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Claims  |
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What is claimed is:
1. A metal decking member having alternatively substantially coplanar
crests and substantially coplanar valleys connected by grooved sidewalls
and a metal snapin cover plate to form a three-cell electrical raceway,
said cover plate comprising:
a single elongated sheet of metal with three lateral sections,
the outer two of three said sections having a flat portion at a first
elevation and an outer edge portion being adapted to engage a groove in
the sidewall of the decking member adjacent one of the crests,
the inner one of said three sections having a flat portion lower than the
flat portion of said outer sections by 3/8 inch or more, the flat portion
of said inner section being interconnected at its lateral extremities with
the flat portions of said outer sections by a dual wall, longitudinally
extending leg open at the upper end and closed at the lower end, said
closed end being adapted to engage the underlying decking member and
thereby form with the underlying decking member three longitudinally
extending cells for electrical wiring, said legs being resiliently
compressible in a lateral direction adjacent said flat portions
sufficiently to permit a snap-on engagement of said outer edge portions
with the grooves in the sidewalls of the adjacent decking members.
2. A metal decking member having alternatively substantially coplanar
crests and substantially coplanar valleys connected by sidewalls and a one
piece metal cover paate to form a three-cell electrical raceway within a
single valley, said cover plate comprising:
a single elongated sheet of metal with three lateral sections,
the outer two of three said sections having a flat portion at the same
elevation and an outer edge portion at an elevation lower than that of
said flat portion, said outer edge portion being adapted to engage a
sidewall of the decking adjacent one of the crests to secure said cover
plate to the decking member;
the inner one of said three sections having a flat portion interconnected
with the flat portions of said outer sections by a dual wall,
longitudinally extending leg open at the upper end and closed at the lower
end, said closed end being adapted to engage the underlying decking member
and thereby form with the underlying decking member three longitudinally
extending cells for electrical wiring in a single valley.
3. A metal decking member having alternatively substantially coplanar
crests and substantially coplanar valleys connected by sidewalls and a
metal cover plate to form a plural cell electrical raceway, said cover
plate comprising outer edge portions adapted to engage a sidewall of the
decking member adjacent one of the crests to thereby secure said cover
plate to the decking member at a height below the height of the crests of
the decking member, and at least one longitudinally extending leg adapted
to engage a valley of the underlying decking member and thereby form with
the underlying decking member when secured thereto at least two
longitudinally extending cells for electrical wiring,
the upper surface of said cover plate rising above the height of said outer
edge portions at one or more points intermediate said outer edge portions
but spaced therefrom as to permit the access of concrete poured thereover
to the sidewalls of the decking members above the elevations of said outer
edge portions when said cover plate is secured to the decking member
whereby the capacity of the cells beneath said cover plate is increased
without loss of composite action adjacent the crests of the decking member
when said cover plate is secured thereto and concrete poured thereover.
4. In combination with a metal decking member having alternatively
substantially coplanar crests and substantially coplanar valleys connected
by sidewalls, said sidewalls having a groove adjacent the crests, a
one-piece metal snap-in cover plate for forming a plural cell electrical
raceway, said cover plate comprising:
a single elongated sheet of metal with at least two lateral sections,
said sheet having outer edge portions curved to substantially conform to
the shape of the grooves in said sidewall to facilitate the insertion
therein and thereby position said cover plate over a valley of the decking
member to form a longitudinally extending electrical raceway,
said cover plate having a width greater than the spacing between adjacent
crests and approximately the spacing between grooves,
adjacent ones of said sections being interconnected by a dual wall,
longitudinally extending leg, open at the upper end and closed at the
lower end, said closed end being adapted to engage the underlying decking
member and thereby form with the underlying decking member longitudinally
plural extending cells for electrical wiring, said legs being generally
V-shaped with a radius of curvature of the lower end thereof not greater
than 1/8 inch and resiliently compressible in a lateral direction adjacent
said sections sufficiently to permit a snap-in engagement of said outer
edge positions with the grooves in the sidewalls of the decking member.
5. The cover plate of claim 4 wherein the number of said legs is two and
the number of said lateral sections is three.
6. The cover plate of claim 4 wherein the number of said legs is one and
the number of said lateral sections is two, said one leg being laterally
displaced from the center of said cover plate to thereby form two cells or
significantly different capacity.
7. The cover plate of claim 6 wherein the valley of the decking member for
which used also includes at least one raised portion and wherein said leg
engages the raised portion of the decking member when in position over the
valley to thereby form said cells.
8. The cover plate of claim 6 wherein the valley of the decking member for
which used also includes at least one raised portion and wherein said leg
engages the decking member adjacent the raised portion when in position
over the valley to thereby form said cells.
9. The cover plate of claim 6 wherein the capacity of said two cells has a
ratio of about 2.5:1.
10. In combination with a decking member having alternatively substantially
coplanar crests and substantially coplanar valleys connected by sidewalls,
a one-piece cover plate comprising:
a single elongated sheet of metal with two lateral sections each having an
outer edge portion adapted to engage a sidewall of the decking member
adjacent one of the crests, and being interconnected by a dual wall,
longitudinally extending leg open at the upper end and closed at the lower
end, said closed end being adapted to engage the underlying decking member
and thereby form with the underlying decking member two longitudinally
extending cells for electrical wiring, said dual walls being sufficiently
close together at said upper end to prevent any substantial amount of
concrete from entering the space there between.
11. A metal decking member having two substantially coplanar crests and an
interior valley connected by sloping sidewalls and a one-piece metal cover
plate to thereby form an electrical raceway, said cover plate comprising:
a single elongated sheet of metal with three lateral sections;
the outer two of three said sections having flat portion at a first
elevation and an outer edge portion at an elevation lower than that of
said flat portion, said outer edge portion being adapted to engage a
sidewall of the decking member adjacent one of the crests to thereby
position said cover plate over said interior valley and contiguous
sidewalls;
the inner one of said three sections having a flat portion at a height
below the height of the flat portions of said outer sections and
interconnected therewith by depending legs.
12. The cover plate of claim 11 including means adjacent the lateral
extremities of said inner section adapted for engagement with an upwradly
extending ridge in the decking member.
13. The cover plate of claim 12 wherein said inner section is below the
height of said outer edge portions whereby said cover plate may be
positioned with said outer edge portions engaging the side walls of a
decking member, with said outer sections substantially coplanar with the
crests thereof and with said inner section below the height of the
connection of said cover plate to the sidewalls of the decking member.
14. The cover plate of claim 13 wherein the width ratio of inner to outer
flat portions is about 1:1.
15. The cover plate of claim 13 wherein the width ratio of inner to outer
sectons is about 1.65:1.
16. The cover plate of claim 11 wherein the differnece in the height of the
flat portion of said inner section and the flat portion of said outer
sections is not less than aobut 3/8 inch.
17. The cover plate of claim 11 wherein the difference in elevation between
the flat and outer edge portions of said outer sections is such that said
flat portions are substantially coplanar with the crests of the metal
decking member when used therewith and the elevation of the flat portion
of said inner section is about the elevation of said outer edge portion.
18. The cover plate of claim 11 including a first pair of knockouts, each
laterally spanning most of the width of one of said legs and more than
about seventy-five percent of the width of one of the flat portions in
said outer sections to thereby provide, when removed, a downwardly and
outwardly entrance through the cover plate to the area beneath said outer
two longitudinal sections.
19. The cover plate of claim 18 including a second pair of knock-outs in
said inner section, said second pair being longitudinally spaced from but
adjacent to said first pair to thereby provide two entrances to the area
beneath the inner longitudinal secton.
20. The cover plate of claim 19 including apertures in the flat portion of
said inner section, longitudinally spaced one each outside of said second
pair of knock-outs for the attachment of a preset insert.
21. In combination with a metal decking member having two substantially
coplanar crests and an interior valley connected by sloping sidewalls, a
one-piece metal cover plate comprising:
a single elongated sheet of metal with three lateral sections;
the outer two of three said sections having a flat portion at a first
elevation and an outer edge portion at an elevation lower than that of
said flat portion, said outer edge portion being adapted to engage a
sidewall of the decking adjacent one of the crests to thereby position
said cover plate over said interior valley and contiguous sidewalls;
said three sections being separated by longitudinally extending upwardly
convex grooves.
22. The cover plate of claim 21 including a pair of knockouts each
extending into one of said flat portions and the one of said grooves
adjacent thereto.
23. The cover plate of claim 22 wherein each of said knockouts are
generally convex into said flat portions.
24. In combination with a metal decking member having two substantially
coplanar crests and an interior valley connected by sloping sidewalls, a
one-piece metal cover plate comprising:
a single elongated sheet of metal with three lateral sections;
the outer two of three said sections having a flat portion at a first
elevation and an outer edge portion at an elevation lower than that of
said flat portion, said outer portion being adapted to engage a sidewall
of the decking adjacent one of the crests to thereby position said cover
plate over said interior valley and contiguous sidewalls;
a pair of longitudinally spaced, raceway access apertures in said inner
section; and
a pair of laterally spaced, raceway access apertures extending one each
into one of said outer sections longtidinally intermediate said pair of
longitudinally spaced apertures.
25. The cover plate of claim 24 wherein said laterally spaced apertures are
generally arcuate and convex into said flat portions; and
including a grommet for the arcuate portion of said laterally spaced
apertures.
26. The cover plate of claim 24 wherein each of said longitudinally spaced
apertures is generally rectangular with a neck portion extending
longitudinally toward the other of said Iongitudinally spaced apertures;
and
including a grommet for each of said longitudinally spaced apertures, said
grommet following the rectangular shape of said aperture in the area of
said neck.
27. In combination with a metal decking having alternatively substantially
coplanar crests and substantailly coplanar valleys connected by sidewalls,
a one-piece metal snap-in cover plate for use with said decking member to
form a three-cell electrical raceway, said cover plate comprising:
a single elongate sheet of metal with three lateral sections,
the outer two of three said sections having a flat portion at a first
elevation and an outer edge portion at an elevation lower than that of
said flat portion, said outer edge portion being adapted to engage a
sidewall of the decking adjacent one of the crests to thereby position
said flat portions substantially coplanar with the crests,
the inner one of said three sections having a flat portion interconnected
with the flat portions of said outer sections by a dual wall,
longitudinally extending leg open at the upper end and closed at the lower
end, said closed end being adapted to engage the valley of the underlying
decking and thereby form with the underlying decking three longitudinally
extending cells for electrical wiring, said legs being resiliently
compressible in a lateral direction adjacent said flat portions
sufficiently to permit a snap-in engagement of said outer edge portions
with the sidewall of the decking member.
28. The cover plate of claim 27 wherein the elevation of the flat portion
of said inner section is less than the flat portion of said two outer
sections,
wherein said legs are joined to the flat portions of said outer portions by
a section including an upwardly and outwardly inclined portion, and
including a first pair of knock-outs, each laterally spanning the width of
one of said inclined portions and more than about seventy-five percent of
the width of one of said flat portions to thereby provide when removed a
downwardly and outwardly entrance through the cover plate to the outer two
longitudinal cells.
29. The cover plate of claim 28 including a second pair of knock-outs
longitudinally spaced in said inner section, each longitudinally spaced
from but adjacent to the knock-outs in said outer sections to thereby
provide two entrances to the inner longitudinal cell.
30. The cover plate of claim 29 including a pair of apertures in the flat
portion of said inner section, said apertures being longitudinally spaced
one each outside of said second pair of knock-outs for the attachement of
preset insert.
31. The cover plate of claim 27 wherein said outer edge portions include a
generally flat portion and an upwardly curved portion presenting an
outwardly convex surface adapted to engage a groove in the upper sidewall
of the decking member, said flat portion including a downwardly projecting
longitudinal groove apertured on the outer sidewall thereof to present a
downwardly and outwardly extending channel for a fastener through said
lateral edge into the decking member.
32. The cover plate of claim 31 wherein the elevation of the flat portion
of inner section is less than the flat protions of said outer sections,
wherein said legs are joined to the flat portions of said outer portions by
a section including an upwardly and outwardly inclined portion, and
including a first pair of knock-outs, each laterally spanning the width of
one of said inclined portions and more than about seventy-five percent of
the width of one of said flat portions; and
including a second pair of knock-outs in said inner section, the
longitudinal spacing of said second pair being greater than the length of
said first pair, said first pair being interior of said second pair.
33. The cover plate of claim 27 including means projecting from one wall of
each of said dual wall legs toward the other wall thereof in the middle
third of the length thereof to thereby increase the resistance to
compression of the upper ends thereof. |
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Claims |
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Description |
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BACKGROUND OF THE INVENTION
The present invention relates to an improved electrified composite
metal/concrete floor.
Such floors are well known and comprise a corrugated metal decking over
which concrete is poured. Such floors are often electrified in that
electrical power and telephone and other communication services are
distributed in the cells underlying the raised portions or crests of the
decking, with access to the interior of the cells from the upper surface
of the floor provided by inserts preset at selected intervals prior to the
concrete pour. Access by the services to the interior of the longitudinal
cells is generally provided by a lateral trench overlying the metal
decking, which trench includes parallel rails covered with a metal plate
coplanar with the upper surface of the concrete floor when poured.
In one aspect, the present invention includes a novel metal decking
profile, with grooves adjacent the lateral edges of the crests to receive
the concrete of the composite floor, stable when stacked during shipment
to the job site.
Grooves adjacent the crests of decking to receive concrete are well known.
For example, FIG. 4 of the French Patent No. 1,176,824 granted Nov. 28,
1958 to Wendel shows a decking profile in which the radii of the bend at
the lateral edge of the crest and the bottom of the groove are equal and
in which the centers for the bends are vertically spaced approximately
twice such radii. Concrete enters the groove to enhance the metal/concrete
interaction, i.e., "composite action", when the concrete is poured.
Stacking is stabilized by making the radius bend of the lateral edge of
the lower side of the groove slightly larger than such radii to mate with
the lateral edge of an underlying decking member. However, the
semi-cylindrical radius bends do not provide adequate deformation
resistance to downward pressure from the lateral edges of the crests.
Grooves adjacent the lateral edge of metal decking are also shown in the
Ting U.S. Pat. No. 4,453,364 dated June 12, 1984. In that patent, the
grooves have a horizontal lower side and an upper side joining the radius
bend of the lateral edge of the crest at an angle of approximately
forty-five degrees. The Ting grooves are constructed such that (a) the
lateral edge of the crest is at or inside of the plane of the sidewall and
(b) a vertical line passing through the lateral edge of the crest
intersects the sidewall structure at a point inside the plane of the
sidewall, i.e., intersects a groove in the sidewall rather than the
sidewall or any projection therefrom. While bending resistance is
enhanced, the amount of concrete which can enter the groove is inadequate
when cover plates are used. Moreover, the location of the lateral edge of
the crests interiorly of the intersection of the planes of the sidewall
and the crests results in instability in stacking.
The decking profiles of the present invention combine the stacking
stability and metal/concrete interaction of Wendel with the improved
strength of Ting, and further enhance the metal/concrete interaction. In
one embodiment, this improvement is obtained by increasing the vertical
separation of the centers of the radius bends of the crest and groove so
as to join the groove and crest edge at an angle of approximately
forty-five degrees. Stacking stability is enhanced by the matching of the
radius bends of the side wall and crest. In another embodiment, the
decking profile of the present invention further enhances composite action
by establishing a projection in the side wall immediately below the groove
to thereby extend the horizontal lower wall of the groove. Stability when
stacked is enhanced by the abutment of the projection with the side wall
at a point on the side wall below the crest.
In other embodiments, the center of the projection is displaced outwardly
so as to increase the shoulder on which cover plates may rest.
In another aspect, the decking profile of the present invention has a
central valley significantly wider than the side-lap valleys and wider
than the crests. Conventional decking sections such as disclosed in the
Albrecht, et al. U.S. Pat. No. 3,812,636 dated May 28, 1974, and the
aforesaid Ting patent have central and side lap valleys of approximately
equal width.
A third embodiment of the decking profile of the present invention provides
adequate space for the use of studs in securing the side-lap valleys to
the structural beams, while greatly increasing the effective space in the
central valley where the services are provided. The structural properties
of the sections are enhanced by upwardly projecting cell dividers as
explained infra in more detail.
In a fourth embodiment, the cell dividers in the central valley decking
profile are elevated to a height adjacent the height of the crests,
further enhancing the structural properties of the decking member and
permitting the use of lighter gauge metal. Raising the cell dividers also
increases the capacity of the central cell.
The elevation of the cell dividers permits attachment of the preset inserts
through the cover plate directly to the decking member, thereby providing
an electrical ground and avoiding the necessity for a secure
metal-to-metal attachment of the cover plate to the decking member along
the lateral edges of the cover plate. The elevation of the cell dividers
also permits the use of the same cover plate with decks of different
depth.
In another aspect, the present invention includes snap-in cover plates for
selected valleys of the decking to form longitudinal cells for
electrification of the floor. Longitudinal cells for this purpose are well
known. They may be formed by welding of the decking to an underlying plate
as disclosed in the Penczak U.S. Pat. No. 4,041,238 dated Aug. 9, 1977,
the Fork U.S. Pat. No. 4,178,469 dated Dec. 11, 1979, or No. 3,426,802
dated Feb. 11, 1969; or the Littrell U.S. Pat. No. 4,338,484 dated July 6,
1982. They may also be formed by snap-in plates beneath the crests of the
decking as disclosed in the Fork U.S. Pat. No. 4,194,332 dated Mar. 25,
1980, and the Albrecht, et al. U.S. Pat. No. 3,812,636 dated May 28, 1974.
The decking, however, is structurally weakened by the apertures necessary
for access to the cells.
Others have avoided the problem of decking penetration by providing cover
plates for a valley to thereby create a longitudinal cell within the
valley. Systems of this type are disclosed in the Fork European Pat. No.
0003506, the Fork U.S. Pat. No. 3,592,956 dated July 13, 1971, or the Lee,
et al. U.S. Pat. No. 2,912,848 dated Nov. 17, 1959.
However, such systems generally provide a smooth upper surface with reduced
composite action, do not provide for separation of services within the
cell, span the valley without intermediate support, are not resiliently
compressible for snap-in and do not have upturned lateral edges for
prevention of water seepage during the concrete pour.
Other systems, such as disclosed in the Ting U.S. patent application Ser.
No. 340,869 filed Jan. 20, 1982 (now abandoned), utilize grooves adjacent
the crests for retention of the flat cover plates. While lowering the
cover plate provides an upturned edge for prevention of water seepage, the
reduced height of the cell is generally unacceptable because of the
resultant reduced capacity for all services, and the capacity (i.e.,
crosssectional area) determines the number of wires and hence the length
that a cell can branch out from the feeder or trench header. The
aforementioned Ting application also teaches support of the cover plates
intermediate the crests by two interconnected but spaced apart legs which
separate the valley into two equal volume cells. However, such cover
plates rely on concrete between the legs for strength, and thus further
reduce the volume or capacity of the two cells, i.e., the use of parallel
legs spaced sufficiently apart for concrete to enter therebetween
significantly reduces the capacity of the two cells.
The cover plates of the present invention are stackable for shipment to the
job site and are easily installed from above the decking. As contrasted
with decking which must span from beam to beam and is thus installed by
steel workers, the cover plates may be of shorter length and installed by
electricians walking on the deck, thus greatly reducing installation
costs.
The cover plates may provide two unequal capacity cells, or three cells of
the same or different capacity, in the same valley. In one embodiment,
they may be made of sheet metal and provided with one or two double walled
legs to provide support intermediate the crests. The legs may be shaped
and/or otherwise constructed to enhance lateral resiliency and thus secure
a positive snap-lock engagement with the grooves. Metal/concrete
interaction is retained and additional space for three services is
provided by the selective raising of a portion of the cover plate above
the point of connection thereof to the sidewalls, even to the same height
as the crests, and by the substantial elimination of concrete between the
walls of the legs. The decking profile permits the entry of significant
concrete into the grooves with the lateral edges of the cover plate
engaged therein, and even with the lateral edges of the preset inserts
engaged therein as described infra. In three cell embodiments, the center
section may be lowered to facilitate access to the two side cells. This
lowering of the center cell provides adequate space for the nearly
vertical mounting of electrical receptacles and increases the volume and
thus the capacity of the preset inserts to house related accessories.
In still another aspect, the present invention includes a preset insert
uniquely cooperating with the cover plates for access to the cells defined
by the valley of the decking member and the cover plate. Known preset
inserts such as disclosed in the Fork U.S. Pat. No. 3,932,696 dated Jan.
13, 1976 and Penczak U.S. Pat. No. 4,041,238 dated Aug. 9, 1977 span
adjacent crests and are designed to provide access to cells beneath the
crests. Others, such as Fork U.S. Pat. No. 3,417,191 dated Dec. 12, 1968,
fit between the crests to provide access to cells beneath the crests, and
still others, such as Fork U.S. Pat. No. 3,592,956 dated July 13, 1971,
span two crests to provide access to cells beneath adjacent crests as well
as a cell in the intervening valley. All require penetration of the
decking.
In various embodiments, the preset inserts of the present invention are
nestable to facilitate safe shipment to the job site, may be constructed
of sheet metal, provide ready access to all three longitudinal cells, and
cooperate with snap-in electrical power receptacles.
In the present invention, preset inserts may be carried solely by the cover
plates, or by the decking, or by both. They may cooperate in snap-lock
fashion with the grooves in the sidewal of the decking along the cover
plate without significant diminution of the capacity of the cell, or may
be snapped into apertures in the cover plate. In one embodiment, they may
be secured directly to the cover plate and/or the cover plate and decking
by threaded fasteners without penetration of such fasteners into the
cells.
In yet another aspect, the present invention includes a novel lateral
trench for distribution of the services to the longitudinal cells. Prior
art trenches, such as disclosed in the Fork U.S. Pat. No. 3,886,702 dated
June 3, 1975, generally extrude vertically adjustable side rails of
aluminum. Many of the above, such as Fork, et al. U.S. Pat. 3,932,696
dated Jan. 13, 1976 and Penczak U.S. Pat. No. 4,056,896 dated Jan. 3,
1978, utilize the decking as the floor of the trench. Such trenches are
often referred to as "bottomless". However, the use of the valley floor as
the bottom of the trench requires that the concrete be interrupted by
depending dams or stops in the valleys beneath the rails to prevent
filling of the trench with concrete flowing upwardly from the valleys
underlying the trench. The use of vertical concrete stops which depend
into the intervening valleys interrupts the concrete beneath the trench
and thus effects a significant loss of strength of the completed floor.
The present invention in various embodiments provides rails of sheet metal
of greatly reduced cost, and snap-in bottoms for the trench intermediate
the electrified cells. Such bottoms may be supported by the crests,
spanning at least two of them and the included valley, and engaging the
grooves in the sidewall on the outside of the decking sections. Concrete
may thus flow uninterrupted through the non-electrified valley beneath the
trench, significntly enhancing the strength of the composite deck.
In other embodiments, the trench bottom plates have upturned lateral edges
to position the trench side rails and a pair of spaced ridges to position
the power channel within the trench.
In a further aspect, the decking members, cover plates and preset inserts
of the present invention may be used to electrify a formed deck supported
by bar joists. Such decks are generally electrified by the suspension of a
header duct between selected pairs of bar joists and by distribution ducts
overlying the corrugated deck which serves as the form for the concrete
slab. Ducts of this type are generally factory welded and non-nestable.
More importantly the capacity of the distribution duct and the preset
inserts is limited by the depth of the concrete slab. The present
invention permits reversal of the position of header and distribution
ducts and thus provides significantly increased capacity for the
electrical services with a reduced slab thickness.
These and the many other aspects and advantages of the present invention
may more readily be understood from the claims and from the following
detailed description when read in conjunction with the appended drawings.
THE DRAWINGS
FIG. 1 is an end view in elevation of one embodiment of a decking member of
the present invention;
FIG. 2 is a section in elevation of the decking member of FIG. 1 with
concrete poured thereon illustrating the concrete decking member
interface;
FIG. 3 is a partial section in elevation taken through lines 3--3 of FIG.
2;
FIG. 4 :s a pictorial view, partly exploded, illus | | |
