U.S. patent application number 14/484051 was filed with the patent office on 2015-03-12 for concrete deck for an integrated building system assembly platform.
This patent application is currently assigned to ADITAZZ, INC.. The applicant listed for this patent is Aditazz, Inc.. Invention is credited to Donald Foldenauer, Sungmin Kim, Zigmund Rubel.
Application Number | 20150068138 14/484051 |
Document ID | / |
Family ID | 52624159 |
Filed Date | 2015-03-12 |
United States Patent
Application |
20150068138 |
Kind Code |
A1 |
Rubel; Zigmund ; et
al. |
March 12, 2015 |
CONCRETE DECK FOR AN INTEGRATED BUILDING SYSTEM ASSEMBLY
PLATFORM
Abstract
Embodiments of a deck assembly module for a steel framed
building include a modular concrete deck platform. The platform
includes a concrete slab having a top major surface and a bottom
major surface and a structural grid pattern of reinforcing bar
within the concrete slab. The concrete slab further includes a
shear connector opening on a side surface of a side of the concrete
slab. The shear connector opening is a recess on the side surface
of the concrete slab. The platform further includes an integrated
attachment assembly within the shear connector opening on the side
of the concrete slab. The integrated attachment assembly includes a
shear connector rebar including an extension of continuous
reinforcing bar extending out of the shear connector opening and
back into the shear connector opening. The shear connector rebar
and the shear connector opening form a closed loop.
Inventors: |
Rubel; Zigmund; (Greenbrae,
CA) ; Foldenauer; Donald; (San Jose, CA) ;
Kim; Sungmin; (Morgan Hill, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Aditazz, Inc. |
San Bruno |
CA |
US |
|
|
Assignee: |
ADITAZZ, INC.
San Bruno
CA
|
Family ID: |
52624159 |
Appl. No.: |
14/484051 |
Filed: |
September 11, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61876475 |
Sep 11, 2013 |
|
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Current U.S.
Class: |
52/98 ; 52/223.6;
52/414; 52/653.1; 52/741.3 |
Current CPC
Class: |
E04B 5/023 20130101;
E04B 5/17 20130101; E04B 5/10 20130101; E04B 5/14 20130101; E04B
2001/2454 20130101; E04B 2001/2424 20130101; E04B 2001/2442
20130101; E04C 2/06 20130101; E04B 2005/176 20130101; E04C 5/04
20130101; E04B 1/24 20130101; E04C 5/16 20130101; E04B 2001/2484
20130101; E04B 5/04 20130101; E04B 5/44 20130101 |
Class at
Publication: |
52/98 ; 52/414;
52/223.6; 52/653.1; 52/741.3 |
International
Class: |
E04C 5/01 20060101
E04C005/01; E04C 5/16 20060101 E04C005/16; E04F 13/02 20060101
E04F013/02; E04H 1/00 20060101 E04H001/00; E04C 2/06 20060101
E04C002/06; E04B 1/38 20060101 E04B001/38; E04B 1/19 20060101
E04B001/19 |
Claims
1. A deck assembly module for a steel framed building, the deck
assembly module comprising: a modular concrete deck platform
comprising: a concrete slab having a top major surface and a bottom
major surface; a structural grid pattern of reinforcing bar within
the concrete slab; wherein the concrete slab further comprises a
shear connector opening on a side surface of a side of the concrete
slab, wherein the shear connector opening is a recess on the side
surface of the concrete slab; an integrated attachment assembly
within the shear connector opening on the side of the concrete
slab, the integrated attachment assembly comprising a shear
connector rebar comprising an extension of continuous reinforcing
bar extending out of the shear connector opening and back into the
shear connector opening, wherein the shear connector rebar and the
shear connector opening form a closed loop.
2. The deck assembly module of claim 1, wherein the shear connector
rebar protrudes from the concrete slab within the geometry of the
shear connector opening.
3. The deck assembly module of claim 1, wherein the modular
concrete deck platform is a polygonal shape, wherein the concrete
slab further comprises shear connector openings on each side of the
concrete slab, wherein each shear connector opening comprises a
corresponding shear connector rebar comprising an extension of
continuous reinforcing bar extending out of each corresponding
shear connector opening and back into each corresponding shear
connector opening, wherein each shear connector rebar and each
corresponding shear connector opening form a corresponding closed
loop.
4. The deck assembly module of claim 1, wherein the shear connector
rebar is separate from the structural grid pattern of reinforcing
bar.
5. The deck assembly module of claim 1, wherein the shear connector
rebar is integrated into the structural grid pattern of reinforcing
bar.
6. The deck assembly module of claim 1, wherein the modular
concrete deck platform has a perimeter shape that corresponds to
dimensions of a bay of the steel framed building, wherein the shear
connector opening on the side of the concrete slab extends from the
top major surface to the bottom major surface of the concrete slab
and wherein the shear connector opening would expose a portion of a
beam or girder of the steel framed building when the modular
concrete deck platform is placed to cover the bay of the steel
framed building.
7. The deck assembly module of claim 1, wherein the modular
concrete deck platform has a perimeter shape that corresponds to
dimensions of a bay of the steel framed building, wherein the bay
is a location in the steel framed building that includes a vertical
support column and wherein the perimeter shape copes at least
partially around the vertical support column, wherein the shear
connector opening on the side of the concrete slab extends from the
top major surface and the bottom major surface of the concrete slab
and wherein the shear connector opening would expose a portion of a
beam or girder of the steel framed building when the modular
concrete deck platform is placed to cover the bay of the steel
framed building.
8. The deck assembly module of claim 1, wherein the modular
concrete deck platform has a perimeter shape that corresponds to
dimensions of a bay of the steel framed building, wherein the
perimeter shape is rectangular, and wherein the concrete slab
further comprises at least one shear connector opening on each side
of the rectangle and an integrated attachment assembly within each
shear connector opening, wherein the bay is a location in the steel
frame building that does not include a vertical support column, and
wherein the shear connector opening on the side of the concrete
slab extends from the top major surface and the bottom major
surface of the concrete slab, and wherein the shear connector
opening would expose a portion of a beam or girder of the steel
framed building when the modular concrete deck platform is placed
to cover the bay of the steel framed building.
9. The deck assembly module of claim 1, wherein the shear connector
opening on the side of the concrete slab comprises a rectangular
geometry extending from the top major surface to the bottom major
surface
10. A steel framed building comprising: a structural frame defining
a footprint of the steel framed building, the structural frame
comprising vertical columns and horizontal beams and girders,
wherein the horizontal beams and girders define bays within the
steel framed building; modular concrete deck platforms attached to
the structural frame, the modular concrete deck platforms
comprising: a concrete slab having a top major surface and a bottom
major surface; a structural grid pattern of reinforcing bar within
the concrete slab; wherein the concrete slab further comprises a
shear connector opening on a side surface of a side of the concrete
slab, wherein the shear connector opening is a recess on the side
surface of the concrete slab; an integrated attachment assembly
within the shear connector opening on the side of the concrete
slab, the integrated attachment assembly comprising a shear
connector rebar comprising an extension of continuous reinforcing
bar extending out of the shear connector opening and back into the
shear connector opening, wherein the shear connector rebar and the
shear connector opening form a closed loop.
11. The steel framed building of claim 10, wherein the modular
concrete deck platforms are supported on edges of the modular
concrete deck platforms by beams and girders of the steel framed
building.
12. The steel framed building of claim 11, wherein the modular
concrete deck platforms have a perimeter shape that corresponds to
dimensions of a bay of the steel framed building, wherein the shear
connector opening on the side of the concrete slab extends from the
top major surface and the bottom major surface of the concrete
slab, and wherein the shear connector opening exposes a portion of
a beam or girder of the steel framed building.
13. The steel framed building of claim 11, wherein the modular
concrete deck platforms have a perimeter shape that corresponds to
dimensions of a bay of the steel framed building, wherein the bay
is a location in the steel framed building that includes a vertical
support column and wherein the perimeter shape copes at least
partially around the vertical support column, wherein the shear
connector opening on the side of the concrete slab extends from the
top major surface and the bottom major surface of the concrete slab
and wherein the shear connector opening would expose a portion of a
beam or girder of the steel framed building.
14. The steel framed building of claim 11, wherein the modular
concrete deck platforms have a perimeter shape that corresponds to
dimensions of a bay of the steel framed building, wherein the bay
is a location in the steel frame building that does not include a
vertical support column and wherein the perimeter shape is
rectangular, wherein the shear connector opening on the side of the
concrete slab extends from the top major surface and the bottom
major surface of the concrete slab, and wherein the shear connector
opening would expose a beam or girder of the steel framed building
when the modular concrete deck platform is placed to cover the bay
of the steel framed building.
15. The steel framed building of claim 10, wherein the modular
concrete deck platforms interface with shear connections, wherein
the shear connections interface with the shear connector rebar, and
wherein the shear connections extend out of a beam or girder of the
steel framed building and within the closed loop.
16. The steel framed building of claim 15, wherein the shear
connector opening is filled with grout after attachment of the
modular concrete deck.
17. A method for constructing a floor in a steel framed building,
the method comprising: placing a modular concrete deck platform on
horizontal beams and girders of a steel framed building, the
modular concrete deck platform having a perimeter shape that
corresponds to dimensions of a bay of the steel framed building,
wherein the beams and girders outline the perimeter of the bay,
wherein the placing the modular concrete deck platform comprises
placing perimeter edges of a bottom surface of the modular concrete
deck platform on a portion of a top surface of the beams and
girders, and wherein shear connector openings on sides of the
modular concrete deck expose a portion of the top surface, wherein
the shear connector openings are recesses on side surfaces of the
modular concrete deck platform, and wherein a shear connector rebar
comprising an extension of reinforcing bar extending out of each
shear connector opening and back into each shear connector opening
and the shear connector openings forms a closed loop; and attaching
shear connections to the horizontal beams and girders of the steel
framed building in the exposed portion of the top surface and
within the closed loop.
18. The method of claim 17, the method further comprising filling
the shear connector openings with a grout after attaching the shear
connections to the horizontal beams and girders of the steel framed
building.
19. The method of claim 17, the method further comprising placing a
second modular concrete deck platform adjacent to the modular
concrete deck platform, wherein the placing the second modular
concrete deck platform comprises placing perimeter edges of a
bottom surface of the second modular concrete deck platform on a
portion of a top surface of the beams and girders, wherein an edge
of the modular concrete deck platform and an edge of the second
modular concrete deck platform each rest on portions of the same
beam.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is entitled to the benefit of provisional
U.S. Patent Application Ser. No. 61/876,475, filed Sep. 11, 2013,
entitled "Concrete Deck for an Integrated Building System Assembly
Platform," which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention relates generally to structural framed
buildings, and, more specifically to modular components for
structural framed buildings.
BACKGROUND
[0003] Structurally framed buildings generally include a steel or
concrete frame of columns, girders, and beams that support concrete
decks. The construction of steel framed building floors and
platforms are assembled onsite without any aggregation of
components into modules prior to arriving on the building site.
Concrete floors are poured onsite at each building under
construction. Onsite pouring of concrete is laden with variability
and problems compared to a factory controlled mix and setting of
concrete. Many factors affect the life, strength, and overall
quality of concrete, including weather conditions and the quality
of skilled labor.
SUMMARY
[0004] Embodiments of a deck assembly module for a steel framed
building are disclosed. In an embodiment, a deck assembly module
includes a modular concrete deck platform. The modular concrete
deck platform includes a concrete slab having a top major surface
and a bottom major surface and a structural grid pattern of
reinforcing bar within the concrete slab. The concrete slab further
includes a shear connector opening on a side surface of a side of
the concrete slab. The shear connector opening is a recess on the
side surface of the concrete slab. The modular concrete deck
platform further includes an integrated attachment assembly within
the shear connector opening on the side of the concrete slab. The
integrated attachment assembly includes a shear connector rebar
including an extension of continuous reinforcing bar extending out
of the shear connector opening and back into the shear connector
opening. The shear connector rebar and the shear connector opening
form a closed loop.
[0005] Embodiments of a steel framed building are disclosed. In an
embodiment, a steel framed building includes a structural frame
defining a footprint of the steel framed building, the structural
frame including vertical columns and horizontal beams and girders.
The horizontal beams and girders define bays within the steel
framed building. The steel framed building further includes modular
concrete deck platforms attached to the structural frame. The
modular concrete deck platforms include a concrete slab having a
top major surface and a bottom major surface and a structural grid
pattern of reinforcing bar within the concrete slab. The concrete
slab further includes a shear connector opening on a side surface
of a side of the concrete slab. There may be at least one shear
connector opening on all sides of the concrete slab. The shear
connector opening is a recess on the side surface of the concrete
slab. The modular concrete deck platforms further include an
integrated attachment assembly within the shear connector opening
on the side of the concrete slab. The integrated attachment
assembly includes a shear connector rebar including an extension of
continuous reinforcing bar extending out of the shear connector
opening and back into the shear connector opening. The shear
connector rebar and the shear connector opening form a closed
loop.
[0006] Embodiments of a method for constructing a floor in a steel
framed building are disclosed. In an embodiment, the method
includes placing a modular concrete deck platform on horizontal
beams and girders of a steel framed building, the modular concrete
deck platform having a perimeter shape that corresponds to
dimensions of a bay of the steel framed building. The beams and
girders outline the perimeter of the bay. The placing the modular
concrete deck platform includes placing the perimeter edges of a
bottom surface of the modular concrete deck platform on a portion
of a top surface of the beams and girders. Shear connector openings
located on the sides of the modular concrete deck expose a portion
of the top surface. The shear connector openings are recesses on
side surfaces of the modular concrete deck platform. A shear
connector rebar extends out of each shear connector opening. The
shear connector rebar includes an extension of reinforcing bar
extending out of each shear connector opening and back into each
shear connector opening and the shear connector openings forms a
closed loop. the method further includes attaching shear
connections to the horizontal beams and girders of the steel framed
building in the exposed portion of the top surface and within the
closed loop.
[0007] Other aspects and advantages of embodiments of the present
invention will become apparent from the following detailed
description, taken in conjunction with the accompanying drawings,
illustrated by way of example of the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 depicts a perspective view of one embodiment of a
structural frame of a framed building.
[0009] FIG. 2A depicts a plan view of an embodiment of a steel
frame of a steel framed building.
[0010] FIG. 2B highlights a mid-bay in the embodiment of the steel
frame of FIG. 2B.
[0011] FIG. 2C highlights two end-bays in the embodiment of the
steel frame of FIG. 2A.
[0012] FIG. 3 depicts an embodiment of three modular concrete deck
platforms side by side.
[0013] FIG. 4 depicts an embodiment of an arrangement of modular
concrete deck platforms in a floor plan.
[0014] FIG. 5A depicts an embodiment of a structural grid pattern
of reinforcing bar.
[0015] FIG. 5B depicts a cut-away view of an embodiment of a
concrete slab including a structural grid pattern of reinforcing
bar within the concrete slab.
[0016] FIG. 6 depicts an embodiment of an integrated attachment
assembly within a shear connector opening of a modular concrete
deck platform.
[0017] FIG. 7 depicts a perspective view of an embodiment of
modular concrete deck platforms placed on the structural frame of a
building.
[0018] FIG. 8 depicts a closer view of the integrated attachment
assembly of FIG. 7.
[0019] FIG. 9 depicts a plan view of an embodiment of shear
connections and the integrated attachment assembly of a modular
concrete deck platform.
[0020] FIG. 10 depicts a cut-away view of an embodiment of a
modular concrete deck platform placed on a beam of a building.
[0021] FIG. 11A depicts an embodiment of an integrated attachment
assembly of a concrete deck platform.
[0022] FIG. 11B depicts another embodiment of an integrated
attachment assembly of a concrete deck platform.
[0023] FIG. 11C depicts another embodiment of an integrated
attachment assembly of a concrete deck platform.
[0024] FIG. 12 depicts a perspective view of a modular concrete
deck platform with attachment elements in a grid pattern at the
surface of the concrete deck.
[0025] Throughout the description, similar reference numbers may be
used to identify similar elements. Additionally, in some cases,
reference numbers are not repeated in each figure in order to
preserve the clarity and avoid cluttering of the figures.
DETAILED DESCRIPTION
[0026] It will be readily understood that the components of the
embodiments as generally described herein and illustrated in the
appended figures could be arranged and designed in a wide variety
of different configurations. Thus, the following more detailed
description of various embodiments, as represented in the figures,
is not intended to limit the scope of the present disclosure, but
is merely representative of various embodiments. While the various
aspects of the embodiments are presented in drawings, the drawings
are not necessarily drawn to scale unless specifically indicated.
In addition, the drawing shapes are illustrative only unless
specifically indicated.
[0027] The described embodiments are to be considered in all
respects only as illustrative and not restrictive. The scope of the
invention is, therefore, indicated by the appended claims rather
than by this detailed description. All changes which come within
the meaning and range of equivalency of the claims are to be
embraced within their scope.
[0028] Reference throughout this specification to features,
advantages, or similar language does not imply that all of the
features and advantages that may be realized with the present
invention should be or are in any single embodiment. Rather,
language referring to the features and advantages is understood to
mean that a specific feature, advantage, or characteristic
described in connection with an embodiment is included in at least
one embodiment. Thus, discussions of the features and advantages,
and similar language, throughout this specification may, but do not
necessarily, refer to the same embodiment.
[0029] Furthermore, the described features, advantages, and
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. One skilled in the relevant art
will recognize, in light of the description herein, that the
invention can be practiced without one or more of the specific
features or advantages of a particular embodiment. In other
instances, additional features and advantages may be recognized in
certain embodiments that may not be present in all embodiments of
the invention.
[0030] Reference throughout this specification to "one embodiment,"
"an embodiment," or similar language means that a particular
feature, structure, or characteristic described in connection with
the indicated embodiment is included in at least one embodiment.
Thus, the phrases "in one embodiment," "in an embodiment," and
similar language throughout this specification may, but do not
necessarily, all refer to the same embodiment.
[0031] While many embodiments are described herein, at least some
of the described embodiments allow for fabrication of modular
concrete deck platforms at a central facility before being
transported to a building site for placement on a steel frame of a
building. The modular concrete deck platforms may be fabricated in
a facility allowing for more optimal control of the curing of the
concrete to better meet building requirements. The modular concrete
deck platforms may be fabricated to the standard size of bays of a
steel frame building. The modular concrete deck platforms have an
integrated attachment assembly located within recesses on the side
of the modular concrete deck platforms. The platforms may be placed
on the steel frame with the recesses exposing the integrated
attachment assemblies and the beam on which the platforms are
placed. Shear connections may then be attached to the beams and can
interface with the integrated attachment assemblies. The recesses
and any gaps between the platforms may then be filled with a grout
material to create a seamless floor for the building.
[0032] Some embodiments allow for better quality control as
platforms may be fabricated at a central site. Greater quality
control allows for potential reduced overall weight of the
platforms without sacrificing design requirements. Some embodiments
allow for rapid connection of platforms to a steel frame. The crew
would not need to wait for concrete floors to set before proceeding
to fabricate the next floor. Buildings utilizing embodiments
described herein may be erected significantly faster as platforms
will have already been fabricated.
[0033] Some embodiments allow for savings in fireproofing material
and time. Embodiments allow for reduction of fire proofing material
(as well as the labor time to apply it) during the fireproofing of
a steel frame building. Fireproofing material is sprayed on metal
decks to meet building codes. Some building codes require
fireproofing to be over-sprayed by at least 12'' when conductive
material touches a structural steel frame. The use of concrete
decks may eliminate or reduce costly fireproofing material.
[0034] FIG. 1 depicts a plan view of one embodiment of a structural
frame 100 of a framed building. The structural frame 100 may
include columns 102--which are generally vertical to the surface on
which the building sits--and girders 104 and other support beams
106, which are generally horizontal to the surface on which the
building sits. Structural frames 100 and framed buildings are well
known in the field.
[0035] In one embodiment, the structural frames 100 are steel
frames. In one embodiment, the columns 102 are "I" shaped steel
beams, referred to as "I-beams". In general, the I-beams may be
spaced apart in a grid structure to create varying sizes of
buildings. The structural frames 100 may be any type, shape, or
material used for framing the framed building. The material for the
framed building may include a composite of more than one
material.
[0036] The spacing of the girders 104 may be determined by the
spacing of the columns 102. The spacing of the beams 106 may be
more flexible than the spacing of the girders 104. The beams 106
may be located between pairs of columns 102, and additional beams
106 may be located between columns 102.
[0037] FIG. 2A depicts a plan view of an embodiment of a steel
frame 200 of a steel framed building. The steel frame includes
support columns 102, which are generally vertical to the surface on
which the building sits, and girders 104 and beams 106, which are
generally horizontal to the surface on which the building sits.
[0038] In the embodiment of FIG. 2A, the columns 102 are "I" shaped
steel beams, referred to as "I-beams." In general, the I-beams are
spaced apart in a grid structure that includes an X-span dimension
and a Y-span dimension. For example, X and Y spans in the range of
10-70 feet are known and X and Y spans in the range of 20-40 feet
are common. Additionally, other dimensions are possible. Although
I-beams are described as one type of steel column, other types
and/or shapes of steel columns are possible. Further, the columns
may be made out of other materials and/or a composite of steel and
at least one other material.
[0039] In the embodiment of FIG. 2A, the girders 104 and beams 106
are "I" shaped steel beams, sometimes referred to as "W sections."
Typically, the girders connect to the columns in one direction and
the beams connect between the girders and the columns 102 in a
direction that is perpendicular to the girders. Although the
girders and beams have been described as I-beams, in alternative
embodiments, the girders and beams may include, for example,
rectangular tubes, tees, angled shaped pieces, and zee shaped
pieces.
[0040] The spacing of the girders 104 is dictated by the spacing of
the columns 102. The spacing of the beams 106 is more flexible. In
an embodiment, beams 106 are located between pairs of columns 102
and additional beams 106 are located between columns 102. In an
embodiment, beams are spaced apart by about 10 feet, although other
spacing is possible. As will be described below, the spacing of the
columns, girders, and beams forms "bays," where a bay is generally
defined as the area bordered by a pair of parallel girders and a
pair of parallel beams. The dimensions of the bays may be the same
from bay-to-bay or may vary depending on the building. In an
embodiment, some of the bays in a building have similar dimensions
while other bays of the building have dimensions that are
customized to correspond to specific features of the building. As
is described below, the deck assembly modules are sized such that a
deck assembly module fills a bay. The shape of a bay may vary
depending on whether the bay is a mid-bay or an end-bay, where a
mid-bay is bordered by girders and beams but does not include any
column connection points and an end-bay includes at least one
column connection point. FIG. 2B highlights a mid-bay 204a in the
steel frame 200 of FIG. 2A. As shown in FIG. 2B, the mid-bay 204a
does not have any sides or corners that are formed by a column 102.
FIG. 2C highlights two end-bays 204b in the steel frame 200 of FIG.
2A. As shown in FIG. 2C, the two end-bays 204b have two corners of
the bays 204b that are at least partially formed by a column 102.
The existence of the columns 102 at the corners of the bays 204b
changes the shape of the end-bays 204b. In an embodiment, deck
assembly modules that are intended for end-bays 204b are configured
to cope around the columns 102 of the steel frame 200.
Additionally, the shape of the deck assembly modules will depend on
which side of the deck assembly module abuts to the columns 102. In
some embodiments, a steel framed building may not include a column
at four points of a bay as depicted in FIGS. 2A-2C. For example, a
steel framed building may not include a column 102 at a perimeter
location of the steel framed building or at a cantilevered floor.
In these cases, it is possible to have a deck assembly module that
has coping to accommodate only one column 102. Additionally, it is
possible to have a deck assembly module that has coping to
accommodate more than two columns 102 or features other than
columns 102.
[0041] In an embodiment, each deck assembly module is configured to
have a shape that corresponds to the shape of the bays 204 that are
formed by the steel frame 200. For example, deck assembly modules
intended for the mid-bays 204a are shaped to correspond to the
shape of the mid-bays 204a and deck assembly modules intended for
the end-bays 204b are shaped to correspond to the shape of the
end-bays 204b. Additionally, deck assembly modules that are
intended for end-bays 204b are shaped to correspond to the
particular location of the columns 102. For example, the two
corners of a deck assembly module that will abut to a column 102
are dependent on the location of the deck assembly module relative
to the columns 102. With reference to FIG. 2cC, the upper end-bay
needs a deck assembly module that has coped corners at the upper
right and upper left corners and the lower end-bay needs a deck
assembly module that has coped corners at the lower right and lower
left corners. The size and shape of the deck assembly module can be
set to correspond to various different sizes and configurations of
steel frames. For example, the deck assembly modules can be
designed to accommodate any size and configuration of girders 104
and/or beams 106. In an embodiment, the deck assembly module is
configured to cooperate with any of the structural configurations
commonly used, such as circular or rectangular tubes, channels,
angles, tees, and/or zee shaped pieces.
[0042] In an embodiment, the exact size and shape of the deck
assembly module may be governed in part by at least one of the
following parameters: structural performance requirements of the
steel frame 200; structural requirements per regulatory
requirements or design codes; the framing geometry of the steel
frame 200; transportation requirements of the jurisdictions in
which the deck assembly module is transported on public roads; and
vehicle availability for transport. In an embodiment, the deck
assembly module is designed with a 10'-0'' maximum width dimension
and a fifty foot maximum length dimension so that the deck assembly
module can be transported as one piece on public roads using
conventional transportation means. In another embodiment, the deck
assembly module is designed with a 15'-0'' maximum width dimension
and a fifty foot maximum length dimension, although it should be
understood that other dimensions are possible.
[0043] Other building design requirements may affect the size and
shape of deck assembly modules, as well as the materials used.
Appropriately sized reinforcing bar (or rebar) and other materials
and additives may be dictated by the specific use of a building.
The deck assembly modules may be designed for a range of vertical
gravity loads, to deflect no more than required under dead and live
loading values, to limit cracking to structurally acceptable
values, to achieve an appropriate fire rating, and to appropriately
cover various shaped bays in a framed building. The deck assembly
modules may be designed such that they can be tiled or patterned in
any configuration over the plan of a building with only shear
connection openings (which is described in more detail below). The
shear force in deck assembly modules may be influenced by many
factors, including but not limited to, seismic design category,
soil category, the lateral system, building height, and building
weight.
[0044] While the majority of steel framed buildings use orthogonal
geometry for framing, the deck assembly modules may be fabricated
to other polygonal and/or curvilinear shapes to correspond to the
structural framing of a building.
[0045] FIG. 3 depicts an embodiment of three modular concrete deck
platforms 202a and 202b side by side. In the illustrated
embodiment, the three modular concrete deck platforms 202a-202b
would correspond to bays 204a-204b. The center modular concrete
deck platform 304a corresponds to bay 204a, and the modular
concrete deck platforms 202b correspond to bay 204b. As
illustrated, the two end modular concrete deck platforms 202b are
shaped to correspond to the particular location of columns 102 of a
building. For example, the two corners of the modular concrete deck
platforms 202b that will abut to a column 102 are shaped to allow
placement of the modular concrete deck platforms 202b next to a
column 102. The shape may vary to correspond directly to any shaped
column that may be present in a building. In some embodiments, the
modular concrete deck platforms 202 will be shaped principally like
the shape of bays 204. In the illustrated embodiment, the shape of
the modular concrete deck platforms 202 is principally rectangular.
The end modular concrete deck platforms 202b have corner notches
that correspond to the placement of the modular concrete deck
platforms 202b in relation to columns 102. The center modular
concrete deck platform 202a does not have corner notches. The
location of such polygonal and/or curvilinear notches is dependent
on the location of the modular concrete deck platform 202 relative
to the columns 102. The location may be along a side of a modular
concrete deck platform 202 instead of a corner of the modular
concrete deck platform 202.
[0046] The illustrated embodiment further depicts shear connector
openings 302 on the side surface of sides of the modular concrete
deck platforms 202. The modular concrete deck platforms 202 are
formed into a concrete slab. Within the concrete slab is
reinforcing bar (not shown). The shear connector openings 302 occur
on the sides of the concrete slabs. In the illustrated embodiment,
each modular concrete deck platform 202 has three shear connector
openings 302 on the long sides of the modular concrete deck
platform 202 and one shear connector opening 302 on the short sides
of the modular concrete deck platform 202. Theses shear connector
openings 302 may house an integrated attachment assembly to allow
for stabilizing of the modular concrete deck platforms 202 to the
beams 106 and girders 104 of a building frame. In some embodiments,
the shear connector openings 302 may be spaced evenly in
standardized increments along the side of a modular concrete deck
platform 202. In some embodiments, the shear connector openings 302
may be staggered in uneven increments. Some embodiments may have
more or less shear connector openings 302 than are illustrated in
FIG. 3. For example, in some embodiments, there may be only one
shear connector opening 302 on each principal side of a modular
concrete deck platform 202. In other embodiments, each principal
side may have more than one shear connector opening 302. The number
and location of shear connector openings 302 may vary depending on
the design requirements of a particular building or other
considerations. In some embodiments, each shear connector opening
302 will interface with shear connections (described more fully
below). Each shear connector opening 302 many interface with as few
as one shear connection or as many as necessary to transfer the
forces from the platform 202 to the structural frame.
[0047] The shear connector openings 302 are notches or recesses on
the side of the concrete slab. The sides of the concrete slab are
fabricated to match the geometry of bays 204 of a building. The
shear connector openings 302 are recesses within the matching
geometry that allow for access to a beam 106 or girder 104 after
setting a modular concrete deck platform 202 in place. The
illustrated embodiment of FIG. 3 shows the modular concrete deck
platforms 202 as they would be placed next to each other on the
beams 106 and girders 104. As shown, even when the modular concrete
deck platforms 202 are placed, the shear connector openings 302
allow for stabilization of the modular concrete deck platform 202
to the beams 106 and girders 104 of the building. Shear connector
openings 302 may be of any shape, size, or geometry. In the
illustrated embodiment, the shear connector opening 302 is a
rectangular geometrical recess. In the illustrated embodiment, the
shear connector opening 302 extends from a top major surface of the
concrete slab to a bottom major surface (not visible) of the
concrete slab.
[0048] FIG. 4 depicts an embodiment of an arrangement of modular
concrete deck platforms 202 in a floor plan. In the illustrated
embodiment, the modular concrete deck platforms 202 may be arranged
in any configuration or floor plan. The modular concrete deck
platforms 202 may be arranged in various configurations. In the
illustrated embodiment, the configuration of modular concrete deck
platforms 202 may be arranged and placed while leaving a void 206.
A void 206 may be necessary for an elevator shaft or other
particular building function. The modular concrete deck platforms
202 may be fabricated offsite, transported to the building site,
and assembled on the beams and girders of a building. The shear
connector openings 302 still allow access to the beams and girders.
While the illustrated modular concrete deck platforms 202 are all
principally rectangular, they may be fabricated in any shape
possible for a concrete deck. For example, the shape may be any
polygonal and/or curvilinear shape.
[0049] FIG. 5A depicts an embodiment of a structural grid pattern
of reinforcing bar 502. The reinforcing bar 502 may be placed in
various patterns to best strengthen and reinforce the concrete
slab. FIG. 5B depicts a cut-away view of an embodiment of a
concrete slab 504 including a structural grid pattern of
reinforcing bar 502a-502b within the concrete slab 504. The
concrete slab 504 is formed around the reinforcing bar 502a-502b.
The illustrated embodiment depicts a lower grid 502a and an upper
grid 502b. Any configuration of reinforcing bar 502 is possible
depending on the size and thickness of the concrete slab 504. The
concrete slab 504 shows a top major surface 506 while the bottom
major surface 510 is not visible.
[0050] FIG. 6 depicts a close-up view of an embodiment of an
integrated attachment assembly within a shear connector opening 302
of a modular concrete deck platform 202. In the illustrated
embodiment, the shear connector opening 302 is similar to the
embodiments show in FIGS. 3 and 4. The shear connector opening 302
is a recess extending from a top major surface 506 to a bottom
major surface of the concrete deck. The geometry of the illustrated
shear connector opening 302 is rectangular as viewed from above the
top major surface 506. The geometry of the shear connector opening
302 is the shape created by the surfaces of the recess and bounded
by the plane of the side surface 508, that is, where the side
surface 508 of the modular concrete deck platform would be if there
was no recess. In some embodiments, the integrated attachment
assembly is fully within the geometry of the shear connector
opening 302. In the illustrated embodiment, the integrated
attachment assembly protrudes from the shear connector opening 302
no further than the side surface 508. This allows for modular
concrete deck platforms to be placed side by side without any
interference. The modular concrete deck platforms can be fabricated
to appropriate size and specifications offsite and transported to
the building site and placed on the beams and girders. As the
integrated attachment assembly does not extend beyond the side
surface of the modular concrete deck platform, the modular concrete
deck platforms may be placed side by side creating an appropriate
floor plan.
[0051] The integrated attachment assembly includes a shear
connector rebar 602. The shear connector rebar 602 is an extension
of continuous reinforcing bar extending out of the surface of the
shear connector opening 302 and back into the surface of the shear
connector opening 302. The concrete slab 504 is formed around the
reinforcing bar but exposes a portion or extension of continuous
reinforcing bar within the shear connector opening 302. The
extension of continuous reinforcing bar and the surface of the
shear connector opening form a closed loop. The closed loop formed
by the shear connector rebar and shear connector opening surface
interfaces with shear connections that are described more fully
below. The shear connections are attached to the beams and girders
of a building.
[0052] FIG. 7 depicts a perspective view of an embodiment of
modular concrete deck platforms 202 as placed on the structural
frame of a building. In the illustrated embodiment, the modular
concrete deck platforms are placed to cover the bays of a building.
The edges of the bottom major surface of the concrete slab rest on
the horizontal I-beam or beam 106. The shear connector openings 302
allow access to the beams or girders even when modular concrete
deck platforms are placed side by side. In an embodiment, shear
connections 604 interface within the closed loop of the integrated
attachment assembly and the shear connections are fastened or
attached to the beams and girders. After the shear connections 604
are attached to the beams and/or girders, the shear connections 604
will restrict major shear movement between the top surface of the
beams and girders and the bottom surface of the modular concrete
deck platform. The shear connections 604 may abut the shear
connector rebar 602 or may interface within the loop created by the
shear connector rebar 602 and the surface of the shear connector
opening 302 to allow minimal shear movement that may occur during
normal expansion and contraction, earthquakes, or other movement
events.
[0053] FIG. 8 depicts a closer view of an integrated attachment
assembly of FIG. 7. The illustrated embodiment depicts the
integrated attachment assembly within the concrete slab and
extending out of the concrete slab. The rebar forms a loop with
dashed lines showing the portion of the rebar formed within the
concrete slab and showing the portion of the reinforcing bar
extending out of the surface of the shear connector opening and
back into the surface of the shear connector opening. The
illustrated embodiment shows the bottom surface of the platform
resting on the top surface of the beam 106. Also depicted are the
shear connections 604 as they are placed to interface within the
closed loop created by the extension of reinforcing bar 602. In the
illustrated embodiment, the shear connections 604 abut the
reinforcing bar 602. In other embodiments, the shear connections
604 are not in contact with the reinforcing bar 602. The shear
connections 604 are then attached or fastened to the beam 106 in
some fashion.
[0054] In an embodiment, an integrated attachment assembly is
integrated into each side of each modular concrete deck platform
202, at appropriate points to resist shear forces. In an
embodiment, the shear connector openings 302 are of a sufficient
size to allow the use of this system with any beams with a flange
width of 6'' or greater. In some embodiments, the shear connector
openings 302 of adjacent modular concrete deck platforms 302 align.
In some embodiments, shear connector openings 302 of adjacent
modular concrete deck platforms 302 do not align. The integrated
attachment assembly is designed for the appropriate loads to
transfer forces to the beams. In an embodiment, the shear connector
rebar 602 focuses the horizontal shear force transfer in the deck
platform 202 to the beam 106 below, as compared to conventional
means where the transfer is distributed through the length of the
beam 106. Such embodiments allow the deck platform 202 to be
manufactured off site and connected to the beam 106 on site because
of the efficient use of integrated attachment assemblies. In an
embodiment, each connection capacity is based on the minimum design
requirement and translated into the specific number and capacity of
the shear connections 604, the factored shear capacity of the
concrete and the top layer of horizontal reinforcement, and the
factored shear capacity of the stirrup legs crossing the interface
between the pre-cast slab and post-installed grout.
[0055] FIG. 9 depicts a plan view of an embodiment of shear
connections 604 and the integrated attachment assembly of a modular
concrete deck platform 202. The plan view depicts a structural grid
pattern of reinforcing bar 502 within the concrete slab. The
reinforcing bar 502 may be spaced appropriately to adequately
reinforce the concrete slab. The plan view also depicts the
integrated attachment assembly and extension of reinforcing bar
602. The concrete slab is formed around a portion of the
reinforcing bar 602 making the reinforcing bar integral to the
concrete slab. A portion of the reinforcing bar extends out of the
concrete slab within the shear connector opening 302. The portion
of the reinforcing bar 602 exposed within the shear connector
opening 302 and a side surface of the shear connector opening form
a closed loop. Within this closed loop, shear connections 604 may
be placed after placing the modular concrete deck platform on the
beams. In some embodiments, the shear connections 604 are pins that
are inserted into the closed loop of the integrated attachment
assembly which are then welded to the beams 106. In some
embodiments, the shear connections 604 are placed before placing
the modular concrete deck platform. In some embodiments, the shear
connections 604 are protrusions on the beams 106 and girders 104
themselves. In the illustrated embodiment, the shear connections
604 do not abut the extension of reinforcing bar 602. In the
illustrated embodiment, the shear connector opening 302 is a
rectangular geometry and the reinforcing bar 602 and integrated
attachment assembly protrude from the concrete slab within the
geometry of the shear connector opening 302. In some embodiments,
the outer edge of the reinforcing bar 602 extends to the plane
created by the side surface of the side of the modular concrete
deck platform 202.
[0056] In the illustrated embodiment, the integrated attachment
assembly is a loop of rebar 602. In some embodiments, the rebar 602
interfaces within the structural grid of reinforcing bar 502. For
example, the rebar 602 may form a loop around the reinforcing bar
502. In some embodiments, the rebar 602 is separate from the
structural grid pattern of reinforcing bar 502. In some
embodiments, the rebar 602 is integrated into or connected to the
structural grid pattern of reinforcing bar 502. For example, the
structural grid pattern of reinforcing bar 502 may have a portion
of the grid exposed within the geometry of the shear connector
opening. This exposed portion may be the shear connector rebar that
interfaces with the shear connections 604.
[0057] The illustrated embodiments of FIGS. 7-9 depict three pins
or shear connections 604. In some embodiments, the number of shear
connections 604 may be more or less than what is depicted.
Embodiments may include the use of one or more shear connections
604. Some embodiments may include the use of as few as one shear
connection 604. Some embodiments may include as many shear
connections 604 as are necessary to transfer forces from the
platform 202 to the structural frame.
[0058] FIG. 10 depicts a cutaway view of an embodiment of a modular
concrete deck platform placed on a beam of a building. The
illustrated embodiment depicts a side cutaway of the structural
grid of reinforcing bar 502 and a side cutaway view of the
reinforcing bar 602 of the integrated attachment assembly. As
illustrated, an extension of continuous reinforcing bar 602
protrudes from the concrete deck 504 within the geometry of the
shear connector opening 302 and does not extend beyond the side
surface of the modular concrete deck platform. The edge of the
bottom surface of the modular concrete deck platform rests on the
top surface of the I-beam 106. In the illustrated embodiment, the
modular concrete deck platform is placed on less than half of the
top surface of the beam 106. This allows for the other half of the
top surface of the beam 106 to support an adjacent modular concrete
deck platform 202. Any gap between adjacent modular concrete deck
platforms 202 may be filled with a grout. In some embodiments, the
modular concrete deck platforms 202 may be placed flush to adjacent
modular concrete deck platforms 202.
[0059] After the modular concrete deck platform 502 is placed on
the beam 106, and the shear connections 604 are attached to the
beam 106, the shear connector openings 302 and any gap between
adjacent modular concrete deck platforms 202 may be filled with
grout. Grout may be any material or substance that fills in the
space within the shear connector openings 302. In some embodiments,
the grout may be a concrete similar to the concrete of the concrete
slab of the modular concrete deck platform 202. In some
embodiments, the grout will be of strength equal to or greater than
the strength of the concrete slab itself. In an embodiment, such
grouting at the shear connection and between the platform pieces
will complete the fire-rating requirement of the floor slab through
the platform pieces and create a composite assembly for the
structure.
[0060] FIGS. 11A-11C depict top views of embodiments of integrated
attachment assemblies and geometries of shear connector openings
302. The geometry of the shear connector openings 302 may be a
recess of any polygonal and/or curvilinear shape. FIGS. 11A and 11B
depict a rectangular geometry of the shear connector openings 302
similar to previous figures described herein. FIG. 11C depicts a
recess in a triangular geometry. In addition, the extension of
continuous reinforcing bar 602 may extend out of the back surface
of the shear connector opening 302 as depicted in FIG. 11A. In some
embodiments, the extension of continuous reinforcing bar 602 may
extend out of the side surfaces of the shear connector opening 302
as depicted in FIG. 11B. In the embodiment of FIG. 11B, the shear
connector rebar 602 and three surfaces of the shear connector
opening still form a closed loop. In addition, the portion (shown
in dashed lines) of the integrated attachment assembly within the
concrete slab may vary. For example, the portion of reinforcing bar
602 within the concrete slab of FIG. 11A forms a loop within the
concrete slab. The portion of reinforcing bar 602 within the
concrete slab of FIG. 11B extends in different directions. The
portion of reinforcing bar 602 within the concrete slab of FIG. 11C
forms a semi-circle.
[0061] FIG. 12 depicts a perspective view of a modular concrete
deck platform with attachment elements 702 in a grid pattern at the
surface of the concrete deck. A mechanical fastening framework may
be provided on the surface of a modular concrete deck platform
surface. A grid pattern of mechanical attachment elements 702
allows for the attachment of anchorages to a platform 202. The
locations of the attachment elements 702 may be predefined in a
grid like pattern independent of the building to which platform 202
is attached. The attachment elements 702 could be on the top major
surface and/or bottom major surface of the platform 202. The
patterned attachment elements 702 have significant value in the
constructing of buildings as it removes the need to drill into the
platform for anchorage points after placement of the platform. The
patterned attachment elements 702 also have significant value in
the lifecycle of a building as it greatly reduces the need to drill
into the platform for anchorage points in an already occupied
building.
[0062] In the above description, specific details of various
embodiments are provided. However, some embodiments may be
practiced with less than all of these specific details. In other
instances, certain methods, procedures, components, structures,
and/or functions are described in no more detail than to enable the
various embodiments of the invention, for the sake of brevity and
clarity.
[0063] Although specific embodiments of the invention have been
described and illustrated, the invention is not to be limited to
the specific forms or arrangements of parts so described and
illustrated. The scope of the invention is to be defined by the
claims appended hereto and their equivalents.
* * * * *