Structural panel, flooring system and corresponding method

Abstract

Disclosed herein is a structural panel, flooring system and method of constructing the flooring system. The structural panel includes two C-shaped channels, a corrugated deck extending between the first C-shaped channel and the second C-shaped channel, wherein the deck, the first C-shaped channel, and the second C-shaped channel define an interior volume, and a concrete slab substantially filling the interior volume and extending above the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels. The flooring system defines a first and second structural panel secured together through an interface component. A corresponding method is disclosed including abutting the two structural members, securing through the interface component, and pouring a concrete slab within the interior volume and extending above the top flanges of the first and second C-shaped channels.

1 . A structural panel comprising:
 a first C-shaped channel defining a first side;   a second C-shaped channel spaced apart from the first C-shaped channel, the second C-shaped channel defining a second side;
 wherein each C-shaped channel comprises a web, a top flange, and a bottom flange; 
   a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channel, the deck having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel,
 wherein the deck, the web of the first C-shaped channel, and the web of the second C-shaped channel define an interior volume; and 
   a concrete slab substantially filling the interior volume and extending above the top flanges of the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels.   
     
     
         2 . The structural panel of  claim 1 , wherein the corrugated deck is manufactured from cold-formed steel. 
     
     
         3 . The structural panel of  claim 1 , wherein the corrugated deck is continuously welded to the inner surface of the web of the first and second C-shaped channels at a first vertical distance from the top flange, wherein the first vertical distance is smaller than a second vertical distance from the bottom flange. 
     
     
         4 . The structural panel of  claim 1 , wherein the corrugated deck is continuously welded to the inner surface of the web of the first and second C-shaped channels at a first vertical distance from the top flange, wherein the first vertical distance is equal to a second vertical distance from the bottom flange. 
     
     
         5 . The structural panel of  claim 1 , wherein the web of each of the first and second C-shaped channels comprises at least one interface component for aligning the structural panel with at least one corresponding web of an adjacent structural panel. 
     
     
         6 . The structural panel of  claim 5 , wherein the corrugated deck has a width such that the bottom flanges of the first and second C-shaped channels and the corrugated deck define a cavity large enough to accommodate placement of one or more members selected from the group of: insulation, electrical wiring, water and/or gas piping, electrical boxes and electrical devices. 
     
     
         7 . The structural panel of  claim 1 , wherein the first and second C-shaped channels are made from cold-formed steel. 
     
     
         8 . The structural panel of  claim 1 , wherein the interaction between the concrete slab and the first and second C-shaped channels provides a composite action. 
     
     
         9 . A flooring system comprising:
 a first structural panel; and   a second structural panel;
 wherein each structural panel comprises:
 a first C-shaped channel defining a first side; 
 a second C-shaped channel spaced apart from the first C-shaped channel, the second C-shaped channel defining a second side;
 wherein each C-shaped channel comprises a web, a top flange, and a bottom flange; 
 
 a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channel having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel,
 wherein the corrugated deck, the web of the first C-shaped channel, and the web of the second C-shaped channel define an interior volume; and 
 
 a concrete slab substantially filling the interior volume and extending above the top flanges of the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels,
 wherein the web of each of the first and second C-shaped channels comprise at least one interface component for aligning the first structural panel with the second structural panel, 
 
 
   wherein an outer surface of the web of the first side of the second structural panel abuts against an outer surface of the web of the second side of the first structural panel;   wherein the at least one interface component of the first structural panel aligns with the at least one interface component of the second structural panel, and   wherein the respective interface components of the first and second structural panels are adapted to secure the first structural panel to the second structural panel.   
     
     
         10 . The flooring system of  claim 9 , further comprising a third structural panel, wherein an outer surface of the web of the first side of the third structural panel abuts against an outer surface of the web of the second side of the second structural panel, wherein the respective interface components of the second and third structural panels align and are adapted to secure the second structural panel to the third structural panel. 
     
     
         11 . The flooring system of  claim 9 , wherein the structural panels are supported by at least two primary support structures. 
     
     
         12 . The flooring system of  claim 11 , wherein the at least two support structures are support beams. 
     
     
         13 . The flooring system of  claim 11 , wherein the at least two support structures are load bearing walls. 
     
     
         14 . A method of assembling a flooring system comprising:
 (a) aligning a first structural member with a second structural member, wherein each structural member comprises:
 a first C-shaped channel defining a first side; 
 a second C-shaped channel spaced apart from the first C-shaped channel, the second C-Shaped channel defining a second side;
 wherein each C-shaped channel comprises a web, a top flange, 
 and a bottom flange; and 
 
 a corrugated deck extending between the web of the first C-shaped channel and the web of the second C-shaped channels having a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second c-shaped channel,
 wherein each web of the first and second C-shaped channels comprises at least one interface component for aligning the first structural member with the second structural member; 
 
   (b) abutting an outer surface of the web of the first side of the second structural member against an outer surface of the web of the second side of the first structural member such that the at least one interface component of the first structural member aligns with the at least one interface component of the second structural member;   (c) securing the first structural member to the second structural member using the respective interface components of the first and second structural members; and   (d) pouring a concrete material onto the first and second structural members, wherein the concrete material forms into a concrete slab, wherein the concrete slab substantially fills the interior volume and extends above the top flanges of each of the first and second structural members, wherein the concrete slab defines a top surface above the top flanges of each C-shaped channel.   
     
     
         15 . The method of  claim 14 , further comprising, prior to the pouring step, repeating steps (a), (b), and (c) with additional structural members.