblies 202 can be configured in a symmetrical and/or regular pattern, but in other embodiments can be arranged in any other known and/or convenient geometry. In some embodiments,foam polymer material 1104 can be added to the spaces within a structure to provide thermal or sound insulation or added strength. In other embodiments, granular, liquid or any other known and/or convenient substance can be added to the spaces within a structure to provide insulation or added strength. In some embodiments, this can increase the relative stiffness of the vertical members to the horizontal members in a structure, thereby achieving a preferred failure mechanism in which failure occurs in the horizontal elements before the vertical elements. -
FIG. 14 c depicts a top cross-sectional view of another embodiment of the present system. In some embodiments, a plurality ofbasic system components 102 and/orprimary assemblies 202 of varied widths can be coupled as previously described to create various staggered-cross-sectionsecondary assemblies 302 for structural or aesthetic purposes. In some embodiments a cross-section can vary in a substantially regular, repeating pattern to create a wall member having regions of varying thicknesses, but in other embodiments can have any other known and/or geometry. In such embodiments, a wall member can be non-bearing. -
FIG. 14 d depicts a side elevation view of the embodiment shown inFIG. 14 c. As shown inFIG. 14 d, a plurality ofbasic system components 102 and/orprimary assemblies 202 of varied lengths can be coupled to create various staggered-profilesecondary assemblies 302. In such embodiments, the length of asecondary system assembly 302 can vary with the depth of asecondary system assembly 302. In the embodiment shown inFIG. 14 d, asecondary system assembly 302 can have a side elevation profile with a region of maximum thickness substantially along the midline and tapering substantially symmetrically to a minimum thickness at the ends of asecondary assembly 302. However, in other embodiments, a side elevation profile can vary in with any other known and/or convenient configuration. Such embodiments can be used as non-bearing wall members in conjunction with aroof member 1404. -
FIG. 14 e depicts a top cross-sectional view of an embodiment of asecondary assembly 302 of the present system (as previously described inFIG. 3 a) used in conjunction with aconcrete surface 210 in use as a wall member. Such embodiments can be used as non-bearing wall members in conjunction with aroof member 1404. In such embodiments, aconcrete surface 210 can be placed on one surface of asecondary assembly 302. In some embodiments, aconcrete surface 210 can be poured in place directly adjacent to a surface of asecondary assembly 202. -
FIG. 14 f depicts a side elevation view of the embodiment shown inFIG. 14 e. Such embodiments can be used as non-bearing wall members in conjunction with aroof member 1404, but in other embodiments can be a load-bearing wall member. -
FIG. 14 g depicts a top cross-sectional view of an embodiment of the present system (as previously described inFIG. 3 h) used in conjunction withconcrete surfaces 210 in use a wall member, which can be load-bearing. In some embodiments, asecondary assembly 302 can have a uniform width, but in other embodiments can have any other known and/or convenient cross-section. -
FIG. 14 h depicts a side elevation view of the embodiment shown inFIG. 14 g. In this embodiment,basic system components 102 can be of varying lengths and arranged from longest length to shortest length from one surface of asecondary assembly 302 to the center line, and then shortest to longest from the center to the opposite surface of asecondary assembly 302. As shown inFIG. 14 h,basic system component 102 length can change substantially symmetrically with respect to the midpoint of the length ofbasic system components 102. Such embodiments can be used as bearing wall members to support aroof member 1404. -
FIG. 14 i depicts a top cross-sectional view of an embodiment having webs placed in between the basic components of the present system (as previously described inFIG. 5 g) in use as a wall member, which can be load-bearing. In such embodiments, as shown inFIG. 14 i, a pair ofbasic system components 102 can be oriented with substantiallyparallel bends 104 andchannels 106 substantially vertical and aligned such that the spacing betweenbasic system components 102 can alternate substantially regularly between a maximum and minimum spacing, wherein a minimum spacing can be determined by the thickness of aweb member 502. In some embodiments, a plurality ofweb members 502 can provide support and spacing in betweenbasic system components 102. - In some embodiments, a
web member 502 can be comprised of a pair ofchannel members 506. A pair ofchannel members 506 can be placed concave-out and substantially along the longitudinal edges of and betweenbasic system components 102 to create aprimary system assembly 202. - In some embodiments, as shown in
FIG. 14 i,concrete surfaces 210 or any other known and or convenient substrate comprised of a liquid material that subsequently hardens into a solid state can be poured into any known and/or convenient form. A plurality ofprimary system assemblies 202 can be aligned substantially laterally adjacent to each other and substantially vertically such that there can be a gap betweenchannel members 506 along the lateral sides of eachprimary system assembly 202 to create an interstitiallongitudinal void 508 betweenchannel members 506. In some embodiments, an interstitiallongitudinal void 508 can measure approximately 16 inches along an axis substantially perpendicular to a wall, and approximately 24 inches along an axis substantially parallel to the wall dimension of a gap. A form can be placed adjacent to the exterior surfaces of aprimary assembly 202 to create a firstconcrete surface 210 and a secondconcrete surface 210. Afirst surface 210 comprised of a pourable and subsequently hardening medium, such as a concrete, can be poured and can flow through the gaps to fill interstitiallongitudinal voids 508 to form a continuous solid member connecting a firstconcrete surface 210 and a secondconcrete surface 210. -
FIG. 14 j depicts a side elevation view of the embodiment shown inFIG. 14 i. Such embodiments can be used as wall members to support aroof member 1404. -
FIGS. 15 a-15 i depict embodiments of the present system in use with various types of shear stiffener supports 1502. These can be end connections ofsecondary assemblies 302 shown inFIGS. 1-14 . In some embodiments, shear stiffener supports 1502 can support high reactions at the ends ofsecondary assemblies 302 where such a deck can span a much longer distance than single conventional deck, and such decks can be prone to local plate buckling due to their thin sections. In some embodiments, shear stiffener supports 1502 can be a partial filling of an end region with concrete or other solids so as the deck does not buckle under high shear at ends. In other embodiments, shear stiffener supports 1502 can involve inserting sheet metal deck profiles at the ends (basically small lengths of similar decks nested in the main deck) to practically thicken the deck in the end region. In other embodiments, shear stiffener supports 1502 can include adding stiffeners at the end, which can be steel plates that are placed perpendicular to the main deck to stop the deck from buckling and thus increase its (bearing) shear capacity, but in other embodiments can be any other known and/or convenient structural member. - As depicted in
FIG. 15 g, in some embodiments,support elements 1504 can be included at the underside of the decking. In some embodiments, thesupport elements 1504 can be “L” sections. However, in alternate embodiments, any other known convenient and/or desired section and/or built-up section can be used and/or thesupport elements 1504 can be absent. - As depicted in
FIGS. 15 h-15 i, in some embodiments,support elements 1504 can be coupled withattachment elements 1506 and/oradditional support elements 1508. In some embodiments theattachment elements 1506 can be studs attached to one or more of thesupport elements 1504 at regular and/or irregular intervals. However, in alternate embodiments the attachment elements can have any known and/or convenient geometry and/or location and/or can be absent. - As depicted in
FIGS. 15 h-15 i,additional support elements 1508 can be selectively coupled with thesupport elements 1504. In the embodiments depicted inFIGS. 15 h-15 i, theadditional support elements 1508 can be truss bars. However, in alternate embodiments theadditional support elements 1508 can have any known, convenient and/or desired positioning and/or geometry and/or can be absent. - In operation, the support elements can act as temporary support structures during construction and/or can act as attachments for equipment that is adapted to lift decking into position during construction.
- In use, the present system offers several advantages. First, only simple and light-weight deck sections need to be kept in a manufacturer's inventory and when needed, they can be rapidly combined into the required complex sections. The present system also offers variation in depth, solid portion width, steel gage and connection frequency, as well as concrete reinforcing along the span and perpendicular to span. This advantage, when combined with the light weight of the system, can enable it to cover longer spans than currently available systems and can reduce the need for intermediate support framing.
- Spans can be increased and the shoring requirements and intermediate field beams can be eliminated. Moreover, with traditional metal deck systems there is often a need for separate end beams to support the reactions from the deck and transport them to the columns. However, with the present system, the ends of the decks can be detailed to form an integral beam when the concrete topping is poured in the field, which can eliminate the need for a separate supporting beam. In addition, the present system can reduce the need for construction shoring, since the metal deck that forms the soffit, top, and web of the combined section can have adequate strength and stiffness to support the construction loads for non-composite construction and also until the concrete hardens for composite construction.
- In the present system, curved surfaces along the span and perpendicular to the span can be achieved, as well as flat finished surfaces at the top or soffit. Thus shallow barrel vault arches as well as shallow dome construction are possible. This can be advantageous for roofs due to the inherent strength of arch systems and the resulting efficiency of drainage systems for the roof. Further, articulated soffit or roof configurations can also be achieved if desired for aesthetic effects or functional reasons.
- Another advantage of the present system is that it can facilitate utility placement in the structure. With the present system, large utilities can be accommodated within the structural depth of the deck. Moreover, the utilities can run in two perpendicular directions within the structural depth, and access to utility chases can be easily accommodated with
hatches 516 placed in the top most and/or bottom most deck layers. - The present system also offers several advantages for the specialized construction of marine and outer-space structures. Compared to typical marine and/or outer-space structures which use solid plate elements for their skin structures, the proposed steel deck can provide reduction in total weight due to its more efficient use of material (structural depth) which can reduce the need for frequent internal compression framing and/or external tension rings. Moreover, the present system, due to its cellular structure, can have more redundancy, and ductility in the case of damage from unexpected impact and/or collision forces. Finally, filling the cells with light-weight foaming material can seal and provide buoyancy for naval structures.
- When applied to outer-space structures, the system can be used as a two-way platform where it is not subject to any differential internal/external pressure, such as for a support structure for solar panels. Alternatively, for sealed inhabitable spaces that are subject to high differential pressures between the inside and outside, the deck can be formed into a cylindrical type structure with external tension rings placed as required. The first inner layer (e.g., a cellular deck) can form one sealing surface. The deck voids can additionally be filled with a lightweight foaming material and/or liquid sealant to provide additional sealing surfaces in case a small puncture occurs.
- The present system can be used to create wall spans as well as decking spans. In creating wall spans, the present system can offer flexibility in designing walls with various cross-sections to withstand shear forces, compression loads, and any other known, unknown, constant, or variable forces.
- Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the invention as described and hereinafter claimed is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
Claims (20)
1. A structural component system, comprising:
at least one substantially planar component having a corrugated cross-section, a surface with substantially parallel channels, and a length measured substantially parallel to said channels;
a first component coupled in layers with a second component to create a primary system assembly;
and a primary system assembly coupled in layers with other primary system assemblies and components.
2. The system of claim 1 , said components coupled such that said channels of each component are substantially parallel and a series of tubular regions are created by the coupling of said components.
3. The system of claim 2 , said primary system assemblies coupled such that the tubular regions of said primary assemblies are substantially parallel and an additional series of adjacent tubular regions are created between said layers of primary assemblies.
4. The system of claim 3 , the widths of said primary system assemblies varied to create longitudinal voids that are substantially parallel to the tubular regions of said primary assemblies within the thickness of a secondary system assembly.
5. The system of claim 4 , a plurality of secondary assemblies placed at intervals between a pair of components, creating a tertiary system assembly having tubular voids running orthogonally to the longitudinal voids.
6. The system of claim 5 , said tertiary assembly having a cambered configuration.
7. The system of claim 3 , the lengths of said primary system assemblies and components varied to create a non-uniform profile.
8. The system of claim 7 , the lengths of said primary system assemblies and components decreasing symmetrically along the vertical midline of a secondary assembly.
9. The system of claim 7 , the lengths of said primary system assemblies and components decreasing and increasing symmetrically along the vertical midline of a secondary assembly.
10. The system of claim 1 , said components coupled in layers such that said channels of adjacent components are substantially orthogonal.
11. The system of claim 10 , said layers of components alternating between a single component and a plurality of components having dimensions less than that of said component to create interstitial spaces between adjacent layers.
12. The system of claim 2 , said primary system assemblies coupled in layers such that the tubular regions of said primary assemblies are substantially orthogonal.
13. The system of claim 12 , said layers of primary system assemblies alternating between a single primary system assembly and a plurality of primary system assemblies having dimensions less than that of said single primary system assembly to create interstitial spaces between adjacent layers.
14. The system of claim 3 , a plurality of secondary system assemblies used in conjunction with a support frame to create curved structures.
15. The system of claim 3 , used in conjunction with additional construction materials selected from the group consisting of: concrete, flooring, cellular decking, channels, angles, fasteners, granular materials, and polymer foams.
16. A structural component system, comprising:
a substrate comprised of a pourable and subsequently hardening medium;
a first substantially planar component and a second substantially planar component having a corrugated cross-section with a series of alternating minima and maxima that creates a surface with substantially parallel channels;
a pair of channel members;
said basic system components substantially vertically aligned such that said channels of each component are substantially parallel and the corrugation maxima points of a first component are substantially aligned with the minima points of a second component,
and said pair of channel members placed concave-out and substantially along the longitudinal edges of and between said components to create a primary system assembly having a tubular void created by the first and second components,
and a plurality of primary system assemblies aligned substantially laterally adjacent and substantially horizontally on the substrate such that there is a gap between the channel members along the lateral sides of each primary system assembly to create an interstitial longitudinal void between the channels;
a top surface comprised of a pourable and subsequently hardening medium,
said surface medium, when poured, flowing through said gaps to fill said interstitial longitudinal void and form a continuous solid member connecting said top surface and substrate.
17. The system of claim 16 , further comprising a plurality of supports placed in the substrate to elevate the lower surface of the secondary assemblies above the lower surface of the substrate.
18. The system of claim 16 , further comprising a plurality of lateral supports placed within said tubular voids.
19. The system of claim 16 , further comprising a plurality of vertical supports placed within said tubular voids.
20. A structural component system, comprising:
a substantially planar plywood form;
a plurality of supports placed substantially perpendicular to the surface of the form;
concrete poured onto the form;
a plurality of first substantially planar components each having a corrugated cross-section with a series of alternating minima and maxima that creates a surface with substantially parallel channels placed on top of the concrete while aligned substantially laterally adjacent to each other and substantially horizontally on the substrate and resting on the plurality of supports;
a pair of channel members placed concave-out and substantially along the longitudinal edges of a first component such that there is a gap between the channel members and forming an interstitial longitudinal void;
a plurality of second components each having a corrugated cross-section with a series of alternating minima and maxima that creates a surface with substantially parallel channels substantially vertically aligned with said first component, such that said channels of each component are substantially parallel and the corrugation maxima points of a first component are substantially aligned with the minima points of a second component, with the longitudinal edges placed adjacent to the top edge of the channel members to create a primary system assembly having a tubular void created by the first and second components,
a concrete surface poured over the plurality of second components, such that the concrete flows through said gaps to fill said interstitial longitudinal void and form a continuous solid member connecting said top surface and substrate.
Priority Applications (2)
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US14/210,264 US20140311077A1 (en) | 2013-03-14 | 2014-03-13 | Structural Component System |
PCT/US2014/028935 WO2014153070A1 (en) | 2013-03-14 | 2014-03-14 | Structural component system |
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US201361783581P | 2013-03-14 | 2013-03-14 | |
US14/210,264 US20140311077A1 (en) | 2013-03-14 | 2014-03-13 | Structural Component System |
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Also Published As
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