Patent ID: 8069633
Filing Date: 2011-12-06
Classification: C04B,E04B,E04F,Y02W,Y10T

Abstract:
1. A method of providing a building structure with a non-combustible flooring system comprising: making a non-combustible flooring system as the flooring of the building structure, said making step comprising forming a horizontal shear diaphragm supported on a metal frame, the system comprising: metal screw fasteners with winged drillers wherein the winged drillers are located above the point and below the first threads of the screw and protrude laterally from a shaft of the screw; the metal frame; the horizontal shear diaphragm fastened by the metal screw fasteners to the metal frame, the horizontal shear diaphragm comprising the reinforced, lightweight, dimensionally stable structural cementitious panel; the cementitious panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to the metal frame and comprising a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 49 to 68 weight % of a blend of reactive powders, 23 to 36.1 weight % uniformly distributed lightweight filler particles, and 5 to 20 weight % uniformly distributed alkali-resistant glass fibers, and optional superplasticizer; the continuous phase being uniformly reinforced with the glass fibers and uniformly containing the lightweight filler particles, the lightweight filler particles comprising ceramic microspheres and optionally at least one member selected from the group consisting of glass microspheres, fly ash cenospheres or perlite, each on a dry basis, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers), and wherein the blend of reactive powders comprises, on a dry basis, 45 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 40 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan comprising silica fume, wherein the flooring system has a horizontal design shear capacity of the floor shear diaphragm of 300 to 1000 pounds per linear foot, and the frame comprising metal joists, said forming comprising: placing the panel on metal joists of the metal frame; attaching the structural cementitious panel on the metal joist; and wherein the cementitious panel has a thickness of about ¼ to 1½ inches.