Patent ID: 12246401

DETAILED DESCRIPTION OF AT LEAST ONE PREFERRED EMBODIMENT OF THE INVENTION

Referring to the drawings more particularly, a metal decking panel for use in composite floor structure10as shown inFIG.1, includes metal decking panels12with a plurality of longitudinally oriented hollow ribs14disposed in generally parallel spaced relationship with a flat panel section16disposed between adjacent ribs. Metal decking panels12have opposing width sides18and opposing length sides20and may be provided in different widths, typically 24″ or 36″, and different lengths, typically 20′ or 30′ lengths, but other widths and lengths may be used. Metal decking panel12is typically formed of 16 to 22 gauge steel and panels may be stacked double thickness or more and plain, coated or galvanized. Length side20of each decking panel12will nestle into the next panel for a continuous floor construction. In an illustrative but non-limiting example, a 24″ panel, ribs14may be 4¾″ wide with a center reinforcing rib ½″ high. Flat panel sections16may also be 4¾″ wide with a center reinforcing rib that is ½″ high.

As shown inFIG.1, a plurality of decking panels12are positioned on underlying I-beams22positioned along width sides18and midway along length side20. Each of I-beams has an upper flange24, a web26and a lower flange28. Upper flange24is in underlying contact with flat panel section16of metal decking panels12. I-beams22are formed of steel and may be coated with mill scale, rust, paint, insulation, galvanizing or the like.

Flat panel sections16of metal decking panels12have a plurality of openings30engineered to align with a theoretical centerline32of each of the underlying I-beams. Openings30are punched, cut or otherwise formed in decking panels12. Each of openings30is sized such a stud34may be passed through. In other instances, opening30may be sized to pass both stud34and a support ferrule (not shown) through. With I-beams22having an 8″ wide upper flange24, openings 1½ by 4″ have been found satisfactory as has a 1½″ circle or a 1½ by 2½ oval. Other shapes are sizes of openings30are possible.

Composite floor structure10is flattened, fastened, ground to form a welding zone in the openings and studs weld through a sequence of steps as shown inFIG.2making use of a flattening and fastening cart36, a grinding cart38and a stud welding cart40as described below.

As more particularly shown in the drawings and identified in the attached list of references, each of carts36,38and40is a rectilinear structure with a top frame100, a bottom frame102and a front frame104. Bottom frame102has front and rear transverse members106,108, respectively, joined to lateral side members110. Front transverse member106is position inside outboard ends112of lateral side members110. A plurality of spaced apart ball rollers114are positioned on an underside of transverse members106,108and lateral members110, said outboard ends112with rollers114forming an outrigger. As shown inFIG.17, carts36and38have one row of rollers and as shown inFIG.18cart40has two rows of rollers.

In each of carts36,38, and40front frame is joined to top frame100and bottom frame102with vertical side members116and with an intermediate vertical member118with upper and lower bearing brackets for attachment of a vertical side120positioned between outboard ends112of lateral side members110. In the case of cart36, slide120is attached to a tool for fastening metal decking panel12to the underlying I-beams22. The weight of cart36together with the equipment and supplies loaded thereon flattens metal decking panel12against the I-beams22. In the case of cart38, the tool removes contaminants from upper flange24in the window provided by openings30providing a clean welding zone. In the case of cart40, the tool delivers and welds studs34in the cleaned welding zone. An important feature of the rectilinear structure of carts36,38and40is that a working end of each tool is held perpendicular to composite floor10during the fastening, flattening, grinding or welding operations. Other than for bottom frame102and the location of ball rollers114, cart40is as described in U.S. Pat. Nos. 8,507,824 and 9,630,270.

The following is a list of reference numbers shown in the drawings. However, it should be understood that the use of these terms is for illustrative purposes only and use of reference numbers correlating a certain term that is both illustrated in the drawings and present in the claims is not intended to limit the claims to only cover the illustrated embodiment:

10Composite floor,12metal decking panels,14ribs,16flat panel sections,18width sides,20length sides,22I-beams,24upper flange,26web,28lower flange,30openings,32centerline,34stud,36flattening & contaminate cart,38contaminate removing cart,40stud welding cart,42ball transfer,44front plate,46tool balancer,48balancer mount,50bearing offset (bracket),52extension slide,54extension,56tool clamp,58fastening tool,60fastener depth analyzer,62storage area for fasteners to add weight for flattening deck,64control cable to analyzer,66distance sensor,68ergonomic spring,70contaminate removal tool,72switch block extension,74moveable trigger handle,80column support, assembly,82alignment guide assembly,84stud catcher assembly,86stud trough assembly,87switch block assembly,88moveable arm assembly,89tool balancer assembly,90gun extension assembly,92time current lift plunge analyzer,94assembled ferrule master ferrules,96ferrule stick dispenser,98box of stud shear connectors,100top frame,102bottom frame,104front frame,106front transverse member,108rear transverse member,110lateral side members,112outboard end,114ball rollers,116vertical side members,118intermediate vertical member and120vertical slide.

In Use how the New Equipment Will Work in the Field

First Crew: A crew will lay down sheets of decking12on upper flange of the I-beams to form a composite floor decking. For now, this process remains the same as traditional. Please note that this new decking is no harder to install, nor does it take any longer to accomplish than the traditional method of laying decking does. In fact, it is believed that the overall process easier to complete and with a much higher level of quality assurance.

Turning now toFIGS.14-16:

Second Crew: The workmen may continue to use the traditional method of puddle welding a ⅝″ diameter puddle weld to fasten the decking. But that requires a welding machine with long weld cables and ground cable, etc. However in the traditional method, the worker cannot be positive that there was a full or complete ⅝″ puddle weld penetration on each and every weld, etc. to the hidden beam. With see-through slots30, fastening of the decking panel12with cart36is more efficient with better quality. A worker can confirm that the distance between the lower of the decking and upper flange is tight.

Third Crew: This would be an additional crew compared to the traditional method and is part of the new design. In it, another worker with cart38will grind the area over the center flange of the beam and inside the opening30to clean and remove any residual contaminates and prepare the weld zone for an optimum weld.

Fourth Crew: The next crew with cart40will place the ferrules and stud into through openings30and weld the stud shear connectors34to the I-beam. Because the welder does not have to burn through the thicknesses of decking and the galvanize coating on the decking approximately 30% less weld current is required and the weld time is shorter, thus reducing cost. Weld quality is far superior on clean steel than through galvanized decking.

Fifth Crew: One ironworker will place any desired covers over any voids showing through the steel and fasten the covers with fasteners.

In view of the present disclosure, among the differences to the traditional process of laying a decking, fasting the decking and welding stud shear connectors may be mentioned:Paint, galvanize, or coat top flanges of beams—never before allowedInstall new deck with openings—never before doneNew deck allows unlimited thickness and the number of sheets that can be stacked—never before allowedOpenings in deck help determine center of beam to help reduce arc blow and if deck is down tight or not—never before accomplishedErgonomically flatten deck—never before doneErgonomically fasten deck and scientifically inspect the fastener depth—never before doneErgonomically Grind or clean weld zone to be free of contaminates—never before doneErgonomically weld studs faster, with less time and current, less arc blow and less weld fumes—never before done when comparing to traditional welding thru deck in composite constructionCap any openings in the deck—never before done

In view of the above, it will be seen that the several benefits of the invention noted above are achieved and other advantageous results attained. As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.