STRUCTURAL PANEL, FLOORING SYSTEM AND CORRESPONDING METHOD

Abstract

Disclosed herein is a structural panel, flooring system and method of constructing the flooring system. The structural panel includes two C-shaped channels, a corrugated deck extending between the first C-shaped channel and the second C-shaped channel, wherein the deck, the first C-shaped channel, and the second C-shaped channel define an interior volume, and a concrete slab substantially filling the interior volume and extending above the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels. The flooring system defines a first and second structural panel secured together through an interface component. A corresponding method is disclosed including abutting the two structural members, securing through the interface component, and pouring a concrete slab within the interior volume and extending above the top flanges of the first and second C-shaped channels.

Description

FIELD

This application relates generally to the field of modular construction, and more particularly to a structural panel and corresponding flooring system.

INTRODUCTION

Composite decking systems consist of steel decking with in-situ reinforced concrete topping. The concrete topping contains steel reinforcement to increase strength properties. In certain implementations, formwork is required to allow the concrete to set in the desired structure and create a level floor surface.

SUMMARY

The following is intended to introduce the reader to the detailed description that follows and not to define or limit the claimed subject matter.

In a first aspect, disclosed is a structural panel comprising a first C-shaped channel defining a first side and a second C-shaped channel spaced apart from the first C-shaped channel. The second C-shaped channel defines a second side, wherein each C-shaped channel comprises a web, a top flange, and a bottom flange. A corrugated deck extends between the web of the first C-shaped channel and the web of the second C-shaped channel. The deck has a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel. The deck, the web of the first C-shaped channel, and the web of the second C-shaped channel define an interior volume, and a concrete slab substantially fills the interior volume and extends above the top flanges of the first and second C-shaped channels. The slab defines a top surface extending above the top flanges of the first and second C-shaped channels.

In some aspects, the corrugated deck is manufactured from cold-formed steel.

In some aspects, the corrugated deck is continuously welded to the inner surface of the web of the first and second C-shaped channels at a first vertical distance from the top flange, wherein the first vertical distance is smaller than a second vertical distance from the bottom flange.

In some aspects, the corrugated deck is continuously welded to the inner surface of the web of the first and second C-shaped channels at a first vertical distance from the top flange, wherein the first vertical distance is equal to a second vertical distance from the bottom flange.

In some aspects, the web of each of the first and second C-shaped channels comprises at least one interface component for aligning the structural panel with at least one corresponding web of an adjacent structural panel.

In some aspects, the corrugated deck has a width such that the bottom flanges of the first and second C-shaped channels and the corrugated deck define a cavity large enough to accommodate placement of one or more members selected from the group of: insulation, electrical wiring, water and/or gas piping, electrical boxes and electrical devices.

In some aspects, the first and second C-shaped channels are made from cold-formed steel.

In some aspects, the interaction between the concrete slab and the first and second C-shaped channels provides a composite action.

In a second aspect, disclosed is a flooring system comprising a first structural panel and a second structural panel. Each structural panel comprises a first C-shaped channel defining a first side and a second C-shaped channel spaced apart from the first C-shaped channel. The second C-shaped channel defines a second side. Each C-shaped channel comprises a web, a top flange, and a bottom flange. A corrugated deck extends between the web of the first C-shaped channel and the web of the second C-shaped channel having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel. The corrugated deck, the web of the first C-shaped channel, and the web of the second C-shaped channel define an interior volume. A concrete slab substantially fills the interior volume and extends above the top flanges of the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels. The web of each of the first and second C-shaped channels comprise at least one interface component for aligning the first structural panel with the second structural panel. An outer surface of the web of the first side of the second structural panel abuts against an outer surface of the web of the second side of the first structural panel, wherein the at least one interface component of the first structural panel aligns with the at least one interface component of the second structural panel, and wherein the respective interface components of the first and second structural panels are adapted to secure the first structural panel to the second structural panel.

In some aspects, the flooring system further comprises a third structural panel, wherein an outer surface of the web of the first side of the third structural panel abuts against an outer surface of the web of the second side of the second structural panel. The respective interface components of the second and third structural panels align and are adapted to secure the second structural panel to the third structural panel.

In some aspects, the structural panels are supported by at least two primary support structures.

In some aspects, the at least two support structures are support beams.

In some aspects, the at least two support structures are load bearing walls.

In a third aspect, disclosed is a method of assembling a flooring system comprising: (a) aligning a first structural member with a second structural member, wherein each structural member comprises a first C-shaped channel defining a first side and a second C-shaped channel spaced apart from the first C-shaped channel, the second C-Shaped channel defining a second side wherein each C-shaped channel comprises a web, a top flange, and a bottom flange, and a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channels having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second c-shaped channel, wherein each web of the first and second C-shaped channels comprises at least one interface component for aligning the first structural member with the second structural member; (b) abutting an outer surface of the web of the first side of the second structural member against an outer surface of the web of the second side of the first structural member such that the at least one interface component of the first structural member aligns with the at least one interface component of the second structural member; (c) securing the first structural member to the second structural member using the respective interface components of the first and second structural members; and (d) pouring a concrete material onto the first and second structural members, wherein the concrete material forms into a concrete slab, wherein the concrete slab substantially fills the interior volume and extends above the top flanges of each of the first and second structural members, wherein the concrete slab defines a top surface above the top flanges of each C-shaped channel.

In some aspects, the method comprises, prior to the pouring step, repeating steps (a), (b), and (c) with additional structural members.

Other aspects and features of the teachings disclosed herein will become apparent to those ordinarily skilled in the art, upon review of the following description of the specific examples of the present disclosure.

DRAWINGS

The drawings included herewith are for illustrating various examples of apparatuses and methods of the present disclosure and are not intended to limit the scope of what is taught in any way. In the drawings:

FIG. 1 is a perspective view of an example structural member according to aspects of the teaching disclosed herein;

FIG. 2 is an elevation view of an end of the structural member of FIG. 1;

FIG. 3 is a perspective view of a structural panel, with a portion of a concrete slab cut away for clarity;

FIG. 4 is a perspective view of the structural panel of FIG. 3;

FIG. 5 is an elevation view of an end of the structural panel of FIG. 3;

FIG. 6 is a perspective view of two structural members connected together to form part of a flooring system;

FIG. 7 is an elevation view of one end of the flooring system;

FIG. 8 is a perspective view of a support structure that supports the flooring system;

FIG. 9 is a perspective view of the flooring system positioned on the support structure of FIG. 8, with a first structural member in an assembled position;

FIG. 10 is a perspective view of the flooring system with multiple structural members positioned on the support structure of FIG. 8;

FIG. 11 is a perspective view of the floor system supporting multiple structural panels with portions of the concrete slabs cut away for clarity; and

FIG. 12 is a perspective view of the floor system assembly of FIG. 11 shown with the full concrete slab.

The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the teaching of the present specification and are not intended to limit the scope of what is taught in any way.

DETAILED DESCRIPTION

Various apparatuses or methods will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover apparatuses and methods that differ from those described below. The claimed inventions are not limited to apparatuses and methods having all of the features of any one apparatus or method described below, or to features common to multiple or all of the apparatuses or methods described below. It is possible that an apparatus or method described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or method described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicant(s), inventor(s) and/or owner(s) do not intend to abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.

Furthermore, the recitation of numerical ranges by endpoints herein includes all numbers and fractions subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is also to be understood that all numbers and fractions thereof are presumed to be modified by the term “about” which means a variation of up to a certain amount of the number to which reference is being made if the end result is not significantly changed, such as 1%, 2%, 5%, or 10%, for example.

It should be noted that terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree may also be construed as including a deviation of the modified term, such as by 1%, 2%, 5% or 10%, for example, if this deviation does not negate the meaning of the term it modifies.

Referring first to FIG. 1, a structural member 1000 includes a first side 1002, a second side 1004, and a corrugated deck 1006 extending from the first side 1002 to the second side 1004. In the illustrated embodiment, the corrugated deck 1006 is of a sinusoidal corrugated form. The first side 1002 is formed by a first C-shaped channel 1008 and the second side 1004 is formed by a second C-shaped channel 1010. The first C-shaped channel 1008 and the second C-shaped channel 1010 each include a web 1012, 1014, a top flange 1016, 1018, and a bottom flange 1020, 1022 (shown in FIG. 2).

The structural member 1000 may have a length of anywhere between 15 feet and 35 feet, and a width of anywhere between 1.5 feet and 5 feet. In one embodiment, the structural members dimensions may be 4 feet wide by 20 feet long. The first and second C-shaped channels 1008, 1010 may have a height of between 150 mm and 380 mm. The top flanges 1016, 1018 and the bottom flanges 1020, 1022 may have a length of between 40 mm and 90 mm. The corrugated deck 1006 may have a thickness between 0.7 mm and 2 mm. In some embodiments, the C-shaped channels 1008, 1010 may have a thickness between 1.4 mm and 6 mm.

FIG. 2 shows an end side view of the structural member 1000 of FIG. 1. The corrugated deck 1006 has a first edge 1024 and a second edge 1026. The corrugated deck 1006 extends between the web 1012 of the first C-shaped channel 1008 on the first side 1002 and the web 1014 of the second C-shaped channel 1010 on the second side 1004. The corrugated deck 1006 is continuously welded along the first edge 1024 to the inner surface of the web 1012 of the first C-shaped channel 1008 and continuously welded along the second edge 1026 to the inner surface of the web 1014 of the second C-shaped channel 1010.

The corrugated deck 1006, the web 1012 of the first C-shaped channel 1008 and the web 1014 of the second C-shaped channel 1010 define an upper interior volume 1034 in the top portion of the corrugated deck 1006 and between the first side 1002 and the second side 1004.

In the illustrated embodiment, top flanges 1016, 1018 extend from their respective webs inwards towards each other above the corrugated deck 1006 in an orientation parallel to corrugated deck 1006. Each top flange 1016, 1018 may further include a downwardly extending portion 1036, which is substantially parallel to the corresponding web 1012, 1014. The upper interior volume 1034 may include the space created between the downwardly extending portion 1036, the corrugated deck 1006 and the corresponding web 1012, 1014. As shown in the illustrated embodiment, the second C-shaped channel 1010 is oriented as a mirror image of the first C-shaped channel 1008.

Continuing to refer to FIG. 2, the welds of the corrugated deck 1006 to the first and second C-shaped channels 1008, 1010 are in an orientation where the corrugated deck 1006 is at the same vertical position on the web of each of the C-shaped channels 1008, 1010. In the illustrated embodiment, the corrugated deck 1006 is continuously welded along the first and second edges 1024, 1026 to the webs 1012, 1014, respectively, of the C-shaped channels. The edges 1024, 1026 of the corrugated deck 1006 are welded at a position on the webs where the distance from the corrugated deck 1006 to the top flanges 1016, 1018 is shorter than the distance from the corrugated deck 1006 to the bottom flanges 1020, 1022. In one exemplary embodiment, the corrugated deck 1006 may be at a distance between 12 mm and 50 mm from the top flanges 1016, 1018. This decreased distance from the corrugated deck 1006 to the top flange 1016 provides a smaller interior volume 1034 with a reduced vertical dimension.

In some embodiments, the corrugated deck 1006 is continuously welded along the edges 1024, 1026 to the webs 1012, 1014 at a position where the distance from the corrugated deck 1006 to the top flanges 1016, 1018 is equal to the distance from the corrugated deck 1006 to the bottom flanges 1020, 1022.

In some embodiments, the corrugated deck 1006 is continuously welded along the edges 1024, 1026 to the webs 1012, 1014 at a position where the distance from the corrugated deck 1006 to the top flanges 1016, 1018 is greater than the distance from the corrugated deck 1006 to the bottom flanges 1020, 1022.

The corrugated deck 1006, the web 1012 of the first C-shaped channel 1008 and the web 1014 of the second C-shaped channel 1010 define a lower volume 1040 in the bottom portion of the corrugated deck 1006 and between the first side 1002 and the second side 1004. In some embodiments, the lower volume 1040 may accommodate components for connecting the structural member 1000 with an adjacent structural member, as shown and described in FIGS. 6 and 7.

In the illustrated embodiment, bottom flanges 1020, 1022 extend from their respective web 1012, 1014 in an orientation parallel to corrugated deck 1006. Each bottom flange 1020, 1022 may further include an upwardly extending portion 1038, which is substantially parallel to the corresponding web 1012, 1014. The lower volume 1040 may include the space created between the upwardly extending portion 1038, the corrugated deck 1006 and the corresponding web 1012, 1014. As shown in the illustrated embodiment, the second C-shaped channel 1010 is oriented as a mirror image of the first C-shaped channel 1008.

In some embodiments, the lower volume 1040 may be used to accommodate placement of one or more structural or construction components, including but not limited to insulation, electrical wiring, water and/or gas piping, electrical boxes, electrical devices, etc. The upwardly extending portions 1038 into the lower volume 1040 may assist with holding the structural or construction components in place in the lower volume 1040.

The downwardly extending portions 1036 and upwardly extending portions 1038 may vary in length. In some embodiments, the extending portions 1036, 1038 may have a length between 12 mm to 50 mm. In some other embodiments, the flanges 1016, 1018 may not have any downwardly extending portions 1036, and flanges 1020, 1022 may not have any upwardly extending portions 1038.

FIGS. 3-5 show the structural member 1000 having a concrete slab 1028 (for illustration purposes, a portion of the slab is cut away in FIG. 3) filling the upper interior volume 1034 above the corrugated deck 1006. The concrete slab 1028 fills the entirety of the upper interior volume 1034 of the structural member 1000 and extends above the top flanges 1016, 1018 of each of the first and second C-shaped channels 1008, 1010. A top surface 1030 of concrete slab 1028 is located above the top flanges 1016, 1018 of the C-shaped channels 1008, 1010. The concrete slab 1028 may be at a distance of 30 mm to 100 mm above the top flanges 1016, 1018 of the C-shaped channels 1008, 1010. In another exemplary embodiment, the concrete slab 1028 may be about 50 mm above the top flanges 1016, 1018 of the C-shaped channels 1008, 1010. The combination of the structural member 1000 and the concrete slab 1028 defines a structural panel 1050.

In the illustrated embodiment, the decreased vertical distance from the corrugated deck 1006 to the top flanges 1016, 1018 creates a smaller interior volume 1034 to be filled by the concrete slab 1028. This smaller interior volume 1034 may result in a concrete slab 1028 that is not required to contain any reinforcement to maintain the required strength properties for a surface to be used within flooring or roofing applications. The primary purpose of reinforcement (such as rebar, mesh, aggregate materials, etc.) within concrete applications is to increase the tensile strength of the concrete and prevent cracking due to high tensile forces. Reinforcement is recommended in concrete applications where the concrete is of an increased thickness. However, due to the decreased thickness of the concrete slab 1028 of the structural panel 1050 due to the smaller interior volume 1034, reinforcement may not be required.

The interaction between the concrete slab 1028, the corrugated deck 1006 and the first and second C-shaped channels 1008, 1010 creates a composite action. The corrugated decking 1006 creates a shear bond with the concrete slab 1028 such that, when the concrete has cured and gained strength, the C-shaped channels 1008, 1010 and the concrete slab 1028 work together compositely to create a flooring surface with increased bending strength properties. Composite action occurs based on the physical connection between the structural member 1000 and the concrete slab 1028. The first and second C-shaped channels 1008, 1010 protrude from the corrugated deck 1006 into the cured concrete slab 1028 and act as shear connectors. A shear connector is a protrusion from the decking surface into the concrete that increases the shear capacity of the flooring surface. The shear connectors further increase the surface area contacted by the concrete slab 1028, leading to a stronger connection between the concrete slab 1028 and the corrugated deck 1006. Without a shear connector, the concrete slab 1028 and the corrugated decking 1006 would independently maintain their structural properties. With the addition of the first and second C-shaped channels 1008, 1010 as shear connectors, the strength properties of the concrete slab 1028 and the corrugated decking 1006 are combined and improved upon to create a structural panel 1050 with increased flexural strength properties.

When the concrete slab 1028 has been poured and cured, the top flanges 1016, 1018 and webs 1012, 1014 of the C-shaped channels 1008, 1010, are utilized as the shear connectors to create the composite action between the corrugated decking 1006, the C-shaped channels 1008, 1010 and the concrete slab 1028.

The protrusion of the C-shaped channels 1008, 1010 into the concrete slab 1028 may further decrease the need for reinforcement within the concrete slab 1028. The webs 1012, 1014, top flanges 1016, 1018 and downwardly extending portions 1036 of each the first and second C-shaped channels 1008, 1010 are located within the concrete slab 1028. These components may increase the tensile strength and act as reinforcement within the concrete slab 1028. Removing the need for reinforcement may reduce construction time.

In some embodiments, the corrugated deck 1006 may be manufactured from bare cold-formed steel. In other embodiments, the corrugated deck 1006 may be manufactured from galvanized cold-formed steel. In some embodiments, the first and second C-shaped channels 1008, 1010 may be manufactured from cold-formed steel. In other embodiments, the first and second C-shaped channels 1008, 1010 may be manufactured from hot rolled steel. In some embodiments, the corrugated deck 1006 and the C-shaped channels 1008, 1010 are manufactured by shaping steel products at room temperature using techniques such as rolling, pressing, stamping, bending, or any other suitable manufacturing technique.

In some embodiments, the concrete slab 1028 may be mixed using Type I or Type II Portland cement. In other embodiments, any other type of concrete may be used, such as light weight, high-strength, high-performance, shrinkage-compensating, or any other type of concrete. In other embodiments, additives may be included within the concrete mix to increase strength, increase durability, or reduce shrinkage.

In some embodiments, a single structural panel 1050 may be used to create a flooring surface. In such an embodiment, the single structural panel 1050 may be placed in the desired location using any of the necessary support structure, such as support beams, columns, load bearing walls, or any other support.

In at least one embodiment, the structural panel 1050, including the structural member 1000 and the concrete slab 1028, may be fully assembled at a facility different from the final location of the flooring surface (i.e. the construction site). The structural panel 1050 may be transported from the manufacturing facility to the construction site once the concrete has been poured within the upper interior volume 1034 of the structural member 1000 and cured.

In another embodiment, the structural member 1000 may be transported from its manufacturing location and placed into its designated position at the construction site. The concrete slab 1028 may then be poured into the upper interior volume 1034 of the structural member.

In other embodiments, the structural member 1000 may be connected to adjacent structural members to form a multi-paneled flooring system. Referring to FIGS. 6 and 7, a first structural member 1000 of a first structural panel 1050 is aligned and connected to an adjacent second structural member 2000 of a second structural panel 2050. In the illustrated embodiment, the second structural member 2000 has an identical structure to the first structural member 1000.

First structural member 1000 and second structural member 2000 are aligned through the interface components 1032 and 2032 located on the webs 1014, 2012 of the C-shaped channels 1010, 2008 of each the first and second structural members 1000, 2000 respectively. In some embodiments, there may be multiple interface components 1032, 2032 along the length of the structural members 1000, 2000. The multiple interface components 1032, 2032 may allow for the structural members 1000, 2000 to be fastened to one another more securely and at multiple locations along their length.

When aligned, the outer surface of web 1014 of the second side 1004 of the first structural member 1000 abuts against the outer surface of web 2012 of the first side 1002 of the second structural member 2000. At least one interface component 1032 of the second C-shaped channel 1010 of the first structural member 1000 is placed in vertical alignment with at least one interface component 2032 of the first C-shaped channel 2008 of the second structural member 2000.

Interface components 1032, 2032 may be, for example, a nut and bolt through matching holes, a screw, a hook and loop fastener, a weld, a female connector and corresponding male connector, a plate and screw connection, or any other method of securing the first structural member 1000 to the second structural member 2000.

In some embodiments, the interface components 1032, 2032 are located on any other location along the web 1014, 2012 of the structural members 1000, 2000. In some embodiments, the interface components 1032, 2032 may be located along the top flanges 1018, 2016. For example, in some embodiments, the interface component 1032, 2032 may be used prior to the pouring of the concrete slab 1028 to connect the first structural member 1000 with the second structural member 2000.

Additional structural members may be secured to either the first structural member 1000 or the second structural member 2000 to create a larger flooring surface.

In some embodiments, structural member 1000 may be connected to structural member 2000 through interface components 1032, 2032 prior to the addition of the concrete slab 1028. This may increase the strength of connection between the first and second structural panels 1050, 2050 once the concrete slab 1028 has cured.

Further disclosed herein is a method of assembling a flooring system.

FIG. 8 shows an example support structure that may be used to support the flooring system 3000. As illustrated, four support columns 3002, 3004, 3006, 3008 may be positioned longitudinally to accommodate the length of the structural members and laterally to accommodate the desired width of the flooring structure. Support beams 3010, 3012 may be positioned laterally at the top of the support columns along the width of the desired flooring structure for connection to the structural members. Support beams 3010, 3012 may be used to provide the required load distribution from the flooring system to the support columns 3002, 3004, 3006, 3008. In other embodiments, the support columns 3002, 3004, 3006, 3008 may be replaced with load bearing walls,

FIG. 9 shows an example support structure as described in FIG. 8 with a first structural member 3014a in its designated position. The first structural member 3014a may be secured to the example support structure by any securing method such as, for example, bolting, screwing, welding, fastening, etc.

Referring next to FIG. 10, shown therein is the example support structure having multiple structural members 3014a-e aligned with one another and supported by the support structure.

The structural members 3014a-e are aligned and secured to one another using the interface components 1032, 2032 described above. For example, the second structural member 3014b is aligned with the first structural member 3014a such that the outer surface of the web of the first side of the second structural member 3014b abuts against the outer surface of the web of the second side of the first structural member 3014a.

The first structural member 3014a is then secured to the second structural member 3014b using the respective interface components 1032, 2032. The structural members 3014a, 3014b may be secured to one another through bolting, screwing, welding, fastening, or any other suitable securing method.

In some embodiments, the first structural member 3014a and the second structural member 3014b may be aligned prior to placement on the support structure. In some embodiments, the first structural member 3014a may be positioned and secured into the example support structure prior to abutting and securing the second structural member 3014b to the first structural member 3014a.

Additional structural members 3014c-e may be abutted and secured to the adjacent structural member in the method described above to create the desired width of the flooring system 3000.

As shown in FIGS. 11 and 12, when the desired number of structural members 3014a-e are in place and secured to the support structure, a concrete material 3016 is poured onto the structural members 3014a-e to form the concrete slab, substantially filling the upper interior volume and extending above the top flanges of each of the structural members 3014a-e to form a top surface above the top flanges of each C-shaped channel of the structural members 3014a-e. In some embodiments, the concrete material 3016 may be vibrated through use of a vibrating rod, vibrating plate, or any other vibration technique to ensure the concrete material 3016 flows into the entirety of the upper interior volume of the structural members 3014a-e.

In some embodiments, a permanent pour stop may be used to hold the concrete material 3016 in place above the upper interior volume and top flanges of the structural member 3014a-e.

Referring now to FIG. 12, shown therein is a complete flooring system of structural panels including the structural members 3014a-e with cast-in-place concrete layer 3016 filling the upper interior volume and covering the top flanges of each structural member 3014a-e to form a concrete slab. As described above, the lower volume of the structural members 3014a-e may be used to accommodate building or structural requirements.

The flooring system allows for individual structural members to be shipped to and installed on site with ease prior to the inclusion of concrete. The ability to connect and secure multiple panels together using simple interface connections may simplify and speed up construction of flooring systems to desired measurements.

The use of the C-shaped channels as formwork for the cast-in-place concrete may reduce the need for building and tearing down formwork used to create concrete traditional flooring systems. As the structural members act as formwork to hold the concrete material, once the concrete has cured, the structural members are kept in place to form the composite flooring system. This may reduce or eliminate the need for shoring to support the weight of the concrete prior to curing.

While the above description provides examples of one or more apparatuses or methods, it will be appreciated that other apparatuses or methods may be within the scope of the accompanying claims.

Items

Item 1: A structural panel comprising:

• • a first C-shaped channel defining a first side;
  • a second C-shaped channel spaced apart from the first C-shaped channel, the second C-shaped channel defining a second side;
  • wherein each C-shaped channel comprises a web, a top flange, and a bottom flange;
  • a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channel, the deck having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel,
  • wherein the deck, the web of the first C-shaped channel, and the web of the second C-shaped channel define an interior volume; and
  • a concrete slab substantially filling the interior volume and extending above the top flanges of the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels.

Item 2: The structural panel of any preceding item, wherein the corrugated deck is manufactured from cold-formed steel.

Item 3: The structural panel of any preceding item, wherein the corrugated deck is continuously welded to the inner surface of the web of the first and second C-shaped channels at a first vertical distance from the top flange, wherein the first vertical distance is smaller than a second vertical distance from the bottom flange.

Item 4: The structural panel of any preceding item, wherein the corrugated deck is continuously welded to the inner surface of the web of the first and second C-shaped channels at a first vertical distance from the top flange, wherein the first vertical distance is equal to a second vertical distance from the bottom flange.

Item 5: The structural panel of any preceding item, wherein the web of each of the first and second C-shaped channels comprises at least one interface component for aligning the structural panel with at least one corresponding web of an adjacent structural panel.

Item 6: The structural panel of any preceding item, wherein the corrugated deck has a width such that the bottom flanges of the first and second C-shaped channels and the corrugated deck define a cavity large enough to accommodate placement of one or more members selected from the group of: insulation, electrical wiring, water and/or gas piping, electrical boxes and electrical devices.

Item 7: The structural panel of any preceding item, wherein the first and second C-shaped channels are made from cold-formed steel.

Item 8: The structural panel of any preceding item, wherein the interaction between the concrete slab and the first and second C-shaped channels provides a composite action.

Item 9: A flooring system comprising:

• • a first structural panel; and
  • a second structural panel;
  • wherein each structural panel comprises:
  • a first C-shaped channel defining a first side;
  • a second C-shaped channel spaced apart from the first C-shaped channel, the second C-shaped channel defining a second side;
  • wherein each C-shaped channel comprises a web, a top flange, and a bottom flange;
  • a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channel having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel,
  • wherein the corrugated deck, the web of the first C-shaped channel, and the web of the second C-shaped channel define an interior volume; and
  • a concrete slab substantially filling the interior volume and extending above the top flanges of the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels,
  • wherein the web of each of the first and second C-shaped channels comprise at least one interface component for aligning the first structural panel with the second structural panel,
  • wherein an outer surface of the web of the first side of the second structural panel abuts against an outer surface of the web of the second side of the first structural panel;
  • wherein the at least one interface component of the first structural panel aligns with the at least one interface component of the second structural panel, and
  • wherein the respective interface components of the first and second structural panels are adapted to secure the first structural panel to the second structural panel.

Item 10: The flooring system of any preceding item, further comprising a third structural panel, wherein an outer surface of the web of the first side of the third structural panel abuts against an outer surface of the web of the second side of the second structural panel, wherein the respective interface components of the second and third structural panels align and are adapted to secure the second structural panel to the third structural panel.

Item 11: The flooring system of any preceding item, wherein the structural panels are supported by at least two primary support structures.

Item 12: The flooring system of any preceding item, wherein the at least two support structures are support beams.

Item 13: The flooring system of any preceding item, wherein the at least two support structures are load bearing walls.

Item 14: A method of assembling a flooring system comprising:

• • aligning a first structural member with a second structural member, wherein each structural member comprises:
  • a first C-shaped channel defining a first side;
  • a second C-shaped channel spaced apart from the first C-shaped channel, the second C-Shaped channel defining a second side;
  • wherein each C-shaped channel comprises a web, a top flange, and a bottom flange; and
  • a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channels having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second c-shaped channel,
  • wherein each web of the first and second C-shaped channels comprises at least one interface component for aligning the first structural member with the second structural member;
  • abutting an outer surface of the web of the first side of the second structural member against an outer surface of the web of the second side of the first structural member such that the at least one interface component of the first structural member aligns with the at least one interface component of the second structural member;
  • securing the first structural member to the second structural member using the respective interface components of the first and second structural members; and
  • pouring a concrete material onto the first and second structural members, wherein the concrete material forms into a concrete slab, wherein the concrete slab substantially fills the interior volume and extends above the top flanges of each of the first and second structural members, wherein the concrete slab defines a top surface above the top flanges of each C-shaped channel.

Item 15: The method of any preceding item, further comprising, prior to the pouring step, repeating steps (a), (b), and (c) with additional structural members.

Claims

1. A structural panel comprising: a first C-shaped channel defining a first side;a second C-shaped channel spaced apart from the first C-shaped channel, the second C-shaped channel defining a second side; wherein each C-shaped channel comprises a web, a top flange, and a bottom flange;a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channel, the deck having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel, wherein the deck, the web of the first C-shaped channel, and the web of the second C-shaped channel define an interior volume; anda concrete slab substantially filling the interior volume and extending above the top flanges of the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels.

2. The structural panel of claim 1, wherein the corrugated deck is manufactured from cold-formed steel.

3. The structural panel of claim 1, wherein the corrugated deck is continuously welded to the inner surface of the web of the first and second C-shaped channels at a first vertical distance from the top flange, wherein the first vertical distance is smaller than a second vertical distance from the bottom flange.

4. The structural panel of claim 1, wherein the corrugated deck is continuously welded to the inner surface of the web of the first and second C-shaped channels at a first vertical distance from the top flange, wherein the first vertical distance is equal to a second vertical distance from the bottom flange.

5. The structural panel of claim 1, wherein the web of each of the first and second C-shaped channels comprises at least one interface component for aligning the structural panel with at least one corresponding web of an adjacent structural panel.

6. The structural panel of claim 5, wherein the corrugated deck has a width such that the bottom flanges of the first and second C-shaped channels and the corrugated deck define a cavity large enough to accommodate placement of one or more members selected from the group of: insulation, electrical wiring, water and/or gas piping, electrical boxes and electrical devices.

7. The structural panel of claim 1, wherein the first and second C-shaped channels are made from cold-formed steel.

8. The structural panel of claim 1, wherein the interaction between the concrete slab and the first and second C-shaped channels provides a composite action.

9. A flooring system comprising: a first structural panel; anda second structural panel; wherein each structural panel comprises: a first C-shaped channel defining a first side;a second C-shaped channel spaced apart from the first C-shaped channel, the second C-shaped channel defining a second side; wherein each C-shaped channel comprises a web, a top flange, and a bottom flange;a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channel having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel, wherein the corrugated deck, the web of the first C-shaped channel, and the web of the second C-shaped channel define an interior volume; anda concrete slab substantially filling the interior volume and extending above the top flanges of the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels, wherein the web of each of the first and second C-shaped channels comprise at least one interface component for aligning the first structural panel with the second structural panel,wherein an outer surface of the web of the first side of the second structural panel abuts against an outer surface of the web of the second side of the first structural panel;wherein the at least one interface component of the first structural panel aligns with the at least one interface component of the second structural panel, andwherein the respective interface components of the first and second structural panels are adapted to secure the first structural panel to the second structural panel.

10. The flooring system of claim 9, further comprising a third structural panel, wherein an outer surface of the web of the first side of the third structural panel abuts against an outer surface of the web of the second side of the second structural panel, wherein the respective interface components of the second and third structural panels align and are adapted to secure the second structural panel to the third structural panel.

11. The flooring system of claim 9, wherein the structural panels are supported by at least two primary support structures.

12. The flooring system of claim 11, wherein the at least two support structures are support beams.

13. The flooring system of claim 11, wherein the at least two support structures are load bearing walls.

14. A method of assembling a flooring system comprising: (a) aligning a first structural member with a second structural member, wherein each structural member comprises: a first C-shaped channel defining a first side;a second C-shaped channel spaced apart from the first C-shaped channel, the second C-Shaped channel defining a second side; wherein each C-shaped channel comprises a web, a top flange,and a bottom flange; anda corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channels having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second c-shaped channel, wherein each web of the first and second C-shaped channels comprises at least one interface component for aligning the first structural member with the second structural member;(b) abutting an outer surface of the web of the first side of the second structural member against an outer surface of the web of the second side of the first structural member such that the at least one interface component of the first structural member aligns with the at least one interface component of the second structural member;(c) securing the first structural member to the second structural member using the respective interface components of the first and second structural members; and(d) pouring a concrete material onto the first and second structural members, wherein the concrete material forms into a concrete slab, wherein the concrete slab substantially fills the interior volume and extends above the top flanges of each of the first and second structural members, wherein the concrete slab defines a top surface above the top flanges of each C-shaped channel.

15. The method of claim 14, further comprising, prior to the pouring step, repeating steps (a), (b), and (c) with additional structural members.