Method to bond concrete slab to metal

Abstract

The method of bonding concrete to a metal substrate eliminates the additional costs in time and labor involved in providing a mechanical bond between concrete and metal surfaces (e.g., construction steel). The method involves the use of an adhesive bonding agent applied between the concrete and metal components that cures to bond the two components together. The method may be used to form a laminar composite deck formed by a concrete slab bonded to a metal deck, a composite joint formed by bonding a concrete slab to a metal beam or joist, and other composite structures.

1 . A method of bonding concrete material to a metal substrate material, comprising the steps of: 
 (a) coating at least a portion of the surface of either material with a liquid adhesive bonding agent;    (b) applying the concrete material to the metal substrate material before the bonding agent has cured, capturing the bonding agent coating therebetween; and    (c) completely curing the bonding agent coating between the metal substrate material and the concrete material, thereby forming a concrete and metal composite.    
   
   
       2 . The method of bonding concrete to a metal substrate according to the method of  claim 1 , further including the steps of: 
 (a) applying the bonding agent coating only to the metal substrate material;    (b) allowing the bonding agent coating to cure partially;    (c) pouring a wet concrete slurry onto the coated metal substrate material; and    (d) allowing the bonding agent to blend with adjacent concrete slurry as the bonding agent and concrete slurry cure completely together.    
   
   
       3 . The method of bonding concrete to a metal substrate according to the method of  claim 1 , further including the step of applying the concrete material to the metal substrate material in a hardened, fully cured state.  
   
   
       4 . The method of bonding concrete to a metal substrate according to the method of  claim 1 , further including the step of applying the bonding agent to the entire contact surface of the material.  
   
   
       5 . The method of bonding concrete to a metal substrate according to the method of  claim 1 , further including the step of mixing the adhesive bonding agent from two separate parts before application.  
   
   
       6 . The method of bonding concrete to a metal substrate according to the method of  claim 1 , wherein the step of applying the adhesive bonding agent coating comprises spraying, brushing, or rolling the bonding agent onto the material.  
   
   
       7 . The method of bonding concrete to a metal substrate according to the method of  claim 1 , further including the step of attaching a metal support component to the metal substrate material.  
   
   
       8 . The method of bonding concrete to a metal substrate according to the method of  claim 7 , wherein the step of attaching the metal support component to the metal substrate material comprises bolting, riveting, or welding.  
   
   
       9 . A laminar composite material, comprising: 
 a layer of concrete;    a layer of metal; and    a bonding agent joining the layers of concrete and metal, the bonding agent forming adhesive bonds to the concrete and adhesive bonds to the metal.    
   
   
       10 . A composite joint, comprising: 
 a slab of concrete;    a metal beam; and    a bonding agent joining the slab of concrete and the metal beam, the bonding agent forming adhesive bonds to the concrete slab and adhesive bonds to the metal beam.