U.S. patent application number 09/794421 was filed with the patent office on 2001-09-06 for sound control system for steel roof decks.
Invention is credited to Jones, Robert G. JR., Nunley, C. Lynn, Shepard, Joseph B..
Application Number | 20010018815 09/794421 |
Document ID | / |
Family ID | 24055747 |
Filed Date | 2001-09-06 |
United States Patent
Application |
20010018815 |
Kind Code |
A1 |
Nunley, C. Lynn ; et
al. |
September 6, 2001 |
Sound control system for steel roof decks
Abstract
A steel roof deck diaphragm to provide structural rigidity to a
building wherein loads of varying intensity can cause movement of
structural members, which tends to generate noise when two members
rub or work against each other. Corrugated sheets of high tensile
steel are supported from below and span the distance between
purlins, the corrugated sheets having over-lapping side edges and
end edges and upper and lower surfaces. Non-metallic strips of felt
form spacers positioned between the over-lapping side edges and end
edges to prevent generation of noise resulting from relative
movement of the corrugated sheets.
Inventors: |
Nunley, C. Lynn; (Duluth,
GA) ; Jones, Robert G. JR.; (Alpharetta, GA) ;
Shepard, Joseph B.; (Marietta, GA) |
Correspondence
Address: |
Gerald G. Crutsinger
Crutsinger & Booth
Suite 1950
1601 Elm Street
Dallas
TX
75201-4744
US
|
Family ID: |
24055747 |
Appl. No.: |
09/794421 |
Filed: |
February 27, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09794421 |
Feb 27, 2001 |
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09516473 |
Mar 1, 2000 |
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6250036 |
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Current U.S.
Class: |
52/410 ;
52/537 |
Current CPC
Class: |
E04D 3/365 20130101;
E04D 13/1643 20130101; E04D 3/3606 20130101; E04D 3/38
20130101 |
Class at
Publication: |
52/410 ;
52/537 |
International
Class: |
E04B 005/00 |
Claims
Having described the invention, we claim:
1. A steel roof deck diaphragm to provide structural rigidity to a
building wherein loads of varying intensity can cause movement of
structural members, which tends to generate noise when two members
rub or work against each other, the roof deck comprising: purlins
spaced apart a predetermined distance to form spans; corrugated
sheets of steel supported from below and spanning the distance
between said purlins, said corrugated sheets having overlapping
side edges and end edges and upper and lower surfaces; spacer means
between said overlapping side edges and end edges, said spacer
means being configured to vertically space said upper and lower
surfaces to prevent generation of noise resulting from relative
movement of the corrugated sheets; and fastener means for securing
said overlapping side edges and for securing said over-lapping end
edges.
2. A steel roof deck diaphragm according to claim 1, said fastener
means comprising screws extending through adjacent side edges and
through adjacent end edges.
3. A steel roof deck diaphragm according to claim 1, said spacer
means between said overlapping side edges and end edges comprising:
strips of felt.
4. A steel roof deck diaphragm according to claim 1, said spacer
means between said overlapping side edges and end edges comprising:
strips of tape.
5. A steel roof deck diaphragm according to claim 1, said spacer
means between said overlapping side edges and end edges comprising:
strips of sprayed-on polymeric material.
6. A steel roof deck diaphragm according to claim 1, said spacer
means between said overlapping side edges and end edges comprising:
strips of generally channel-shaped edge molding.
7. A roof deck diaphragm according to claim 1 with the addition of
a sheet of flat rigid material secured to ridges of the corrugated
material; and screws extending through the flat rigid material and
anchored in the upper ridges of the corrugated material to form a
truss extending transversely of the ridges, said truss being
generally parallel to and spaced between said purlins.
8. A roof deck diaphragm according to claim 1, each of said
corrugated sheets of steel having a plurality of spaced ridges
alternating above a neutral axis forming compression ridges and
below the neutral axis forming tension ridges, said spaced ridges
extending longitudinally of said corrugated sheet; a rigid sheet
having a front face and a back face; and a sheet of sound deadening
material between the compression ridges and the back face of the
rigid sheet, said fastener means securing said rigid sheet to said
compression ridges of said corrugated sheet with the sheet of sound
deadening material therebetween.
9. A deck assembly according to claim 8 further comprising: a layer
of thermal insulation interposed between said rigid sheet and said
corrugated sheet.
10. A deck assembly according to claim 1 wherein said spacer means
between overlapping side edges and end edges comprise: strips of
resilient material having a width varying from approximately 3
inches to 4 inches.
11. A roof deck assembly comprising: (a) spaced horizontally
disposed roof joists; (b) a corrugated sheet of material, said
corrugated sheet having a plurality of spaced ribs alternating
above the neutral axis forming compression ribs and below the
neutral axis forming tension ribs, said spaced ribs extending
longitudinally of said corrugated sheet and said corrugated sheet
being supported on said roof joists; (c) a layer of thermal
insulation superposed over said corrugated sheet; (d) a sheet of
resilient sound deadening material between said corrugated sheet
and said thermal insulation; and (e) means to secure said layer of
thermal insulation to said compression ribs, said means having a
longitudinal extent extending through said layer of insulation and
capturing said sheet of sound deadening material between said layer
of thermal insulation and said corrugated sheet.
12. A roof deck assembly according to claim 11, said sheet of
resilient sound deadening material comprising: roofing felt.
13. A roof deck assembly comprising: spaced steel purlins having
upper surfaces; a rigid steel deck spanning between said spaced
steel purlins, said steel deck being formed of a plurality of
sheets, each sheet having side edges, end edges and upper and lower
surfaces; non-metallic sound deadening material; and means securing
said steel deck to said steel purlins, such that said non-metallic
sound deadening material is positioned between upper surfaces on
said steel purlins and lower surfaces on said steel sheets.
14. A roof deck assembly according to claim 13, said steel deck
comprising: sheets of corrugated steel; and means securing said
sheets, such that said non-metallic material is positioned between
upper and lower surfaces on said sheets to form overlapping side
edge joints and overlapping end edge joints.
15. A roof deck assembly according to claim 13, said corrugated
sheet of material comprising: a plurality of corrugated sheets of
steel, said corrugated sheets having overlapping side edges and
overlapping end edges and upper and lower surfaces strips of sound
deadening material extending along said side edges and end edges of
said corrugated sheets; and fastener means for securing said
overlapping side edges and for securing said overlapping end edges
such that said sound deadening material prevent scrubbing of
adjacent upper and lower surfaces of said corrugated sheet upon
relative movement of the corrugated sheets.
16. A roof deck assembly according to claim 15, said strips of
sound deadening material comprising polymeric material.
17. A roof deck assembly according to claim 15, said strips of
sound deadening material between said roof joists and said
corrugated sheet comprising: strips of fiberglass felt.
18. A method of forming a deck comprising the steps of: positioning
sound deadening material between steel supporting members and steel
sheets; and securing the steel sheets to the supporting members
such that upon movement of the steel sheet relative to the
supporting structure the sound deadening material is maintained in
a position to prevent generation of popping sounds upon movement of
surfaces on the sheet relative to the supporting structure.
19. The method of claim 18 wherein the sound deadening material is
compressible for absorbing energy and to prevent impact of a
surface the steel sheet against a surface on the supporting
structure.
20. A method according to claim 18, with the addition of the step
of positioning sound deadening material between adjacent side edges
and adjacent end edges of steel sheets secured together to form
overlapping joints.
Description
TECHNICAL FIELD
[0001] A steel roof deck diaphragm having non-metallic spacers
between over-lapping side edges and end edges of steel sheets to
prevent noise resulting from relative movement of the sheets and
resilient cushions between the steel sheets and supporting
purlins.
BACKGROUND OF INVENTION
[0002] Roof deck systems, composed of a high tensile steel base
with thermal insulation and high performance mineral board
mechanically anchored to the steel sections, provide composite
strength. The resultant assembly is a strong, durable substrate for
roofing applications. Composite roof deck assemblies are disclosed
in U.S. Pat. No. 4,601,151; U.S. Pat. No. 4,736,561; U.S. Pat. No.
4,707,961; U.S. Pat. No. 4,783,942 and U.S. Pat. No. 5,584,153.
[0003] Corrugated steel sections are positioned over structural
supports and anchored in place with welded connections through
special weld washers, of the type disclosed in U.S. Pat. No.
4,601,151, or with mechanical fasteners. Thermal insulation,
available in a variety of types and thicknesses, is placed over the
steel sections. High density tongue-and-grooved mineral board
panels are placed over the thermal insulation or directly on the
steel sections.
[0004] Corrosion resistant screw fasteners anchor the thermal
insulation and mineral board to the steel sections, thereby
developing composite strength and stability for the roofing
foundation. Corrosion resistant compression discs provide
concentrated load deflection continuity at all abutting mineral
board locations. Pressure sensitive weather resistant tape is
applied over all mineral board joints to provide a continuous plane
across the joints of the roof covering foundation. With the
application of joint tape, the roof deck assembly is complete and
ready to receive the roof covering.
[0005] U.S. Pat. No. 4,601,151 discloses a roof system comprising a
sheet of corrugated material having ridges and a rigid substrate,
such as a mineral board, fastened to the upper ridges of the
corrugated sheet. The corrugated sheet is welded to roof purlins.
The mineral board, on the other hand, is fastened to the
corrugations of the corrugated sheet by threaded fasteners which
extend through the mineral board and through the ridges to form a
truss-like structure that spans between the roof purlins.
[0006] When an insulated roof is desired, insulation is interposed
between the mineral board and the corrugated sheet. As the
insulation thickness increases the length of the threaded fasteners
increases, creating potential rotation and bending problems for the
fasteners. As a result, the thickness of the insulation is limited
by the threaded fastener length. Additionally, since fasteners
typically extend all the way through the roofing layers from the
exterior of the roof to the interior supporting structure of the
roof, thermal shorts may be created between the exterior of the
roof and the interior of the roof, which is undesirable in
extremely hot or cold climates.
[0007] Although the roof may be well insulated, the temperature of
the metallic sheets changes significantly during a 24 hour period
when the temperature gradient between the interior and exterior of
the building is high. For example, the temperature of a steel deck
on an air-conditioned building will gradually increase and
decrease. Thermal expansion and contraction of the steel sheets and
the steel purlins can cause movement of adjacent surfaces, which
generates noise when the surfaces rub or work against each other.
Expansion and contraction creates noise at the juncture between
edges and ends of the sheets and between the lower surface of the
sheets and upper surfaces of the purlins which support them.
[0008] Architectural designs may feature roofs which are flat or
inclined without an insulated ceiling between the roof and the
interior of the building. Generally, an insulated ceiling will
serve as an acoustical barrier so that popping and cracking noises
resulting from thermal expansion of the steel roof deck is not a
problem. However, when the insulated ceiling is eliminated,
unwanted noise may become a problem. For example, in the sanctuary
of a church, constructed without a ceiling, in a hot sunny climate,
thermal expansion of steel sheets in the roof deck may result in
excessive noise during church services. The noise is particularly
noticeable during prayer or other periods of silence.
[0009] Recently, exposed steel composite roof decks have been
utilized more and more on specialized applications where no ceiling
is utilized and the roof deck is exposed on the interior of the
structure. While this type of construction is not new, designers
have found themselves more and more on projects where the interior
use of the structure requires a high degree of "quietness." When
exposed steel composite roof decks are used on church sanctuaries,
where during prayer and meditation times, the occupants expect
quiet to reign within the building. Other buildings such a
libraries, media centers, condominiums and classroom teaching areas
are also using this type of design.
[0010] It has been reported that under certain conditions and at
particular times of the year, ministers had trouble conducting
services because of the popping and crackling noises emanating from
the roof deck. The noises, popping sounds, occurred every two to
three seconds and were very distracting. The noise level reached
its peak at high noon, or during maximum thermal exposure, which is
often the time for church services.
[0011] Investigation revealed that while the noises were not
exactly the same in all cases, the degree of disturbance was real
in all cases and a solution to the noise problem was required if
this type of architectural design were to be implemented
successfully.
[0012] The noise can be generated by three separate conditions.
[0013] Condition 1: Interior of the Building
[0014] Movement of the steel deck section within the assembly
produced popping noises. This movement can be caused by walking
over the deck surface or, as more commonly seems to occur, by
thermal changes of the steel section due to heat loading from the
sun. It has been observed that, even in highly insulated roof deck
assemblies (R=30 type of insulation), the temperature of the steel
deck can cycle up to 40 or 50 degrees F. during a normal day. This
change in temperature produced movement of the steel deck section.
Additionally, friction between the top of the steel section and
components, such as thermal insulation or mineral board, laid
directly on top of the steel also produce noise.
[0015] Condition 2: Perimeter of Building
[0016] The same situation exists where the building has steel
supporting members exposed to the outside temperatures, such as at
overhangs. The supporting steel moves under thermal changes and
causes movement of the steel decking, which causes noises or
popping. The popping noise is generated at the contact points
between the steel deck and the steel supporting structure.
[0017] Condition 3: Metal Roofing
[0018] It was observed that most metal roofs make noises when
expanding and contracting under thermal change.
[0019] A need exists for a method and apparatus for preventing
unwanted noise as a result of thermal expansion or other variable
loading of structural members and particularly between structural
members used in roof decks.
SUMMARY OF INVENTION
[0020] We have found that by isolating the steel deck sections from
contact with all steel surfaces, the noise created by deck movement
could be eliminated. We placed sound deadening material such as a
heavy felt, between the supporting structure and the steel sheets,
so that the steel roof deck sheets did not touch the steel
supporting structure. Further, deadening felt was positioned
between each side lap and end joint of the steel sheets, so that
the steel sheets did not touch each other, even though they are
side lapped one full corrugation and end lapped about three
inches.
[0021] The steel sheets were then anchored in place with a
non-destructive anchor. On the test frame, powder actuated pins
were used. However, we contemplate the use of screws when solid
spacer material is used and welding through openings or between
segments of spacer.
[0022] The entire top surface of the steel deck is covered with the
same deadening felt prior to placing the insulation over the steel
deck.
[0023] After completing the assembly, with all screws, etc.
installed, the roof deck was tested for sound and found it to be
sound free. The popping sound was eliminated by isolating the steel
from direct contact with any other component.
[0024] While conventional glass roofing felt was used as the
isolator, we contemplate the use of non-saturated felts and certain
types of glass tapes to improve the combustible aspects and aid in
the installation.
[0025] The method and apparatus disclosed herein preferably
includes non-metallic spacers positionable between adjacent edge
and end surfaces of sheets of formed steel to prevent rubbing
between adjacent surfaces resulting from expansion or contraction
of the sheets. The spacer is sufficiently resilient to permit
limited relative movement of adjacent surfaces, but sufficiently
rigid and of a thickness which does not permit sufficient movement
to detract from the diaphragm strength of the roof deck. Thus, the
spacers eliminate the need for insulated ceilings or other noise
barriers in the facility.
[0026] Several different embodiments of suitable spacers are
disclosed. In the first embodiment, strips of glass roofing felt
are positioned between side and end surfaces of the steel sheets
and between upper surfaces of purlins and lower surfaces of the
steel sheets. It is contemplated that the strips of glass roofing
felt may be replaced with strips of polymeric membrane of the type
disclosed in U.S. Patent No. 4,707,961. In a second embodiment of
the invention, strips of polyurethane foam are formed by spraying
strips along upper and lower edges of the sheets such that metallic
surfaces at joints between over-lapping side edges and end edges of
adjacent sheets are not in rubbing engagement with each other. In a
third embodiment, generally U-shaped molding strips are configured
to grippingly engage the edge of a sheet, the molding being
generally channel-shaped such that at least one flange is
positioned between adjacent metallic surfaces at the joints between
adjacent sheets.
[0027] A coating of non-conductive material, such as Teflon, is
preferably formed on threaded fasteners used for securing adjacent
edges of the sheets together to prevent metal-to-metal contact
between the portion of the screws adjacent the head with the metal
sheets through which the screws extend.
DESCRIPTION OF THE DRAWINGS
[0028] Drawings of a plurality of preferred embodiments of the
invention are annexed hereto, so that the invention may be better
and more fully understood, in which:
[0029] FIG. 1 is a fragmentary perspective view of a roof deck
supported by purlins;
[0030] FIG. 2 is a cross-sectional view taken substantially along
line 2-2 of FIG. 1;
[0031] FIG. 3 is an enlarged cross-sectional view taken
substantially along line 3-3 of FIG. 1;
[0032] FIG. 4 is a cross-sectional view taken through overlapping
side edges of corrugated steel sheets separated by a sound
deadening strip;
[0033] FIG. 5 is a cross-sectional view through overlapping end
edges separated by a sound deadening strip, taken along line 5-5 of
FIG. 4;
[0034] FIG. 6 is a diagrammatic plan view of a corrugated sheet
illustrating sprayed-on side strips and end strips of sound
deadening material; and
[0035] FIG. 7 illustrates a fourth embodiment wherein resilient
molding strips are positioned around the periphery of adjacent
corrugated sheets to form sound deadening strips between
overlapping side edges and overlapping end edges of corrugated
sheets.
[0036] Numeral references are employed to designate like parts
throughout the various figures of the drawing.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0037] Referring to FIGS. 1, 2 and 3 of the drawings, the numeral
10 generally designates a steel roof deck comprising a plurality of
sheets 12 of corrugated material, optional sheets 14 of foamed
insulation material and sheets 16 of rigid mineral board, the
sheets of mineral board 16 being secured by screws 18 to ridges 11
of the corrugated sheets, as will be hereinafter more fully
explained. Valleys 13 of the corrugated sheet are secured to span
across space between purlins 20, which in the illustrated
embodiment are formed by open web steel joists. Valleys 13 are
preferably secured to purlins 20 by powder actuated drive pins 21,
self-drilling screws or by welding.
[0038] Corrugated sheet 12 preferably has flat ridge portions 11
and flat valley portions 13 of substantially equal length joined by
connector portions 15 providing straight, parallel, regular and
equally curved ridges and hollows. As best illustrated in FIG. 2,
this configuration has a substantially equal distribution of
surface area of the corrugated sheet above and below a neutral axis
19.
[0039] The sheet 14 of insulation material preferably comprises a
closed cell foamed material such as polystyrene or polyisocyanurate
formulated to provide a high degree of thermal insulating quality
at ambient atmospheric temperatures. This component is optional and
is used when a high degree of thermal insulation is desired.
[0040] Sheet 16 of mineral board preferably comprises a flat smooth
sheet of incombustible, water resistant, fiberglass reinforced
material having an impervious paper cover to permit migration of
moisture from the mineral board when hot asphalt is applied
thereto.
[0041] Screws 18 extend through sheets 14 of thermal insulation and
sheets 16 of mineral board and are anchored in upper ridges 1 1 of
corrugated sheet 12. It will be appreciated that screws 18 secure
sheets 14 and 16 relative to upper ridges 11 of the corrugated
sheet but do not extend into purlins 20. Thus, screws 18 contribute
to the shear strength and shear stiffness of roof deck 10, but are
not employed for securing the roof deck to the purlins.
[0042] It should be noted that screws 18 have enlarged heads 17
which engage the rigid sheet 16. As hereinbefore noted, sheet 14 of
thermal insulation material has very low density and consequently
has insufficient internal strength to hold screw heads 17 without
pulling through the material.
[0043] The roof deck assembly 10 provides a flat surface having
sufficient strength to support a waterproof roofing membrane and
permits use of a symmetrical rib pattern in the corrugated sheet 12
which provides both flexural and diaphragm shear strength and shear
stiffness when the upper ridges 11 are restrained against movement
in a horizontal direction by the flat sheet 16 and screws 18.
[0044] Ridges 11 are in compression when a downwardly directed
force is applied to the upper surface on the roof deck. Ridges 11
on the thin corrugated sheet 12 are somewhat analogous to a slender
column when in compression. Screws 18 are positioned such that the
unsupported length of the thin ridges is significantly less than
the distance between spaced purlins 20 to increase the load
carrying capability of corrugated sheet 12. The horizontally
disposed sheet 16, screws 18, and connector portions 15 of the
symmetrically corrugated sheet 12 of high tensile strength steel
interact to form a truss-like structure extending generally
parallel to the purlins intermediate ends of the span. This
truss-like structure greatly increases the shear strength of the
corrugated sheet 12.
[0045] If corrugated sheet 12 is 32 feet long, spanning over
purlins 20 spaced apart 8 feet, the total expansion of sheet 12 is
approximately 0.124 inches (1/8inch) as a result of a 50 degree
Fahrenheit temperature change. The thermal expansion of one of the
eight-foot spans is approximately 0.0312 inches ({fraction
(1/32)}inch). The thermal expansion of steel sheet 12 generates
popping sounds as a result of the rubbing action of one hard
metallic surface on another.
[0046] As will be hereinafter more fully explained, an ideal sound
deadening material positioned between the upper surfaces of purlins
20 and lower surfaces of steel sheets 12 for preventing the popping
noises is a thin relatively soft, compressible sound absorbing
material which permits relative movement of the upper and lower
surfaces of the sound deadening material a distance of at least the
distance the span moves as a result of thermal expansion or
contraction. In the example above, assuming that pins 12c securing
corrugated sheet 12 to purlins 20 securely attaches the sheet 12 to
the intermediate supporting purlins 20, then the thermal expansion
will be equally divided between the supporting purlins 20. This
thermal expansion will cause the corrugated steel sheets 12 to
buckle upwardly or downwardly, since the sheet 12 cannot move along
its length due to being restrained by the supporting purlins. In
the example above, the eight-foot span, when experiencing a fifty
degree temperature change would expand approximately {fraction
(1/32)}inch which would result in either a slight vertical movement
of contact points between the steel deck 12 and purlin 20 which may
result in a sudden impact or deformation of the steel sheet 12 at
contact points with purlin 20. In the event that the steel
corrugated sheet 12 is already in contact with surfaces of purlin
20, the thermal expansion may result in slight sliding action of
surfaces in a horizontal direction. In either case, we have found
that positioning sound deadening material between the lower surface
of sheet 12 and the upper surface of purlin 20 alleviates the
problem. The sound deadening material should be sufficiently
resilient to permit relative movement between sheet 12 and purlin
20 in a horizontal or vertical direction by an amount sufficient to
accommodate the thermal expansion of the span distance between
purlins 20 of sheet 12. The materials hereinafter described are
selected to provide a cushioning effect resulting from vertical
movement which may result from slight buckling of sheets 12 as a
result of thermal expansion and also to keep the surfaces separated
to prevent generation of noise as a result of wiping action which
may result from horizontal movement of lower surfaces of sheet 12
relative to contact points with purlin 20. Heretofore, vapor
barriers, constructed of materials which have good resistance to
the passage of water vapor and gasses have been positioned above
and below corrugated sheets in decks. Such vapor barriers have
included polyethylene film, asphalt saturated felt, metal foil and
vinyl sheet material. These vapor barriers generally have hard
impervious surfaces and consequently are not sufficiently resilient
to permit deformation of the material vertically or horizontally to
function as a sound barrier to eliminate the popping sounds
hereinbefore described. It is important that the material be
compressible to absorb energy as the deck expands or contracts. The
sound deadening material functions as a resilient cushion or shock
absorber.
[0047] Materials such as EPDM, Neoprene rubber, felt which is not
saturated with asphalt or tar, and inorganic felt are soft,
pliable, porous and generally noncombustible. These materials are
sufficiently resilient, capable of being deformed by shear loading
to permit movement of the lower surface of the material relative to
the upper surface when oppositely directed forces are applied to
upper and lower surfaces of the material. Further, the materials
provide a cushioning effect and deform slightly when forces are
applied generally perpendicular to upper and lower surfaces of the
material.
[0048] Referring to FIGS. 1, 2 and 3 of the drawing, a strip 25 of
sound deadening material is positioned to extend longitudinally of
the upper surface of each purlin 20 for separating the upper
surface of the purlin from the lower surface of the steel sheet 12.
Strip 25 of sound deadening material is preferably formed of heavy
glass reinforcing felt or polymeric membrane, such as vulcanized
ethylene propylene diene terpolymer (EPDM). However, other
elastomeric polymer materials which are generally classified as "M"
class rubbers may be used. Further disclosure of the EPDM material
can be found in U.S. Pat. No. 4,783,942 entitled "COMPOSITE ROOF
DECK ASSEMBLY WITH POLYMERIC MEMBRANE ADHERED TO FIBERGLASS
MAT."
[0049] For maintaining the diaphragms performance and stiffness,
the thickness of the sound deadening material 25 positioned between
the upper surface of purlins 20 and the lower surface of corrugated
sheet 12 and sheet 30 positioned above corrugated sheet 12 is
preferably less than about 1/2inch.
[0050] Powder actuated pins 21 extend through valley 13 of
corrugated sheets 12 of high tensile steel, through strip 25 of
sound deadening material and the upper flange of purlin 20.
Suitable power actuated pins for metal deck attachment are
commercially available for ITW Buildex, product number BX14.
[0051] Referring again to FIGS. 1, 2 and 3 of the drawing, a sheet
30 of sound deadening material is positioned to cover ridges 11 of
corrugated sheets 12 to separate upper surfaces of the sheet 12
from the lower surface of thermal insulation material 14. If the
optional sheet of thermal insulation material is not utilized,
sheet 30 of sound deadening material would engage the lower surface
of mineral board 16 or any other material positioned
therebetween.
[0052] As best illustrated in FIG. 4 of the drawing, each
corrugated sheet 12 has side edges 12a and 12b which are positioned
in overlapping relation to form joints between adjacent sheets 12
of corrugated material. Strips 26 of sound deadening material are
positioned between the lower surface of edge 12a of one sheet and
the upper surface of edge 12b of an adjacent sheet 12 such that the
metallic surfaces on sheets 12 are separated by the strip 26 of
sound deadening material. Side edges 12a and 12b preferably overlap
about three inches and are secured together by pins 12c or sheet
metal screws (not shown).
[0053] As best illustrated in FIG. 5 of the drawing, end edges 12e
and 12f on adjacent sheets 12 are positioned one above the other to
form overlapping joints separated by a strip 27 of sound deadening
material and secured together by pins 12c'or sheet metal screws
(not shown). Edges 12e and 12f preferably overlap about four
inches.
[0054] In the embodiment of the invention illustrated in FIG. 6 of
the drawing, corrugated sheet 12 is provided with side strips 36
and end strips 37 of non-metallic material, such as polyurathane
foam, sprayed onto the lower surface and positioned to extend
around the periphery of corrugated sheet 12. In the embodiment
illustrated in FIG. 6, sound deadening strips 36 and 37 may be
applied to upper and lower surfaces of the corrugated sheet.
However, in most instances strips 36 and 37 can be formed on only
one surface, such as the top or the bottom of the sheet such that a
strip 36 is positioned between overlapping side edges of adjacent
sheets and sound deadening strips 37 are positioned between
adjacent surfaces of end edges of adjacent sheets 12 to prevent
physical contact between adjacent metal surfaces on the sheets.
[0055] In the embodiment of FIG. 7, resilient molding strips 40 and
41 are positioned to extend around the periphery of each corrugated
sheet 12 such that molding strips are positioned in substantially
the same position as the sprayed-on strips 35 and 37 illustrated in
FIG. 6 of the drawing.
[0056] Strips 25, 26, 27, 36 and 37 and sheet 30 of sound deadening
material are a porous material which does not block passage of
vapor and has a relatively soft sound absorbing characteristic in
both its composition and surface finish.
[0057] It should be understood that while the best mode of the
invention hereinbefore described relates to a composite roof deck
constructed with high tensile steel, it should be appreciated that
the problem exists with conventional assemblies constructed of mild
steel decking and we contemplate the use of sound deadening
material disclosed herein in other and further assemblies. Further,
while a roof deck has been disclosed, it should be understood that
the invention applies to floor decks, walls and partitions.
[0058] Terms such as "left," "right," "horizontal," "vertical,"
"up" and "down," when used in reference to the drawings, generally
refer to the orientation of the parts in the illustrated embodiment
and not necessarily during use. These terms used herein are meant
only to refer to relative positions and/or orientations, for
convenience, and are not to be understood to be in any manner
otherwise limiting.
[0059] It should be readily apparent that other and further
embodiments of the invention may be devised without departing from
the spirit and scope of the appended claims.
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