US20090151278A1 - Flooring system and method for installing involving a corrugated member and a panel flooring member - Google Patents
Flooring system and method for installing involving a corrugated member and a panel flooring member Download PDFInfo
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- US20090151278A1 US20090151278A1 US11/958,655 US95865507A US2009151278A1 US 20090151278 A1 US20090151278 A1 US 20090151278A1 US 95865507 A US95865507 A US 95865507A US 2009151278 A1 US2009151278 A1 US 2009151278A1
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- flooring
- panel
- rib
- corrugated
- panel flooring
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
- E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
- E04B5/10—Load-carrying floor structures formed substantially of prefabricated units with metal beams or girders, e.g. with steel lattice girders
Definitions
- the present invention relates generally to flooring systems and methods for installing flooring systems and more particularly to those systems and methods involving a corrugated member and a panel flooring member.
- Conventional flooring systems include mezzanine flooring systems which provide one or more floor levels between the main floor and the main ceiling and are used, for example, in warehouses.
- the mezzanine floor typically is used by people with or without wheeled carts or wheeled pallet jacks to store goods on, and remove goods from, one or more shelf levels accessible from the mezzanine floor.
- B-type roof deck has each rib have a transverse width equal to 3.50 inches and each valley have a top transverse width equal to 2.50 inches with a height of each rib above the bottom of each adjoining valley equal to 1.5 inches.
- N-type roof deck has each rib have a transverse width equal to 5.38 inches and each valley have a top transverse width equal to 2.62 inches with a height of each rib above the bottom of each adjoining valley equal to 3 inches.
- At least some of the valleys of the B or N type roof deck are attached to a structural mezzanine substructure or are attached to rack-supported or shelving-supported substructure at a height above a main floor. Tongue-and-groove wood-product flooring panels are then placed over the ribs of the B or N type roof deck.
- topside screws are used to attach a flooring panel to at least some of the ribs of the B or N type roof deck. Attachment by bottom-side screws is also known.
- U.S. Pat. No. 6,718,720 teaches attachment by a bottom-side radially-expanding fastener such as a rivet.
- Another flooring-panel mezzanine flooring system which uses a corrugated member having parallel and longitudinally extending 6 inch wide ribs and six inch wide valleys with a rib height of 7 to 8 inches, wherein each rib has 3 or 4 longitudinally-extending surface grooves which are about one-half of an inch across and about three-eighths of an inch deep.
- a known topside screw design for attaching a wood-product flooring panel to a steel rib of B or N type roof deck includes in serial flow relationship a counter-sinkable head, a pair of opposing upper wings to help cut the flooring panel to counter-sink the head, a threaded portion to threadably engage the rib, a non-threaded portion at least substantially equal in length to the roof deck thickness to prevent thread-caused roof deck lift-up as a drill bit encounters the steel rib, and the drill bit to drill through the roof deck and then the rib.
- a known topside screw design for attaching a wood-product flooring panel to a thick, non-corrugated steel, heavy gage support member includes in serial flow relationship a counter-sinkable head, a pair of opposing upper wings to help cut the flooring panel to counter-sink the head, a threaded portion to threadably engage the rib, a pair of opposing, less-radially-extending lower wings to widen the hole to prevent the threaded portion from threadably engaging the flooring panel to prevent thread-caused flooring panel lift-up as a drill bit encounters the steel support member, and the drill bit to drill through the roof deck and then the support member, wherein the lower wings break off when they encounter the thick, heavy gage support member.
- Conventional concrete mezzanine flooring systems pour concrete over composite or non-composite steel deck, such as 18 to 24 gage, non-composite 1.5C type deck having parallel and longitudinally extending ribs and valleys.
- the 1.5C type deck has each rib have a transverse width equal to 1.75 inches and each valley have a top transverse width equal to 4.25 inches with a height of each rib above the bottom of each adjoining valley equal to 1.5 inches.
- Composite steel deck is fabricated to bond to the concrete so that the concrete and steel act together as a composite section.
- Non-composite steel deck serves strictly as a form for the concrete requiring reinforcing bars to be placed in the slab. Typically, enough concrete is poured to extend several inches above the ribs.
- Conventional roofs include exposed corrugated roof deck, such as 16 to 24 gage steel 1.0E type roof deck having parallel and longitudinally extending ribs and valleys.
- the 1.0E type roof deck has each rib have a transverse width equal to 1.13 inches and each valley have a top transverse width equal to 2.87 inches with a height of each rib above the bottom of each adjoining valley equal to 1.0 inches.
- a first method of the invention is for installing a flooring system and includes steps a) through e).
- Step a) includes obtaining a corrugated member having a plurality of substantially parallel and longitudinally extending ribs and valleys, wherein the corrugated member contains metal, wherein each rib has a transverse width of up to three inches, wherein each valley has a top transverse width of up to three inches, wherein a ratio of the transverse top width of each valley to the transverse width of each adjoining rib has a range from 1.0 to 3.5, wherein each valley has a bottom, and wherein each rib has a substantially equal height above the bottom of each adjoining valley.
- Step b) includes obtaining a panel flooring member having top and bottom sides.
- Step c) includes positioning the panel flooring member over and in contact with the corrugated member with the bottom side of the panel flooring member contacting a multiplicity of the ribs of the corrugated member.
- Step d) includes obtaining a fastener.
- Step e) includes attaching the panel flooring member to one of the ribs of the corrugated member using the fastener.
- a first expression of an embodiment of the invention is for a flooring system including a corrugated member, a panel flooring member, and a fastener.
- the corrugated member has a plurality of substantially parallel and longitudinally extending ribs and valleys, and the corrugated member contains metal.
- Each rib has a transverse width of up to three inches, and each valley has a top transverse width of up to three inches.
- a ratio of the transverse top width of each valley to the transverse width of each adjoining rib has a range from 1.0 to 3.5.
- Each valley has a bottom, and each rib has a substantially equal height above the bottom of each adjoining valley.
- the panel flooring member has top and bottom sides.
- the panel flooring member is positioned over and in contact with the corrugated member with the bottom side of the panel flooring member contacting a multiplicity of the ribs of the corrugated member.
- the fastener attaches the panel flooring member to one of the ribs of the corrugated member.
- a second method of the invention is for installing a flooring system and includes steps a) through e).
- Step a) includes obtaining a corrugated member having a plurality of substantially parallel and longitudinally extending ribs and valleys, wherein the corrugated member contains metal, wherein each valley has a bottom, and wherein each rib has a substantially equal height above the bottom of each adjoining valley.
- Step b) includes obtaining a panel flooring member having top and bottom sides, wherein the panel flooring member has a substantially constant thickness.
- Step c) includes positioning the panel flooring member over and in contact with the corrugated member with the bottom side of the panel flooring member contacting a multiplicity of the ribs of the corrugated member.
- Step d) includes obtaining a screw including in serial flow relationship a counter-sinkable head, a pair of opposing upper wings, a threaded portion, a pair of opposing lower wings, and a drill bit, wherein the lower wings radially extend more than the drill bit, at least as much as the threaded portion, and less than the upper wings, and wherein the upper wings radially extend more than the threaded portion and less than the head.
- Step e) includes attaching the panel flooring member to one of the ribs of the corrugated member using the screw by inserting the screw first into the top side of the panel flooring member, then out through the bottom side of the panel flooring member, and then into the one rib of the corrugated member with the threaded portion threadably engaged with the one rib.
- a second expression of an embodiment of the invention is for a flooring system including a corrugated member, a panel flooring member, and a screw.
- the corrugated member has a plurality of substantially parallel and longitudinally extending ribs and valleys, and the corrugated member contains metal.
- Each valley has a bottom, and each rib has a substantially equal height above the bottom of each adjoining valley.
- the panel flooring member has top and bottom sides.
- the panel flooring member has a substantially constant thickness.
- the panel flooring member is positioned over and in contact with the corrugated member with the bottom side of the panel flooring member contacting a multiplicity of the ribs of the corrugated member.
- the panel flooring member includes a through hole extending from the top side to the bottom side.
- the screw includes in serial flow relationship a head positioned in the through hole and countersunk in the top side of the panel flooring member, a pair of opposing upper wings positioned in the through hole, a threaded portion threadably engaged with one of the ribs of the corrugated member but not threadably engaged with the panel flooring member, a pair of locations of broken-off opposing lower wings, and a drill bit positioned below the one rib.
- the through hole has a diameter below the upper wings which radially extends more than the drill bit, at least as much as the threaded portion, and less than the upper wings.
- the upper wings radially extend more than the threaded portion and less than the head.
- the configuration of the geometry of the corrugated member allows a thinner corrugated member to support a desired dynamic rolling load on the panel flooring member, using conventional topside screw fasteners, thereby substantially reducing the total cost of the flooring system without reducing the performance of the flooring system.
- the configuration of the geometry of the screw allows a shorter screw to be used while still preventing panel-flooring-member lift-up, thereby preventing, in short height rib flooring systems, undesired contact of a screw positioned directly over a solid portion of the underlying substructure.
- FIG. 1 is a cross-sectional, end elevational view of an embodiment of a flooring system of the invention showing a topside-screw-type fastener attachment of the panel flooring member of the flooring system to one rib of the corrugated member of the flooring system with the corrugated member supported on a solid portion of a substructure;
- FIG. 2 is a top planar view of the corrugated member of FIG. 1 before the panel flooring member is disposed over the corrugated member;
- FIG. 3 is an end elevational view of the corrugated member of FIG. 2 ;
- FIG. 4 is an end elevational view of a different corrugated member whose ribs have undulations
- FIG. 5 is an end elevational view of a different corrugated member whose ribs have top indentations
- FIG. 6 is an end elevational view of a different corrugated member having a curved edge joining each rib to each adjoining valley;
- FIG. 7 is a side elevational view of the screw-type fastener of FIG. 1 before it is used to attach the panel flooring member to the one rib of the corrugated member;
- FIG. 8 is an enlarged view of a portion of FIG. 1 showing the screw-type fastener attaching the panel flooring member to the one rib of the corrugated member.
- FIGS. 1-3 and 7 - 8 show an embodiment of the present invention.
- a first expression of the embodiment of FIGS. 1-3 and 7 - 8 is for a flooring system 10 including a corrugated member 12 , a panel flooring member 14 , and a fastener 16 .
- the corrugated member 12 has a plurality of substantially parallel and longitudinally extending ribs 18 and valleys 20 , and the corrugated member 12 contains metal.
- Each rib 18 has a transverse width 22 of up to three inches
- each valley 20 has a top transverse width 24 of up to three inches.
- a ratio of the transverse top width 24 of each valley 20 to the transverse width 22 of each adjoining rib 18 has a range from 1.0 to 3.5.
- Each valley 20 has a bottom 26
- each rib 18 has a substantially equal height 28 above the bottom 26 of each adjoining valley 20 .
- the panel flooring member 14 has top and bottom sides 30 and 32 .
- the panel flooring member 14 is disposed over and in contact with the corrugated member 12 with the bottom side 32 of the panel flooring member 14 contacting a multiplicity of the ribs 18 of the corrugated member 12 .
- the fastener 16 attaches the panel flooring member 14 to one of the ribs 18 of the corrugated member 12 .
- the top side 30 of the flooring panel member 14 is exposed to at least one of walking floor traffic and rolling floor traffic.
- the ribs 18 are substantially identical and the valleys 20 are substantially identical, and the corrugated member 12 has a substantially constant thickness and the panel flooring member 14 has a substantially constant thickness.
- the corrugated member 12 is a C type galvanized or painted steel deck available from Vulcraft (a division of Nucor Corporation of Charlotte, N.C.), and the panel flooring member 14 is a ResinDek® panel available from Cornerstone Specialty Wood Products of Cincinnati, Ohio.
- the ribs 18 and the bottom 26 of the valleys 20 are substantially planar and parallel.
- the corrugated member 12 consists essentially of steel, has a thickness of substantially 24 gage, and has a yield strength of substantially 80 ksi (thousand pounds per square inch), and the top side 30 of the panel flooring member 14 is exposed to rolling floor traffic having a dynamic rolling load of at least 350 psi (pounds per square inch).
- the corrugated member 112 is a monolithic member, and each rib 118 has a plurality of undulations 134 .
- the corrugated member 212 is a monolithic member, and each rib 218 has a plurality of top indentations 236 .
- the corrugated member 312 is a monolithic member having a curved edge 338 joining each rib 318 to each adjoining valley 320 .
- a valley 20 also includes two sides 40 joining the bottom 26 of the valley 20 to the two adjoining ribs 18 . Note the same is true for the two sides 140 seen in FIG. 4 , the two sides 240 seen in FIG. 5 , and the two sides 340 seen in FIG. 6 .
- transverse width of a rib is defined to be the actual transverse width of the rib when the rib meets the two adjoining valley sides along a substantially straight edge (such as straight edge 42 seen end-on and shown along with the transverse width 22 in FIG. 3 ) and is defined to be the transverse distance the panel flooring member contacts and is within one-eighth inch of contacting the two adjoining valley sides when the rib meets the two adjoining valley sides along a curved edge (such as curved edge 338 shown along with the transverse width 322 in FIG. 6 ).
- top transverse width of a valley is defined to be the actual transverse distance between the tops of the two sides 40 of the valley 40 when the sides of the valley meet the two adjoining ribs along a substantially straight edge (such as straight edge 42 seen end-on and shown along with the top transverse width 24 in FIG. 3 ) and is defined to be the transverse distance between the two sides at points along the two sides which are one-eighth inch from the panel flooring member when the two sides of the valley meet the two adjoining ribs along a curved edge (such as curved edge 338 shown along with the top transverse width 324 in FIG. 6 ).
- the fastener 16 is a screw 44 having an upper portion 46 and a lower portion 48 .
- the upper portion 46 is disposed in the panel flooring member 14 and extends substantially the entire thickness of the panel flooring member 14 .
- the lower portion 48 threadably engages one of the ribs 18 of the corrugated member 12 .
- Other types of fasteners, including adhesives, are left to the artisan.
- the panel flooring member 14 includes a through hole 50 extending from the top side 30 to the bottom side 32 .
- the screw 44 includes in serial flow relationship a head 52 disposed in the through hole 50 and countersunk in the top side 30 of the panel flooring member 14 , a pair of opposing upper wings 54 disposed in the through hole 50 , a threaded portion 56 threadably engaged with the one rib 18 but not threadably engaged with the panel flooring member 14 , a pair of locations 58 of broken-off opposing lower wings 60 , and a drill bit 62 disposed below the one rib 18 .
- the through hole 50 has a diameter below the upper wings 54 which radially extends more than the drill bit 62 , at least as much as the threaded portion 56 , and less than the upper wings 54 .
- the upper wings 54 radially extend more than the threaded portion 56 and less than the head 52 .
- the screw 44 has a length which is less than the thickness of the panel flooring member 14 plus the height 28 of the one rib 18 . In another illustration, the design of the screw is left to the artisan.
- a first method of the invention is for installing a flooring system 10 and includes steps a) through e).
- Step a) includes obtaining a corrugated member 12 having a plurality of substantially parallel and longitudinally extending ribs 18 and valleys 20 , wherein the corrugated member 12 contains metal, wherein each rib 18 has a transverse width 22 of up to three inches, wherein each valley 20 has a top transverse width 24 of up to three inches, wherein a ratio of the transverse top width 24 of each valley 20 to the transverse width 22 of each adjoining rib 18 has a range from 1.0 to 3.5, wherein each valley 20 has a bottom 26 , and wherein each rib 18 has a substantially equal height 28 above the bottom 26 of each adjoining valley 20 .
- Step b) includes obtaining a panel flooring member 14 having top and bottom sides 30 and 32 .
- Step c) includes disposing the panel flooring member 14 over and in contact with the corrugated member 12 with the bottom side 32 of the panel flooring member 14 contacting a multiplicity of the ribs 18 of the corrugated member 12 .
- Step d) includes obtaining a fastener 16 .
- Step e) includes attaching the panel flooring member 14 to one of the ribs 18 of the corrugated member 12 using the fastener 16 .
- the first method also includes, after step e), exposing the top side 30 of the panel flooring member 14 to at least one of walking floor traffic and rolling floor traffic.
- the ribs 18 are substantially identical and the valleys 20 are substantially identical, and the corrugated member 12 has a substantially constant thickness and the panel flooring member 14 has a substantially constant thickness.
- the ribs 18 and the bottom 26 of the valleys 20 are substantially planar and parallel.
- the corrugated member 12 consists essentially of steel, has a thickness of substantially 24 gage, and has a yield strength of substantially 80 ksi, and the first method includes, after step e), exposing the top side 30 of the panel flooring member 14 to rolling floor traffic having a dynamic rolling load of at least 350 psi.
- the corrugated member 112 is a monolithic member, and each rib 118 has a plurality of undulations 134 .
- the corrugated member 212 is a monolithic member, and each rib 218 has a plurality of top indentations 236 .
- the corrugated member 312 is a monolithic member having a curved edge 338 joining each rib 318 to each adjoining valley 320 .
- the fastener 16 is a screw 44 having an upper portion 46 and a lower portion 48 .
- the upper portion 46 is disposed in the panel flooring member 14 and extends substantially the entire thickness of the panel flooring member 14 .
- the lower portion 48 threadably engages one of the ribs 18 of the corrugated member 12 .
- Other types of fasteners, including adhesives, are left to the artisan.
- the screw 44 includes in serial flow relationship a counter-sinkable head 52 , a pair of opposing upper wings 54 , a threaded portion 56 , a pair of opposing lower wings 60 , and a drill bit 62 .
- the threaded portion 56 radially extends more than the drill bit 62 .
- the lower wings 60 radially extend more than the drill bit 62 , at least as much as the threaded portion 56 , and less than the upper wings 54 .
- the upper wings 54 radially extend more than the threaded portion 56 and less than the head 52 .
- the lower wings 60 are adapted to remain intact while passing through the panel flooring member 14 and to break off upon encountering the one rib 18 allowing the threaded portion 56 to threadably engage the one rib 18 during step e).
- the screw 44 has a length which is less than the thickness of the panel flooring member 14 plus the height of the one rib 18 .
- the screw 44 includes in serial flow relationship a counter-sinkable head 52 , a pair of opposing upper wings 54 , a threaded portion 56 , a pair of opposing lower wings 60 , and a drill bit 62 .
- the threaded portion 56 radially extends more than the drill bit 62 .
- the lower wings 60 radially extend more than the drill bit 62 , at least as much as the threaded portion 56 , and less than the upper wings 54 .
- the upper wings 54 radially extend more than the threaded portion 56 and less than the head 52 .
- the lower wings 60 are adapted to remain intact while passing through only a portion of the panel flooring member 14 and to break off in the panel flooring member 14 before encountering the one rib 18 allowing the threaded portion 56 to threadably engage the one rib 18 during step e).
- the screw 44 has a length which is less than the thickness of the panel flooring member 14 plus the height of the one rib 18 .
- design of the thickness and/or the longitudinal extent of the lower wings 60 should be able to be determined by experimentation. Thinner and/or longitudinally shorter lower wings 60 should be able to break off in a panel flooring member 14 of a specified density and still prevent panel-flooring-member lift-up. Thicker and/or longitudinally longer lower wings 60 should be able to pass completely through the panel flooring member 14 of a specified density and break off upon encountering the one rib 18 unless the one rib 18 is too thin which could result in the lower wings creating a hole in the rib as wide or wider than the threaded portion 56 preventing the threaded portion 56 from threadably engaging the one rib 18 .
- a second expression of the embodiment of FIGS. 1-3 and 7 - 8 is for a flooring system 10 including a corrugated member 12 , a panel flooring member 14 , and a screw 44 .
- the corrugated member 12 has a plurality of substantially parallel and longitudinally extending ribs 18 and valleys 20 , and the corrugated member 12 contains metal.
- Each valley 20 has a bottom 26
- each rib 18 has a substantially equal height 28 above the bottom 26 of each adjoining valley 20 .
- the panel flooring member 14 has top and bottom sides 30 and 32 .
- the panel flooring member 14 has a substantially constant thickness.
- the panel flooring member 14 is disposed over and in contact with the corrugated member 12 with the bottom side 32 of the panel flooring member 14 contacting a multiplicity of the ribs 18 of the corrugated member 12 .
- the panel flooring member 14 includes a through hole 50 extending from the top side 30 to the bottom side 32 .
- the screw 44 includes in serial flow relationship a head 52 disposed in the through hole 50 and countersunk in the top side 30 of the panel flooring member 14 , a pair of opposing upper wings 54 disposed in the through hole 50 , a threaded portion 56 threadably engaged with one of the ribs 18 of the corrugated member 12 but not threadably engaged with the panel flooring member 14 , a pair of locations 58 of broken-off opposing lower wings 60 , and a drill bit 62 disposed below the one rib 18 .
- the through hole 50 has a diameter below the upper wings 54 which radially extends more than the drill bit 62 , at least as much as the threaded portion 56 , and less than the upper wings 54 .
- the upper wings 54 radially extend more than the threaded portion 56 and less than the head 52 .
- the screw 44 has a length which is less than the thickness of the panel flooring member 14 plus the height of the one rib 18 .
- the top side 30 of the flooring panel member 14 is exposed to at least one of walking floor traffic and rolling floor traffic.
- the corrugated member 12 is B-type roof deck or N-type roof deck. In another variation, the corrugated member 12 is C-type deck.
- a second method of the invention is for installing a flooring system 10 and includes steps a) through e).
- Step a) includes obtaining a corrugated member 12 having a plurality of substantially parallel and longitudinally extending ribs 18 and valleys 20 , wherein the corrugated member 12 contains metal, wherein each valley 20 has a bottom 26 , and wherein each rib 18 has a substantially equal height 28 above the bottom 26 of each adjoining valley 20 .
- Step b) includes obtaining a panel flooring member 14 having top and bottom sides 30 and 32 , wherein the panel flooring member 14 has a substantially constant thickness.
- Step c) includes disposing the panel flooring member 14 over and in contact with the corrugated member 12 with the bottom side 32 of the panel flooring member 14 contacting a multiplicity of the ribs 18 of the corrugated member 12 .
- Step d) includes obtaining a screw 44 including in serial flow relationship a counter-sinkable head 52 , a pair of opposing upper wings 54 , a threaded portion 56 , a pair of opposing lower wings 60 , and a drill bit 62 , wherein the lower wings 60 radially extend more than the drill bit 62 , at least as much as the threaded portion 56 , and less than the upper wings 54 , and wherein the upper wings 54 radially extend more than the threaded portion 56 and less than the head 52 .
- Step e) includes attaching the panel flooring member 14 to one of the ribs 18 of the corrugated member 12 using the screw 44 by inserting the screw 44 first into the top side 30 of the panel flooring member 14 , then out through the bottom side 32 of the panel flooring member 14 , and then into the one rib 18 of the corrugated member 12 with the threaded portion 56 threadably engaged with the one rib 18 .
- the screw 44 has a length which is less than the thickness of the panel flooring member 14 plus the height of the ribs 18 .
- additional fasteners (not shown) are used for additional attachments of the panel flooring member 14 to the one, and/or to others, of the ribs 18 .
- the second method also includes, after step e), exposing the top side 30 of the panel flooring member 14 to at least one of walking floor traffic and rolling floor traffic.
- the corrugated member 12 is B-type roof deck or N-type roof deck. In another variation, the corrugated member 12 is C-type deck.
- the lower wings 60 are adapted to remain intact in the panel flooring member 14 and to break off upon encountering the one rib 18 of the corrugated member 12 .
- the lower wings 60 are adapted to remain intact while passing through only a portion of the panel flooring member 14 and to break off in the panel flooring member 14 before encountering the one rib 18 of the corrugated member 12 .
- the one rib 18 is attached to an underlying mezzanine-flooring-system substructure 64 , and the flooring system 10 is a mezzanine flooring system.
- the panel flooring member (such as panel flooring member 14 ) contains wood such as compressed wood fibers such as a ResinDek® panel available from Cornerstone Specialty Wood Products of Cincinnati, Ohio.
- the panel flooring member contains resin-impregnated non-wood fibers.
- the panel flooring member contains plastic.
- the panel flooring member is a pre-cast concrete panel.
- the panel flooring member contains plywood veneers, or oriented strand board chips pressed together under heat and pressure with wax and resin binders.
- the panel flooring member contains medium density fiberboard fibers or industrial particleboard wood particles.
- the configuration of the geometry of the corrugated member allows a thinner corrugated member to support a desired dynamic rolling load on the panel flooring member, using conventional topside screw fasteners, thereby substantially reducing the total cost of the flooring system without reducing the performance of the flooring system.
- the configuration of the geometry of the screw allows a shorter screw to be used while still preventing panel-flooring-member lift-up, thereby preventing, in short height rib flooring systems, undesired contact of a screw positioned directly over a solid portion of the underlying substructure.
Abstract
Description
- The present invention relates generally to flooring systems and methods for installing flooring systems and more particularly to those systems and methods involving a corrugated member and a panel flooring member.
- Conventional flooring systems include mezzanine flooring systems which provide one or more floor levels between the main floor and the main ceiling and are used, for example, in warehouses. The mezzanine floor typically is used by people with or without wheeled carts or wheeled pallet jacks to store goods on, and remove goods from, one or more shelf levels accessible from the mezzanine floor.
- Conventional flooring-panel mezzanine flooring systems use 20 to 16 gage corrugated steel B or N type roof deck having parallel and longitudinally extending ribs and valleys. B-type roof deck has each rib have a transverse width equal to 3.50 inches and each valley have a top transverse width equal to 2.50 inches with a height of each rib above the bottom of each adjoining valley equal to 1.5 inches. N-type roof deck has each rib have a transverse width equal to 5.38 inches and each valley have a top transverse width equal to 2.62 inches with a height of each rib above the bottom of each adjoining valley equal to 3 inches. At least some of the valleys of the B or N type roof deck are attached to a structural mezzanine substructure or are attached to rack-supported or shelving-supported substructure at a height above a main floor. Tongue-and-groove wood-product flooring panels are then placed over the ribs of the B or N type roof deck. Typically, topside screws are used to attach a flooring panel to at least some of the ribs of the B or N type roof deck. Attachment by bottom-side screws is also known. U.S. Pat. No. 6,718,720 teaches attachment by a bottom-side radially-expanding fastener such as a rivet. Another flooring-panel mezzanine flooring system is known which uses a corrugated member having parallel and longitudinally extending 6 inch wide ribs and six inch wide valleys with a rib height of 7 to 8 inches, wherein each rib has 3 or 4 longitudinally-extending surface grooves which are about one-half of an inch across and about three-eighths of an inch deep.
- A known topside screw design for attaching a wood-product flooring panel to a steel rib of B or N type roof deck includes in serial flow relationship a counter-sinkable head, a pair of opposing upper wings to help cut the flooring panel to counter-sink the head, a threaded portion to threadably engage the rib, a non-threaded portion at least substantially equal in length to the roof deck thickness to prevent thread-caused roof deck lift-up as a drill bit encounters the steel rib, and the drill bit to drill through the roof deck and then the rib.
- A known topside screw design for attaching a wood-product flooring panel to a thick, non-corrugated steel, heavy gage support member includes in serial flow relationship a counter-sinkable head, a pair of opposing upper wings to help cut the flooring panel to counter-sink the head, a threaded portion to threadably engage the rib, a pair of opposing, less-radially-extending lower wings to widen the hole to prevent the threaded portion from threadably engaging the flooring panel to prevent thread-caused flooring panel lift-up as a drill bit encounters the steel support member, and the drill bit to drill through the roof deck and then the support member, wherein the lower wings break off when they encounter the thick, heavy gage support member.
- Conventional concrete mezzanine flooring systems pour concrete over composite or non-composite steel deck, such as 18 to 24 gage, non-composite 1.5C type deck having parallel and longitudinally extending ribs and valleys. The 1.5C type deck has each rib have a transverse width equal to 1.75 inches and each valley have a top transverse width equal to 4.25 inches with a height of each rib above the bottom of each adjoining valley equal to 1.5 inches. Composite steel deck is fabricated to bond to the concrete so that the concrete and steel act together as a composite section. Non-composite steel deck serves strictly as a form for the concrete requiring reinforcing bars to be placed in the slab. Typically, enough concrete is poured to extend several inches above the ribs.
- Conventional roofs include exposed corrugated roof deck, such as 16 to 24 gage steel 1.0E type roof deck having parallel and longitudinally extending ribs and valleys. The 1.0E type roof deck has each rib have a transverse width equal to 1.13 inches and each valley have a top transverse width equal to 2.87 inches with a height of each rib above the bottom of each adjoining valley equal to 1.0 inches.
- What is needed is an improved flooring system and method for installing involving a corrugated member and a panel flooring member.
- A first method of the invention is for installing a flooring system and includes steps a) through e). Step a) includes obtaining a corrugated member having a plurality of substantially parallel and longitudinally extending ribs and valleys, wherein the corrugated member contains metal, wherein each rib has a transverse width of up to three inches, wherein each valley has a top transverse width of up to three inches, wherein a ratio of the transverse top width of each valley to the transverse width of each adjoining rib has a range from 1.0 to 3.5, wherein each valley has a bottom, and wherein each rib has a substantially equal height above the bottom of each adjoining valley. Step b) includes obtaining a panel flooring member having top and bottom sides. Step c) includes positioning the panel flooring member over and in contact with the corrugated member with the bottom side of the panel flooring member contacting a multiplicity of the ribs of the corrugated member. Step d) includes obtaining a fastener. Step e) includes attaching the panel flooring member to one of the ribs of the corrugated member using the fastener.
- A first expression of an embodiment of the invention is for a flooring system including a corrugated member, a panel flooring member, and a fastener. The corrugated member has a plurality of substantially parallel and longitudinally extending ribs and valleys, and the corrugated member contains metal. Each rib has a transverse width of up to three inches, and each valley has a top transverse width of up to three inches. A ratio of the transverse top width of each valley to the transverse width of each adjoining rib has a range from 1.0 to 3.5. Each valley has a bottom, and each rib has a substantially equal height above the bottom of each adjoining valley. The panel flooring member has top and bottom sides. The panel flooring member is positioned over and in contact with the corrugated member with the bottom side of the panel flooring member contacting a multiplicity of the ribs of the corrugated member. The fastener attaches the panel flooring member to one of the ribs of the corrugated member.
- A second method of the invention is for installing a flooring system and includes steps a) through e). Step a) includes obtaining a corrugated member having a plurality of substantially parallel and longitudinally extending ribs and valleys, wherein the corrugated member contains metal, wherein each valley has a bottom, and wherein each rib has a substantially equal height above the bottom of each adjoining valley. Step b) includes obtaining a panel flooring member having top and bottom sides, wherein the panel flooring member has a substantially constant thickness. Step c) includes positioning the panel flooring member over and in contact with the corrugated member with the bottom side of the panel flooring member contacting a multiplicity of the ribs of the corrugated member. Step d) includes obtaining a screw including in serial flow relationship a counter-sinkable head, a pair of opposing upper wings, a threaded portion, a pair of opposing lower wings, and a drill bit, wherein the lower wings radially extend more than the drill bit, at least as much as the threaded portion, and less than the upper wings, and wherein the upper wings radially extend more than the threaded portion and less than the head. Step e) includes attaching the panel flooring member to one of the ribs of the corrugated member using the screw by inserting the screw first into the top side of the panel flooring member, then out through the bottom side of the panel flooring member, and then into the one rib of the corrugated member with the threaded portion threadably engaged with the one rib.
- A second expression of an embodiment of the invention is for a flooring system including a corrugated member, a panel flooring member, and a screw. The corrugated member has a plurality of substantially parallel and longitudinally extending ribs and valleys, and the corrugated member contains metal. Each valley has a bottom, and each rib has a substantially equal height above the bottom of each adjoining valley. The panel flooring member has top and bottom sides. The panel flooring member has a substantially constant thickness. The panel flooring member is positioned over and in contact with the corrugated member with the bottom side of the panel flooring member contacting a multiplicity of the ribs of the corrugated member. The panel flooring member includes a through hole extending from the top side to the bottom side. The screw includes in serial flow relationship a head positioned in the through hole and countersunk in the top side of the panel flooring member, a pair of opposing upper wings positioned in the through hole, a threaded portion threadably engaged with one of the ribs of the corrugated member but not threadably engaged with the panel flooring member, a pair of locations of broken-off opposing lower wings, and a drill bit positioned below the one rib. The through hole has a diameter below the upper wings which radially extends more than the drill bit, at least as much as the threaded portion, and less than the upper wings. The upper wings radially extend more than the threaded portion and less than the head.
- Several benefits and advantages are derived from one or more or all of the methods and expressions of an embodiment of the invention. In one example involving the first method and the first expression of an embodiment having the detailed dimensional description of the corrugated member, the configuration of the geometry of the corrugated member allows a thinner corrugated member to support a desired dynamic rolling load on the panel flooring member, using conventional topside screw fasteners, thereby substantially reducing the total cost of the flooring system without reducing the performance of the flooring system. In one example involving the second method and the second expression of an embodiment having the detailed description of the screw used to attach the panel flooring member to one of the ribs of the corrugated member, the configuration of the geometry of the screw allows a shorter screw to be used while still preventing panel-flooring-member lift-up, thereby preventing, in short height rib flooring systems, undesired contact of a screw positioned directly over a solid portion of the underlying substructure.
-
FIG. 1 is a cross-sectional, end elevational view of an embodiment of a flooring system of the invention showing a topside-screw-type fastener attachment of the panel flooring member of the flooring system to one rib of the corrugated member of the flooring system with the corrugated member supported on a solid portion of a substructure; -
FIG. 2 is a top planar view of the corrugated member ofFIG. 1 before the panel flooring member is disposed over the corrugated member; -
FIG. 3 is an end elevational view of the corrugated member ofFIG. 2 ; -
FIG. 4 is an end elevational view of a different corrugated member whose ribs have undulations; -
FIG. 5 is an end elevational view of a different corrugated member whose ribs have top indentations; -
FIG. 6 is an end elevational view of a different corrugated member having a curved edge joining each rib to each adjoining valley; -
FIG. 7 is a side elevational view of the screw-type fastener ofFIG. 1 before it is used to attach the panel flooring member to the one rib of the corrugated member; and -
FIG. 8 is an enlarged view of a portion ofFIG. 1 showing the screw-type fastener attaching the panel flooring member to the one rib of the corrugated member. - It is noted that like parts are numbered alike throughout the figures. Referring now to the drawings,
FIGS. 1-3 and 7-8 show an embodiment of the present invention. A first expression of the embodiment ofFIGS. 1-3 and 7-8 is for aflooring system 10 including acorrugated member 12, apanel flooring member 14, and afastener 16. Thecorrugated member 12 has a plurality of substantially parallel and longitudinally extendingribs 18 andvalleys 20, and thecorrugated member 12 contains metal. Eachrib 18 has atransverse width 22 of up to three inches, and eachvalley 20 has a toptransverse width 24 of up to three inches. A ratio of the transversetop width 24 of eachvalley 20 to thetransverse width 22 of each adjoiningrib 18 has a range from 1.0 to 3.5. Eachvalley 20 has a bottom 26, and eachrib 18 has a substantiallyequal height 28 above the bottom 26 of each adjoiningvalley 20. Thepanel flooring member 14 has top andbottom sides panel flooring member 14 is disposed over and in contact with thecorrugated member 12 with thebottom side 32 of thepanel flooring member 14 contacting a multiplicity of theribs 18 of thecorrugated member 12. Thefastener 16 attaches thepanel flooring member 14 to one of theribs 18 of thecorrugated member 12. - In one application of the first expression of the embodiment of
FIGS. 1-3 and 7-8, thetop side 30 of theflooring panel member 14 is exposed to at least one of walking floor traffic and rolling floor traffic. In the same or a different application, theribs 18 are substantially identical and thevalleys 20 are substantially identical, and thecorrugated member 12 has a substantially constant thickness and thepanel flooring member 14 has a substantially constant thickness. - In a first enablement of the first expression of the embodiment of
FIGS. 1-3 and 7-8, thecorrugated member 12 is a C type galvanized or painted steel deck available from Vulcraft (a division of Nucor Corporation of Charlotte, N.C.), and thepanel flooring member 14 is a ResinDek® panel available from Cornerstone Specialty Wood Products of Cincinnati, Ohio. - In one construction of the first expression of the embodiment of
FIGS. 1-3 and 7-8, theribs 18 and the bottom 26 of thevalleys 20 are substantially planar and parallel. In one variation, thecorrugated member 12 consists essentially of steel, has a thickness of substantially 24 gage, and has a yield strength of substantially 80 ksi (thousand pounds per square inch), and thetop side 30 of thepanel flooring member 14 is exposed to rolling floor traffic having a dynamic rolling load of at least 350 psi (pounds per square inch). - Applicants tested an example of the flooring system having a conventional screw as the fastener, a ResinDek® LD panel as the
panel flooring member 14, and a 22 gage 10C type deck as thecorrugated member 12. Over 40,000 cycles of simulated repeat pallet jack wheel traffic were run to simulate 10 years of pallet jack traffic with the equivalent of 2,000 pounds on a pallet jack with a dynamic rolling load of 350 psi. There were no failures of the flooring system upon completion of the cycle testing. Applicants have had made a limited number of thescrews 44 ofFIG. 7 and have tested fifteen of them to test attaching a ResinDek® LD panel (as the panel flooring member) to a 22 gage 1.0C type deck (as the corrugated member). There were no failures in attaching the ResinDek® LD panel to the 22 gage 1.0C type deck using the screw ofFIG. 7 . Applicants have yet to undertake the cycle testing of theflooring system 10 having thescrews 44 ofFIG. 7 as was done with the flooring system having the conventional screws. - In a first different construction, as shown in
FIG. 4 , thecorrugated member 112 is a monolithic member, and eachrib 118 has a plurality ofundulations 134. In a second different construction, as shown inFIG. 5 , thecorrugated member 212 is a monolithic member, and eachrib 218 has a plurality oftop indentations 236. In a third different construction, as shown inFIG. 6 , thecorrugated member 312 is a monolithic member having acurved edge 338 joining eachrib 318 to eachadjoining valley 320. - It is noted that in
FIGS. 1-3 and 7-8, avalley 20 also includes twosides 40 joining the bottom 26 of thevalley 20 to the two adjoiningribs 18. Note the same is true for the twosides 140 seen inFIG. 4 , the twosides 240 seen inFIG. 5 , and the twosides 340 seen inFIG. 6 . - In any construction, such as those shown in
FIGS. 3-6 , it is noted that the terminology “transverse width” of a rib is defined to be the actual transverse width of the rib when the rib meets the two adjoining valley sides along a substantially straight edge (such asstraight edge 42 seen end-on and shown along with thetransverse width 22 inFIG. 3 ) and is defined to be the transverse distance the panel flooring member contacts and is within one-eighth inch of contacting the two adjoining valley sides when the rib meets the two adjoining valley sides along a curved edge (such ascurved edge 338 shown along with thetransverse width 322 inFIG. 6 ). - Likewise, it is noted that the terminology “top transverse width” of a valley is defined to be the actual transverse distance between the tops of the two
sides 40 of thevalley 40 when the sides of the valley meet the two adjoining ribs along a substantially straight edge (such asstraight edge 42 seen end-on and shown along with the toptransverse width 24 inFIG. 3 ) and is defined to be the transverse distance between the two sides at points along the two sides which are one-eighth inch from the panel flooring member when the two sides of the valley meet the two adjoining ribs along a curved edge (such ascurved edge 338 shown along with the top transverse width 324 inFIG. 6 ). - In one enablement of the first expression of the embodiment of
FIGS. 1-3 and 7-8, thefastener 16 is ascrew 44 having anupper portion 46 and alower portion 48. Theupper portion 46 is disposed in thepanel flooring member 14 and extends substantially the entire thickness of thepanel flooring member 14. Thelower portion 48 threadably engages one of theribs 18 of thecorrugated member 12. Other types of fasteners, including adhesives, are left to the artisan. - In one variation, the
panel flooring member 14 includes a throughhole 50 extending from thetop side 30 to thebottom side 32. In one illustration, thescrew 44 includes in serial flow relationship ahead 52 disposed in the throughhole 50 and countersunk in thetop side 30 of thepanel flooring member 14, a pair of opposingupper wings 54 disposed in the throughhole 50, a threadedportion 56 threadably engaged with the onerib 18 but not threadably engaged with thepanel flooring member 14, a pair oflocations 58 of broken-off opposinglower wings 60, and adrill bit 62 disposed below the onerib 18. The throughhole 50 has a diameter below theupper wings 54 which radially extends more than thedrill bit 62, at least as much as the threadedportion 56, and less than theupper wings 54. Theupper wings 54 radially extend more than the threadedportion 56 and less than thehead 52. In one example, thescrew 44 has a length which is less than the thickness of thepanel flooring member 14 plus theheight 28 of the onerib 18. In another illustration, the design of the screw is left to the artisan. - A first method of the invention is for installing a
flooring system 10 and includes steps a) through e). Step a) includes obtaining acorrugated member 12 having a plurality of substantially parallel and longitudinally extendingribs 18 andvalleys 20, wherein thecorrugated member 12 contains metal, wherein eachrib 18 has atransverse width 22 of up to three inches, wherein eachvalley 20 has a toptransverse width 24 of up to three inches, wherein a ratio of the transversetop width 24 of eachvalley 20 to thetransverse width 22 of each adjoiningrib 18 has a range from 1.0 to 3.5, wherein eachvalley 20 has a bottom 26, and wherein eachrib 18 has a substantiallyequal height 28 above the bottom 26 of each adjoiningvalley 20. Step b) includes obtaining apanel flooring member 14 having top andbottom sides panel flooring member 14 over and in contact with thecorrugated member 12 with thebottom side 32 of thepanel flooring member 14 contacting a multiplicity of theribs 18 of thecorrugated member 12. Step d) includes obtaining afastener 16. Step e) includes attaching thepanel flooring member 14 to one of theribs 18 of thecorrugated member 12 using thefastener 16. - In one example of the first method, additional fasteners (not shown) are used for additional attachments of the
panel flooring member 14 to the one, and/or to others, of theribs 18. In the same or a different example, the first method also includes, after step e), exposing thetop side 30 of thepanel flooring member 14 to at least one of walking floor traffic and rolling floor traffic. - In one application of the first method, the
ribs 18 are substantially identical and thevalleys 20 are substantially identical, and thecorrugated member 12 has a substantially constant thickness and thepanel flooring member 14 has a substantially constant thickness. - In one implementation of the first method, the
ribs 18 and the bottom 26 of thevalleys 20 are substantially planar and parallel. In one variation, thecorrugated member 12 consists essentially of steel, has a thickness of substantially 24 gage, and has a yield strength of substantially 80 ksi, and the first method includes, after step e), exposing thetop side 30 of thepanel flooring member 14 to rolling floor traffic having a dynamic rolling load of at least 350 psi. - In a first different implementation, as shown in
FIG. 4 , thecorrugated member 112 is a monolithic member, and eachrib 118 has a plurality ofundulations 134. In a second different implementation, as shown inFIG. 5 , thecorrugated member 212 is a monolithic member, and eachrib 218 has a plurality oftop indentations 236. In a third different implementation, as shown inFIG. 6 , thecorrugated member 312 is a monolithic member having acurved edge 338 joining eachrib 318 to eachadjoining valley 320. - In a first enablement of the first method, the
fastener 16 is ascrew 44 having anupper portion 46 and alower portion 48. Theupper portion 46 is disposed in thepanel flooring member 14 and extends substantially the entire thickness of thepanel flooring member 14. Thelower portion 48 threadably engages one of theribs 18 of thecorrugated member 12. Other types of fasteners, including adhesives, are left to the artisan. - In a first variation of the first enablement of the first method, the
screw 44 includes in serial flow relationship acounter-sinkable head 52, a pair of opposingupper wings 54, a threadedportion 56, a pair of opposinglower wings 60, and adrill bit 62. The threadedportion 56 radially extends more than thedrill bit 62. Thelower wings 60 radially extend more than thedrill bit 62, at least as much as the threadedportion 56, and less than theupper wings 54. Theupper wings 54 radially extend more than the threadedportion 56 and less than thehead 52. Thelower wings 60 are adapted to remain intact while passing through thepanel flooring member 14 and to break off upon encountering the onerib 18 allowing the threadedportion 56 to threadably engage the onerib 18 during step e). In one example, thescrew 44 has a length which is less than the thickness of thepanel flooring member 14 plus the height of the onerib 18. - In a second variation of the first enablement of the first method, the
screw 44 includes in serial flow relationship acounter-sinkable head 52, a pair of opposingupper wings 54, a threadedportion 56, a pair of opposinglower wings 60, and adrill bit 62. The threadedportion 56 radially extends more than thedrill bit 62. Thelower wings 60 radially extend more than thedrill bit 62, at least as much as the threadedportion 56, and less than theupper wings 54. Theupper wings 54 radially extend more than the threadedportion 56 and less than thehead 52. Thelower wings 60 are adapted to remain intact while passing through only a portion of thepanel flooring member 14 and to break off in thepanel flooring member 14 before encountering the onerib 18 allowing the threadedportion 56 to threadably engage the onerib 18 during step e). In one example, thescrew 44 has a length which is less than the thickness of thepanel flooring member 14 plus the height of the onerib 18. - In one procedure involving adapting the
screw 44 to have thelower wings 60 break off where desired, design of the thickness and/or the longitudinal extent of thelower wings 60 should be able to be determined by experimentation. Thinner and/or longitudinally shorterlower wings 60 should be able to break off in apanel flooring member 14 of a specified density and still prevent panel-flooring-member lift-up. Thicker and/or longitudinally longerlower wings 60 should be able to pass completely through thepanel flooring member 14 of a specified density and break off upon encountering the onerib 18 unless the onerib 18 is too thin which could result in the lower wings creating a hole in the rib as wide or wider than the threadedportion 56 preventing the threadedportion 56 from threadably engaging the onerib 18. - In a third variation of the first enablement of the first method, the design of the screw is left to the artisan.
- A second expression of the embodiment of
FIGS. 1-3 and 7-8 is for aflooring system 10 including acorrugated member 12, apanel flooring member 14, and ascrew 44. Thecorrugated member 12 has a plurality of substantially parallel and longitudinally extendingribs 18 andvalleys 20, and thecorrugated member 12 contains metal. Eachvalley 20 has a bottom 26, and eachrib 18 has a substantiallyequal height 28 above the bottom 26 of each adjoiningvalley 20. Thepanel flooring member 14 has top andbottom sides panel flooring member 14 has a substantially constant thickness. Thepanel flooring member 14 is disposed over and in contact with thecorrugated member 12 with thebottom side 32 of thepanel flooring member 14 contacting a multiplicity of theribs 18 of thecorrugated member 12. Thepanel flooring member 14 includes a throughhole 50 extending from thetop side 30 to thebottom side 32. - In the second expression, the
screw 44 includes in serial flow relationship ahead 52 disposed in the throughhole 50 and countersunk in thetop side 30 of thepanel flooring member 14, a pair of opposingupper wings 54 disposed in the throughhole 50, a threadedportion 56 threadably engaged with one of theribs 18 of thecorrugated member 12 but not threadably engaged with thepanel flooring member 14, a pair oflocations 58 of broken-off opposinglower wings 60, and adrill bit 62 disposed below the onerib 18. The throughhole 50 has a diameter below theupper wings 54 which radially extends more than thedrill bit 62, at least as much as the threadedportion 56, and less than theupper wings 54. Theupper wings 54 radially extend more than the threadedportion 56 and less than thehead 52. - In one example of the second expression of the embodiment of
FIGS. 1-3 and 7-8, thescrew 44 has a length which is less than the thickness of thepanel flooring member 14 plus the height of the onerib 18. In one application of the second expression of the embodiment ofFIGS. 1-3 and 7-8, thetop side 30 of theflooring panel member 14 is exposed to at least one of walking floor traffic and rolling floor traffic. In one variation, thecorrugated member 12 is B-type roof deck or N-type roof deck. In another variation, thecorrugated member 12 is C-type deck. - A second method of the invention is for installing a
flooring system 10 and includes steps a) through e). Step a) includes obtaining acorrugated member 12 having a plurality of substantially parallel and longitudinally extendingribs 18 andvalleys 20, wherein thecorrugated member 12 contains metal, wherein eachvalley 20 has a bottom 26, and wherein eachrib 18 has a substantiallyequal height 28 above the bottom 26 of each adjoiningvalley 20. Step b) includes obtaining apanel flooring member 14 having top andbottom sides panel flooring member 14 has a substantially constant thickness. Step c) includes disposing thepanel flooring member 14 over and in contact with thecorrugated member 12 with thebottom side 32 of thepanel flooring member 14 contacting a multiplicity of theribs 18 of thecorrugated member 12. - Step d) includes obtaining a
screw 44 including in serial flow relationship acounter-sinkable head 52, a pair of opposingupper wings 54, a threadedportion 56, a pair of opposinglower wings 60, and adrill bit 62, wherein thelower wings 60 radially extend more than thedrill bit 62, at least as much as the threadedportion 56, and less than theupper wings 54, and wherein theupper wings 54 radially extend more than the threadedportion 56 and less than thehead 52. Step e) includes attaching thepanel flooring member 14 to one of theribs 18 of thecorrugated member 12 using thescrew 44 by inserting thescrew 44 first into thetop side 30 of thepanel flooring member 14, then out through thebottom side 32 of thepanel flooring member 14, and then into the onerib 18 of thecorrugated member 12 with the threadedportion 56 threadably engaged with the onerib 18. - In one example of the second method, the
screw 44 has a length which is less than the thickness of thepanel flooring member 14 plus the height of theribs 18. In the same or a different example, additional fasteners (not shown) are used for additional attachments of thepanel flooring member 14 to the one, and/or to others, of theribs 18. In the same or a different example, the second method also includes, after step e), exposing thetop side 30 of thepanel flooring member 14 to at least one of walking floor traffic and rolling floor traffic. In one variation, thecorrugated member 12 is B-type roof deck or N-type roof deck. In another variation, thecorrugated member 12 is C-type deck. - In a first variation of the second method, the
lower wings 60 are adapted to remain intact in thepanel flooring member 14 and to break off upon encountering the onerib 18 of thecorrugated member 12. - In a second variation of the second method, the
lower wings 60 are adapted to remain intact while passing through only a portion of thepanel flooring member 14 and to break off in thepanel flooring member 14 before encountering the onerib 18 of thecorrugated member 12. - In one arrangement of either or both of the methods and either or both of the expressions the embodiment of
FIGS. 1-3 and 7-8, the onerib 18 is attached to an underlying mezzanine-flooring-system substructure 64, and theflooring system 10 is a mezzanine flooring system. - In a first choice of materials for one or more or all of the methods and expressions of an embodiment of the invention, and different constructions thereof, the panel flooring member (such as panel flooring member 14) contains wood such as compressed wood fibers such as a ResinDek® panel available from Cornerstone Specialty Wood Products of Cincinnati, Ohio. In a second choice, the panel flooring member contains resin-impregnated non-wood fibers. In a third choice, the panel flooring member contains plastic. In a fourth choice, the panel flooring member is a pre-cast concrete panel. In a fifth choice, the panel flooring member contains plywood veneers, or oriented strand board chips pressed together under heat and pressure with wax and resin binders. In a sixth choice, the panel flooring member contains medium density fiberboard fibers or industrial particleboard wood particles. Other choices of materials for the panel flooring member, and choices (such as, but not limited to, steel) for the metal contained in the metal-containing
corrugated member - Several benefits and advantages are derived from one or more or all of the methods and expressions of an embodiment of the invention. In one example involving the first method and the first expression of an embodiment having the detailed dimensional description of the corrugated member, the configuration of the geometry of the corrugated member allows a thinner corrugated member to support a desired dynamic rolling load on the panel flooring member, using conventional topside screw fasteners, thereby substantially reducing the total cost of the flooring system without reducing the performance of the flooring system. In one example involving the second method and the second expression of an embodiment having the detailed description of the screw used to attach the panel flooring member to one of the ribs of the corrugated member, the configuration of the geometry of the screw allows a shorter screw to be used while still preventing panel-flooring-member lift-up, thereby preventing, in short height rib flooring systems, undesired contact of a screw positioned directly over a solid portion of the underlying substructure.
- The foregoing description of several methods and several expressions of an embodiment of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise form and steps disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto.
Claims (30)
Priority Applications (1)
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US11/958,655 US20090151278A1 (en) | 2007-12-18 | 2007-12-18 | Flooring system and method for installing involving a corrugated member and a panel flooring member |
Applications Claiming Priority (1)
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US11/958,655 US20090151278A1 (en) | 2007-12-18 | 2007-12-18 | Flooring system and method for installing involving a corrugated member and a panel flooring member |
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US20090151278A1 true US20090151278A1 (en) | 2009-06-18 |
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US11/958,655 Abandoned US20090151278A1 (en) | 2007-12-18 | 2007-12-18 | Flooring system and method for installing involving a corrugated member and a panel flooring member |
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US11332928B2 (en) * | 2016-05-16 | 2022-05-17 | Soluciones E Innovaciones Estructurales S.A.S. | Panel of compound sheets for the construction of light-weight one-way joist slabs |
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US20140044914A1 (en) * | 2011-05-02 | 2014-02-13 | Didier Kurtz | Self-stiffened composite panel particularly for aircraft floors and method for manufacturing the same |
US11332928B2 (en) * | 2016-05-16 | 2022-05-17 | Soluciones E Innovaciones Estructurales S.A.S. | Panel of compound sheets for the construction of light-weight one-way joist slabs |
ES2914819A1 (en) * | 2022-02-16 | 2022-06-16 | Estrutec Sist Sl | Structural sheet system (Machine-translation by Google Translate, not legally binding) |
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