Insulated deck structure
OwnerTommy Lee Carverinventor
Life of this patent
Estimating the term…
Abstract
There is provided a self-supporting insulated deck structure for buildings whereby the deck can be constructed inexpensively and efficiently and can attain a desirable fire rating in addition to improved sound absorption properties. The self-supporting insulated deck structure is made of a cementitious material and has no exposed structural steel members. Formwork for the insulated deck structure is made of integral panels formed from foam insulation members, fire retarding boards, and sound attenuating boards. The integral panels are supported on shored steel support brackets. Once the cementitious material cures, the shoring is removed as the deck structure is self-supporting. The adjacent integral panels provide the insulated deck structure with desirable fire rating and sound absorption properties.
Claims25
An insulated deck structure for buildings, comprising:
- a self-supporting slab formed of a cementitious material and having a substantially planar upper surface and a lower surface, said lower surface defining a plurality of downwardly depending beam members extending in parallel directions and a plurality of recessed surfaces therebetween, said beam members being dimensioned to be sufficiently self-supporting to provide structural strength sufficient to support said deck structure and design loads placed thereon;
- a foam insulation member positioned between each adjacent pair of bean members and adjacent to the respective recessed surface;
- a fire retardant board provided below each of said foam insulation members;
- and
- a support bracket affixed to a downward end of each of said beam members, said support bracket having an upwardly extending portion secured within said beam member and a pair of generally horizontally extending portions for supporting said fire retardant board and said foam insulation member, said support bracket providing negligible structural support.
An insulated deck structure for buildings, comprising:
- a slab formed of a cementitious material and having a substantially planar upper surface and a lower surface, said lower surface defining a plurality of downwardly depending beam members extending in parallel directions and a plurality of recessed surfaces therebetween, said beam members having a predetermined depth extending between said recessed surfaces and a downward end of each beam member and being otherwise dimensioned to provide structural strength sufficient to support said deck structure and design loads placed thereon;
- a foam insulation member positioned between each adjacent pair of beam members and adjacent to the respective recessed surface;
- a fire retardant board provided below each of said foam insulation members;
- and
- a support bracket affixed to the downward end of each of said beam members, said support bracket having an upwardly extending portion secured within said beam member and a pair of generally horizontally extending portions for supporting said fire retardant board and said foam insulation member, said upwardly extending portion extending into the downward end of said beam member by a distance less than the depth of said beam member.
A method of forming an insulated deck structure comprising the steps of:
- providing a pair of spaced end supports for supporting the deck structure;
- extending a plurality of support brackets in parallel directions between the end supports;
- shoring the support brackets from below to provide reinforcement;
- securing a fire retardant board to a foam insulation member;
- placing the laminated fire retardant board and foam insulated member between an adjacent pair of support brackets so that the firs retardant board is supported on the support brackets;
- pouring a substantially liquid cementitious material over the support brackets and foam insulation member to a predetermined height above the foam insulation member;
- allowing the cementitious material to dry and harden such that the cementitious material can support the weight of the deck structure;
- and then
- removing the shoring.
Dependencies are inferred from the claim text.