Patent Grant
9845599
This application relates generally to the field of structural decking systems, and more particularly to improvements to structural decking systems due to an improved seam created between adjacent decking panels.
Structural decking is used in commercial or industrial construction (and in some cases residential construction), for example, as a component of poured concrete floors or as structural roofing (e.g., for commercial buildings, industrial buildings, institutional buildings, or the like). The structural decking may be typically manufactured from steel sheets. To create the structural strength and the stiffness of the steel sheets, decking panels with longitudinal profiles are formed from the steel sheets via roll forming, break forming, bending, stamping, or other like processes. The decking panels are secured to each other in order to form the structural steel decking system when installed.
The panels are also connected to the other load resisting structural members of a building, such as beams, joists, walls, or the like. When the panels are connected to each other in a secure manner, the assembled structural steel decking system provides considerable diaphragm (or membrane) strength, which is used to transfer vertical and lateral loads to the vertical and lateral load carrying components of the building. In geographical regions that are prone to seismic activity (e.g., earthquakes) and/or high winds, the panels of structural steel decking are solidly connected to each other and to the other load resisting structural members of the building, so that the building is better able to withstand horizontal shear forces created by the seismic activity and/or high winds. The panels are connected to reduce, or eliminate excessive, vertical separation or lateral movement between adjacent structural steel decking panels. To this end, the seam between adjacent panels of structural steel decking is joined in such a way as to create lateral resistance in a direction parallel to the lengthwise extending axis of the seam to thereby carry loads (e.g., resist forces) and prevent displacement between the deck panels. In addition, the connection of the panels at the seam also creates vertical resistance in a direction perpendicular to the lengthwise extending axis of the seam in order to carry loads (e.g., construction loads) and to maintain the structural integrity of the diaphragm strength of the system.
Structural steel decking panels may be provided with two edges: one edge having an exposed “male lip” (e.g., upwardly extending male lip), and an opposite edge having a “female lip” in the shape of a “U” (e.g., inverted U or V shape, or another like shaped channel with the opening extending downwardly). Individual panels may be coupled together by placing the female lip of a first panel over the male lip of an adjacent panel, thus creating an unjoined side-lap seam along the length of the panel edges. In the present invention, the seam created by placing the female lip over the male, is a four-layer seam. In some embodiments of the invention, the male lip has two-layers and the female lip also has two-layers. The male lip may have a first male layer extending in a generally upright configuration and a second male layer folded (e.g., inwardly or outwardly) back towards the first male layer in an open or closed configuration. The female lip may also have a first female layer extending in a generally upright configuration and a second female layer folded outwardly back towards the first female layer in an open configuration. As such, the two-layer female lip may create a channel in which the two-layer male lip may be inserted in order to form the four-layer seam. In other embodiments of the invention other types of seams having different configurations of the layers or more than four layers may be utilized in the present invention, which are described in further detail below throughout this specification.
In order to couple (e.g., secure, join, or the like) the panels together along the seam to prevent or reduce the movement of one panel lifting off of the other or moving laterally with respect to each other, the panels may be secured through various couplings configurations. The couplings described herein may also be described generally as joints, connections, attachments, or the like. One example of a coupling in the present invention may be a weld, such as a top seam weld (otherwise referred to as a top arc seam weld), in which the top of the female lip (e.g., inverted “U” shaped female lip, or other like shaped lip with a channel) and the top of the male lip are welded together to form the coupling. In other embodiments, a side seam weld may be used in which the welds are created through the sides of the female lip and the male lip. Alternatively, the couplings may be formed by deforming at least a portion of the female lip over at least a portion of the male lip and/or forming a dimple in the seam (e.g., for example crimping the seam and forming a non-piercing button punch). The coupling may also be formed by cutting a portion of the seam, such as punching a hole through the seam, shearing the seam, or the like to create the coupling. One or more of these types of joints may be used to form the coupling, for example, deforming the seam and cutting a portion of the seam may both occur (e.g., in any order) in order to create the coupling. As such, the couplings may be formed by deforming, dimpling (e.g., a non-piercing button punch), and/or cutting (e.g., piercing punch, shearing, or the like) the seam (e.g., in any order). In one example, shearing and deforming of a portion of the seam may create a louver that results in a tab that provides interference at the ends of the tab to resist lateral movement of the adjacent panels. In still other embodiments of the invention, the couplings may be formed through the use of bolts and screws, rivets, or other like mechanical fastener.
The couplings formed in the seam may be located at predetermined optimal intervals along the length of the seam to join the decking panels and prevent or reduce movement between them. Not only do the couplings help prevent or reduce vertical separation between adjacent panels, the couplings prevent or minimize lateral shifting along the seam, and ensure a desired level of shear strength and/or stiffness in the seam and across the structural decking system.
The four-layer seam, illustrated in some embodiments of the present invention, results in improved shear strength along the length of the seam. As such, because of the improved shear strength in the four layer seam, thinner material thicknesses may be used for the decking panels and/or not as many couplings are needed to create a decking system that has a shear strength that is the same as or similar to the shear strength of a decking system that utilizes a three-layer, two-layer, or other like seam. As such, using decking systems with four-layer seams or seams with greater than four-layers, results in decking systems that cost less due to reduced material costs (e.g., reduced price for thinner steel decking panels) and/or due to reduced assembly costs (e.g., assembly time is reduced due to fewer couplings).
One embodiment of the invention comprises a structural decking system. The structural decking system comprising a first decking panel comprising first top flanges, first bottom flanges, first webs, and at least one edge comprising a male lip. The structural decking system further comprises a second decking panel comprising second top flanges, second bottom flanges, second webs, and at least one edge comprising a female lip. The female lip of the second decking panel is placed over the male lip of the first decking panel to create a seam with four or more layers, and one or more couplings are formed in the seam with four or more layers to couple the first decking panel to the second decking panel.
In further accord with an embodiment of the invention, the male lip comprises a first male layer and a second male layer. The second male layer is folded over the first male layer to form a male lip with two layers.
In another embodiment of the invention, the second male layer is an inwardly folded second male layer or an outwardly folded second male layer.
In yet another embodiment of the invention, the second male layer is folded in an open configuration or a closed configuration.
In still another embodiment of the invention, the one or more couplings are top-seam welds or side-seam welds in the seam.
In further accord with an embodiment of the invention, the one or more couplings are tabs that are formed in the seam by shearing through the four or more layers.
In another embodiment of the invention, the one or more couplings in the seam with the four or more layers improves the shear strength of the seam by greater than 5 percent over a three-layer seam with the one or more couplings.
In yet another embodiment of the invention, the one or more couplings in the seam with the four or more layers of the structural decking system results in a shear strength that is the same as or similar to a three-layer seam shear strength with at least 5 percent fewer couplings in the seam with the four or more layers.
In still another embodiment of the invention, the one or more couplings in the seam with the four or more layers of the structural decking system results in a shear strength that is the same as or similar to a three-layer seam shear strength with a material thickness of the first or second decking panels that is at least 5 percent thinner than the three-layer seam decking panel thickness.
In further accord with an embodiment of the invention, the first panel and the second panel of the decking system has a first material thickness, a first number of couplings from the one or more couplings, and a first shear strength that is the same or similar to a second shear strength of a second decking system utilizing a three-layer seam having a second material thickness greater than the first material thickness and a second number of couplings greater than the first number of couplings, and wherein a length and a width of the decking system is the same as the second decking system.
Another embodiment of the invention comprises a structural decking system for a building structure. The structural decking system comprises two or more support members, a first decking panel comprising first top flanges, first bottom flanges, first webs, and at least one edge comprising a male lip, wherein the first decking panel is operatively coupled to at least one of the two or more support members, and a second decking panel comprising second top flanges, second bottom flanges, second webs, and at least one edge comprising a female lip, wherein the second decking panel is operatively coupled to at least one of the two or more support members. The female lip of the second decking panel is placed over the male lip of the first decking panel to create a seam with four or more layers, and one or more couplings are formed in the seam to couple the first decking panel to the second decking panel.
In further accord with an embodiment of the invention, the male lip comprises a first male layer, a second male layer, and wherein the second male layer is folded over the first male layer to form a male lip with two layers.
In another embodiment of the invention, the second male layer is an inwardly folded second male layer or an outwardly folded second male layer, and the second male layer is folded in an open configuration or a closed configuration.
In yet another embodiment of the invention, the one or more couplings are top-seam welds or side-seam welds in the seam.
In still another embodiment of the invention, the one or more couplings are tabs that are formed in the seam by shearing, or shearing and deforming, through the seam with the four or more layers.
In further accord with an embodiment of the invention, the one or more couplings in the seam with four or more layers improves the shear strength of the seam by greater than 5 percent over a three-layer seam with the one or more couplings.
In another embodiment of the invention, the one or more couplings in the seam with the four or more layers of the structural decking system results in a seam shear strength that is the same as or similar to a three-layer seam shear strength with at least 5 percent fewer couplings in the seam with the four or more layers.
In yet another embodiment of the invention, the one or more couplings in the seam with the four or more layers of the structural decking system results in a seam shear strength that is the same as or similar to a three-layer seam shear strength with a material thickness of the first or second decking panels that is at least 5 percent thinner than the three-layer seam decking panel thickness.
In still another embodiment of the invention, the first panel and the second panel of the decking system has a first material thickness, a first number of couplings from the one or more couplings, and a first shear strength that is the same or similar to a second shear strength of a second decking system utilizing a three-layer seam having a second material thickness greater than the first material thickness and a second number of couplings greater than the first number of couplings, and wherein a length and a width of the decking system is the same as the second decking system.
Another embodiment of the invention comprises a method of assembling a decking system. The method comprises assembling a first decking panel to at least one of two or more support members, wherein the first decking panel comprises first top flanges, first bottom flanges, first webs, and at least one edge comprising a male lip. The method further comprises assembling a second decking panel to at least one of the two or more support members, wherein the second decking panel comprises second top flanges, second bottom flanges, second webs, and at least one edge comprising a female lip. The method comprises assembling the female lip of the second decking panel over the male lip of the first decking panel to create a seam with four or more layers, and forming one or more couplings in the seam to couple the first decking panel to the second decking panel.
To the accomplishment of the foregoing and the related ends, the one or more embodiments of the invention comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents.
The foregoing and other advantages and features of the invention, and the manner in which the same are accomplished, will become more readily apparent upon consideration of the following detail description of the invention taken in conjunction with the accompanying drawings, which illustrate embodiments of the invention and which are not necessarily drawn to scale, wherein:
Embodiments of the present invention now may be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure may satisfy applicable legal requirements. Like numbers refer to like elements throughout.
The present invention relates to methods for manufacturing and assembling structural decking panels, as well as the structural decking systems formed from the methods. The present invention relates to decking panels with various types of generally upright side-lap seams (e.g., vertical seams or located at various angles from the vertical orientation that are perpendicular or generally perpendicular to the plane of the decking panels 2) having a male lip on an edge of a first decking panel and a female lip on an edge of an adjacent second decking panel. The seam formed from the male lip and the female lip includes a total of at least four layers when the female lip is placed over the male lip. In other embodiments, there may be additional layers in the seam, such as five layers, six layers, or the like. A four layer seam may provide the desired results (e.g., prevent or reduce vertical separation, prevent or minimize lateral shifting along the seam, and ensure a desired level of shear strength and/or stiffness across the structural decking) when couplings (e.g., welds, sheared sections, fasteners, or the like) are formed in the seam, while still allowing for access to the seam and the ability to cut or weld the four layers of the generally upright seam in order to create the couplings.
In some embodiments, the four or more layers of the seam are cut (e.g., sheared through, punched through, or the like) in multiple locations along the seam in order to couple the first decking panel to the second decking panel. In other embodiments the four or more layers of the seam are welded through a side seam weld or a top seam weld. In some of the couplings the side seam weld or top seam weld may not engage all of the four or more layers. The locations of the couplings in the seam may be placed at specific intervals or interval ranges in order provide the desired shear strength along the length of the seam of the assembled structural decking. The distances at which the couplings are formed in the seam will be discussed in further detail later.
The decking panels 2 used to form the structural decking may be manufactured from a variety of rigid materials including steel, aluminum, titanium, plastic, a composite, or another type of rigid material. Typical decking panels are made of steel and are sized in ranges from 12 inches to 42 inches wide by 1 foot to 50 feet long. These dimensions include some sizes of structural decking, but it should be understood that any sizes of structural decking within these ranges, overlapping these ranges, or outside of these ranges might be utilized with the present invention. The material thickness of the decking panels 2 may be any thickness; however, typical panel thicknesses may range between 22 gage and 16 gage, inclusive. Other material thicknesses of the present invention may be within this range, overlap this range, or be located outside of this range.
The decking panels 2 may have profiles that include top flanges 4 (otherwise described as longitudinal peaks or top flute portions) 4 and bottom flanges 6 (otherwise described as longitudinal troughs or bottom flute portions), which will be generally discussed in further detail below. The top flanges 4 and the bottom flanges 6 are operatively coupled together through the use of a web 5 (e.g., members that are perpendicular or sloped with respect to the flanges). A flute is defined as a top flange 4, the webs 5 on both sides of the top flange 4, and a half of the bottom flanges 6 extending from the webs 5 on both sides of the top flange 4. Multiple flutes form the profile of a steel decking panel 2.
The profiles of the decking panels 2 may be referred to as “fluted profiles,” “hat profiles”, “flat-bottomed profiles”, “triangular profiles,” “trapezoidal profiles,” or other like profiles. The distance from the top of the top flange 4 and the bottom of the bottom flange 6 may generally range from 1½ inches to 3 inches in depth; however other ranges of depths within this range, overlapping this range, or outside of this range may be used in the profiles. For example, in some embodiments the distance may range from 1 inch to 12 inches in depth, or the like (e.g., for the profiles illustrated in
The sizes and thicknesses of the decking panels 2 are determined based on the engineering requirements for the desired application of the structural decking. In one particular embodiment of the invention, the decking panels 2 are used as roofs and are required to meet the structural requirements for withstanding potential seismic activity, high winds, and/or other natural or man-made forces. As discussed in further detail below, if the couplings are not properly spaced along the seam or are not formed properly within the seam, the weakest location of the roof decking may be along the seam of the roof decking. As described herein, the present invention provides improved seams and couplings of the decking panels 2, which allows for the increased shear strengths and/or stiffness at the seams, and thus allows for a reduced thickness of the decking panels 2 and/or couplings that are spaced farther apart from one another without decreasing the shear strength of the overall system. As such, the reduced thickness of the decking panels 2 reduces the material costs and/or the reduced number of couplings reduces the labor costs associated with the decking systems of the present invention, when compared with other decking systems that have the same or similar shear strength.
Each decking panel 2 may be formed (e.g., roll-formed, or the like) into the desired profile. Typically, the decking panel 2 profile includes top flanges 4 and bottom flanges 6 of different shapes and sizes which create the various types of profiles (e.g., hat profiles, vee profiles, triangular profiles, dovetail profiles, or any other type of decking profile) described in further detail later. The top flanges 4 and bottom flanges 6 provide the desired strength and/or stiffness of the decking panels 2.
Panel edges 8 (e.g., the opposite longer sides of the decking panel 2) may be formed into lips that couple a first decking panel 2 to an adjacent second decking panel 2. The lips on opposite edges 8 of a decking panel 2 may include a “male lip” 10 and a “female lip” 12, which interlock with the opposing lips on adjacent decking panels 2. For example, adjacent decking panels 2 may be coupled together by mating the male lip 10 of a first decking panel edge 8 with the female lip 12 of a second decking panel edge 8. The male lip 10 and the female lip 12 may be dimensioned in order to allow for tolerance differences, such that the female lip 12 may fit over the male lip 10 over the length of the edge of the decking panel edges 8 without the use of tools in order to form an unjoined seam 14. In alternate embodiments, the male lip 10 and the female lip 12 may be dimensioned in order to allow for a press fit between the lips. As will be explained in further detail, couplings (also described as connections, attachments, or the like) may be formed in the seam 14 of the decking panels 2 to couple adjacent decking panels 2 to each other. Multiple decking panels 2 may be modularly configured to create a variety of differently sized floors or roofing arrangements (e.g., different parts of the floor or roof may have different panels with different material thicknesses). In other embodiments of the invention, a first decking panel 2 may have two male lips 10 on each edge 8 and a second decking panel 2 may have two female lips 12 on each edge 8, such that the decking panels are alternated when assembled to form the structural decking.
One decking panel edge 8 may include a generally vertical male lip 10 (e.g., located between 45 degrees+/−from a perpendicular orientation with the horizontal plane of the decking panel, or the like) as illustrated in
The male lip 10 may be created at one of the decking panel edges 8 by roll forming (or other like operation) the decking panel edge 8 into a generally inverted U-shape, V-shape, or other like shape. The male lip 10 may have a first male lip layer 20 that is extended generally vertically, for example at an angle “MB” from the horizontal orientation of the decking panel 8, as illustrated in
As illustrated in
In other embodiments, as illustrated in
In some embodiments, the male lip 10 may have a second male lip layer 22 that is folded in an open configuration to the inside or the outside of the decking panel edge 8 (e.g., inwardly or outwardly), as depicted in
In one embodiment of the invention the bend radius “RO” of the male lip 10 in the open configuration may be 0.0625 inches, in other embodiments the bend radius may range from 0.01 to 0.375. In other embodiments of the invention, the bend radius “RO” of the male lip 10 in the open configuration may be within this range, outside of this range, or overlapping this range.
In other embodiments, the second male lip layer 22 may be folded in a closed configuration to the inside or the outside of the decking panel edge 8 (e.g., inwardly or outwardly), as depicted in
When folded, the male lip 10 typically includes a thickness of two layers of the decking panel 2 as illustrated in
The decking panel edge 8 on the opposite side of the decking panel as the male lip 10 may include an inverted “U” shaped female lip 12 as shown in
The female lip 12, in some embodiments, is configured to substantially cover the male lip 10 (e.g., configured to receive the male lip 10), such that the female lip 12 is typically larger than the male lip 10. The female lip 12 may be formed by folding the decking panel edge 8 into an “inverted U” or “inverted V” shape, or other like shape with a channel that fits over the male lip 10. The female lip 12 may have a first female lip layer 30 that is extended generally vertically, for example at an angle “FF” from the horizontal orientation of the decking panel 8. In some embodiments of the invention the angle FF may be 79 degrees or may range from 60 to 120 degrees. It should be understood that in other embodiments of the present invention the angle FF may be within this range, outside of this range, or overlapping this range.
In some embodiments, the height “F” of the first female lip layer 30 may range between 0.625 to 1.625 inches, and in one embodiment may have a height of 0.875 inches. In other embodiments of the invention, the height F of the first female lip layer 30 may be within, overlap, or fall outside of the stated range depending on the type of profile and material thickness of the panel 2 used.
The female lip 12 may have a second female lip layer 32 that is folded outwardly towards the outside of the decking panel edge 8, as depicted in
The second female lip layer 32 may have a height “G,” which may be 0.75 inches, or range from 0.5 to 1.5 inches in some embodiments. In other embodiments of the invention, the height G of the second female lip layer 32 may be within, overlap, or fall outside of this range depending on the type of profile and material thickness of the decking panels 2 used.
As shown in
In order to couple two adjacent panels 2 together, the male lip 10 of a first decking panel 2 may be received by a female lip 12 of a second decking panel 2. The female lip 12 may be placed over the male lip 10 as depicted in
In one embodiment of the invention the four-layer seam (or five-layer, six-layer, or the like) may be top-seam welded or side-seam welded in order to create the coupling (also described as a joint, connection, attachment, or the like) between adjacent decking panels 2. As illustrated by
In other embodiments, as illustrated in
In other embodiments of the invention, instead of a welded seam 14, as previously discussed, the four-layer seam 14 may be deformed and/or cut (e.g., sheared) to couple the decking panels 2 together. In some embodiments of the invention a tool having jaws is used to form the couplings in the seam 14. The jaws (e.g., two or more opposed jaws) of the tool may span the seam 14 on either side of the generally upright seam 14. The jaws may perform the deformation and cutting operations, or the jaws may include blades, cavities, punches, dies, and/or any other feature that deforms and/or cuts at least a portion of the seam 14. When actuated, the jaws, and/or other feature on the jaws, deform and/or cut the seam (e.g., in any order) in order to form the coupling. The jaws may be manually actuated or actuated through a power source, such as but not limited to pneumatically actuated, hydraulically actuated, electromechanically actuated, or actuated using any other type of power source in order to create the coupling. Depending on the material thickness of the four layers of the seam 14, pneumatic or hydraulic actuation may be required in order to cut through the four layers (or more) of the seam 14.
In one embodiment cutting the seam 14 comprises shearing and deforming a portion of the seam 14 to create a louver that results in a tab that provides interference at the ends of the tab to resist lateral movement of the adjacent panels.
As illustrated generally in
The number of cut locations at a particular coupling location in the seam 14 may vary depending on the desired shear strength, thicknesses of the layers, shape of the jaws (or shape of an attachment feature to the jaws). In some embodiments, only one tab 50 (e.g., one rectangular tab) may be sheared into a coupling location in the seam 14. However, in other embodiments multiple tabs (e.g. multiple louvers) may be sheared into the seam 14 at a particular coupling location. Namely, the coupling may contain two or more tabs 50 (e.g., two or more sheared rectangular louvers). More tabs 50 may theoretically mean better shear strength and resistance to lateral forces. As illustrated in
The couplings in the seam 14 may be installed along the seam 14 at strategic distances from adjacent couplings. As depicted in
Creating couplings in a four-layer seam 4 of the structural decking improves the shear strength of the seam 14 over a three-layer seam or a two-layer seam. As such, because of the improved shear strength in the four-layer seam 14, thinner material thicknesses may be used for the panels 2 and/or fewer couplings are needed to create a structural decking system that has a shear strength that is the same as or similar to the shear strength of a decking system that utilizes three-layer or two-layer seams. Therefore, using structural decking systems with four-layer seams 14 may result in structural decking systems that cost less due to reduced material costs (e.g., reduced price for thinner steel decking panels) and due to reduced assembly costs (e.g., assembly time is reduced due to less couplings).
As illustrated in Table 1 below the shear strength of the decking system using a four-layer seam 14 is improved over other seams utilized in decking systems, such as three-layer seams. Table 1 specifically illustrates two examples of the shear strength of a seam using a four-layer seam having a male lip 10 with two layers (one example with an open male lip configuration and one example with a closed male lip configuration) versus one example of the shear strength of a seam using a three-layer seam having a male lip 10 with a single layer. The shear strengths of the three seams were determined for various thicknesses of steel decking panels 2. In all three of the illustrated examples the seams (e.g., both the three-layer and four-layer seams) had the same couplings created in the seams. The couplings were all sheared seams that formed tabs as illustrated in
As illustrated in Table 1, as the thicknesses of the decking panels increase (e.g., as the gage decreases from 22 to 20 to 18 to 16, or the like) the shear strength along the seam between two decking panels generally increases. However, when compared to a three-layer seam having a single male lip layer, a four-layer seam having a two male lip layers shows much better improvements in shear strength. For example, for decking panels that were 0.0299 inches thick (e.g., 22 gage) the two examples tested using the four-layer seams illustrated a 46% improvement in the shear strength (for both the open and closed configurations) over using the same type of coupling in a three-layer seam. With respect to the decking panels that were 0.0359 inches thick (e.g., 20 gage) the two examples tested using the four-layer seam illustrated an improvement in the shear strength of 53% (for the open male lip configuration) and 41% (for the closed male lip configuration), respectively, over the shear strength of the three-layer seam using the same type of coupling. With respect to the decking panels that were 0.478 inches thick (e.g., 18 gage) the two examples tested using the four-layer seam illustrated an improvement in the shear strength of 66% (for the open male lip configuration) and 62% (for the closed male lip configuration), respectively, over the shear strength of the three-layer seam using the same type of coupling. With respect to the decking panels that were 0.0598 inches thick (e.g., 16 gage) only the three layer seam was tested. It should be understood that four or more layers may be created in the seam of the 16 gage material, however, tests were not performed on the 16 gage material with a four-layer seam. As illustrated, the shear strength of the 16 gage material using a three-layer seam was 6628 lbs., while the shear strength of the four-layer seam using the 18 gage material (e.g., thinner than the 16 gage material) was 7717 lbs. As such, the four-layer seam using the thinner material provided improved shear strength of 16% over the three-layer seam using the thicker material.
The values displayed in Table 1 relate to single results of testing of the four layer seams of the present invention versus three layer seams in one example. The actual repeatable product testing may provide different results, but generally it should be understood that with other variables being equal the four-layer seam provides improved shear strength when compared to three-layer seams. As such, based in part on Table 1, the use of a four-layer seam over a three-layer seam generally increases the shear strength of the seam. The increased shear strength, with all other factors being equal, shows at least a 40% improvement in the shear strength. However, in other embodiments of the invention, with smaller material thickness the shear strength of the four-layer seam may also illustrate an improvement over three-layer seams with larger material thicknesses. As such, in the present invention, the shear strength of the four layer seam, may have a 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 150, or more percent improvement over the shear strength of a three-layer seam (e.g., with the other factors of panel thickness and number of couplings being equal). The improvement in shear strength may include a range that falls within, is outside of, or overlaps any of the percent values recited above. It should be noted that the shear strengths illustrated in Table 1 are for the isolated couplings within a sample of a decking system. Moreover, the shear strengths of the seam 14 may be less than, the same as, or greater than what is illustrated in Table 1 based on the type of couplings formed in the seam. For example, a different type of coupling formed by cutting (e.g., different than what is illustrated in
As previously discussed the increased shear strength utilizing the four-layer seam may be an improvement over a three-layer seam because not as many couplings would be needed in the four-layer seam in order to achieve the same or similar shear strength in the three-layer seam. In one example, with respect to Table 1, when using 18 gage panels with a ten (10) foot long seam of mating decking panels 10 and couplings that are located one foot apart (e.g., at 0.5 ft, 1.5 ft, 2.5 ft . . . 9.5 ft) a decking system that utilizes the three-layer seam may have a shear strength of 46,560 (e.g., 10 couplings multiplied by the 4656 lbs. shear strength of a single coupling in the 18 gage panel). In the present invention, the same system (e.g., 18 gage panels with a ten (10) foot long seam, and the same type of couplings) can achieve the same or similar shear strength in the four-layer seam by utilizing only 6 couplings (e.g., 46,560/7717 equals 6.033 couplings). This illustrates a 40% reduction in the amount of couplings. As such in some embodiments of the invention, depending on the gage thickness, the length of the seam, the type of four-layer seam, the type of couplings, or other like parameters, the number of couplings used in the four layer seam of the present invention may be reduced by 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or more percent when compared to the number of couplings used in a three layer seam (e.g., with all the other factors of the systems being equal) while maintaining the same or similar shear strength. As such, the number of couplings may be reduced by any percentage illustrated or by any range that falls within, is outside of, or overlaps any of the percentages listed above. As illustrated in
As previously discussed the increased shear strength utilizing the four-layer seam may be an improvement over a three-layer seam because using the four-layer seam may allow a four-layer seam system to drop gage thicknesses (e.g., move from 18 gage to 20 gage) without sacrificing shear strength. As illustrated in Table 1, by using either the open double layer male lip or the closed double layer male lip, a system may be able to utilize 20 gage panels using the four layer seam to achieve a shear strength (e.g., 5164 lbs. or 4750 lbs.) that is the same or similar to the shear strength (e.g., 4656 lbs.) using a three-layer seam with an 18 gage panel (e.g., thicker than the 20 gage panel) and the same number of couplings. In some embodiments of the invention, a reduction in the thickness of the panels (e.g., a drop down in the gage thickness from 18 to 20, or any other drop) may not be achieved without also increasing the number couplings used in the four-layer seam. This would only occur when a reduction in the thickness of the panels using a four-layer seam with the same number of couplings as the three-layer seam using the thicker panels would not result in the same shear strength. Adding additional couplings in the four-layer seam may achieve the desired shear strength, while still reducing costs because the material is less expensive (e.g., thinner decking panels), even though creating the additional couplings in the seam would increase the cost of assembly. As such, in some embodiments of the invention, depending on the gage thickness, the length of the seam, the type of four-layer seam, the type of couplings, or other like parameters, the thickness (or in other embodiments of the invention the weight) of the panels may be reduced by 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or more percent, while still achieving the same shear strength as a three layer seam that utilizes the same, more, or in some cases less couplings. As illustrated in
As previously discussed, any type of decking profile may utilize the four-layer seam 14 in order to improve the shear strength along the seam, and thus, reduce the thickness of the decking material used in a structural decking system and/or reduce the number of couplings used to couple the decking panels together in a structural decking system.
With respect to
At block 1120 the process includes forming a female lip 12 along at least one edge 8 of the decking panel 2. The female lip 12 may be formed within the roll forming process by bending (or cutting and bending depending on the size of the female lip) the edge 8 into a first female layer 30 and a second female layer 32. The female lip 12 is configured to fit over an adjacent male lip 10 of an adjacent decking panel 2.
At block 1130 the process includes forming a male lip 10 on at least one edge 8 of the decking panel 2. The male lip 10 may be formed by bending (or cutting and bending depending on the size of the male lip) the edge 8 of the decking panel 2 into a first male layer 20.
At block 1140 the process includes forming a two layer male lip 10 at the edge 8 of the decking panel 2 by bending a portion of the first male layer 20 into a second male layer 22 that is folded back onto the first male layer 20, or by using another like process. The bending may be inwardly or outwardly depending on the desired configuration of the four-layer seam. Moreover, the second male layer 22 is either bent into an open configuration or a closed configuration.
Block 1230 illustrates that the first and/or second decking panels 2 are operatively coupled to the building structure, such as but not limited through couplings with the joists, beams, walls, headers, or any other like building structure member. The couplings between the decking panels 2 and the building structure may be made through the use of welds, fasteners, or other like couplings. In some embodiments of the invention, the first and/or second decking panels 2 may be coupled to the building structure before, during, or after the unjoined seam 14 is created between adjacent panels 2, or before, during, or after the couplings are formed in the seam 14 (e.g., in the four-layer seam 14).
At block 1240 the process includes creating a coupling (e.g., joint, connection, attachment, or the like) at a first location on the seam 14. As previously discussed, the coupling may be created by shearing substantially through the four-layer seam 14 (or other seam with more than four-layers) at the first location. In other embodiments, the coupling may be created by welding (e.g., top-seam weld or side-seam weld) the female lip 12 to the male lip 10 to create the coupled seam 14. At block 1250 the process includes creating couplings at one or more additional locations along the seam 14. As with the coupling at the first location the couplings may be created by cutting (e.g., shearing, punching, or the like), welding, fastening fasteners, or through other like means. In some embodiments of the invention, the spacing of the couplings in the seam 14 are positioned to create the desired shear strength in the assembled structural decking system based at least in part on the requirements of the building, the type of couplings used, the thickness of the panels 2, the longitudinal ribs 7 in the panels 2, cutouts 9 in the panels 2, or the like.
As such, in one example a first decking panel with a male lip 10 is secured to the building structure through one or more couplings, the second decking panel 2 with a female lip 12 is placed over the male lip 10, and the second decking panel is secured to the building structure through one or more couplings. Couplings are also formed in the seam 14 created by the first decking panel 2 and the second decking panel 2 in order to couple the decking panels to each other. Other decking panels 2 are added, and the couplings are made until the decking system is complete.
In still other embodiments of the invention when the female lip 12 is placed over the male lip 10, as illustrated in
As illustrated by the profile view 1304 in
As illustrated by the profile view 1306 in
As illustrated by the profile view 1308 in
As illustrated by the profile view 1310 of
As illustrated by the profile view 1312 of
As illustrated by the profile view 1314 of
As illustrated by the profile view 1316 of
As illustrated by the profile view 1318 of
As illustrated by the profile view 1320 of
As illustrated by the profile view 1322 of
As illustrated by the profile view 1324 of
The process illustrated in
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations, modifications, and combinations of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
Also, it will be understood that, where possible, any of the advantages, features, functions, devices, and/or operational aspects of any of the embodiments of the present invention described and/or contemplated herein may be included in any of the other embodiments of the present invention described and/or contemplated herein, and/or vice versa. In addition, where possible, any terms expressed in the singular form herein are meant to also include the plural form and/or vice versa, unless explicitly stated otherwise. Accordingly, the terms “a” and/or “an” shall mean “one or more.”
The present application for a patent claims priority to U.S. Provisional Patent Application Ser. No. 61/983,277 entitled “Structural Steel Decking System and Method of Securing” filed on Apr. 23, 2014 and assigned to the assignees hereof and hereby expressly incorporated by reference herein.
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