Method of making corrugated metal deck assembly with integrated support channels

Abstract

A method of making a corrugated metal deck assembly including an elongated corrugated metal deck portion having substantially longitudinally extending, generally U-shaped peaks and valleys. One or more support channels are formed integrally with the corrugated metal deck portion prior to casting concrete thereon. Each of the support channels are configured with a generally U-shaped cross-section having generally opposed side walls having leg portions extending generally laterally inwardly from the corresponding side walls and defining a slot facing generally downwardly from the corrugated metal deck. The support channels are adapted for receiving therethrough and supportably engaging at least portions of anchors or support items. The slots may be provided with one or more internal threads into which externally threaded portions of anchors or support items may be screwed to fixedly attach the anchors or support items to the one or more integrated support channels.

Claims

1. A method of making a metal deck assembly for use in combination with a curable construction material and adapted for holding suspended construction equipment, the method comprising: providing an elongated, corrugated metal deck portion having a length defining peaks and valleys; providing one or more support channels; and cold forming said one or more support channels integrally with said corrugated metal deck portion prior to casting curable construction material thereon.

2. The method of making a metal deck assembly for use in combination with a curable construction material and adapted for holding suspended construction equipment, as set forth in claim 1, wherein each of said support channels extending generally parallel to said peaks and said valleys along the length of said corrugated metal deck portion and being configured with a cross-section having generally opposed side walls and leg portions extending generally laterally inwardly from said side walls and defining one or more slots facing generally downwardly from said corrugated metal deck portion, each of said slots being adapted for receiving therethrough and supportably engaging at least portions of anchors or support items before or after setting concrete on the metal deck assembly.

3. A method of making a metal deck and curable construction material assembly adapted for holding suspended construction equipment, the method comprising: providing an elongated, corrugated metal deck portion having a length defining peaks and valleys; providing one or more support channels; cold forming said one or more support channels integrally with said corrugated metal deck portion; and casting curable construction material thereon.

4. A method of making a metal deck and curable construction material assembly adapted for holding suspended construction equipment, the method comprising: providing an elongated, corrugated metal deck portion having a length defining peaks and valleys; providing one or more support channels; cold forming said one or more support channels integrally with said corrugated metal deck portion prior to casting curable construction material thereon, each of said support channels extending generally parallel to said peaks and said valleys along the length of said corrugated metal deck portion and being configured with a cross-section having generally opposed side walls and leg portions extending generally laterally inwardly from said side walls and defining one or more slots facing generally downwardly from said corrugated metal deck portion, each of said slots being adapted for receiving therethrough and supportably engaging at least portions of anchors or support items before or after setting concrete on the metal deck assembly; and casting curable construction material thereon.

5. The method of making and using a metal deck and curable construction material assembly adapted for holding suspended construction equipment, as set forth in claim 4, the method further comprising: positioning at least portions of anchors or support items in said slots for supportable engagement by said leg portions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a top plan view of a preferred embodiment of the invention.

[0016] FIG. 2 is a front plan view of a preferred embodiment of the invention.

[0017] FIG. 3 is an exploded partial sectional view of a preferred embodiment of the invention.

[0018] FIG. 4 is a front plan view of a preferred embodiment of the invention with concrete set thereon.

[0019] FIG. 5 is a front plan view of a preferred embodiment of the invention with concrete set thereon and a portion of a t-head bolt received through and supportably engaged by a slot of a support channel.

[0020] FIG. 6 are front plan views illustrating support channels configured with a generally C-shaped cross-section and a generally V-shaped cross-section in alterative embodiments of the invention.

[0021] FIG. 7 is a front plan view illustrating a slot with internal threads into which externally threaded portions of anchors or support items may be screwed to fixedly attach the anchors or support items to an integrated support channel in an alternative embodiment of the invention.

[0022] FIG. 8 is a front plan view of a preferred embodiment of the invention illustrating a support channel permanently attached between two deck portions by welding in an alternative embodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0023] While this present invention is susceptible of embodiments in many different forms, there are shown in the drawings and will be described in detail herein, a preferred embodiment, with like parts designated by like reference numerals and with the understanding that the present disclosure is to be considered as an exemplification of the principles of the present invention, and is not intended to limit the claims to the illustrated preferred embodiment.

[0024] Referring now to FIGS. 1-5, in a preferred embodiment, an elongated corrugated metal deck assembly generally indicated at reference numeral 10 including a deck portion 12 defining substantially longitudinally extending, generally U-shaped peaks generally indicated at reference numeral 14 and valleys generally indicated at reference numeral 16 is illustrated. One or more support channels 20 are formed integrally with the deck portion 12, such as by cold-forming, prior to casting concrete 30 thereon. It should be readily understood by those skilled in the art that other suitable manufacturing methods may be employed, without departing from the scope and spirit of the invention. The support channels 20 extend generally parallel to the peaks 14 and valleys 16 along the length of the corrugated metal deck assembly 10. In the preferred embodiment, the support channels 20 are constructed of metal.

[0025] In the preferred embodiment, each of the support channels 20 is configured with a generally U-shaped cross-section having generally opposed side walls 22 having leg portions 24 extending generally laterally inwardly from the corresponding side walls 22 and defining a slot generally indicated at reference numeral 26 facing generally downwardly from the corrugated metal deck portion 12. Each slot 26 being adapted for receiving therethrough and supportably engaging at least portions of anchors or support items 40, e.g., rivets, channel nuts, t-head bolt, hammerhead bolt, or the like.

[0026] In the preferred embodiment, the corrugated metal deck assembly 10 with one or more integrated support channels 20 is galvanized for corrosion protection prior to setting concrete 30 thereon, although it should be readily understood by those skilled in the art that other suitable protective coatings may be applied, without departing from the scope and spirit of the invention. It should also be readily understood by those skilled in the art the concrete 30 may be precast or cast in situ.

[0027] In alternative embodiments, as shown in FIG. 6, one or more of the support channels 20 may be configured with a generally C-shaped cross-section or a generally V-shaped cross-section, although it should be readily understood by those skilled in the art that one or more of the support channels may be configured with other cross-sections that provide generally opposed side walls 22 having leg portions 24 extending generally laterally inwardly from the corresponding side walls 22 and defining a slot 26 facing generally downwardly from the corrugated metal deck portion 12, without departing from the scope and spirit of the invention. It should also be readily understood by those skilled in the art that the slot 26 may be any size suitable for receiving therethrough and supportably engaging at least portions of anchors or support items 40.

[0028] In an alternative embodiment, shown in FIG. 7, each slot 26 may be provided with internal threads 28 into which externally threaded portions 42 of anchors or support items 40 may be screwed to fixedly attach the anchors or support items 40 to the one or more integrated support channels 20.

[0029] In an alternative embodiment, as shown in FIG. 8, one or more support channels 20 are permanently attached, such as by welding generally indicated at reference numeral 50, between two or more corrugated metal deck portions 12, prior to casting concrete 30 thereon.

[0030] It should be readily understood by those skilled in the art that the elongated corrugated metal deck portions 10 may be constructed of alternative, generally planar shapes without departing from the scope and spirit of the invention.

[0031] Hence, while the invention has been described in connection with a preferred embodiment and alternative embodiments, it will be understood that it is not intended that the invention be limited to those embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as disclosed.

[0032] As to the manner of usage and operation of the instant invention, same should be apparent from the above disclosure, and accordingly no further discussion relevant to the manner of usage and operation of the instant invention shall be provided.

[0033] With respect to the above description then, it is to be realized that the optimum proportions for the elements of the invention, and variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships described in the specification are intended to be encompassed by the present invention.

[0034] Therefore, the foregoing is considered illustrative of only the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact method, construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.