US3918230A - Building deck construction - Google Patents

Building deck construction Download PDF

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Publication number
US3918230A
US3918230A US515892A US51589274A US3918230A US 3918230 A US3918230 A US 3918230A US 515892 A US515892 A US 515892A US 51589274 A US51589274 A US 51589274A US 3918230 A US3918230 A US 3918230A
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US
United States
Prior art keywords
formboard
deck structure
poured
building deck
sheet metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US515892A
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English (en)
Inventor
Frank E Carroll
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Decks Inc
Original Assignee
Decks Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Decks Inc filed Critical Decks Inc
Priority to US515892A priority Critical patent/US3918230A/en
Priority to CA235,255A priority patent/CA1051682A/fr
Priority to GB40455/75A priority patent/GB1495798A/en
Priority to US05/630,504 priority patent/US4006731A/en
Application granted granted Critical
Publication of US3918230A publication Critical patent/US3918230A/en
Assigned to CARROLL, FRANK E. reassignment CARROLL, FRANK E. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: CARROLL RESEARCH, INC.
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D11/00—Roof covering, as far as not restricted to features covered by only one of groups E04D1/00 - E04D9/00; Roof covering in ways not provided for by groups E04D1/00 - E04D9/00, e.g. built-up roofs, elevated load-supporting roof coverings
    • E04D11/02—Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition

Definitions

  • the deck construction of this invention utilizes subpurlins formed from sheet metal and clips formed from sheet metal to provide a deck construction system which is extremely versatile.
  • the deck structures of this invention are generally poured gypsum or other pured concrete-like deck systems wherein rigid formboard is laid on the sheet metal structural shape sub-purlin and held in place by the sheet metal clips. The sheet metal clips further provide uplift resistance to the composite structure.
  • the deck construction of this invention also provides for insulated decks of varying insulation capabilities.
  • the utilization of the sheet metal sub-purlins in the deck construction of this invention allows utilization of various spacings of the sub-purlins and various thicknesses and sizes of the formboard.
  • the deck construction of this invention further provides for utilizat tion of both moisture permeable and moisture impermeable formboards.
  • the sheet metal sub-purlin shapes utilized in this invention have previously been used with similar sheet metal clips for holding tongue and groove precast deck planks such as sold under the trademark TECTUM by National Gypsum Company.
  • TECTUM trademark of National Gypsum Company.
  • Conventional poured deck construction utilizes bulb tees or truss tees as subpurlins. Both the bulb tees and truss tees have upstanding portions which govern the spacing due to the projection into the poured gypsum or concrete in an attempt to obtain resistance to uplift.
  • the deck construction of this invention provides a method of construction in which the sub-purlin is flat on top and is totally beneath the deck structure, thus, providing a framework in which the sub-purlins may be placed at any desired spacing to obtain various strength characteristics and the deck structure is placed on top of the flat upper surface of the sub-purlin. Uplift resistance is obtained by the sheet metal clip extending into the poured structure.
  • FIG. 1 is a perspective cutaway view of a deck construction according to one embodiment of this invention
  • FIG. 2 is a sectional view of the deck construction shown in FIG. 1;
  • FIG. 3 is a perspective cutaway view of an insulated roofing structure according to one preferred embodiment of this invention.
  • the sheet metal structural shape utilized in this invention provides excellent structural characteristics while reducing weight and providing a structural shape that can be readily fabricated from sheet metal. To obtain comparable structural strength characteristics the sheet metal shape used in this invention is about 40 percent lighter than the bulb tee section required. It is highly desirable to fabricate structural shapes from sheet metal to minimize energy requirements in production and to conserve steel.
  • Prior attempts to utilize sheet metal shapes in poured deck construction have not been entirely satisfactory. Some prior attempts have utilized sheet metal 1, shapes as substitutes for bulb tees in roof deck construction. Some of these sheet metal .1. shapes while providing sufficient strength in the composite assembled poured roof, do not have satisfactory strength characteristics themselves and in the erection bend over or roll when walked upon by the erectors. This results in very dangerous Working conditions for workers.
  • the sheet metal structural shapes utilized in this invention provide desirable strength characteristics themselves and sufficient strength characteristics to be walked upon during erection without dangerous bending or rolling. Further, the sheet metal sub-purlins utilized in the deck construction of this invention provide a flat upper surface upon which the base material for the deck construction may be laid. All prior sub-purlins known to the inventor utilized in poured deck construction, have extended into the poured structure and thus the spacing of the sub-purlins has been governed by the width of formboard or rigid board material laid between them.
  • the rigid board such as formboard
  • the sub-purlins may be utilized in closer spacing allowing thinner formboards and poured decks to be placed on top of the closer spaced sub-purlin structure.
  • design of deck construction of the poured type has been limited by width of boards available which govern the spacing of the sub-purlins since the boards had to be set between the sub-purlins.
  • the deck construction of this invention allows the use of any width or length board to be placed upon the top surface of any desired spacing of subpurlins Referring to FIG.
  • the sheet metal shape utilized in this invention is shown as box section 20 having a lower horizontal base 21 resting upon purlin structure 30, vertical sides 22 and 23 and upper horizontal flanges 24 and 25.
  • Slot 26 between the terminal ends of flanges 24 and 25 is preferred to be continuous to permit the most flexible use of the sheet metal box section. However, it is understood that slot 26 may be'discontinuous and flanges 24 and 25 joining to enclose the top of the box section where it is not necessary to utilize the sheet metal clips.
  • the sheet metal box sections may be fabricated by well-known roll forming techniques from sheet metal from about gauge to about 14 gauge. It is preferred to use galvanized, commercial grade steel of 16 and 18 gauge.
  • the depth of the box section to be used as a subpurlin may be about 2 inches to about 3 inches, preferably about 2% inches to about 2 /2 inches.
  • the width of the box section may be about 1 /2 inch to about 2%. inches, preferably about 1% inch to about 2 inches.
  • the slot for receiving the sheet metal clip may be any width to suit the clip section. Slots about three-eighths inch to about three-fourths inch are suitable, about five-eighths inch being preferred. It should be recognized that the above dimensions are governed only by conventionally desired strength characteristics of described uses as sub-purlins and may be outside the above ranges to obtain out-of-the ordinary requirements.
  • the sheet metal clip is shown as 40 having opposing slots 42 between vertical portion 41 and 43 which engage flanges 24 and 25 of the sheet metal box section so that when the axis of the clip is 90 the axis of the box section, the clip is anchored with the opposing flanges of the top of the box section engaging the slots and vertical portion 41 being within the box section.
  • Vertical portion 43 of the sheet metal clip extends upward from the top of the box section a suitable height to provide, when bent into horizontal portion 44, snug fitting of desired rigid board such as formboard 12 between horizontal portion 44 and the top flanges 24 and 25 of the sheet metal box section.
  • Horizontal portion 44 extends a sufficient distance to provide such snug fitting and then bends to form vertical portion 45 which extends substantially vertically upward for the desired distance to provide a support for reinforcing mesh 14.
  • the sheet metal clip is then provided with substantially horizontal portion 46 which holds the reinforcing mesh 14 and provides for uplift resistance in the poured deck.
  • Clip is readily inserted at any location into slot 26 by simply turning it so that the axis of the clip and the box section are parallel and inserting the clip for the distance so that slot 42 will engage flanges 24 and 25 and then turning the clip so that axis of the clip is approximately 90 to the axis of the sub-purlin.
  • the sheet metal clips may be fabricated by well known stamping and bending techniques from sheet metal from about 20 gauge to about l4 gauge. It is preferred to used galvanized, commercial steel of 16 and 18 gauge.
  • the vertical portion of the clip extending above the box section may be about one-half to abut l /2 inch to accommodate the thickness of various desired formboards.
  • the vertical portion of the clip extending into the sheet metal box section may be any desired length so as to provide adequate stiffness of the clip when the flanges of the box section are engaged in the opposing slots of the clip.
  • Horizontal portion 44 of the clip extends for a suitable distance to adequately hold the formboard in place, about one-half to about l inch being suitable.
  • Vertical portion extends upward for a suitable distance to provide support for reinforcing mesh and to provide suitable height for the poured concrete to firmly engage the clip for uplift resistance about one-half to about 1 inch being suitable.
  • Horizontal portion 46 is of suitable length to provide firm clipping of the poured concrete to provide for uplift resistance about one-half to about 1 /2 inch being suitable.
  • the sheet metal box section subpurlin 20 rests upon structural purlin member 30 and clip 40 secures gypsum formboard against the top of sub-purlin 20.
  • Over formboard 12 is a polymeric foam board 18 having seams at right angles to the seams of formboard 12. It is prefe rred to staple the foam in place to prevent uplift while pouring cement as indicated by staples 51.
  • the foam board may also be adhered to the formboard with any suitable mastic or adhesive. The foam is broken out in the area of each clip 40 so that the poured concrete surrounds the top of the clip to provide uplift resistance.
  • a poured gypsum or lightweight concrete is applied above the foam board with reinforcing mesh 14, gypsum concrete 15 with built-up roofing layers 16 and wear surface 17.
  • This type of gypsum structure may be dried from the top using ventilators shown as 19 and presently available as McKinley Roof Ventilators. This structure provides a primarily top drying system allowing the use of moisture impervious formboards.
  • the synthetic organic polymer foam may be any substantially rigid organic polymer foam having good insulating properties and preferably a high temperature at which thermal decomposition occurs.
  • Suitable foams include polystyrene, styrene-maleic anhydride, phenolic, such as phenol formaldehyde, polyurethane, vinyl, such as polyvinyl chloride and copolymers of polyvinyl chloride and polyvinyl acetate, epoxy, polyethylene, urea formaldehyde, acrylic, polisocyanurate and the like.
  • Preferred foams are selected from the goup consisting of polystyrene and polyurethane.
  • Particularly suitable foams are closed cell foams which provide high insulating properties and low internal permeability to moisture.
  • Such organic polymer foams are substantially rigid bodies of foam and are well known for their low density and outstanding thermal insulating properties.
  • the foam is preferably in board form and may be utilized in sheets of any workable size. It is preferred to have the foam board at right angles to the formboard to minimize seam exposure. Any thickness providing desired insulation is suitable, about 1 inch to about 6 inches being preferred and about 1 inch to about 3 inches being especially preferred.
  • the gypsum formboard-foam structure as disclosed in my pending application Ser. No. 457,996 may advantageously be used in the roof structure of this invention, permitting complete flexibility with respect to sub-purlin spacing.
  • the gypsum formboardfoam construction disclosed in my pending application Ser. No. 410,874 may be utilized in a similar fashion without the need for ventilator 19 since the roof structure disclosed in my pending application Ser. No. 410,874 provides for drying of the gypsum concrete through the bottom of the roof.
  • the deck con struction of this invention eliminates the need for grouting as shown in my above identified co-pending applications and provides for full, continuous insulation.
  • Any moisture permeable or moisture impervious formboard of a wide variety of sizes may be used in the deck construction of this invention.
  • the structure of this invention allows the use of less expensive water impervious formboard such as felted rock wool materials (such as FESCO board sold by Johns Manfille Com.- pany).
  • Any gypsum formboard, moisture permeable or moisture impermeable, fiberglas or other conventional formboard material is suitable.
  • Formboard thickness of about one-fourth inch to about 2 inches are suitable, about three-eighths inch to about three-fourths inch being preferred.
  • the sub-purlin system with formboard at right angles to the sub-purlines prevents formboard fall-out and undesired deflection experienced with bulb tee and truss tee systems now used.
  • Any gypsum formboard providing a two'hour fire rating when used with poured gypsum slabs is especially suitable.
  • the least expensive of the gypsum formboards, the rigid one-half inch thick gypsum formboard is suitable for use in the roof structure of this invention, however, various surfaced gypsum formboards having suitable ceiling surfaces may be utilized as long as the incombustibility and flame spread ratings are satisfactory.
  • This invention provides a deck structure in which gypsum formboard may be used as the lower surface.
  • the gypsum formboard buckled when wet due to the long drying time of lightweight concrete.
  • the sub-purlins may be spaced about 12 to about 36 inches providing a superior base for the gypsum formboard and prevention of such previous buckling.
  • the poured structure shown as 15 in FIGS. 1 and 2 and satisfactorily be lightweight concrete.
  • the gypsum concrete utilized may be preferably standard gypsum concrete. However, modified concretes containing various fillers, such as perlite, aggregate for thermal insulation and lighter weight are suit able, or exploded mica in portland cement is suitable, but not necessary in the roof structure of this invention.
  • the gypsum concrete is especially desirable for use in roof structures not only because it is incombustible but also because the gypsum sets within a few minutes to form a slab that is hard enough to walk upon thereby permitting, in many cases, a waterproof wearing surface to be laid the same day the slab is poured.
  • the thickness of the poured concrete may be about 1 inch to about 4 inches.
  • FIG. 1 a built up roofing membrane comprising alternate layers of roofing felt and hot asphalt is shown as 16 with waterproof wearing surface 17 of tar and gravel.
  • Any suitable waterproof wearing surface for flat type roofs is suitable for the roof structure of this invention, or the gypsum concrete may be Waterproofed with plastic membrane, such as on dome type roof structures.
  • the concrete top surface may be left exposed.
  • Any suitable ceiling structure may be installed beneath the deck structure of this invention as long as suitable ventilation is furnished.- However, in contrast to prior roof structures,- it isnot necessary that the ceiling provide the insulation or fireproofing qualities.
  • the roof structure ofthis invention provides high insulation and fireproof properties without any structure beneath it and may be left exposed.
  • a poured building deck structure comprising the combination:
  • sub-purlins of sheet metal structural shapes of a box section having a horizontal base, opposing vertical sides and upper horizontal flanges extending inwardly from the top of said sides forming an open slot between the terminus of said flanges, saud subpurlins at right angles to and said base resting on top of said purlins; formboard adjacent to and secured against the top of said upper horizontal flanges of said subpurlins;
  • sheet metal clips having a vertical portion extending upwardly and downwardly from opposing slots, each of said opposing slots engaging one of said horizontal flanges of said box section when the axis of said clip and box section are at about to each other, said upwardly extending vertical portion bending to a horizontal portion to engage the top of said formboard securing it against the top of said flanges, then bending to a substantially vertical upward portion and then bending to a substantially horizontal portion to provide uplift resistance when surrounded by concrete;
  • the building deck structure of claim 1 wherein said formboard is selected from the group consisting of felted rock wool materials, moisture permeable gypsum, moisture impermeable gypsum and fiber glass.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)
US515892A 1974-10-18 1974-10-18 Building deck construction Expired - Lifetime US3918230A (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US515892A US3918230A (en) 1974-10-18 1974-10-18 Building deck construction
CA235,255A CA1051682A (fr) 1974-10-18 1975-09-11 Construction de platelages
GB40455/75A GB1495798A (en) 1974-10-18 1975-10-03 Building deck construction
US05/630,504 US4006731A (en) 1974-10-18 1975-11-10 Building deck construction

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Application Number Priority Date Filing Date Title
US515892A US3918230A (en) 1974-10-18 1974-10-18 Building deck construction

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US3918230A true US3918230A (en) 1975-11-11

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US515892A Expired - Lifetime US3918230A (en) 1974-10-18 1974-10-18 Building deck construction

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CA (1) CA1051682A (fr)
GB (1) GB1495798A (fr)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4120131A (en) * 1976-09-03 1978-10-17 Carroll Research, Inc. Building structure
US4870794A (en) * 1988-12-09 1989-10-03 National Gypsum Company Clip for outwardly opening C-stud
US5025522A (en) * 1990-01-25 1991-06-25 Eskew Larry R Bridge deck panel support system and method
US5359826A (en) * 1992-10-26 1994-11-01 Multuloc International Systems Corporation Structural framing member and prefabricated panel structure
US5644880A (en) * 1984-02-27 1997-07-08 Georgia-Pacific Corporation Gypsum board and systems containing same
US5704179A (en) * 1984-02-27 1998-01-06 Georgia-Pacific Corporation Finishing and roof deck systems containing fibrous mat-faced gypsum boards
US5930965A (en) * 1997-09-23 1999-08-03 Carver; Tommy Lee Insulated deck structure
US20040216399A1 (en) * 2003-01-30 2004-11-04 Kyocera Corporation Fixing apparatus
US20050229529A1 (en) * 2002-11-15 2005-10-20 Massimiliano Frascari Anchoring element for the linking of stanchion structures
US7049251B2 (en) 2003-01-21 2006-05-23 Saint-Gobain Technical Fabrics Canada Ltd Facing material with controlled porosity for construction boards
US7225590B1 (en) * 2003-07-14 2007-06-05 The Steel Network, Inc. Brick tie
US20100170163A1 (en) * 2009-01-06 2010-07-08 Solarcity Corporation Roof support apparatus for solar panels
US7846278B2 (en) 2000-01-05 2010-12-07 Saint-Gobain Technical Fabrics America, Inc. Methods of making smooth reinforced cementitious boards
US20130231019A1 (en) * 2001-04-09 2013-09-05 Jeffrey T. Dinkel Asymmetrical Concrete Backerboard
CN106760289A (zh) * 2016-12-21 2017-05-31 北京东方悦工程技术有限公司 一种泡沫混凝土的抗裂施工方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2756638C1 (ru) * 2021-01-29 2021-10-04 Алина Сергеевна Лозенко Эксплуатируемая крыша

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2002927A (en) * 1931-06-24 1935-05-28 Nat Gypsum Co Building construction
US2855869A (en) * 1952-11-28 1958-10-14 Munters Carl Georg Roofs of buildings
US2900677A (en) * 1954-08-11 1959-08-25 Georgia Pacific Plywood Compan Board securing means
US3282008A (en) * 1963-02-14 1966-11-01 Dow Chemical Co Roof structure
US3345246A (en) * 1964-07-13 1967-10-03 Dow Chemical Co Leveling base sheet for reroofing
US3435580A (en) * 1966-03-17 1969-04-01 Otto Buehner & Co Insulated,reinforced concrete,panel-type building unit
US3439464A (en) * 1967-04-12 1969-04-22 Powerlock Floors Inc Floor and wall system

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2002927A (en) * 1931-06-24 1935-05-28 Nat Gypsum Co Building construction
US2855869A (en) * 1952-11-28 1958-10-14 Munters Carl Georg Roofs of buildings
US2900677A (en) * 1954-08-11 1959-08-25 Georgia Pacific Plywood Compan Board securing means
US3282008A (en) * 1963-02-14 1966-11-01 Dow Chemical Co Roof structure
US3345246A (en) * 1964-07-13 1967-10-03 Dow Chemical Co Leveling base sheet for reroofing
US3435580A (en) * 1966-03-17 1969-04-01 Otto Buehner & Co Insulated,reinforced concrete,panel-type building unit
US3439464A (en) * 1967-04-12 1969-04-22 Powerlock Floors Inc Floor and wall system

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4120131A (en) * 1976-09-03 1978-10-17 Carroll Research, Inc. Building structure
US5644880A (en) * 1984-02-27 1997-07-08 Georgia-Pacific Corporation Gypsum board and systems containing same
US5704179A (en) * 1984-02-27 1998-01-06 Georgia-Pacific Corporation Finishing and roof deck systems containing fibrous mat-faced gypsum boards
US5791109A (en) * 1984-02-27 1998-08-11 Georgia-Pacific Corporation Gypsum board and finishing system containing same
US4870794A (en) * 1988-12-09 1989-10-03 National Gypsum Company Clip for outwardly opening C-stud
US5025522A (en) * 1990-01-25 1991-06-25 Eskew Larry R Bridge deck panel support system and method
US5359826A (en) * 1992-10-26 1994-11-01 Multuloc International Systems Corporation Structural framing member and prefabricated panel structure
US5930965A (en) * 1997-09-23 1999-08-03 Carver; Tommy Lee Insulated deck structure
US7846278B2 (en) 2000-01-05 2010-12-07 Saint-Gobain Technical Fabrics America, Inc. Methods of making smooth reinforced cementitious boards
US9017495B2 (en) 2000-01-05 2015-04-28 Saint-Gobain Adfors Canada, Ltd. Methods of making smooth reinforced cementitious boards
US20130231019A1 (en) * 2001-04-09 2013-09-05 Jeffrey T. Dinkel Asymmetrical Concrete Backerboard
US20050229529A1 (en) * 2002-11-15 2005-10-20 Massimiliano Frascari Anchoring element for the linking of stanchion structures
US7049251B2 (en) 2003-01-21 2006-05-23 Saint-Gobain Technical Fabrics Canada Ltd Facing material with controlled porosity for construction boards
US7300892B2 (en) 2003-01-21 2007-11-27 Saint-Gobain Technical Fabrics Canada, Ltd. Facing material with controlled porosity for construction boards
US7300515B2 (en) 2003-01-21 2007-11-27 Saint-Gobain Technical Fabrics Canada, Ltd Facing material with controlled porosity for construction boards
US20040216399A1 (en) * 2003-01-30 2004-11-04 Kyocera Corporation Fixing apparatus
US7225590B1 (en) * 2003-07-14 2007-06-05 The Steel Network, Inc. Brick tie
US20100170163A1 (en) * 2009-01-06 2010-07-08 Solarcity Corporation Roof support apparatus for solar panels
US7797883B2 (en) * 2009-01-06 2010-09-21 Solarcity Corporation Roof support apparatus for solar panels
CN106760289A (zh) * 2016-12-21 2017-05-31 北京东方悦工程技术有限公司 一种泡沫混凝土的抗裂施工方法

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Publication number Publication date
CA1051682A (fr) 1979-04-03
GB1495798A (en) 1977-12-21

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Owner name: CARROLL, FRANK E.; 237 MAPLE RD., BARRINGTON, IL.

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