Structural Floor and Roof Joists

Abstract

A floor includes structural floor joist that includes a flange and tabs punched out of the flange (forming holes in the flange). Flooring material of the floor that extrudes through at least one of the holes is bonded to some of the tabs and the flange of the structural floor joist, forming a bonded composite assembly of the structural floor joist and the forming material, that has a centroid that is located in or near the forming material, placing some of the forming material in compression and placing at least 90% of the structural floor joist in tension.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure generally relates to the field of building construction. More particularly, the present disclosure relates to devices and methods for floor construction and roof construction, as well as a monolithic structure.

2. Related Art

FIG. 1 is a side view of a conventional floor 100, according to an implementation. The conventional floor 100 includes a cementitious forming material 102 over a metal deck 104. A joist 106 is attached to the metal deck 104. In the conventional floor 100, about half (50%) of the joist 106 is in compression 108 and about half (50%) of the joist 106 is in tension 110. The centroid 112 of the compression 108 and the tension 110 is in the middle of the joist 106. The centroid 112 is the equilibrium point of the compression 108 and the tension 110. All of the joist compression 108 is in the top half of the joist 106 and all of the joist tension is in the bottom half of the joist 106.

In FIG. 1, the cementitious forming material 102 is not designed as a part of the structural system of the floor 100, in which the cementitious forming material 102 is a dead load and provides no structural support. The cementitious forming material 102 and a joist 106 structurally act independently.

All of the conventional pre-cast structural floor systems involve either placing the pre-cast forming material between the joists and adhering them to the joists or laying the pre-cast flooring on top of the joists.

All of the conventional site cast structural floor system applications involve one of the following: applying the structural floor system over the joists; applying the structural floor system between the joists or applying the structural floor system between and over the joists. The conventional site case applications involve either a support onto which the cementitious forming material is cast that is affixed between the joists or a deck on top of the joists.

SUMMARY

An important aspect is that the structural floor joist facilitates the communication of stress, compression and tension between the component parts of the structural floor joist allowing components of the structural floor joist to work in an integrated, monolithic and composite fashion. An increased level of bonding between the structural floor joist and forming material (or in instances where a metal deck is used, between the structural floor joist, the metal deck and floor material) allows for design considerations with respect to the level of transfer of stress, compression and tension through the placement of the centroid above the midpoint of the joist all of the way to the top of tab. Materials used in the structural floor joist; the material and design of the metal deck and the materials used for the design mix of the forming material can all be adjusted as called for by the design to effect the strength-to-weight as well as the deflection of the finished structural floor joist. Increasing the strength-to-weight ratio and the amount of deflection of the finished structural floor joist results in longer spans and an increase in the distance in the distance between joists. The composite nature and decreased deflection as well as the ability to adjust the strength and weight characteristics of the joist, the metal deck and the forming material also allows for the opportunity to decrease the thickness of the structural floor joist and increase the thermal dynamic capability of the structural floor joist. The same attributes also result and allow for decrease in cost and providing a structural floor joist with the same structural capacity and deflection as conventional structural floor joists, but at a lower cost.

The level of bonding between the joist, metal deck and floor material result in a monolithic sheer plane to increase the structural capacity of the walls, foundations and roof of the structure in which the structural floor joist is used. The increase in bonding between the structural floor joist and forming material results in a composite relationship of the sheer plane created by the structural floor joist and a load bearing exterior wall.

The structural floor joist can also be used as a roofing system using rafters with the same tab system, with or w/o a roof metal deck. The roofing system bonds the rafter with the roof deck and roofing material to increase the strength-to-weight ratio towards a composite in the same matter as the floor system. The forming and roofing systems can both be used to create even higher strength-to-weight ratios in the total structure of the structural floor joist and the roofing system resulting in a structure approaching a true composite nature.

In some implementations, a floor includes a forming material and a cold form metal floor joist having: a flange having a central longitudinal axis and a web that extends from the flange, a plurality of tabs punched out of the flange, forming a hole for each of the plurality of tabs, forming a plurality of holes, wherein a portion of the forming material extrudes through at least one of the holes and the portion of the forming material is bonded to the tabs and the flange of the metal floor joist, forming a bond approaching or achieving a true composite state. The increased composite nature of the flooring and the metal joist result in having a centroid above the center of the web and typically that is located at or near the bottom of the forming material, typically placing 100% or near 100% of the forming material in compression and placing more than 50% and typically at least 90% of the metal floor joist in tension. In this implementation, the forming material is optimally utilized because the greatest structural attribute of the forming material is its compressive strength and the metal joist is optimally utilized because the greatest structural attribute of cold form metal is its high tensile strength, thus by increasing the bonding between the metal floor joist and the forming material and thus increasing the composite state of the two components the overall structural strength of the floor system is greatly increased.

Implementations of the present disclosure include a structural floor joist that allows for improved adhesion between the floor joist that is made of cold formed metal and the forming material.

A further benefit of the structural floor joist of certain implementations of the present disclosure is that the structural floor joist can be formed by a device and a process that is less expensive and has less problems than the devices and processes by which conventional floor joists are formed.

In certain implementations, the structural floor joist of the present disclosure includes a floor joist having a flange and a tab punched out of the flange, the tab comprising: a tab leg that is substantially planar and extends from the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; and a tab foot extending from the tab leg and curving either away from or toward a hole in the flange created by the tab punched out of the flange.

In some implementations, the hole in the flange is defined by a base side and a top side, the base side has a greater length than the top side and the tab leg extends from the base side.

In certain implementations, the structural floor joist includes a plurality of tabs of undefined spacing. In still other implementations, the plurality of tabs is spaced such that the center-to-center spacings between tab leg connections to the flange are at or about six inches. In other implementations, the center-to-center spacings between tab leg extensions from the flange are about four inches. In other implementations, the center-to-center spacings between tab leg extensions from the flange are other dimensions.

Implementations of the present disclosure include a structural floor joist that allows for improved adhesion between the floor joist that is made of cold formed metal and the forming material. A further benefit of the structural floor joist of certain implementations of the present disclosure is that it can be formed by a device and a process that is less expensive and has less problems than the devices and processes by which other floor joists are formed. In certain implementations, the structural floor joist of the present disclosure includes a floor joist having a flange and a tab punched out of the flange, the tab comprising: a tab leg that is substantially planar and extends from the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; and a tab foot extending from the tab leg and curving either away from or toward a hole in the flange created by the tab punched out of the flange. In some implementations, the hole in the flange is defined by a base side and a top side, the base side has a greater length than the top side and the tab leg extends from the base side. In certain implementations, the structural floor joist includes a plurality of tabs. In still other implementations, the plurality of tabs is spaced such that the center-to-center spacings between tab leg connections to the flange is at or about six inches. In other implementations, the center-to-center spacings between tab leg extensions from the flange is about four inches. In other implementations, the center-to-center spacings between tab leg extensions from the flange are other dimensions.

Implementations of the present disclosure also include a method of forming a structural floor joist comprising obtaining a floor joist having a flange; striking the flange of the floor joist with a punch; and forcing the punch into a die, creating a tab punched out of the flange, the tab comprising: a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange at to the flange; may contain the foot away from or toward a hole in the flange created by the tab punched out of the flange. In some implementations, the hole created in the flange is defined by a base side and a top side, and the tab leg extends from the base side. In other implementations, the flange of the floor joist is struck with a plurality of punches, creating a plurality of tabs in the flange. In certain implementations, the plurality of tabs are spaced such that the center-to-center spacings between tab leg connections to the flange can be any dimension. In still other implementations, the center-to-center spacings between tab leg connections to the flange are defined about four inches or 6 inches. In yet another implementation, the tab is created in one strike of the flange with the punch.

Implementations of the present disclosure also include a device for forming a structural floor joist comprising a punch for striking a flange of the floor joist and a die into which the punch is forced, where striking the flange with the punch and forcing the punch into the die creates a tab punched out of the flange, the tab comprising: a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; and a tab foot extending from the tab leg and curving either away from or toward a hole in the flange created by the tab punched out of the flange. In some implementations, the hole in the flange is defined by a base side and a top side, the base side has a greater length than the top side and the tab leg extends from the base side. In other implementations, the device includes a plurality of punches and dies and creates a plurality of tabs in the flange. In certain implementations, the plurality of tabs is spaced such that the center-to-center spacings between tab leg connections to the flange is less than about six inches. In still other implementations, the center-to-center spacings between tab leg connections to the flange is about four inches. In yet another implementation, the device is capable of creating the tab in one strike of the flange with the punch.

Implementations of the present disclosure also include a method of building a floor comprising: obtaining a plurality of structural floor joists, each floor joist comprising: a floor joist having a flange; and a tab punched out of the flange, the tab comprising: a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; and a tab foot extending from the tab leg and curving either away from or toward a hole in the flange created by the tab punched out of the flange; combining the plurality of structural floor joists with a structural reinforcement (structural mesh or microfibers) on a substantially horizontal surface such that the floor joists and mesh are substantially parallel to each other and to the substantially horizontal surface and there are voids formed between the structural floor joists; embedding the structural floor joists and structural reinforcement in forming material to form a floor.

In pre-cast some implementations, the method further includes laying lifting anchors in the voids formed between the structural floor joists prior to embedding the structural floor joists and structural mesh in forming material; embedding the structural floor joists, structural re-enforcement and lifting anchors in forming material to form a floor, such that a portion of each lifting anchor is exposed. In other implementations, the method further includes laying support anchors in the voids formed between the structural floor joists prior to embedding the structural floor joists and structural re-enforcement in forming material; embedding the structural floor joists, structural re-enforcement and support anchors in forming material to form a floor, such that a portion of each support anchor is exposed; and attaching supports to the support anchors.

Implementations of the present disclosure also include a floor comprising a plurality of structural floor joists, each floor joist comprising a floor joist having a flange; and a tab punched out of the flange, the tab comprising: a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange; and a tab foot extending from the tab leg and curving either away from or toward a hole in the flange created by the tab punched out of the flange; and a structural re-enforcement, where the plurality of structural floor joists and the structural re-enforcement are embedded in forming material. In some implementations, the floor further includes at least one lifting anchor embedded in the forming material, while in other implementations the floor further includes at least one support anchor embedded in the forming material.

In other implementations, the present disclosure includes a structural floor joist comprising: a floor joist having a flange; a lateral tab punched out of the flange and a lateral hole resulting from the lateral tab, the tab comprising a tab leg that is substantially planar and extends from the flange at one end of the tab leg and that projects outwardly from the flange; in some cases and a tab foot extending from the tab leg of the lateral tab punched out of the flange and curving either away from or toward the longitudinal hole in the flange resulting from the lateral tab punched out of the flange; and a longitudinal tab punched out of the flange and a longitudinal hole resulting from the longitudinal tab, the tab comprising a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; a tab foot extending from the tab leg of the longitudinal tab punched out of the flange and curving either away from or toward the longitudinal hole in the flange resulting from the lateral tab punched out of the flange; where the end of lateral tab that is connected to the flange is substantially perpendicular to the end of the longitudinal tab that is connected to the flange.

In another implementation, both the lateral and longitudinal hole is defined by a base side and a top side, the base side has a greater length than the top side and the lateral and longitudinal tab leg extends from the base side; the base side has a greater length than the top side.

In other implementations, the structural floor joist includes a plurality of lateral tabs and resulting lateral holes and longitudinal tabs and resulting longitudinal holes. In another implementation, the lateral tabs and lateral holes and the longitudinal tabs and longitudinal holes are positioned in a consistent or inconsistent in the consistent alternating arrangement, there is a longitudinal tab and longitudinal hole between each lateral tab and lateral hole. In yet another implementation, the longitudinal holes and the longitudinal holes are spaced such that the distance between the centers of successive longitudinal holes is less than about 6 inches. In still another implementation, the longitudinal holes and the longitudinal holes are spaced such that the distance between the centers of successive longitudinal holes is about 4 inches. The size, shape and configuration of the hole is based on the size, shape and configuration of the tab.

In other implementations, the present disclosure includes a method of building a floor comprising: obtaining a plurality of structural floor joists, each floor joist comprising: a floor joist having a flange; a lateral tab punched out of the flange and a longitudinal hole resulting from the lateral tab, the tab comprising a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; and a longitudinal tab punched out of the flange and a longitudinal hole resulting from the longitudinal tab, the tab comprising a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; where the end of lateral tab that is connected to the flange is substantially perpendicular to the end of the longitudinal tab that is connected to the flange; combining the plurality of structural floor joists with a structural mesh on a substantially horizontal surface such that the floor joists and mesh are substantially parallel to each other and to the substantially horizontal surface and there are voids formed between the structural floor joists; embedding the structural floor joists and structural mesh in forming material to form a floor.

In still other implementations, the present disclosure includes a floor comprising: a plurality of structural floor joists, each floor joist comprising: a floor joist having a flange; a lateral tab punched out of the flange and a longitudinal hole resulting from the lateral tab, the tab comprising a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; and a longitudinal tab punched out of the flange and a longitudinal hole resulting from the longitudinal tab, the tab comprising a tab leg that is substantially planar and is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than ninety degrees to the flange; where the end of lateral tab that is connected to the flange is substantially perpendicular to the end of the longitudinal tab that is connected to the flange; and a structural mesh, where the plurality of structural floor joists and the structural mesh are embedded in forming material.

Descriptions of well known processing techniques, components and equipment are omitted so as not to unnecessarily obscure the present methods and devices in unnecessary detail. The descriptions of the present methods and devices are exemplary and non-limiting. Certain substitutions, modifications, additions and/or rearrangements falling within the scope of the claims, but not explicitly listed in this disclosure, may become apparent to those or ordinary skill in the art based on this disclosure.

Additional implementations of the present disclosure and details associated with those implementations, are described below. The following drawings illustrate by way of example and not limitation. Identical reference numerals do not necessarily indicate an identical structure. Rather, the same reference numeral may be used to indicate a similar feature or a feature with similar functionality. Every feature of each implementation is not always labeled in every figure in which that implementation appears, in order to keep the implementations clear. The drawings form part of the present specification and are included to further demonstrate certain aspects of the present disclosure. The disclosure may be better understood by reference to one or more of these drawings in combination with the description of illustrative implementations presented herein:

FIG. 1 is a side view of a conventional floor, according to an implementation.

FIG. 2 is a side view of one implementation of the present floor, according to an implementation.

FIG. 3 is a side view of one implementation of the present floor, according to an implementation.

FIG. 4 is a side view of one implementation of the present structural floor joists, according to an implementation.

FIG. 5 is a partial isometric view of one implementation of the present structural floor joists, according to an implementation.

FIG. 6 is a side view of one implementation of the present structural floor joists, according to an implementation.

FIG. 7 is a front view of one implementation of the present structural floor joists, according to an implementation.

FIG. 8 is a top view of one implementation of the present structural floor joists, according to an implementation.

FIG. 9 is a partial isometric view of one implementation of the present structural floor joists, according to an implementation.

FIG. 10 is a side view of one implementation of the present structural floor joists, according to an implementation.

FIG. 11 is a side view of one implementation of the present structural floor joists, according to an implementation.

FIG. 12 is an isometric view of another implementation of the present structural floor joists, according to an implementation.

FIG. 13 is a side view of another implementation of the present structural floor joists, according to an implementation.

FIG. 14 is a front view of another implementation of the present structural floor joists, according to an implementation.

FIG. 15 is a top view of another implementation of the present structural floor joists, according to an implementation.

FIG. 16 is a top view of another implementation of the present structural floor joists, according to an implementation.

FIG. 17 is a top view of another implementation of the present structural floor joists, according to an implementation.

FIG. 18 is a side view of another implementation of the present structural floor joists, according to an implementation.

FIG. 19 is a partial isometric view of one implementation of the present structural floor joists, according to an implementation.

FIG. 20 is a partial isometric view of one implementation of the present structural floor joists, according to an implementation.

FIG. 21 is a partial isometric view of one implementation of the present structural floor joists, according to an implementation.

FIG. 22 is an isometric view of another implementation of the present structural floor joists, according to an implementation.

FIG. 23 is an isometric view of another implementation of the present structural floor joists, according to an implementation.

FIG. 24 is an isometric view of another implementation of the present structural floor joists, according to an implementation.

FIG. 25 is an isometric view of another implementation of the present structural floor joists, according to an implementation.

FIG. 26 is an isometric view of another implementation of the present structural floor joists, according to an implementation.

FIG. 27 is an isometric view of another implementation of the present structural floor joists, according to an implementation.

FIG. 28 is an isometric view of a metal deck flooring system 2800, according to an implementation, according to an implementation.

FIG. 29 is an isometric view of a metal deck flooring system 2900, according to an implementation, according to an implementation.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “contain” (and any form of contain, such as “contains” and “containing”) and “include” (and any form of include, such as “includes” and “including”) are open-ended linking verbs. As a result, a structural floor joist, device, or method that “comprises,” “has,” “contains,” or “includes” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements or steps. Likewise, an element of a structural floor joist, device, or method that “comprises,” “has,” “contains,” or “includes” one or more features possesses those one or more features, but is not limited to possessing only those one or more features. Furthermore, a structure that is configured in a certain way must be configured in at least that way, but also may be configured in a way or ways that are not specified.

DESCRIPTION OF ILLUSTRATIVE IMPLEMENTATIONS

The terms “a” and “an” are defined as one or more than one unless this disclosure explicitly requires otherwise. The terms “substantially” and “about” are defined as at least close to (and includes) a given value or state (preferably within 10% of, more preferably within 1% of and most preferably within 0.1% of).

The structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that provide significant adherence between the forming material and the floor deck and between the joist or the forming material to the joist to the extent that the joist is placed in tension and compression. Placing the joist in tension and compression increases the structural strength of the structural floor system past the sum of the strength of the independent component parts or the component parts of the flooring system.

The structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that place the joist in tension and compression resulting in a significant increase of the structural strength of the structural floor system past the sum of the strength of the independent component parts or the strength of the component parts of the flooring system.

The pre-cast structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that utilize a tab punched from the joist (creating a hole in the joist referred to as the tab hole) to embed in the structural floor system material. The site cast structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that utilize a tab punched from the joist (creating a hole in the joist referred to as the tab hole) to embed in the structural floor system material.

The pre-cast structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that utilize a tab punched from the joist to pass through a hole in the deck of the structural floor system and then embed in the forming material. The site cast structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that utilize a tab punched from the joist to pass through a hole in the deck of the structural floor system and then embed in the forming material.

The pre-cast structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that utilize a tab punched from the joist to embed in the forming material as a means to adhere the forming material to the joist as well as allowing the floor material to flow through the tab hole to form a secondary monolithic mechanism of adherence. The site cast structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that utilize a tab punched from the joist to embed in the forming material as a means to adhere the forming material to the joist as well as allowing the floor material to flow through the tab hole to form a secondary monolithic mechanism of adherence.

The pre-cast structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that utilize a tab punched from the joist to pass through the hole in the floor deck and then embed in the forming material above as a means to adhere the forming material to the floor deck and joist as well as allow the floor material to flow through the hole in the deck and the tab hole to form a secondary monolithic mechanism of adherence. The site cast structural floor systems that are shown and described in FIG. 2-FIG. 27 are composed of independent component parts that utilize a tab punched from the joist to pass through the hole in the floor deck and then embed in the forming material as a means to adhere the forming material to the floor deck as well as the joist as well as allowing the floor material to flow through the hole in the floor deck and the tab hole to form a secondary monolithic mechanism of adherence.

The apparatus shown and described in FIG. 2-FIG. 27 provide a site cast structural floor system that adheres the forming material to the floor deck and joist or adheres the forming material to the joist in a way that places the joist in both tension and compression.

The apparatus shown and described in FIG. 2-FIG. 27 provide a site cast structural floor system that increases the stability of the structural floor system beyond what is currently available.

The apparatus shown and described in FIG. 2-FIG. 27 provide a site cast structural floor system that increases the structural strength of the flooring system past the sum of the strength of the component parts and move the structural strength of the structural floor system towards achieving or achieving composite strength.

The apparatus shown and described in FIG. 2-FIG. 27 provide a pre-cast structural floor system that adheres the forming material to the floor deck and joist or adheres the forming material to the joist in a way that places the joist in both tension and compression.

The apparatus shown and described in FIG. 2-FIG. 27 provide a pre-cast structural floor system that increases the stability of the structural floor system beyond what is currently available.

The apparatus shown and described in FIG. 2-FIG. 27 provide a pre-cast structural floor system that increases the structural strength of the flooring system past the sum of the strength of the component parts and move the structural strength of the structural floor system towards achieving or achieving composite strength.

Increasing the adherence between the structural floor system material and the floor deck and the joist or between the structural floor system material and the joist and placing the joist in both tension and compression would increase the stability of the structural floor system and greatly reduce or eliminate vibration in the structural floor system during use.

Increasing the adherence between the forming material, the deck and the joist or the forming material and the joist to the degree that the joist is placed both in tension and compression increases the structural strength of the structural floor system past just the sum of the strength of its component parts.

Increasing the adherence between the structural floor system material with the floor deck and the joist or between the forming material and the joist to the point of placing the joist in both tension and compression would: reduce the overall cost of the structure in which the structural floor system is utilized; reduces the overall weight of the structure in which the structural floor system is utilized; reduce vibration in the structural floor system when stress is applied to it; increases the structural strength of the structural floor system in a way that allows the floor to better sustain seismic and other movement imposed upon the floor by natural forces; increases the structural strength of the structural floor system to better sustain the stress imposed on the floor by the other component parts of the structure; allows the structural floor system to become a significant component part of the overall structural strength of the structure in which it is used to a degree not currently possible.

The apparatus shown and described in FIG. 2-FIG. 27 involve a support onto which the forming material is cast placed between the joists use both a metal anchor imbedded in the forming material at the time of the site casting of the forming material and the passing of the forming material into or through the joist as an additional adherence between the support for the forming material, the forming material and the joist. In addition, The apparatus shown and described in FIG. 2-FIG. 27 involve a support onto which the flooring material is cast reduces the overall cost of the structure in which the structural floor system is utilized; reduces the overall weight of the structure in which the structural floor system is used; reduces vibration in the structural floor system when stress is applied to the structural floor system; increases the structural strength of the structural floor system in a way that allows the floor to better sustain seismic and other movement imposed upon the floor by natural forces; increases the structural strength of the structural floor system to better sustain the stress imposed on the floor by the other component parts of the structure; allows the structural floor system to become a significant component part of the overall structural strength of the structure in which it is used to a degree not currently possible

The apparatus shown and described in FIG. 2-FIG. 27 involve a support onto which the forming material is cast placed between the joists uses a metal anchor imbedded in the forming material and the joist that significantly increases the structural strength of the structural floor system at a whole past the strength of the component parts of the structural floor system.

The apparatus shown and described in FIG. 2-FIG. 27 involve a deck system placed above the joists use both a metal anchor imbedded in the forming material at the time of the site casting of the forming material and the passing of the forming material into or through the deck and the joist as an additional adherence between the forming material; the deck and the joist.

The apparatus shown and described in FIG. 2-FIG. 27 involve a deck system placed above the joists use a metal anchor imbedded in the forming material at the time of the site casting of the forming material that significantly increases the structural strength of the structural floor system above the combined strength of the component parts or that perform some or all of the following to an extent not currently available: reduces the overall cost of the structure in which the structural floor system is utilized; reduces the overall weight of the structure in which the structural floor system is used; reduces vibration in the structural floor system when stress is applied to the structural floor system; increases the structural strength of the structural floor system in a way that allows the floor to better sustain seismic and other movement imposed upon the floor by natural forces; increases the structural strength of the structural floor system to better sustain the stress imposed on the floor by the other component parts of the structure; allows the structural floor system to become a significant component part of the overall structural strength of the structure in which it is used to a degree not currently possible.

The apparatus shown and described in FIG. 2-FIG. 27 involve the placing of the pre-cast flooring between the joists and adhering them to the joists involve the use of a metal anchor affixed to the joist and embedded in the forming material and additional adherence caused by the passage of the forming material into the joist in a monolithic fashion.

The apparatus shown and described in FIG. 2-FIG. 27 involve the placing of the pre-cast flooring between the joists significantly increase the structural strength of the structural floor system above the combined strength of the component parts or that perform some of all of the following to an extent not currently available: reduces the overall cost of the structure in which the structural floor system is utilized; reduces the overall weight of the structure in which the structural floor system is used; reduces vibration in the structural floor system when stress is applied to the structural floor system; increases the structural strength of the structural floor system in a way that allows the floor to better sustain seismic and other movement imposed upon the floor by natural forces; increases the structural strength of the structural floor system to better sustain the stress imposed on the floor by the other component parts of the structure; allows the structural floor system to become a significant component part of the overall structural strength of the structure in which it is used to a degree not currently possible.

The apparatus shown and described in FIG. 2-FIG. 27 involve the placing of the pre-cast flooring on top of the joists use a metal anchor that extends from the joist; passes through the deck and is embedded in the forming material.

The apparatus shown and described in FIG. 2-FIG. 27 involve placing of the pre-cast flooring on top of the joists use a metal anchor that is affixed to the joist; extends through the deck and is embedded in the forming material.

The apparatus shown and described in FIG. 2-FIG. 27 involve the placing of the pre-cast flooring on top of joists use a metal anchor extending from the joist; through the metal deck and is embedded into the forming material and also uses the forming material flooring through the metal deck and the joist in a monolithic fashion as an additional adherence.

The apparatus shown and described in FIG. 2-FIG. 27 involve the placing of the pre-cast flooring on top of joists increases the structural strength of the structural floor system as a whole above the sum of the strength of the component parts of the components of the structural floor system.

The apparatus shown and described in FIG. 2-FIG. 27 involve the placing of the pre-cast flooring on top of the joists accomplish the following to a degree not currently available: some of all of the following to an extent not currently available: reduces the overall cost of the structure in which the structural floor system is utilized; reduces the overall weight of the structure in which the structural floor system is used; reduces vibration in the structural floor system when stress is applied to the structural floor system; increases the structural strength of the structural floor system in a way that allows the floor to better sustain seismic and other movement imposed upon the floor by natural forces; increases the structural strength of the structural floor system to better sustain the stress imposed on the floor by the other component parts of the structure; allows the structural floor system to become a significant component part of the overall structural strength of the structure in which it is used to a degree not currently possible.

The first variation of the apparatus shown and described in FIG. 2-FIG. 27 involves forming material other than wood, which would include forming materials, such as Portland cement. The forming material would be of varying structural strength and rigidity as called for by the particular application. The forming material can be reinforced using rebar, welded wire mat, micro-fibers or chemicals as called for by the application.

The first variation of the apparatus shown and described in FIG. 2-FIG. 27 that calls for a joist can be of any material from which a return can be formed and from which tabs can be punched from the return or onto which tab strips can be adhered. When the joist used is made of metal, the gage of the metal will be as called for by the particular application. The size of the return and web will be as called for by the application.

The first variation of the structural floor systems that are shown and described in FIG. 2-FIG. 27 that calls for tabs of various widths, lengths and orientations, as required for by the application. The first variation of the structural floor systems that are shown and described in FIG. 2-FIG. 27 that calls for tabs to be punched from the return of the joist over which the forming material will be poured. The tab width, length and orientation may be consistent or varied along the length of each individual joist, as called for by the application. The tab width, length and orientation may be consistent with respect to all of the joists of the structural floor system. The width, length and orientation of the tabs may also vary once or variably amongst the joists forming the floor. The angle of the tab as it protrudes from the joist may be of any angle with such angel remaining continuous or varying as much or as little as is called for by the application. The tab may be plainer or may undulate or may be plainer and then curve either toward the tab hole or away from the tab hole. The punching of the tab from the return will result in a hole in the joist. This hole is referred to as the tab hole.

The first variation of the structural floor systems that are shown and described in FIG. 2-FIG. 27 that calls for the forming material to be caught after it passes through the tab hole. The forming material retention can either be continuous and planar; or continuous and formed to create a uniform area under each tab hole or can be only beneath the tab hole either in a uniform or non-uniform manner. The forming material retention can also be punched from the web of the joist. If punched from the joist, the area of retention can either be uniform or not uniform.

The forming material retention can either be affixed to the joist at the job site or when the joist is fabricated.

The structural floor system can also be pre-cast allowing the tab to be embedded in the forming material and allowing the forming material to pass through the tab hole. The joists can be set in a frame with the tabs extending into the cavity created by affixing the joists, header and track to a frame some distance from the ground. In the alternative, the track and joists can be lowered into the frame and into the forming material that has been poured into the frame. The frame can be lowered into the forming material to the extent that the forming material flows through the tab hole and forms within the return.

FIG. 2 is a side view of one implementation of the present floor 200, according to an implementation. The floor 200 includes a joist 202 that includes a plurality of tabs 204 punched out of the joist top flange 206. The joist top flange 206 has one hole for each of the plurality of tabs 204, forming a plurality of holes (the holes not shown in FIG. 2) in the joist top flange 206. The joist flange has a joist return 207. A metal deck 208 is laid down upon the joist top flange 206. The metal deck 208 has holes punched that allow the plurality of tabs 204 of the joist top flange 206 of the joist 202 to pass through holes of the metal deck 208. The joist 202 is typically made of metal of varying gages. The joist 202 also has a joist bottom flange 209.

A portion of a forming material 210 forms around the plurality of tabs 204 and bonds to the plurality of tabs 204. Furthermore, another portion of the forming material 210 extrudes through at least one of the holes in the metal deck 208 and the holes in the joist top flange 206 of the joist 202 and then forms beneath the joist top flange 206 of the joist 202. In some implementations, the forming material 210 is cementitious forming material.

The joist 202 has a centroid (not shown in FIG. 2) in a variable centroid area 212. The variable centroid area 212 is an area in which the centroid is located, depending on materials of the joist 202, the plurality of tabs 204, the joist top flange 206, the metal deck 208 and the forming material 210. The centroid is always above a mid-point 213 of the joist 202 in the variable centroid area 212. The centroid is the equilibrium point of a variable area of compression 216 and a variable tension area 214. The variable tension area 214 is below the centroid and the variable compression area 216 is above the centroid.

The tabs utilized in floor 200 results in a bonded assembly of the joist 202, the metal deck 208 and the forming material 210. The bonding of the materials provides for movement of the location of the centroid, in comparison to FIG. 1, depending on the strengths of the materials of the joist 202, the plurality of tabs 204, the joist top flange 206, the metal deck 208 and the forming material 210.

The bonded composite assembly in the floor 200 results in the centroid location moving up within the variable centroid area 212 in comparison to FIG. 1. that results in location or placement of the centroid in a position that is closer to the top of joist, where the joist 202, the metal deck 208 and the forming material 210 meet, thus putting more of the joist 202 in tension than in FIG. 1.

FIG. 2 shows that as the centroid is located higher, the variable tension area 214 below the centroid increases. As the area of tension below the centroid increases, the variable area of compression 216 in the joist 202 decreases and the variable area of compression 216 in the forming material 210 increases when the forming material 210 is solidified. Locating the centroid above the mid-point 213 of the joist 202 increases the area of the joist 202 that is in tension, which results in increased structural capacity of the floor 200 using no additional materials than in FIG. 1.

The bonded composite assembly of floor 200 that has a centroid that is above the mid-point 213 provides a higher total strength than the strength of the individual components of the forming material 210, the metal deck 208 and the joist 202 and results in higher composite strength-to-weight ratio of the floor 200.

FIG. 3 is a side view of one implementation of a floor 300 in which the centroid is located in or near the forming material, according to an implementation. In FIG. 3, the centroid 302 is located where the top of the joist meets the metal deck and floor material with 100% of the compression area 310 in the forming material 304 and the metal deck above the centroid and with 100% of the joist below the centroid and 100% of the joist in tension.

FIG. 3 also illustrates a cementitious forming material 304. Having all of the compression area 310 in the cementitious forming material 304 and the metal deck 208 is highly beneficial when the forming material is cementitious because cementitious material has high compression strength. Having a large portion of the tension in the joist 306 is highly beneficial when the joist is made of metal because metal has a high tensile strength.

FIG. 4-FIG. 9 are detailed illustrations of the apparatus in FIGS. 2 and 3, according to an implementation. In FIGS. 4-FIG. 9, the structural floor joist 400 comprises a floor joist 400 having a web 410, a top flange 415 connected to the web 410 and a tab 420 punched out of the top flange 415. The tab 420 comprises a tab leg base 440, a tab leg 425 that is substantially planar and is connected to the top flange 415 at the tab leg base 440. The tab leg 425 extends from the tab leg base 440. The tab leg 425 projects outwardly from the top flange 415 at an angle of less than ninety degrees to the top flange 415. Having the tab leg 425 project outwardly at an angle of less than ninety degrees results in improved adhesion between the structural floor joist 400 and the surrounding forming material (not shown).

The tab 420 also comprises a tab foot 430 extending from the tab leg 425 created by the tab 420 being punched out of the top flange 415. The tab foot 430 in various implementations can curve in a variety of directions and at a variety of angles to the central longitudinal axis of the web 410 and the tab leg 425.

In FIG. 4, the tab foot 430 extends from the tab leg 425 and curves in a direction that is approximately 45 degrees to the central longitudinal axis of the web 410 and perpendicular to the tab leg 425 and toward the hole 435 in the top flange 415 that is created by the tab 420 being punched out of the top flange 415. The structural floor joist 400 also includes a flange return 450.

In some implementations, a hole 435 in the top flange 415 is defined by the tab leg base 440 and a top side of hole 445. The tab leg base 440 has a greater length than the top side.

In FIG. 5-FIG. 9, the tab foot 504 extends from the tab leg 425 and curves in a direction that is approximately 45 degrees to the central longitudinal axis and perpendicular to the tab leg 425 and away from the hole 435 in the top flange 415 created by the tab 502 being punched out of the top flange 415. Having the tab foot 504 curve away from the hole 435 in the top flange 415 further results in improved adhesion between the structural floor joist 500 and surrounding forming material (not shown).

Another implementation is shown in FIG. 9. In this implementation, the structural floor joist 900 comprises a web 410, a top flange 415, a plurality of tabs 502, 502 and 502 punched out of the top flange 415 and a plurality of holes 435, 435 and 435 created by the tabs 502, 502 and 502 punched out of the top flange 415. In some implementations, the plurality of tabs 502, 502 and 502 is spaced such that the center-to-center spacings between tab leg bases 440, 440 and 440 are anywhere from about 4 to about 12 inches, including about 4, 6, 8 and 12 inches, or any range derivable within these numbers. In some implementations, the center-to-center spacings between tab leg bases 440, 440 and 440 are less than about six inches, which further results in improved adhesion between the structural floor joist 900 and the surrounding forming material (not shown). In other implementations the center-to-center spacings between tab leg bases 440, 440 and 440 are about four inches.

While FIG. 9 only depicts three tabs in the top flange 415 of the structural floor joist 900, the number of tabs, the sizes of the tabs and the spacing of the tabs can vary depending on the size, thickness and tensile strength of the structural floor joist 900. For example, the implementations described above where the center-to-center spacings between tab leg connections are less than about six inches and in particular about four inches, encompass a structural floor joist 900 where the width of the top flange 415 is about 2″, 2½″ to 3″ inches and the floor joist is composed of metal that is 16 gage in thickness and has a tensile strength of 50 ksi for steel (i.e., kilo-pound per square inch). For floor joists of different sizes and/or metal thicknesses and tensile strengths, the sizes of the gaps can be proportionally scaled. Other metal thicknesses that are suitable for use in certain implementations of the structural floor joists 900 of the present disclosure include 12, 14 or 18 gage metal. Other metal tensile strengths that are suitable for use in certain implementations of the structural floor joists 900 of the present disclosure include 33 or 50 ksi, or any range derivable within these numbers. In addition to metal, the joist 900 can be made of composite materials.

With regard to the size and number of the tabs, in some implementations, the size and number of the tabs is such that the total surface area of the top flange 415 is divided by the total surface area of the holes created by the tabs results in a ratio of less than about 9.6. More particularly, the ratio is any of the following: 9.6, 9.5, 9.4, 9.3, 9.2, 9.1, 9.0, 8.9, 8.8, 8.7, 8.6, 8.5, 8.4, 8.3, 8.2, 8.1, 8.0, 7.9, 7.8, 7.7, 7.6, 7.5, 7.4, 7.3, 7.2, 7.1, 7.0, 6.9, 6.8, 6.7, 6.6, 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.5, 3.0, 2.5, 2.0 and 1.5, or any range derivable within these numbers.

In some implementations, the size and number of tabs is such that the total surface area of the holes created by the tabs is about 10% of the total surface area of the top flange 415. In other implementations, the size and number of tabs is such that the total surface area of the holes created by the tabs is about 15% of the total surface area of the top flange 415. For apparatus with 4″ center-to-center spacings between tab leg connections, the openings percentage is approximately 15% of the area of the top “flange”. For apparatus with 6″ center-to-center spacings between tab leg connections, the openings percentage is approximately 10% of the area of the top “flange”. For apparatus with 8″ center-to-center spacings between tab leg connections, the openings percentage is approximately 5% of the area of the top “flange”. More particularly, the total surface area of the holes created by the tabs is any of the following percentages of the total surface area of the top flange 415: 10.1%, 10.2%, 10.3%, 10.4%, 10.5%, 10.6%, 10.7%, 10.8%, 10.9%, 11.0%, 11.1%, 11.2%, 11.3%, 11.4%, 11.5%, 11.6%, 11.7%, 11.8%, 11.9%, 12.0%, 12.1%, 12.2%, 12.3%, 12.4%, 12.5%, 12.6%, 12.7%, 12.8%, 12.9%, 13.0%, 13.1%, 13.2%, 13.3%, 13.4%, 13.5%, 13.6%, 13.7%, 13.8%, 13.9%, 14.0%, 14.1%, 14.2%, 14.3%, 14.4%, 14.5%, 14.6%, 14.7%, 14.8%, 14.9%, 15.0%, 15.1%, 15.2%, 15.3%, 15.4%, 15.5%, 15.6%, 15.7%, 15.8%, 15.9%, 16.0%, 17%, 18%, 19%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, or 70%, or any range derivable within these numbers.

FIG. 10 is an isometric side view of one implementation of the present structural floor joists, according to an implementation. FIG. 11 is a side view of one implementation of the present structural floor joists. FIG. 10 and FIG. 11 include a floor joist 1005 such as floor joist in FIG. 4-FIG. 9 or FIG. 12-FIG. 22. The floor joist 1005 is connected to a wall 1010 by an L bracket 1015.

FIG. 11 shows forming material 102 bonded to the tabs and the flange of the metal floor joist 1005, forming a bonded composite assembly between the metal floor joist and the forming material.

FIGS. 12-FIG. 17 show joists with alternating longitudinal tabs and lateral tabs, according to an implementation.

In FIG. 12-FIG. 13, the structural floor joist 1200 comprises a web 1203, a joist bottom flange 209, a joist return bottom 1260, a flange 1205, a plurality of lateral tabs punched out of the flange 1205 and a plurality of lateral holes 1219 and 1221 created by the lateral tabs being punched out of the flange 1205. FIG. 12-FIG. 13, the structural floor joist 1200 comprises a plurality of longitudinal tabs (such as 502) punched out of the flange 1205 and a plurality of longitudinal holes 435 and 435 created by the longitudinal tabs being punched out of the flange 1205.

The lateral tabs comprise tab legs 1239 and 1241 that are substantially planar and are connected to the flange 1205 at one end of the tab leg bases. The tab legs 1239 and 1241 project outwardly from the flange 1205 at an angle of less than ninety degrees to the flange 1205. Having the tab legs 1239 and 1241 project outwardly at an angle of less than ninety degrees results in improved adhesion between the structural floor joist 1200 and the surrounding forming material. The lateral tabs also comprise tab feet 504 extending from the tab legs 1239 and 1241 and curving parallel to the lateral holes 1219 and 1221 created by the lateral tabs punched out of the flange 1205. Having the tab feet 504 curve parallel to the longitudinal holes 435 in the flange 1205 further results in improved adhesion between the structural floor joist 1200 and the surrounding forming material. In some implementations, the lateral holes 1219 and 1221 in the flange 1205 are defined by top sides 1251 and 1253, the base sides have a greater length than the top sides and the tab legs 1239 and 1241 extend from the base sides.

The longitudinal tabs comprise tab legs 425 and 425 that are substantially planar and are connected to the flange 1205 at one end of the tab leg bases 440 and 440. The tab legs 425 and 425 project outwardly from the flange 1205 at an angle of less than ninety degrees to the flange 1205. Having the tab legs 425 and 425 project outwardly at an angle of less than ninety degrees results in improved adhesion between the structural floor joist 1200 and the surrounding forming material. The longitudinal tabs also comprise tab feet 504 and 504 extending from the tab legs 425 and 425 and curving away from longitudinal holes 435 and 435 created by the longitudinal tabs being punched out of the flange 1205. Having the tab feet 504 and 504 curve away the longitudinal holes 435 and 435 in the flange 1205 further results in improved adhesion between the structural floor joist 1200 and the surrounding forming material.

In some implementations, the longitudinal holes 435 and 435 in the flange 1205 are defined by tab leg bases and opposing top sides 445 and 445. The tab leg bases have a greater length than the opposing top sides 445 and 445. In the implementation shown in FIGS. 12-FIG. 17, tab leg bases and opposing top sides 445 and 445 for longitudinal holes 435 and 435 are substantially perpendicular to tag leg bases 1239 and 1241 and opposing top sides 1251 and 1253 for lateral holes 1219 and 1221. This substantially perpendicular arrangement results in further improved adhesion between the structural floor joist 1200 and the surrounding forming material and makes floors that comprise the floor joist and forming material combination more resistant to shear stress.

In the implementation shown in FIGS. 12-FIG. 17, the lateral tabs and lateral holes 1219 and 1219 are positioned in an alternating arrangement on flange 1205 to the longitudinal tabs and longitudinal holes 1219 and 1221 such that there is a longitudinal tab and longitudinal hole between each lateral tab and lateral hole.

In some implementations of FIG. 12, the longitudinal tabs and the lateral tabs are spaced such that the distance between the centers of successive tabs is anywhere from about 4 to about 12 inches, including about 4, 6, 8 and 12 inches, or any range derivable within these numbers. In some implementations, the distance between the centers of successive tabs is less than about 6 inches, which further results in improved adhesion between the structural floor joist 1200 and the surrounding forming material. In other implementations the distance between the centers of successive tabs is about four inches.

In some implementations of FIG. 12 that utilize the alternating lateral and longitudinal tabs, the spacing between closest two longitudinal tabs varies from 8 to 12 inches.

While FIGS. 12-FIG. 17 only depict four tabs in the flange 1205 of the structural floor joist 1200, the number of tabs, the sizes of the tabs and the spacing of the tabs can vary depending on the size, thickness and tensile strength of the structural floor joist 1200. For example, the implementations described above where the distance between the centers of successive longitudinal holes is less than about six inches and in particular about four inches, encompass a structural floor joist 1200 where the width of the web 1203 is about 6 inches, the width of the flange 1205 is about 2 inches and the floor joist is composed of metal that is 16 gage in thickness and has a tensile strength of 50 ksi (i.e., kilo-pound per square inch). For floor joists of different sizes and/or metal thicknesses and tensile strengths, the distances between the holes can be proportionally scaled. Other metal thicknesses that are suitable for use in certain implementations of the structural floor joists 1200 of the present disclosure include 12, 14 or 18 gage metal. Other metal tensile strengths that are suitable for use in certain implementations of the structural floor joists 1200 of the present disclosure include 33 or 50 ksi, or any range derivable within these numbers.

FIG. 15 shows only the lateral and the longitudinal holes of FIG. 12 and FIG. 13, without showing the tabs. The lateral holes in FIG. 15 include tab leg bases 1502 and 1504.

FIG. 16 is a top view of another implementation of the present structural floor joist 1600, according to an implementation. Structural floor joist 1600 includes a lateral tab 1602, longitudinal tab 502 and a lateral tab 1604; having holes 1219, 435 and 1221, respectively. The structural floor joist 1600 also includes the web 410 side 1608 of the structural floor joist 1600 and an open side 1606 of the structural floor joist 1600.

FIG. 17 is a top view of another implementation of the present structural floor joist 1700 having an inverse pattern of longitudinal tabs and lateral tabs, according to an implementation. Structural floor joist 1700 includes longitudinal tab 502, lateral tab 1602 and longitudinal tab 502, having holes 435, 1219 and 435, respectively. The structural floor joist 1700 also includes a web 410 side of the structural floor joist 1700 and an open side of the structural floor joist 1700. The pattern of longitudinal tabs and lateral tabs is variable.

FIG. 18 is a side view of another implementation of the present structural floor joist 1800, according to an implementation. The structural floor joist 1800 includes a lateral tab 1602, a longitudinal tab 502, a return 450 in the foreground and an indication of a width 1802 of the return 450 and a web 410 in background.

FIG. 19 is a partial isometric view of one implementation of the present structural floor joist 1900 having an inverse pattern of longitudinal tabs and lateral tabs, according to an implementation. The structural floor joist 1900 includes a lateral tab 1602, a longitudinal tab 502, a return 450 in the foreground and an indication of a width 1802 of the return 450 and a web 410 in background. The pattern of longitudinal tabs and lateral tabs is variable.

FIG. 20 is a partial isometric view of one implementation of the present structural floor joist 2000, according to an implementation. The structural floor joist 2000 includes a lateral tab 1602, a longitudinal tab 502, a top flange 415, a flange return 450 and a web 410.

FIG. 21 is a partial isometric view of one implementation of the present structural floor joist 2100, according to an implementation. The structural floor joist 2100 includes a longitudinal tab 502, a top flange 415 and a lateral tab 1602, the web 410 side 1608 of the structural floor joist 2100 and an open side 1606 of the structural floor joist 2100. From the top flange 415 the web 410 side 1608 of the structural floor joist 2100 extends downward to the base of the structural floor joist 2100 and on the opposite of the top flange 415 the return extends downward from the top flange 415 only partially leaving the open side 1606 of the structural floor joist 2100.

FIG. 22 is an isometric view of another implementation of the present structural floor joist 2200 having an inverse pattern of longitudinal tabs and lateral tabs, according to an implementation. The structural floor joist 2200 includes two longitudinal tabs 502, a top flange 415 and two lateral tabs 1602 and a web 410. The pattern of longitudinal tabs and lateral tabs is variable.

FIG. 23 is an isometric view of another implementation of the present structural floor joist 2300, according to an implementation. FIG. 23 illustrates one of the ways in which the form can be held in place. The floor joist 2300 as shown in FIG. 23 includes a longitudinal tab 502, a forming material mound 2302 of forming material, a blocking 2304, a form 2306, a forming material 210, a reinforcing 2308, a top flange 415, a clip 2310 (temporary or permanent), and a joist 400. The reinforcing 2308 is used when a cementitious forming material 102 is used for the forming material 210. This implementation does not utilize metal deck (such as in FIG. 2 and FIG. 3). Instead of metal deck, a form 2306 is placed between the joists such that the form 2306 becomes the base for the forming material 210. The form 2306 may either be permanent or temporary. The form 2306 extends from joist to joist, typically extending from the open side 1606 of the joist to the web side of the adjacent joist. In situations where the form 2306 meets the open side 1608 of a joist, the form 2306 continues under the return 450 until the form 2306 meets the web 410, which allows for the form 2306 to become the base of the forming material 210 between the two adjacent joists as well as the forming material 210 that extrudes through the holes in the joist created as the result of punching out the lateral and longitudinal tabs (e.g. 1602 and 502). The form 2306 can be held in place in various conventional manners.

FIG. 24 is an isometric view of the present structural floor joist 2300, according to an implementation. The floor joist 2300 as shown in FIG. 24 includes a joist bottom flange 209, a top flange 415, flange return 450, a joist return bottom 1260, forming material 210, a form 2306 and a clip 2310 that is affixed to the web 410 of the joist. The temporary clip 2320 is used to support the form 2306 on the web side of the floor joist 2300

FIG. 25 is an isometric view of another implementation of the present structural floor joist 2400, according to an implementation. The floor joist 2300 as shown in FIG. 25 includes a blocking 2304, a web 410, a joist bottom flange 209, a top flange 415, flange return 450 and a joist return bottom 1260. The floor joist 2300 as shown in FIG. 25 includes a form 2036 positioned on the open side of the floor joist 2300. The blocking 2304 is supported by the joist flange bottom 209 and held in place by the joist return bottom 1260. The blocking 2304 is located on the opposite side of the web 410 as the clip 2310.

The floor joist 2300 as shown in FIG. 25 also illustrates a separate form that is placed on the clip side of the web. The web 410 separates the form of the blocking side of the floor joist 2300 as shown in FIG. 25 from the form 2306 on the clip side of the joist. The form 2036 is supported by the blocking 2304 below. The clip on the web side of the joist 2300 supports the form 2036 on the web side of the floor joist 2300. The floor joist 2300 as shown in FIG. 25 includes a form 2036 that is positioned on the web side of the floor joist 2300, that are separated by the web 410. When the forming material 210 is poured on top of the form 2036, the forming material 210 forms around the portion of the web 410 above the form 2036 on the clip side over the top flange 415 and around the flange return 450 on the blocking side 2036 of the web and the open side 1606 of the floor joist 2300. Although not shown in FIG. 25, the forming material 210 also extrudes through the hole in the top flange 415 and is caught by the form 2036 that is positioned under the flange return 450 on the blocking side 2036 of the web and the open side 1606 of the floor joist 2300.

FIG. 26 is an isometric view of the present structural floor joist 2300, according to an implementation. FIG. 26 shows structural flood joist 2300 in situations where temporary forms and temporary clips have been used and are removed after the forming material 210 is solidified. The floor joist 2300 as shown in FIG. 26 includes a forming material 210, a forming material mound 2302, a joist bottom flange 209 and a joist return bottom 1260.

FIG. 27 is an isometric view of the present structural floor joist 2300, according to an implementation. The floor joist 2300 as shown in FIG. 27 includes a longitudinal tab 502, a hole 435 in the top flange 415, a forming material mound 2302, a reinforced forming material 2702, and a form 2306. The reinforced forming material 2702 can be reinforced using different types and quantities of reinforcing material.

FIG. 28 is an isometric view of a metal deck flooring system 2800, according to an implementation. The metal deck flooring system 2800 illustrates the use of metal deck placed on top of the joists as opposed the use of forms that are placed between the joists. The metal deck flooring system 2800 includes a metal deck 2802; the corrugation of the metal deck by a rib 2804 and valley 2806; holes 2808 in the metal deck 2802 that allow the longitudinal tabs 502 and lateral tabs 1602 to penetrate through the metal deck 2802; the holes 435 and 1219 in the top flange of the joist; the web 410; the joist flange bottom 209; the joist return bottom 1260; the top flange 415 and the forming material stop 2810.

The dimensions of the deck holes 2808 are variable. Typically, the dimensions of the deck holes 2808 allow for both the longitudinal tabs 502 and the lateral tabs 1602 to pass through the metal deck 2802. In addition, the deck holes 2808 typically allow for the adjustment of the metal deck longitudinally and laterally. The deck holes 2808 and the flange holes 435 and 1219 align to allow the forming material 210 to extrude through the deck holes 2808 and the flange holes 435 and 1219 when the forming material 210 is poured onto the metal deck 2802. The forming material stop 2810 catches the extruding forming material 210 and allows the extruding forming material 210 to form and solidify in a forming material mound 2302 that typically has a larger circumference than both the deck holes 2808 and the flange holes 435 and 1219.

FIG. 28 includes a forming material stop 2810 that is an optional component part of FIG. 2-FIG. 9 and FIG. 12-FIG. 22 that is not shown in those figures. The forming material stop 2810 can be formed using light gauge metal or similar materials (e.g. plastic). The forming material stop 2810 can be adhered or attached to the web 410 of the joist, adhered to or attached to the bottom of the top flange 415 or adhered to or attached to the flange return 450 or supported from the joist flange bottom 209. The forming material stop 2810 forms a stop under the top flange 415 and below the plurality of tabs (e.g. 502 and 1602). When the forming material 210 extrudes through the deck holes 2808 and the flange holes 435 and 1219, the forming material 210 forms on and is supported by the forming material stop 2810.

FIG. 29 is an isometric view of a metal deck flooring system 2900, according to an implementation. The metal deck flooring system 2900 as shown in FIG. 29 includes a metal deck 2802; the corrugation of the metal deck by a rib 2804 and valley 2806; holes 2808 in the metal deck 2802 that allow the longitudinal tabs 502 and lateral tabs 1602 to penetrate through the metal deck 2802; the holes 435 and 1219 in the top flange of the joist; the web 410; the joist flange bottom 209; the joist return bottom 1260; the top flange 415; the forming material stop 2810; the forming material 210; a forming material stop web attachment area 2902 and a forming material stop flange return attachment area 2904.

FIG. 30 is an isometric view of a metal deck flooring system 3000, according to an implementation. The metal deck flooring system 3000 as shown in FIG. 30 includes a metal deck 2802; the corrugation of the metal deck by a rib 2804 and valley 2806; holes 2808 in the metal deck 2802 that allow the longitudinal tabs 502 and lateral tabs 1602 to penetrate through the metal deck 2802; the holes 435 and 1219 in the top flange of the joist; the web 410; the joist flange bottom 209; the joist return bottom 1260; the top flange 415. In FIG. 30, the flange return 450 is bent back towards the web 410 to form the forming material stop 3002 upon which the extruded forming material 210 can form.

FIG. 31 is an isometric view of a metal deck flooring system 3100, according to an implementation. The metal deck flooring system 3100 as shown in FIG. 31 includes a metal deck 3102; the corrugation of the metal deck by ribs 2804 and valleys 2806; longitudinal tabs 502 and lateral tabs 1602 that are fixed to the topside of the valleys 2806 of metal deck 3102; the web 410; the joist flange bottom 209; and the top flange 415. In metal deck flooring system 3100, the metal deck 3102 is placed upon the top flange 415 and then secured to the top flange 415. Longitudinal tabs 502 and lateral tabs 1602 are affixed to the metal deck 3102 and the top flange 415 of the joist below. Forming material 210 (not shown in FIG. 31) is then poured on to the metal deck 3102 and allowed to form around the longitudinal tabs 502 and the lateral tabs 1602.

FIG. 32 is a side view of a block diagram of longitudinal tabs or lateral tabs fixed to the topside of the valleys of a metal deck 3102, according to an implementation. In FIG. 32, the longitudinal tabs or lateral tabs are affixed to the topside of the valleys of a metal deck 3102 via one or more screws 3202 that are screwed through a tab base 3204 of the tab, the metal deck 3102 and the top flange of the joist below.

In some implementations, the present disclosure comprises methods and devices for forming a structural floor joists in FIG. 2-9 and FIG. 12-22. The device used in certain implementations of the method comprises a punch and die mechanism to form the tabs in the flange of the structural floor joists in FIG. 2-9 and FIG. 12-22 according to certain implementations of the present disclosure. A major advantage of some implementations of these methods and devices is that only one strike by the punch and die mechanism is needed to form the tabs of the present structural floor joists in FIG. 2-9 and FIG. 12-22. One implementation of the method comprises striking the flange of the floor joist in FIG. 2-9 and FIG. 12-22 with a punch and forcing the punch into a die, creating a tab punched out of the flange. The tab comprises a tab leg that is substantially planar and is connected to the flange at the tab base. The tab leg projects outwardly from the flange at an angle of less than ninety degrees to the flange. The tab also comprises a tab foot extending from the tab leg created by the tab being punched out of the flange. In some implementations, the hole in the flange is defined by the base of the tab and the top side of hole. The side of the hole where the base of the tab is located has a greater length than the top side of the hole. The tab leg extends from the tab leg base.

The tapered shape of the hole in the flange allows for better clearance of the die that forms the tab in the structural floor joists in FIG. 2-9 and FIG. 12-22.

All of the methods and devices disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the methods and devices of this disclosure have been described in terms of preferred implementations, it will be apparent to those of skill in the art that variations may be applied to the methods and devices and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the disclosure. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the disclosure as defined by the appended claims.

The claims are not to be interpreted as including means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.

Claims

1. An apparatus comprising:

a forming material; and

a member having: a flange having a central longitudinal axis; and a web that extends from the flange; a plurality of tabs punched out of the flange, forming a hole for each of the plurality of tabs, yielding a plurality of holes,

wherein a portion of the forming material extrudes through at least one of the holes and the portion of the forming material is bonded to the forming material to the tabs and the flange of the member, forming a bonded composite assembly of the member and the forming material,

wherein the bonded composite assembly having a centroid that is located in or near the forming material, placing 100% or near or about 100% of the forming material in compression and placing at least 90% of the member in tension.

2. The apparatus of claim 1, wherein the centroid of the bonded composite assembly is located at a bottom plane of the forming material.

3. The apparatus of claim 2, wherein the centroid of the bonded composite assembly is located at the middle of the flange and between the web and the flange return.

4. The apparatus of claim 1, wherein each of the plurality of tabs comprise:

a tab leg that is substantially planar and is connected to the flange at one end of the tab leg of each of the plurality of tabs and that projects outwardly from the flange at an angle of less than 90 degrees to the flange; and

a tab foot extending from the tab leg of each of the plurality of tabs and curving in a direction that is (i) toward a plane extending perpendicular to the central longitudinal axis through the one end of the tab leg of each of the plurality of tabs and (ii) away from a hole in the flange created by the tab being punched out of the flange, wherein the hole is defined by a base side and a top side, the base side has a greater length than the top side and the tab leg of each of the plurality of tabs the extends from the base side, wherein the tabs of each of the plurality of the member comprises a first tab and a second tab, wherein one of the first tab and the second tab of each member being a lateral tab and the other of the first and second tabs of each member being a longitudinal tab; a total surface area of the holes created by the tabs is greater than about 10% of the total surface area of the flange; and

wherein the tabs of the member and a structural mesh is embedded in the forming material with the tab foot of each tab curving in the direction that is away from the respective hole in the respective flange created by the tab punched out of the respective flange and with the webs not embedded in the forming material.

5. The apparatus of claim 4 being pre-cast and further comprising:

at least one lifting anchor embedded in the forming material.

6. The apparatus of claim 5 being pre-cast and further comprising:

the at least one lifting anchor being embedded in the structurally reinforced forming material.

7. The apparatus of claim 5, wherein the end of the tab leg of each lateral tab that is connected to the respective flange is substantially perpendicular to the end of the tab leg of each longitudinal tab that is connected to the respective flange.

8. The apparatus of claim 4, wherein the member further comprises:

16 gage in thickness.

9. The apparatus of claim 8, wherein the member further comprises:

a tensile strength of 50 ksi.

10. An apparatus comprising:

a plurality of members, each of the plurality of members comprising: a forming material; a flange having a central longitudinal axis; and a web extending from the flange; and a plurality of tabs punched out of the flange, forming a hole for each of the plurality of tabs, forming a plurality of holes,

wherein a portion of the forming material extrudes through at least one of the holes and the portion of the forming material is bonded to the forming material to the tabs and the flange of the member, forming a bonded composite assembly of the member and the forming material, that has a centroid that is located in or near the forming material, placing 100% or near or about 100% of the forming material in compression and placing at least 90% of the member in tension.

11. The apparatus of claim 10, wherein the centroid is located at a bottom plane of the forming material.

12. The apparatus of claim 11, wherein the centroid is located above the middle of the web.

13. The apparatus of claim 12, wherein each of the tabs comprise:

a tab leg that is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than 90 degrees to the flange; and

a tab foot extending from the tab leg and curving in a direction that is (i) toward a plane extending perpendicular to the central longitudinal axis through the one end of the tab leg and (ii) away from a hole in the flange created by the tab being punched out of the flange,

wherein the hole is defined by a base side and a top side, the base side has a greater length than the top side and the tab leg the extends from the base side,

wherein the tabs of each of the plurality of the members comprises a first tab and a second tab,

wherein one of the first tab and the second tab of each floor member being a lateral tab and the other of the first and second tab of each member being a longitudinal tab;

a total surface area of the holes created by the tabs is greater than about 10% of the total surface area of the flange; and

wherein the tabs of the plurality of members and a structural mesh are embedded with the tab foot of each tab curving in the direction that is away from the respective hole in the respective flange created by the tab punched out of the respective flange.

14. The apparatus of claim 13, wherein the end of the tab leg of each lateral tab that is connected to the respective flange is substantially perpendicular to the end of the tab leg of each longitudinal tab that is connected to the respective flange.

15. The apparatus of claim 13, wherein each of the plurality of members further comprise:

16 gage in thickness.

15. (canceled)

16. The apparatus of claim 13, wherein the each tab leg is substantially planar.

17. The apparatus of claim 13, wherein the tabs of the plurality of member and a structural mesh are embedded in forming material.

18. The apparatus of claim 17 being pre-cast and wherein the tabs are embedded in structurally reinforced forming material.

19. The apparatus of claim 18 being pre-cast and further comprising:

at least one lifting anchor is embedded in the forming material with the plurality of member and the structural mesh.

20. The apparatus of claim 10, wherein the forming material further comprises microfibers.

21-120. (canceled)

121. A monolithic structure comprising:

a floor having: a first web; a first top flange extending from a top of the first web; and a first tab attached to, or extending from, the first top flange.

a roof having: a second web; a second top flange extending from a top of the second web; and a second tab attached to, or extending from, the second top flange.

122. The monolithic structure of claim 121, wherein the monolithic structure has a first mid-point between the first top flange and a bottom of the first web, wherein a first centroid being located above the first mid-point, the first centroid being an first equilibrium point of a first compression area of the floor and a first tension area of the floor, the first tension area being below the first centroid and the first compression area being above the first centroid; and wherein the monolithic structure has a second mid-point between the second top flange and a bottom of the second web, wherein a second centroid being located above the second mid-point, the second centroid being an second equilibrium point of a second compression area of the floor and a second tension area of the floor, the second tension area being below the second centroid and the second compression area being above the second centroid.

123. The monolithic structure of claim 122 further comprising:

a first deck on the top of the first top flange, the first deck having a hole, the first tab protruding through the hole in the first deck;

a first forming material on the top of the first deck;

a second deck on the top of the second top flange, the second deck having a hole, the second tab protruding through the hole in the second deck; and

a second forming material on the top of the second deck,

wherein the first web, the first top flange and the first tab comprise a first member,

wherein a portion of the first forming material solidifies around the first tab and the portion of the first forming material is bonded to the first tab, forming a first bonded composite assembly of the first member, the first deck and the first forming material,

wherein the second web, the second top flange and the second tab comprise a second member,

wherein a portion of the second forming material solidifies around the second tab and the portion of the second forming material is bonded to the second tab, forming a second bonded composite assembly of the second member, the second deck and the second forming material.

124-130. (canceled)

131. The monolithic structure of claim 123, wherein the first tab is attached to the first top flange through the first deck via a first attachment apparatus, and the first attachment apparatus does not leave an open hole in the first top flange and the first attachment apparatus does not leave an open hole in the first deck, and wherein the second tab is attached to the second top flange through the second deck via a second attachment apparatus, and the second attachment apparatus does not leave an open hole in the second top flange and the second attachment apparatus does not leave an open hole in the second deck.

132. The monolithic structure of claim 131, wherein the attachment apparatus is selected from the group consisting of screws, welds or pop-rivets, wherein the attachment apparatus is selected from the group consisting of screws, welds or pop-rivets.

133-138. (canceled)