U.S. patent application number 13/849977 was filed with the patent office on 2014-01-09 for architectural pavements in elevated exterior deck applications.
This patent application is currently assigned to Casata Technologies Inc.. The applicant listed for this patent is Casata Technologies Inc.. Invention is credited to John R. Naccarato, Joseph A. Severini.
Application Number | 20140007540 13/849977 |
Document ID | / |
Family ID | 43755380 |
Filed Date | 2014-01-09 |
United States Patent
Application |
20140007540 |
Kind Code |
A1 |
Naccarato; John R. ; et
al. |
January 9, 2014 |
Architectural Pavements in Elevated Exterior Deck Applications
Abstract
A deck assembly uses plurality of joists preferably formed from
metal located side by side and each having a web portion and a deck
portion Integrally formed with the web portion. The deck portion
extends laterally from the web portion and the joists are spaced
from one another such that the deck portions from a continuous deck
surface with the joists being connected to one another.
Inventors: |
Naccarato; John R.; (Sault
Ste. Marie, CA) ; Severini; Joseph A.; (Sault Ste.
Marie, CA) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Casata Technologies Inc.; |
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|
US |
|
|
Assignee: |
Casata Technologies Inc.
Sault Ste. Marie
CA
|
Family ID: |
43755380 |
Appl. No.: |
13/849977 |
Filed: |
March 25, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13458553 |
Apr 27, 2012 |
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13849977 |
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12889234 |
Sep 23, 2010 |
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13458553 |
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12270645 |
Nov 13, 2008 |
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12889234 |
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PCT/CA2007/001142 |
Jun 26, 2007 |
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12270645 |
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60816348 |
Jun 26, 2006 |
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Current U.S.
Class: |
52/650.3 ;
52/831 |
Current CPC
Class: |
E04B 5/10 20130101; E04C
3/09 20130101; E04F 11/025 20130101; E04F 11/00 20130101; E04C 3/02
20130101; E04C 3/07 20130101; E04F 11/112 20130101; E04B 2103/06
20130101; E04C 3/04 20130101; E04B 1/18 20130101; E04F 15/06
20130101; E04C 2003/046 20130101 |
Class at
Publication: |
52/650.3 ;
52/831 |
International
Class: |
E04C 3/02 20060101
E04C003/02; E04B 1/18 20060101 E04B001/18 |
Claims
1. (canceled)
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. (canceled)
12. (canceled)
13. (canceled)
14. (canceled)
15. (canceled)
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
20. (canceled)
21. (canceled)
22. (canceled)
23. A joist for assembly with like joists to provide a deck
assembly, said joist having a web portion and a deck portion
extending orthogonally from the web portion and defining a
generally planar surface, said deck portion having a shelf section
formed by an offset at the intersection of the web portion and deck
portion to lie below the general planar surface of the deck
portion, an offset at a distal edge of the deck portion to provide
a tail, said offsets being relatively dimensioned such that when a
tail of one joist is supported on the shelf section of an adjacent
joist, the deck portions lie in a common plane.
24. A joist assembly according to claim 23 wherein ribs are formed
in at least one of the web portion and deck portion and extend
laterally relative to the longitudinal axis of the joist.
25. A joist assembly according to claim 24 wherein ribs are formed
in each of said web portion and deck portion.
26. A joist assembly according to claim 24 wherein said ribs are
recessed from said generally planar surface.
27. A joist assembly according to claim 24 wherein said ribs are
part circular in cross section.
28. A joist according to claim 23 wherein said shelf section is
wider than the tail to facilitate adjustment of one joist relative
to another.
29. A joist according to claim 23 wherein a flange is formed at the
free edge of the web portion and extends orthogonal to the web
portion.
30. A joist according to claim 29 wherein said flange extends in a
direction opposite to said deck portion.
31. A joist according to claim 30 wherein said flange extends in
the same direction as said deck portion.
32. A joist according to claim 29 wherein said flange terminates in
a return extending generally perpendicular to the flange to impart
stiffness thereto.
33. A deck assembly having a plurality of joists extending side by
side and connected to one another, each of said joists having a web
portion and a deck portion extending orthogonally from the web
portion and defining a generally planar surface, said deck portion
having a shelf section formed by an offset at the intersection of
the web portion and deck portion to lie below the general planar
surface of the deck portion, an offset at a distal edge of the deck
portion to provide a tail, said joists being connected to one
another by placing a tail of one joist over a shelf section of
another, said offsets being relatively dimensioned such that when a
tail of one joist is supported on the shelf section of an adjacent
joist, the deck portions lie in a common plane.
34. A deck assembly according to claim 33 wherein ribs are formed
in at least one of the web portion and deck portion and extend
laterally relative to the longitudinal axis of the joist.
35. A deck assembly according to claim 34 wherein ribs are formed
in each of said web portion and deck portion.
36. A deck assembly according to claim 34 wherein said ribs are
recessed from said generally planar surface.
37. A deck assembly according to claim 36 wherein said ribs are
part circular in cross section.
38. A deck assembly according to claim 33 wherein said shelf
section is wider than the tail to facilitate adjustment of one
joist relative to another.
39. A deck assembly according to claim 33 wherein a flange is
formed at the free edge of the web portion and extends orthogonal
to the web portion.
40. A deck assembly according to claim 33 wherein said flange
extends in a direction opposite to said deck portion.
41. A deck assembly according to claim 40 wherein said flange
extends in the same direction as said deck portion.
42. A deck assembly according to claim 39 wherein said flange
terminates in a return extending generally perpendicular to the
flange to impart stiffness thereto.
43. (canceled)
44. (canceled)
45. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 13/458,553 filed Apr. 27. 2012 which is a
continuation of U.S. patent application Ser. No. 12/889,234 filed
Sep. 23, 2010 which is a continuation-in-part of U.S. application
Ser. No. 12/270,645 filed Nov. 13, 2008, now abandoned, which is a
continuation-in-part of International PCT Application No.
PCT/CA2007/001142 filed on Jun. 26, 2007, now abandoned, which
claims priority from U.S. Provisional Application No. 60/816,348
filed Jun. 26, 2006 the contents of which are all incorporated
herein by reference. U.S. patent application Ser. No. 12/889,234
also claims priority from U.S. Provisional Application No.
60/987,528 filed Nov. 13, 2007, incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an integrated platform
joist, an integrated platform joist system, and a method for
assembling such a system.
DESCRIPTION OF THE PRIOR ART
[0003] Joist systems are used in the construction industry to span
a distance between opposing walls and provide a structural support
for a floor, a roof or other platform. The joists are individual
units spaced apart and support a decking that forms a sub-floor.
Such joists can be manufactured from a variety of materials
including softwood, wood based laminates, metals and metal
alloys.
[0004] Joists manufactured from a metal, in particular steel, may
be fabricated in an open-web configuration or in a roll-formed
configuration. Open-web joists consist of spaced-apart upper and
lower chord members that are connected with truss members such as
steel rods. Typically, open-web joists are coated or finished with
a coloured primer. Roll-formed joists are generally shaped from
sheet-steel and cold-formed into a shape, such as a C-shape when
viewed in cross section. Other configurations may include the
assembly of multiple cold-formed sections to form an I-shape
section. Roll-formed joists can be made from hot-rolled steel,
cold-rolled steel, metallic-coated sheet-steel, and/or painted
steel. Such joists are intended to be located at spaced locations
and provide point supports for the decking.
[0005] Traditionally, joist systems have required bridging of the
upper and lower chord members to brace the joists laterally to
resist twisting during, or after installation. Sub-floors, or
roofing, or sheathing of various materials is then usually
installed on top of the joist system. These joist systems sometimes
require multiple fastening means, such as, for example, a tongue
and groove joint between the sub-floor components, an adhesive to
secure the sub-floor to the joist and a screw to hold the sub-floor
in situ and a bolt a rivet or a weld.
[0006] Over the years, the building industry has introduced various
types of composite steel concrete and non-combustible floor and
roof systems in which the upper chord members are embedded within a
concrete slab. The concrete slab has both load bearing and fire
resistant properties. Examples of such composite joist can be found
in U.S. Pat. Nos. 5,941,035; 4,741,138; and 4,454,695 and U.S.
Patent Publication No. 2002/0069606 A1. A composite joist design
permits the upper chord member of a joist to be designed with less
steel in comparison with the non-composite system, since the
concrete slab, when properly bonded to the upper chord member,
provides additional load support for the floor or roof system.
[0007] One of the major drawbacks of modern joist systems is that
they require substantial time to erect. They are also dependent on
the availability of skilled labour.
[0008] It is an object of the present invention to obviate or
mitigate the above-mentioned drawback.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention provides a deck assembly
comprising a plurality of joists located side by side and each
having a web portion and a deck portion integrally formed with the
web portion. The deck portion extending laterally from the web
portion and said joists being spaced from one another such that the
deck portions form a continuous deck surface with said joists being
connected to one another in a nested engagement.
[0010] The adjacent joists, once assembled in nested engagement,
may be secured together using fastening means. The fastening means
may be selected from the group consisting of a screw, a nail, a
bolt, an adhesive, a weld, a folded seam and a toggle lock.
[0011] The joist system may have various sectional designs
depending on the application the joist system is to be used for.
The web and deck portions may each include ribbing, or other
reinforcement means to resist deflection of the platform system
during use. Most preferably, both the web and deck portions of the
joist are provided with ribbing or other reinforcement means.
[0012] At the intersection of the deck portion and web portion, the
deck portion preferably is jogged inwardly to provide an offset
shelf section running longitudinally along the length of the joist.
The shelf section is set below the upper surface of the deck
portion to provide support for the distal edge of the deck portion
of an adjacent joist. The distal edge of the deck portion is also
jogged inwardly to provide an offset shelf section running
longitudinally along the length of the joist. The offsets are
relatively dimensioned such that when a tail of one joist is
supported on the shelf section of an adjacent joist, the deck
portions lie in a common plane. These continuous longitudinal
offsets are recessed into the plane of the deck portion to allow
for nesting and fastening while maintaining a singe horizontal
datum surface on which to apply stone pavers, tiles, or the like on
a common datum surface and minimize rocking, splitting or cracking
of stones or pavers due to an uneven surface or the projection of
the fastener heads above the datum surface. In a nested
configuration, the continuous longitudinal offsets provide
increased sectional rigidity which contributes to limit vertical
deflections and resist crippling under loading conditions, and
achieves a structural efficiency that is not achievable with a
single piece structural element of similar thickness. The next
joist is then positioned with its tail resting on the shelf section
of the preceding joist. The wider shelf section allows the tail to
be adjusted along the length of the joist to maintain the required
alignment between the joists and provides for flexibility of
alignment and pitch during assembly of the joists to accommodate
variability and dimensional inaccuracies of structures in an
as-built condition. Normally, such an alignment is parallel to one
another, but in some circumstances the joists may be fanned
relative to each other to provide an arcuate surface in plan. With
the joists positioned, fasteners are inserted through the tail and
shelf section, and fasteners inserted through the flange in to the
supporting beam.
[0013] The deck assembly may optionally comprise lower chord
bridging to span an open area beneath the platform portion of the
joist to provide increased structural rigidity, and prevent the
platform from tortionally deforming.
[0014] According to a further aspect of the present invention there
is provided a joist for use in a deck assembly, said joist having a
web portion integrally formed with a deck portion that projects
laterally to one side of said deck portion and has a distal edge
for connection to an adjacent joist, whereby said deck portion
maintains said web portions of adjacent joists in spaced
relationship and provides a continuous deck surface between said
web portions.
[0015] Preferably, the joists of the deck assembly are manufactured
from a metal or a metal alloy, such as flat rolled steel with a
galvanized or organic coatings to prevent corrosion. Alternatively,
the joists may be manufactured from prepainted steel, a composite
material, or a plastics material, depending on the intended use and
loading conditions. The joists of the deck are preferably
manufactured using light gage galvanized steel in thickness of
between 1 mm and 3 mm with 1.42 mm to 2 mm preferred, to provide a
lightweight structure for ease of assembly of a deck and satisfying
structural performance conditions required by applicable building
regulations.
[0016] The joists, when manufactured from a metal or a metal alloy,
may be formed by cold-forming techniques such as roll-forming,
stamping, or a combination thereof. Alternatively, the joist may be
extruded into a desired shape when said joist is manufactured from
aluminium, a plastics material, or a composite material.
[0017] Preferred uses of the deck assembly in accordance with the
present invention include flooring systems; sub-floor
systems(including for use with a patio); transverse or longitudinal
walkways; stairway treads; specialty floors, for example, raised
floors for computer rooms, electronic and other manufacturing
plants and the like and flat or pitched roof systems. The selection
of material thickness and dimensions of the joist are dependent on
achieving minimum structural performance for static and dynamic
loading, deflection, and flexural strength of the architectural
pavements.
[0018] The present invention also provides a method for assembling
a deck assembly in accordance with the present invention; on top of
a suitable support structure which may comprise beam supports,
column supports, wall supports or combinations thereof; which
method comprises the steps of a) intercalating a pair of adjacent
platform joist in nesting engagement and b) fastening the platform
joists to each other to create a continuous deck surface.
[0019] Before explaining at least one embodiment of the invention
in detail, it is to be understood that the invention is not limited
in its application to the details of construction and to the
arrangements of the components set forth in the following
description or illustrated in the drawings. The invention is
capable of other embodiments and of being practiced and carried out
in various ways. Also, it is to be understood that the phraseology
and terminology employed herein are for the purpose of description
and should not be regarded as limiting. As such, those skilled in
the art will appreciate that the conception, upon which this
disclosure is based, may readily be utilized as a basis for the
designing of other structures, methods and systems for carrying out
the several purposes of the present invention. It is important,
therefore, that the claims be regarded as including such equivalent
constructions insofar as they do not depart from the spirit and
scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The features of the invention will become more apparent in
the following detailed description in which reference is made to
the appended drawings wherein:
[0021] FIG. 1 is a sectional view of a joist for use in the deck
assembly;
[0022] FIG. 2 is a sectional view showing a deck assembly
comprising two joists of FIG. 1;
[0023] FIG. 3 is a sectional view of an alternative joist;
[0024] FIG. 4 is a sectional view showing a deck assembly
comprising two joists of FIG. 2;
[0025] FIG. 5A to 5C show a sequence of a closure of a seam formed
by intercalating male and female portions from adjacent joists;
[0026] FIG. 6 is a sectional view of a deck assembly in a stair
configuration;
[0027] FIG. 7 shows a joist with reinforcing ribs;
[0028] FIG. 8 is a sectional view of a further embodiment of
joist;
[0029] FIG. 9 is a sectional view of a yet further embodiment of
joist;
[0030] FIG. 10 is an enlarged view of a portion of the joist shown
in FIG. 8;
[0031] FIG. 11 is a view on the line XI-XI of FIG. 10;
[0032] FIG. 12 is a perspective view of a deck assemble utilizing
the joists shown in FIGS. 1 to 11; and
[0033] FIG. 13 shows a deck assembly in accordance with the present
invention in a specialty floor configuration.
[0034] FIG. 14 is a perspective view of a further embodiment of
deck assembly, similar to that of FIG. 12,
[0035] FIG. 15 is a section on the line XV-XV of FIG. 14,
[0036] FIG. 16 is an enlarged view of FIG. 15 showing in greater
detail the connection between adjacent joists
[0037] FIG. 17 is a section on the line XVII-XVII
[0038] FIG. 18 is a plan view of the deck assembly of FIG. 14 on an
enlarged scale.
[0039] FIG. 19 is a side elevation of a stair assembly
[0040] FIG. 20 is an enlarged view of a section of the stair
assembly of FIG. 19,
[0041] FIG. 21 is a side elevation of a stairway using the assembly
of FIG. 19;
[0042] FIG. 22 is a side elevation similar to FIG. 19 of an
alternative embodiment of stair assembly.
[0043] FIG. 23 is a side elevation similar to FIG. 19 of a further
alternative,
[0044] FIG. 24 is a side elevation similar to FIG. 19 of a yet
further alternative.
[0045] In the figures, like numerals denote like parts.
DETAILED DESCRIPTION OF THE INVENTION
[0046] Referring to FIG. 1, a joist 1 for use in a deck assembly 40
comprises a web portion 2 and a deck portion 3. It will be
appreciated that the joists are of indeterminate length L and may
be customized to the length required. The deck portion 3 extends
outwardly from the web portion 2 and the included angle between the
deck portion 3 and web portion 2 is typically 90.degree., although
other angles may be incorporated. The deck portion 3 is provided
with a pair of V-shaped recesses 4, 5 at spaced locations that are
proximal to and distal from the web portion 2 respectively. The
joist 1 is formed from a rolled steel strip of appropriate gauge
and the joists 1 may be pre-finished by painting, powder coating or
galvanising to inhibit corrosion.
[0047] A plurality of joists 1, 1' of FIG. 1 are assembled as shown
in FIG. 2 to form a deck assembly 40. The web portions 2, 2' of
each joist are aligned vertically in parallel with the deck
portions 2, 2' overlapping. The distal V-shaped recess 5 engages
the recess 4 to provide a positive inter-engagement of the decking
portions 3, 3'. The joists 1, 1' are joined together by fasteners
6, such as self tapping screws or pop rivets to form an integral
unit. A lower chord bridge 50, 50' is located between upstanding
portions of adjacent joists spaced from the deck portion to provide
additional support and prevent tortional deformation of the deck
assembly 40.
[0048] The bridge 50, 50' has a planar body 52 with a pair of
flanges 54 that are secured to the webs 2, 2'. The bridges 50
maintain the webs 2, 2' in spaced relationship and provide a box
section to enhance the structural rigidity. The bridges 50 may be
continuous along substantially the entire length of the joist 1 or
may be relatively short lengths spaced apart along the joist 1 to
provide rigidity of select locations.
[0049] The joists 1 may be added side by side to the deck assembly
40 to provide a platform of the required width and length. The
individual joists are relatively light to handle and assemble but
provide high strength and rigidity when in place. The joists 1 may
be fastened together with mechanical fasteners, such as screws,
bolts, clips or rivets, or may be permanently connected, as for
example by welding. In typical applications for a residential deck,
the joists 1 are formed from rolled steel strip having a thickness
of between 1 mm and 3 mm with 1.42 mm to 2 mm preferred. The deck
portion 3 has a lateral extent dependent on structural
requirements, and is typically between 10 inches and 16 inches, and
preferably 12 inches. The web has a height of between 31/2 inches
and 8 inches with a preferred height of 51/2 inches. In a nested
arrangement, the spacing between adjacent web portions is dependent
on structural requirements, and is typically between 10 inches and
14 inches, and preferably 10 inches. For such application, a joist
length L of 12 feet has been found appropriate spanning a distance
of 8 feet between beams. The dimensions may be varied to suit the
loading and the unsupported span as per normal engineering
practices.
[0050] The deck assembly 40 may be used as the final platform or
may be used to support a non structural decking surface, such as
slate, stone, porcelain tile, concrete or exotic hardwood. The deck
assembly may also be used as a roof deck with a membrane bonded to
the deck portions 3 after assembly.
[0051] Referring to FIG. 3, an alternative design of a joist 1 of
the deck system is shown in which like components will be
identified with like reference numbers with a suffix a added for
clarity. The joist 1a comprises a web portion 2a and a deck portion
3a. One end of the web portion 2a includes a raised parapet
structure 8 where part of the web portion 2a is bent back on itself
and projects above the deck portion 3a. The deck portion 3a extends
outwardly from the parapet.
[0052] The distal edge of deck portion 3a has an upstanding rib 11
of complimentary configuration to the parapet 8 of an adjacent
joist la of the deck assembly 40.
[0053] The parapet 8 and rib 11 provide inter-engaging male and
female portions that are exaggerated compared with the recesses 4,
5 in FIG. 2 but perform a similar function.
[0054] In use, the ribs 11, 11' of a first joist 1a intercalates
with the return portion 8 of corresponding configuration on an
adjacent joist 1a'. The resulting seam 12 formed by the
intercalating male and female portions is then secured together
using a suitable fastening means, either mechanical or by
welding.
[0055] The joists 1a are arranged, as can be seen at FIG. 4 to
define a deck assembly 40a. In this embodiment each joist 1a, 1a'
is interconnected in nested engagement by intercalating the parapet
8 with the rib 11 located on adjacent joists 1, 1'. Such
intercalation of male and female portions results in an upstanding
seam 12 which can be folded and swaged (see FIG. 5) as an
alternative to individual mechanical fasteners.
[0056] FIGS. 5A to 5C show a sequence of a closure of the seam 12.
FIG. 5A shows the open seam 12 formed by intercalating adjacent
joists. A pneumatic seam closing apparatus (not shown) is used to
fold the open seam in the direction of arrow A (FIG. 5B). This
results in a closed seam 13 that is impervious to the environment
external of the deck assembly and inclement weather.
[0057] FIG. 5C shows that the closed seam 13 of FIG. 6B can be
swaged to reduce material thickness at the closed seam. The closed
seam 13 has been swaged in the direction of arrows B and B'.
[0058] As may be seen in FIG. 6 where a suffix b is added for
clarity, a plurality of joists 1b, 1b', 1b'' may be assembled in a
stair-like configuration. Each joist 1b, 1b', 1b'' has an
exaggerated web portion 2b, 2b', 2b'' which is bent back on itself
to form a parapet 8b, 8b', 8b''. The deck portion 3b, 3b', 3b'' of
the joists 1b extends substantially perpendicularly outwardly from
the upstanding portions 2b, 2b', 2b''. The parapet 8b, 8b', 8b''
projects above the deck portion 3b, 3b', 3b'' to form the
individual steps of the stair-like deck assembly 40b.
[0059] The deck 3b of the joists 1b, 1b', 1b'' are provided with
V-shaped recesses 5b as shown in the embodiment of FIG. 1.
Similarly, the upper end face 10 of the parapet 8b has a V-shaped
recess 4b formed to receive the recess 5b of the deck 3b. The
height of the web 2b will vary for each step and bridges may be
incorporated between the webs to interconnect them if so required.
The joists 1 are connected by fasteners as described above with
respect to FIG. 1.
[0060] FIG. 7 shows a joist 1c with reinforcing ribs in the deck
portion 3c. The joist 1c comprises an upstanding portion 2c and a
platform portion 3c extending substantially perpendicularly
outwardly from the upstanding portion 2c. The platform portion 3c
is provided with a plurality of castellations 80. The castellations
80 provide additional structural rigidity to the deck 3c to prevent
twisting of the platform 40c. The castellations 80 are arranged
parallel to the longitudinal axis of the joist portion 3c, however,
the ribs 80 can be positioned perpendicular to longitudinal axis
depending on the application the deck assembly is being used
for.
[0061] It will be noted that the V-shaped recesses 4c, 5c are
provided in the deck portion 3c adjacent the web 2c and distal edge
of the deck 3c. The castellations 80 are located between recesses
4.5 to permit the units 1c to be joined side by side.
[0062] A further embodiment is shown in FIG. 8 in which like
reference numerals will be used to denote like component with a
suffix d added for clarity. In the embodiment of FIG. 8, each of
the joists has a flange 60, 62 formed at the free edge of the web
portion 2d and the deck portion 3d respectively. To form a
continuous deck, the flange 62 is butted against the web of the
adjacent unit 1d with the decks aligned. The flange 62 may then be
secured to the adjacent web 2a as described above. The flange 60 at
the lower end of the web 2d enhances the bending stiffness of the
joist and provides a bearing surface when the deck assembly is
located on a support.
[0063] A similar arrangement is shown in FIG. 9 in which a pair of
webs 2e', 2e'' extend perpendicularly from opposite edges of deck
3e. Each of the webs 2e', 2e'' terminates in a flange 64. The deck
assembly 40e is assembled by abutting the webs 2e', 2e'' of
adjacent joists le against one another and securing the webs 2e',
2e'' by mechanical fasteners or the like.
[0064] The attachment of the adjacent units to one another is shown
in greater detail in FIGS. 10 and 11, as applied to the embodiment
shown in FIG. 8. It will be appreciated however that a similar
arrangement may be utilized in each of the embodiments described
above. Referring therefore to FIGS. 10 and 11, a hole 90 is punched
into the web 2e'' and elongate slot 92 punched into the web 2e'.
The hole 90 and slot 92 are aligned permitting limited fore and aft
adjustment between the two joists. A fastener 94 is inserted
through the slot and engages with the hole 90. The fastener 94 is
preferably self tapping so as to cut the thread on the hole 90 and
pull the web 2e'' up to and in abutment with the web 2e'.
[0065] To assist alignment of the units 1, each of the opposed
portions of the joists 1, either the web portions or the deck
portions may be formed with a registrar such as a witnessed
deformations or dimples 96 that provide for registration of one
unit against another. Such an arrangement assists in the rapid
assembly and alignment of the deck assembly.
[0066] In each of the embodiments described above, it will be noted
that the joists may be assembled to provide a continuous deck
surface whilst providing integral support for that surface in the
form of the webs. The deck assembly 40 may be used in a variety of
environments and under different conditions. As illustrated in FIG.
12, the deck assembly 40 may be utilized as an elevated deck in
residential or commercial environments. Referring therefore to FIG.
12, a pair of posts 100, 102 support a beam 104 that extends
generally parallel to the face of a building B. The beam 104 is
dimensioned to support the load imposed upon the deck in the normal
use and in accordance with the relevant building standards. It will
also be appreciated that whilst a steel beam is preferred, a wooden
beam may be used with the span adjusted accordingly.
[0067] The joists 1 are then assembled side by side to run
perpendicular to the beams 104. The joists 1 are connected to one
another through the fastening and enhanced rigidity provided by the
bridges 50 that may extend either continuously along the length of
the joist 1 or extend intermittently along the length.
[0068] The webs 2 of the joists 1 are secured to the beams 104 by
clips, screws or other fasteners to secure the joists.
[0069] Depending upon the cross section of the joists 1 that is
utilized, it may be necessary to support the distal edge of the
final unit with an additional web that may be fastened to the
distal edge of the joist 1 and may be provided with an
inter-engaging formation.
[0070] During assembly of the deck assembly 40, each of the joists
is relatively easy to handle due to the light weight construction.
The joists 40 may be aligned and interconnected through the use of
the inter-engaging formations and secured to one another by
fasteners, either mechanical or permanent. Where necessary, the
length of the units 1 may be extended by joining two joists end to
end with an overlap between the ends of the joists over a beam.
[0071] With the deck assembly 40 assembled, it is possible to
utilize a variety of structural and non-structural finishes
providing increased flexibility in achieving the desired
aesthetics, since the finishes are not required to provide
structural support to the deck assembly. The deck assembly 40 may,
for example, support tile, stone, slate, concrete, pavers, wood
tiles or the like. These may be free floating on the deck surface
or may be attached with adhesive or screws or the like.
[0072] As may be seen in FIG. 13, the deck assembly 40 using joists
1a as shown in FIG. 3 provides a recessed area into which cement or
concrete or other filler or substrate 100, 100' can be poured. This
is particularly useful when a raised floor is required in, for
example, special equipment rooms. The cement or other filler serves
to provide a durable surface and also provides structural support
to the deck assembly by preventing twisting of the platform
structure. The deck assembly is also provided with lower chord
bridging 50, 50' to further support the deck assembly 40.
[0073] Although the joists have been described above in the context
of building a deck assembly, it will be appreciated that a similar
system may be used to provide a flat roof of a building or as an
inclined roof with the rafters integrally formed by the webs. The
deck assembly may also be used as a self supporting structural
vertical wall.
[0074] Although described principally in a construction
environment, the product may also be used in other horizontal
applications, such as the bed of a trailer, or in a vertical
application such as a billboard.
[0075] In each embodiment, the webs 2 may be formed with predefined
apertures to accommodate services being provided beneath the deck 3
and to minimize the cutting necessary at final installation. This
enables the applied finish to be maintained after installation and
inhibit corrosion.
[0076] The decking assembly 200 shown in FIG. 14 utilises an
alternative profile of joists that are particularly suitable for
providing a deck assembly on conventional substructure to support a
paved area. The deck assembly 200 is formed from joists 201 that
are arranged side by side and connected to one another as generally
shown in the previous embodiments. The joists 201 run generally
perpendicular to the support beams 204 and are secured to the beams
for stability.
[0077] As can best be seen in FIG. 15, two different profiles of
joist are used in the deck assembly of FIG. 14, a main joist
indicated at 201a and an end joist indicated at 201b. Both joists
201 have a web portion 202 to extend generally vertically and a
deck portion 203 that extends generally horizontally from the web
portion 202 for engagement with an adjacent joist. Each of the web
portions and deck portions has inwardly directed ribs, 210, formed
at spaced intervals along the respective portions. Each of the ribs
210 extends laterally relative to the length of the joist and has a
generally part circular cross section, indicated at 212, as seen in
FIG. 17, and a part spherical end section indicated at 214, as seen
in FIG. 18. The ribs 210 thus merge smoothly with the generally
planar deck portion and web portion whilst providing local
stiffening. A drainage hole 211 is provided in each of the ribs 210
of a deck portion to prevent accumulation of water.
[0078] At the intersection of the deck portion 203 and web portion
202, the deck portion 203 is jogged inwardly to provide an offset
shelf section 216 running longitudinally along the length of the
joist 201. The shelf section 216 is set below the upper surface of
the deck portion 203 to provide support for the distal edge 218 of
the deck portion 203 of an adjacent joist 201.
[0079] As can be seen in FIG. 15, the distal edge 218 of the deck
portion 203 is itself jogged to provide an offset tail 220 along
the distal edge 218. The offset of the shelf section 216 is greater
than the offset of the tail 220 by the thickness of the material
used in the deck portion 203, so that when the tail 220 rests on
the shelf, the deck portions 203 of adjacent joists 201 are level
with one another. The shelf section 216 is also wider than the tail
220 to accommodate relative adjustment between the joists 201, as
described more fully below.
[0080] The lower edge of the web portion 202 terminates in a flange
230 that extends generally perpendicular to the web portion 202. In
the case of the main joist 210a, the flange 230 extends outwardly,
i.e. in the opposite direction to the deck portion 203, whereas in
the end joist 201b, the flange 230 extends inwardly in the same
direction as the deck portion 203. The flange 230 terminates in an
upstanding return 232 to impart stiffness to the flange. Small
holes may be located at intervals longitudinally along the flange
230 to provide for adequate drainage of accumulated or shedding
water.
[0081] To assemble the joists 210 on the beams to form a deck
assembly 200, an edge strip 234 is first secured to the beams at
one side. The edge strip 234 has a vertical web 236 with a flange
238 at its lower edge and a ledge 240 at its upper edge. The
spacing between the flange 238 and ledge 240 corresponds to the
distance from the underside of the flange 230 to the underside of
the tail 220 of a joist 201. If a particulate material such as sand
or gravel is to be placed on the deck assembly 200, the edge strip
234 is formed with an upstanding wall 242 beyond the ledge 240.
This is integrally formed by folding the web 236 back on itself.
Fasteners 244 are inserted through the flange 238 of the edge strip
234 in to the beams to hold the edge strip 234 in place. The
fasteners 244 may be self piercing, or holes may be formed in the
flange 238 at suitable increments to allow the fastener 244 to be
inserted.
[0082] With the edge strip 234 in situ, a main joist 201a is
positioned with the tail 220 resting on the ledge 240. The tail 220
may be secured to the ledge 240 with fasteners 246 and the joist
201a is secured to the beam by further fasteners 244 passing
through the flange 230. The out-turned flange 230 of the main joist
201a facilitates the insertion of the fasteners 244 as the flange
230 is exposed and allows the fasteners 244 to be easily inserted.
It will also be appreciated that the offset of the tail 200 from
the deck portion 203 allows the fasteners 246 used to secure it to
the ledge 240 to be flush with or below the general level of the
deck portion 203.
[0083] The next joist 201 is then positioned with its tail 220
resting on the shelf section 216 of the preceding joist 201. The
wider shelf section 216 allows the tail 220 to be adjusted along
the length of the joist to maintain the required alignment between
the joists 201 and provides for flexibility of alignment and pitch
during assembly of the joists 201 to accommodate variability and
dimensional inaccuracies of structures in an as-built condition.
Normally, such an alignment is parallel to one another, but in some
circumstances the joists 201 may be fanned relative to each other
to provide an arcuate surface in plan. With the joists positioned,
fasteners 246 are inserted through the tail 220 and shelf section
216, and fasteners 244 inserted through the flange 230 in to the
supporting beam.
[0084] Further main joists 201a are connected side by side in a
similar manner to complete the required extent of the deck
assembly. At each connection, the tail 220 is supported on the
shelf section 216 of the preceding joist and secured with fasteners
246.
[0085] At the opposite side of the deck assembly 200, an end joist
201 b is used so that the flange 230 is directed inwardly relative
to the deck portion 203 and a flush end face is maintained. Access
to the interior of the flange 230 is available to place fasteners
244, or alternatively the fasteners may be inserted diagonally
through the web portion 202 and flange 230. If a retaining edge is
required, an angle piece 248 may be secured to the shelf section
216.
[0086] With the deck assembly 200 complete, the surface may be clad
with the requisite covering. The deck assembly provides a modular
structural diaphragm that can be rapidly and securely placed in new
construction or over an existing substructure to provide a
generally continuous structural diaphragm to support a variety of
coverings such as architectural pavers. The continuous structural
diaphragm may be fabricated of different material. The selection of
material thickness, and other dimensions is dependent on achieving
minimum structural performance for static and dynamic loading,
deflection, and flexural strength of the architectural
pavements.
[0087] The modular structural diaphragm material may be selected
from a flat-rolled steel having a corrosion resistant coating.
Where the modular structural diaphragm material is steel, it should
have material yield strength from at least 33 ksi, preferably at
least 50 ksi; and substrate having a thickness of between 1 mm and
3 mm with 1.42 mm to 2 mm preferred,. The integral joist element
and integral deck stiffeners may be designed for maximum section
modulus at a given material thickness and material properties for
steel to achieve design criteria for longitudinal deflection.
[0088] The material thickness of each modular element remains
constant to within normal production tolerances. The particular
design of the joist, web stiffener, the transverse stiffener, and
deck element are selected to satisfy structural conditions due to
static and dynamic loading in accordance with local building
regulations, including the maximum vertical displacement across the
particular element; and maximum permissible slopes, moments,
stresses, and shear forces for the particular element. In addition,
the layout of the joist, the transverse stiffener, and deck element
relative to each other may be designed to limit the maximum
permissible span of any individual paver over any single element.
Typically, the maximum displacement of any element is limited to at
most L/360, and preferably L/480, where L is the length of the span
of the particular joist between supports.
[0089] Where individual pavers are used, an underlayment may be
positioned between the metal diaphragm and the pavers to assist
with cushioning, and water drainage. The thin pavers may be either
placed in a floating arrangement on top of the structural metal
diaphragm with or without the underlayment, or adhered to the metal
diaphragm with a suitable mortar or adhesive.
[0090] In a preferred embodiment, floating architectural pavers
have a minimum weight of 15 pounds per square foot, a minimum
flexural strength of 580 pounds per square inch ("psi) when tested
per ASTM C-293, and minimum breaking force of 1125 pounds.
Depending on the mass density of the pavers, such pavers with these
attributes would have a minimum thickness of 1.25 inches per square
foot for concrete pavers, and 1.00 inch per square foot for most
dimension stone tiles.
[0091] As the thickness of the paver is decreased, then there is a
requirement for increased flexural strength of the paver to prevent
cracking and breaking, as well as the use in combination with
adhesives or mortar to prevent wind uplift. The use of an
underlayment or adhesive is based on the dimensions of the paver,
paver weight per square foot, flexural strength of the paver to
support loading and prevent cracking, and applicable building codes
and regulations (including standards relating to wind uplift
forces). If preferred, pavers with integral "feet" may be used to
allow water to pass beneath without obstruction.
[0092] A suitable form of main joist 201a intended for residential
installations and conforming to the Ontario Building Code has an
overall height of the web portion 202 of 51/2 (5.5) inches and an
overall width of the deck portion of 113/4 (11.75) inches. The
flange 230 has a width of 1.9 inches. The shelf section 216 has a
width of 15/8 (1.625) inches and that of the tail 220 9/16 inch.
The ribs 210 in the deck portion have a length along the major
access of the rib 210 of 7 inches, starting 2 inches from the
intersection of the web portion and deck portion, and a minimum
depth of 1/2 inch to provide a width of 1 inch. The ribs 210 in the
web portion 202 are centred on the web portion and have a length of
4.5 inches and a minimum depth of 0.460 inches for a width of 0.92
inches. The ribs 210 repeat at intervals of 3 inches.
[0093] The material conforms to ASTM A653 and has a nominal
substrate thickness of 0.056 inches. The offset of the shelf
section from the main deck portion is 1/4 inch, and that of the
tail 220 correspondingly reduced by the thickness of the
material.
[0094] This configuration of joist 201 is sufficient to support a
covering of pavers when placed on beams at eight-foot centres.
[0095] More generally, the preferred dimensions provide for a
continuous offset of the shelf section to provide a 0.25'' recess
beneath the common surface to accommodate most screw fastener
heads. The shelf section is from 1 inch to 2 inches, preferably
1.625 inches. The tail 220 forming the free edge may be as large 1
inch to 2 inches, preferably 1 inch. In nested arrangement, the
tail may be laterally adjusted up to 1-inch on each end of a mating
shelf section of an adjacent joist to accommodate variations of
dimensions of as-built structures. This avoids the tedious work of
precisely fitting the joists 201 to conform with as-built
structures, such as a perimeter wall.
[0096] The configuration of joist 201 may also be adapted to
provide stairs, as illustrated in FIG. 19 to 21. Traditional wood
stairs in a straight configuration from one floor to the next
requires around 280 saw cuts and can easily take a single highly
skilled carpenter 4-6 hours to complete. Even existing prefab
stairs require skilled trades to complete the installation of the
pre-fab stair in the field.
[0097] In building a set of stairs, the homeowner has limited
choices with respect to materials and dimensions. Prefabricated
concrete stairs are limited in width, rise and run due to fixed
tooling and manufacturing methods, and are susceptible to cracking
during transport and installation. Prefabricated and site-built
concrete stairs are expensive and are susceptible to spalling and
wear from environmental factors. Prefabricated steel stairs are
also expensive and limited in width, rise and run dimensions due to
fixed tooling and manufacturing methods, and require specialised
tools and skills to install.
[0098] As shown in FIGS. 19 to 21, use of the joist arrangement
provides a modular system that allows the stair system to be
assembled quickly and easily. Referring to FIGS. 19 to 20, a stair
assembly 300 is formed from a series of joists 301, connected to
one another. The profile of each joist 301 is similar to that of
the deck assembly 200 described above, with a web portion 302 and a
deck or tread portion 303. The tread portion 303 has a shelf
structure 316 formed at the intersection of the web portion 302 and
tread portion 303 and a tail 320 on the distal edge 318. Ribs 310
are formed in each of the web portion and tread portion having a
similar configuration to those used in the joists 201. A flange 330
is inturned, as in the end joist 201b.
[0099] As best seen in FIG. 20, the tail 320 has an upturned flange
321 that extends at right angles to the tail 320 along the length
of the joists 301. The flange 321 serves as an attachment surface
to connect adjacent joists 301 in stepped manner.
[0100] As can be seen in FIG. 19, the flange 321 of the lower joist
301 is connected to the lower edge of the web portion 302 by
fasteners 344. The vertical face of the flange 321 provides for
connection of the two joists while at the same time permitting
limited vertical adjustment of the exposed face of the web portion
302 to determine the rise of the steps preferably from between 5.5
to 7.5 inches. Similar connections are made with successive joists
until the required number of treads is obtained. Thereafter, as
shown in FIG. 21, the stair assembly is fastened via side plates
350 to stringers 352 and finish surfaces 354 can be attached to the
tread portions 303. The stringers may be made of a material and
dimensions suitable for the structural performance desired such as
with wood or metal, and are preferably made from cold formed steel
tubing that has cross section dimensions of 2 inches by 6 inches
and is 0.080 inches thick and coated to prevent or retard
corrosion, such as with zinc, aluminum zinc or organic coatings.
Preferably a zinc coating is applied using the hot dipped
galvanized process. Galvanised zinc coating thickness may vary
depending on location in use, but is generally within the range of
0.6-2.35 ounces per square foot applied (i.e. G60 to G235), and
preferably 0.6 ounces per square foot, (i.e. G60).
[0101] The joists 301 are preferably made from cold formed steel
having a thickness of between 1 mm and 3 mm with 1.42 mm to 2 mm
preferred and coated to prevent or retard corrosion, such as with
zinc, aluminum zinc or organic coatings. Preferably a zinc coating
is applied using the hot dipped galvanized process. Galvanised zinc
coating thickness may vary depending on location in use, but is
generally within the range of 0.6-2.35 ounces per square foot
applied (i.e. G60 to G235), (i.e. G60 to G235), and preferably 0.9
ounces per square foot, (i.e. G90).
[0102] This stair assembly 300 is secured using galvanized steel
brackets and fasteners to at least two stair stringers preferably
made from galvanized steel. The number of stair stringers required
is dependent on loading conditions to be satisfied and the width
selection of the stairs. The actual spacing between stringers is
variable, but is preferably between 30-48 inches apart. The bracket
may be made from galvanized steel in standard C-sections known and
available in the art preferably with dimensions of 2 inches by 4
inches and is 0.080 inches thick.
[0103] The ribs 310 provide increased structure and stability to
the stair assembly, depending on loading conditions. The ribs are
generally semi-circular in cross section for improved rigidity and
are formed contiguously into the web portion 302 to increase the
resistance to deflections, web crippling strength of the section
and increase the lateral-torsional strength. The ribs 310 also
provides a means to balance material flow between the first web and
the lateral ribbing of the deck or tread portion during
manufacturing to control acceptable flatness and camber of the deck
or tread portion and straightness of the first web.
[0104] The continuous longitudinal shelf sections 316 and 320 are
recessed into the plane of the tread portion to allow for fastening
to brackets while maintaining a singe horizontal datum surface on
which to apply stone pavers, tiles, or the like on a common datum
surface and minimize rocking, splitting or cracking of stones or
pavers due to an uneven surface or the projection of the fastener
heads above the datum surface.
[0105] The shelf sections also provide increased sectional rigidity
which contributes to limit vertical deflections and resist
crippling under loading conditions, and achieves a structural
efficiency that is not achievable with a single piece structural
element of similar thickness.
[0106] An alternative arrangement is shown in FIG. 21 where the web
portion 302 is extended and formed without the flange 310. The
vertical adjustability is therefore increased whilst still
providing attachment surfaces between the adjacent joists.
Knockouts are generally provided in the web portion to allow
adjustability without interference with the stringers.
[0107] To achieve a stair with an enhanced variable run capability,
the joist 301 may be manufactured without the vertical flange 301
and the tail 320 increased. Multiple joists may be combined to
achieve a large run dimension in the stair tread. The tail 320
provides for lateral adjustment to accommodate variability and
dimensional inaccuracies of structures in an as-built condition.
This arrangement also allows for variable pitch nesting to create a
curved stair surface.
[0108] As best seen in FIGS. 23 and 24, alternatively, the flange
330 may be turned out to form a ledge 330a to receive the next
adjacent stair tread joist, thereby providing for a fixed stair
riser dimension and simplying assembly. The ledge 330a may be fixed
at a right angle so as to be horizontal in use as shown in FIG. 23,
through to an angle matching the supporting stringer 352 as shown
in FIG. 24. The ledge is attached with fasteners 344 to side plates
350 as shown in FIG. 23 or directly to the stringer as shown in
FIG. 24. The flange 321 of the lower joist 301 is connected by
fasteners 344 to the ledge 330a. Alternatively, the flange 321 of
the lower joist 301 may be connected by fasteners 344 to the lower
edge of the web portion 302 to permit some adjustment to the riser
height. Similar connections are made with successive joists until
the required number of treads is obtained. The final bottom tread
380 is normally provided with the inturned flange 330 to allow for
finish surfaces to be applied. Thereafter finish surfaces can be
attached to the tread portions 303 and the riser portion 302.
* * * * *