PANNEAU D'ACTION COMPOSITE MODULAIRE ET SYSTEMES STRUCTURELS L'UTILISANT

MODULAR COMPOSITE ACTION PANEL AND STRUCTURAL SYSTEMS USING SAME

Abrégé français

L'invention concerne un panneau structural composite modulaire préfabriqué comprenant un système de plancher structural composite. Le panneau structural comprend des panneaux en bois reliés de manière rigide à des éléments de raidissement en acier alignés dans la direction d'envergure entre des éléments de support. En assemblant de multiples panneaux préfabriqués dans un réseau modulaire et en ajoutant du béton, on peut créer un système de plancher en béton composite qui est adaptable à n'importe quelle géométrie de bâtiment. Le panneau en bois agit en composite avec les éléments de raidissement en acier pour fonctionner en tant que coffrage dans l'état temporaire avec un étayage minimal ou nul. Dans l'état permanent, l'élément de raidissement en acier est utilisé pour renforcer la dalle en béton, et le panneau en bois peut agir en composite avec la dalle en béton pour satisfaire aux exigences de résistance et d'aptitude à l'entretien autorisées par le code. L'invention concerne également des procédés de raccordement d'acier à des composants en bois ainsi que des procédés de raccordement de panneaux à des poutres de support. Les panneaux structuraux peuvent également être orientés verticalement et attachés ensemble selon les besoins pour créer un coffrage pour d'autres éléments de construction tels que des murs, des colonnes, des entretoises et des poutres.

Abrégé anglais

A prefabricated modular composite structural panel comprising a composite structural floor system. The structural panel comprises timber panels rigidly connected to steel stiffening elements aligned in the direction of span between supporting elements. By assembling multiple prefabricated panels in a modular array and adding concrete, a composite concrete floor system can be created which is adaptable to any building geometry. The timber panel acts in composite with the steel stiffening elements to function as formwork in the temporary condition with minimal or no shoring. In the permanent condition, the steel stiffening element is used to reinforce the concrete slab, and the timber panel can act in composite with the concrete slab to meet strength and serviceability requirements where permitted by code. Methods for connecting steel to timber components as well as methods for connecting panels to supporting beams are also disclosed. The structural panels can also be oriented vertically and tied together as required to create formwork for other building elements such as walls, columns, braces, and beams.

Revendications

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CLAIMS
What is claimed is:
1. A composite action panel comprising:
steel stiffening elements aligned parallel to each other and each extending
along a span
direction; and
a timber panel secured to the steel stiffening members via structural
connectors,
wherein,
the steel stiffening members function as a first chord and a web element of
the and the
timber panel functions as a second chord of the composite action panel, and
the steel stiffening members and the timber panel achieve composite action and
truss
behavior.
2. The composite action panel of claim 1, wherein the structural connectors
are
positioned at discrete locations along the steel stiffening members.
3. The composite action panel of claim 1, wherein the structural connectors
secure the
steel stiffening elements and the timber panel continuously along the span
direction.
4. The composite action panel of claim 1, wherein the steel stiffening
members and
the timber panel are connected together by means of connector structures
comprising metal
plates to which the steel stiffening elements are welded or bolted, and
fastener elements
selected from the group consisting of mechanical fasteners, nails, spiked
plates, and
adhesive.
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5. The composite panel of claim 1, wherein the timber panel is selected
from the group
consisting of cross-laminated timber(CLT), nail-laminated timber(NLT), dowel-
laminated
timber(DLT), and glue-laminated timber(GLT).
6. The composite panel of claim 1, wherein the steel stiffening element are
either
three-dimensional or planar rebar trusses.
7. The composite action panel of claim 1, wherein each steel stiffening
member
comprises a three-dimensional rebar truss comprising (a) a deformed rebar as
the top chord,
two continuous bars bent to form two web diagonals and secured to the deformed
rebar,
and two bottom bars, each attached to a respective base of the web diagonals,
the web
diagonal bars being bent in a galloping fashion.
8. The composite action panel of claim 1, wherein each steel stiffening
member
comprises a planar truss comprising (a) a top bar, (b) one continuous web
diagonal bent in
a galloping fashion, and (c) one bottom bar attached to the base of the web
diagonal.
9. The composite action panel of claim 1, wherein the steel stiffening
elements
comprise perforated metal plates or prefabricated steel shapes.
10. The composite action panel of claim 1, wherein the composite action
panel is
prefabricated.
1 1 . The composite action panel of claim 1, wherein the steel
stiffening elements extend
in both the span direction and another direction traversing the span
direction.
12. A structural element, comprising:
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a composite action panel according to claim 1; and
concrete in which the steel stiffening elements are embedded.
13. The structural element of claim 12, wherein the structural element is
part of a roof
system, a floor system, a wall, a column, a brace, or a beam.
14. The structural element of claim 13, wherein the structural element is
part of a roof
system or a floor system.
15. A composite monolithic system, comprising:
a plurality of composite action panels according to claim 1;
splice reinforcements between adjoining composite action panels; and
concrete embedding the steel stiffening elements.
16. The composite monolithic system of claim 15, wherein the composite
monolithic
system is a floor system or a roof system.
17. The composite monolithic system of claim 16, further comprising a
support
framework for the floor system or the roof system, the support framework being
selected
from the group consisting of steel beams, precast concrete beams, a cast-in
place concrete
beams, or timber beams.
18. The composite monolithic system of claim 17, wherein the composite
panels are
either simple spans between the supporting framework or continue across a top
of the
supporting framework with openings for the concrete slab to achieve composite
action with
the support framework.
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19. The composite monolithic system of claim 17, wherein the timber panel
can be
designed to contribute to the strength and/or serviceability of the structural
floor in the
permanent condition, with the panel and concrete thickness selected based on
desired
participation from the timber panel, and additional shear connectors added for
desired level
of composite action.
20. The composite monolithic system of claim 17, wherein void forms may be
attached
to the top of the timber panels to reduce the amount of concrete within the
slab.
21. A method comprising.
prefabricating a composite action panel according to claim 1;
nanspoiting the composite action panel to an installation site,
supporting the panel in a desired orientation; and
embedding the steel reinforcement elements in a concrete slab.
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NOTE: STEEL TRUSS NOT SHOWN FOR CLARITY
SUBSTITUTE SHEET (RULE 26)
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44
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FIGURE 13B
NOTE: STEEL TRUSS NOT SHOWN FOR CLARITY
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21 _____________________ N / ___ 14
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FIGURE 14
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WO 2022/150224 PCT/ITS2021/065747
46
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FIGURE 15B
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47
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FIGURE 15C
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WO 2022/150224 PCT/ITS2021/065747
48
21A -\ 22 44 / ___________
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FIGURE 16B
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49
[ 25A /¨ 27B _______________________________________ 27A
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FIGURE 18
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51
S1 FABRICATION
S2
TIMBER PANEL CONNECTOR
STEEL TRUSS
S3 PREFABRICATED
PANEL
S4 TRANSPORT
S5 ERECTION
CONCRETE
S6 MODULAR COMPOSITE
TIMBER FLOOR SYSTEM
FIGURE 19A
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52
. = - '" = = -- = .
FABRICATION
=
-== - = - =
S1 Erection/Piece shop
drawing generation.
52.1 S2.2 S2.3
TIMBER PANEL CONNECTOR STEEL
TRUSS
S3.1 S3.2
1 S3.3
V
S4 1. Fabricatc pancl using 1. Cut platcs to lcngth 1. Cut
straight bars to lcngth
standard industry techniques. 2. Drill fastener holes 2. Bend
Diagonal Truss Bars
3. Weld bars
S4.1 S4.2
V S5
S5 Are epoxy connections used? 1110. Router connection plate
pockets or rip dado groove.
Weld trusses to connector
plates.
S6
4.
Install transverse rebar.
4 ______________________
Are the steel trusses shipped _____________________________
individually?
What connection type will be 1 ______________________________________________
used?
A
S7.1 S7.2 S7.3
V V V
Attached connector plate with Attached connector plate nails Apply
epoxy and set
self tapping lag screws. and minimal self tapping connector
plates.
screws for withdrawal
S8
Weld trusses to connector
plates.
S9
1r
Install transverse rebar.
FIGURE 19B
ci mc-ri-PlulBrITIPLTE-FrIEF;ri(IT-E-F-M
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53
ERECTION
What is the building structural
S10 material type?
STEEL CONCRETE
Heavy Timber
S11.1 S11.3 S11.4
Erect steel framing Is the system pre-cast _10
Erect forms for vertical Erect timber framing.
concrete? structural elements
(columns,
walls & braces).
S11.2 Y S12
Erect pre-cast elements Place concrete for vertical
(columns, walls, braces & elements.
beams)
S13
Install temporary or
permanent form work for floor
beams
______________________________________ Will panels be hoisted in
groups?
S14.1 S15
Hoist panel group to staging Hoist individual
panel piece
location. location.
S14.2 V
Distribute panels to piece
location.
S16
Will rebar cage extend
beyond end of CLT?
S17.1
Secure panels.
S17.2 V S19
Install additonal splice and Remove temporary
formwork
edge reinforcement
S18 V S20
Cast concrete. Remove timber
protection
FIGURE 190
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54
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/ __ 10
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56
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57
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FIGURE 210
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Description

WO 2022/150224
PCT/US2021/065747
1
MODULAR COMPOSITE ACTION PANEL AND
STRUCTURAL SYSTEMS USING SAME
RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S. Patent
Application No.
17/143,543 filed January 7,. 2021, the entirety of which is incorporated
herein by reference
to the extent permitted by law.
BACKGROUND
[0002] The present disclosure generally relates to the construction of
structural systems.
More specifically, the disclosure relates to construction of floor, ceiling,
and wall systems.
[0003] Structural floors are one of the main components of building structural
systems.
They carry loads (such as occupants, furniture, and equipment) to structural
beams and
columns, which in turn transfer the loads to the foundation. Conventional
modern structural
floors are typically constructed from concrete due to its versatility in
creating different
shapes of floor plates, its ability to span long distances when acting in
composite with steel
reinforcement, and its resistance to vibrations and sound transfer. Timber
floors are also
used, typically with a concrete topping slab. However, in most jurisdictions
timber floors
are currently not permitted in high-rise buildings with 6 or more stories
above ground level
without extensive limitations due to concerns that fire would significantly
reduce their load
carrying capacity.
[0004] During construction of concrete floors, wet concrete needs to be
supported by a
form until the concrete is set Commonly used forms for structural floors
include: leave-
in-place corrugated metal deck forms, typically used in steel buildings;
temporary plywood
formwork supported on closely spaced shoring, typically used in concrete
buildings; and
precast concrete panels that act in composite with the cast-in-place topping
slab during
building service, typically used in precast concrete buildings. The metal deck
forms are
commonly used to span approximately 10' without shoring, but at longer spans
the depth
of corrugation required to stiffen the form results in excessive floor
thickness and higher
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cost. Trussed deck is commonly used in Asian markets in lieu of corrugated
metal deck in
steel buildings: a rebar lattice truss is used to stiffen the flat metal.
Trussed deck is typically
limited to the same span range as corrugated metal deck. The temporary plywood
formwork also has drawbacks. shoring for the plywood formwork interferes with
construction activities on the floors below, the time required for shoring and
formwork to
remain in place impedes construction schedule, and the plywood forms are
typically
discarded after removal, creating negative environmental impact. The precast
concrete
panels typically require temporary shoring for longer spans.
[0005] The Filigree Wideslab System (Mid-State Filigree Systems, Inc. 1992)
consists of
reinforced precast floor panels that serve as permanent formwork, with a steel
lattice truss
projecting from the top of the precast unit to stiffen the panel (refer to
product document).
However, similar to other precast concrete panel forms, they are heavy to
transport and lift
into place.
[0006] In addition, most occupied spaces use an additional ceiling finish such
as dry wall
or timber below the structural slab, particularly metal decks. This incurs
additional material
and labor cost, as well as increased environmental impact.
SUMMARY
[0007] Disclosed herein are one or more inventions relating to a prefabricated
modular
composite action panel, structural systems employing the composite action
panel, methods
of fabricating the composite action panel, and methods of erecting structural
systems
employing the composite action panel.
[0008] The disclosed composite action panel can provide a lightweight formwork
that can
achieve long spans without shoring, and at the same time remain in place as an
attractive
permanent ceiling finish. Even more efficiency can be achieved if the formwork
can act in
composite with concrete as part of a structural system. To that end,
lightweight timber
panels with stiffening elements fabricated from conventional concrete
reinforcements can
serve this purpose.
[0009] As used herein:
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"Timber- includes natural and manmade wood unless stated otherwise. "Timber-
and
"lumber" are used interchangeably herein.
"Timber panel" means a layer of timber whether comprised of one sheet or
multiple sheets
of timber and whether a given sheet of timber is single or multi-ply.
"Composite action panel" means a panel embodying principles disclosed herein.
It may
also be referred to as a timber-rebar truss panel, a lumber-rebar truss panel,
or a
prefabricated modular panel.
"Galloping" means a serpentine profile in reference to the bent shape of a
steel rod or bar,
including a sinusoidal characteristic.
"Prefabricated" means built in advance and transportable to an installation
site for
installation at the installation site.
[00010] In an embodiment, a composite action panel comprises:
steel stiffening elements aligned parallel to each other and each extending
along a span
direction; and
a timber panel secured to the steel stiffening members via structural
connectors,
wherein,
the steel stiffening members function as a first chord and a web element of
the
composition action panel and the timber panel functions as a second chord of
the
composite action panel, and
the steel stiffening members and the timber panel achieve composite action and
truss behavior.
[00011] In an embodiment, the structural connectors are
positioned at discrete
locations along the steel stiffening members.
[00012] In an embodiment, the structural connectors secure the
steel stiffening
elements and the timber panel continuously along the span direction.
[00013] In an embodiment, the steel stiffening members and the
timber panel are
connected together by means of connector structures comprising metal plates to
which the
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4
steel stiffening elements are welded or bolted, and fastener elements selected
from the
group consisting of mechanical fasteners, nails, spiked plates, and adhesive.
[00014] In an embodiment, the timber panel is selected from the
group consisting of
cross-laminated timber(CLT), nail-laminated timber(NLT), dowel-laminated
timber(DLT), and glue-laminated timber(GLT).
[00015] In an embodiment, the steel stiffening element are
either three-dimensional
or planar rebar trusses.
[000161 In an embodiment, each steel stiffening member
comprises a three-
dimensional rebar truss comprising (a) a deformed rebar as the top chord, two
continuous
bars bent to form two web diagonals and secured to the deformed rebar, and two
bottom
bars, each attached to a respective base of the web diagonals, the web
diagonal bars being
bent in a galloping fashion.
[00017] In an embodiment, each steel stiffening member
comprises a planar truss
comprising (a) a top bar, (b) one continuous web diagonal bent in a galloping
fashion, and
(c) one bottom bar attached to the base of the web diagonal.
[000 I X] In an embodiment, the steel stiffening elements
comprise perforated metal
plates or prefabricated steel shapes.
[00019] In an embodiment disclosed herein, the composite action
panel is
prefabricated.
[00020] In an embodiment, the steel stiffening elements extend
in both the span
direction and another direction traversing the span direction.
[0002 I ] In an embodiment, a structural element, comprises:
a composite action panel according to any of the prior embodiments; and
concrete or cementitious material in which the steel stiffening elements are
embedded.
[00022] In an embodiment, the structural element is part of a
roof system, a floor
system, a wall, a column, a brace, or a beam.
[00023] In an embodiment, the structural element is part of a
roof system or a floor
system.
[00024.] In an embodiment a composite monolithic system,
comprises:
a plurality of composite action panels according to any of the embodiment
above;
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splice reinforcements between adjoining composite action panels; and
concrete or cementitious material embedding the steel stiffening elements.
[00025] In an embodiment, the composite monolithic system is a
floor system or a
roof system.
[00026] In an embodiment, the composite monolithic system
further comprises a
support framework supporting the floor system or the roof system, the support
framework
being selected from the group consisting of steel beams, precast concrete
beams, a cast-in
place concrete beams, or timber beams.
[00027] In an embodiment of a composite monolithic system the
composite panels
are either simple spans between the supporting framework or continue across a
top of the
supporting framework with openings for the concrete slab to achieve composite
action with
the support framework
[00028] In an embodiment of a monolithic structural system, the
timber panel can
be designed to contribute to the strength and/or serviceability of the
structural floor in the
permanent condition, with the timber panel and concrete thicknesses selected
based on
desired participation from the timber panel, and additional shear connectors
added for
desired level of composite action.
[00029] In an embodiment, a method comprises:
prefabricating a composite action panel according to any of the prior
embodiments,
transporting the composite action panel to an installation site;
supporting the composite action panel in a desired orientation; and
embedding the steel reinforcement elements in a concrete slab.
[00030] As can be appreciated, the timber panels act in
composite with the steel
stiffening elements to support wet weight of concrete in the temporary
condition, and can
be designed to span with minimal or no shoring up to typical spans of one-way
or two-way
reinforced concrete slabs. In the permanent condition, the steel stiffening
element can be
used to reinforce the concrete slab, and the timber panel can act in composite
with the
concrete slab to meet strength and serviceability requirements. The underside
of the timber
panel preferably is protected with a protective layer during construction, and
can serve as
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6
a visually pleasing ceiling finish in the permanent condition. The
prefabricated formwork
preferably is prepared in advance, reducing site labor and increasing
construction speed.
The significant reduction of shoring allows construction activity to take
place on the levels
below, further reducing construction schedule. By assembling multiple
prefabricated
composite action panels in a modular array, a floor system can be created
which is
adaptable to any building geometry. The prefabricated composite action panels
are
lightweight and stackable, facilitating transportation and erection. The leave-
in timber
ceiling finish eliminates the need for additional ceiling material, reducing
overall
environmental impact. The system is versatile and can be used with steel
framing, concrete
cast-in place beams and columns, precast concrete systems, and timber framing.
[0003 I ]
Other systems, methods, features, and advantages of the one or more
disclosed inventions will be or will become apparent to one with skill in the
art upon
examination of the following figures and detailed description. It is intended
that all such
additional systems, methods, features, and advantages be included within this
description,
be within the scope of the invention(s), and be protected by the accompanying
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[000321
The accompanying drawings, which are incorporated in and constitute a
part of this specification, illustrate an implementation of the system
disclosed herein,
together with the description, explain the advantages and principles of the
disclosed
system. In the drawings:
[00033]
FIG! is a perspective view of an illustrative example of a single
composite
action panel that can be used as a composite timber floor system panel after
the placement
(pouring) of concrete or cementitious material which is consistent with
principles disclosed
herein
[00034]
FIG 2 is a perspective view of an illustrative example of a single
composite
action panel prior to the placement of concrete which is consistent with
principles disclosed
herein.
[00035]
FIG. 3 is an exploded view of an exemplary composite action panel or
timber-rebar truss panel depicting individual components of the timber-rebar
truss panel
shown in FIG. 2 prior to assembly of the timber-rebar truss panel shown in
FIG. 2.
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7
[00036]
FIG. 4a is a perspective view of an exemplary rebar truss assembly
depicting the components of a single rebar truss assembly that may be employed
as a steel
stiffening element of the single timber-rebar truss panel shown in FIG. 3.
[00037]
FIG 4b is an exploded view of the exemplary rebar truss assembly shown
in FIG. 4a.
[00038]
FIG. 5a is a plan view of the prefabricated rebar truss illustrated in
FIG. 4a.
[00039]
FIG. 5b is an elevation view of the prefabricated rebar truss illustrated
in
FIG. 4a. Refer to FIG. 5a for location of section 5b.
[00040]
FIG. 6a is a section view cut at a typical cross section of the
prefabricated
rebar truss illustrated in FIG. 4a. Refer to FIG. 5b for location of section.
[00041]
FIG. 6b is a section view cut at the end of the prefabricated rebar truss
illustrated in FIG. 4a. Refer to FIG. 5b for location of section.
[00042]
FIG. 6c is a section view cut at the end looking perpendicular to the span
direction of the prefabricated rebar truss illustrated in FIG. 4a. Refer to
FIG. 5a for location
of section.
[00043]
FIG. 7 is a plan view of the illustrative single composite action panel
shown
in FIG 2 which illustrates the layout of the prefabricated rebar truss and the
transverse
reinforcement shown in FIG. 3.
[00044]
FIG. 8a & FIG. 813 are longitudinal and transverse elevation views of the
composite action panel assembly shown in FIG. 7 taken along lines 8a-8a' and
8b-8b',
respectively.
[00045]
FIG. 9 is a plan view showing the connectors laid out on the timber panel
as shown in the illustrative single composite timber floor system panel shown
in FIG.
2.
[00046]
FIG. 10a is a plan detail of a corner of the timber panel and connector
plate
assembly as shown in section 10a in FIG. 9
[00047]
FIG. 10b is a plan detail of a side edge of the timber panel and connector
plate assembly as shown in section 10b in FIG. 9
[00048]
FIG. ha is a section detail cut at the end of the illustrative composite
action
panel shown in FIG. 2 which is consistent with the current disclosure, as
shown by section
hamn FIG. 9
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[00049]
FIGS. lib & 11c are additional section details cut through the composite
action panel shown in FIG. 2, as shown by sections lib and 11c, respectively,
in FIG. 9.
[00050]
FIGS. 12a-f depict sections of alternative connection types that can be
used
to make a positive connection between the timber panel and rebar truss cage
components
depicted in FIG. 3. Any of these connection types may be used in combination
with any
of the other connection types to form a positive connection between the timber
panel and
rebar truss cage.
[00051]
FIG. 13a is a perspective view of an illustrative structural system using
structural steel for the beam (end 42 a side 43) and column 41 framing, and a
series of the
prefabricated modular composite action panels 50 (refer to FIG. 2) to
construct a floor
system.
[00052]
FIG. 13b is a plan view of the illustrative structural system shown in FIG
13 showing the modular nature of the disclosed composite action panels when
employed
on structural steel framing.
[00053]
FIG. 14 is a section depicting the side connection detail between two
adjacent composite action panels of the modular system as shown by section 14
in Fig.
13b. This section depicts the mechanism that is installed between composite
action panels
to prevent bleeding of concrete during the construction process.
[00054]
FIG. 15a is a section detail showing an end support detail of a
prefabricated
modular composite action panel supported by a steel wide flange beam at an
interior
support condition, as shown by section 15a in FIG. 13b.
[00055]
FIG. 15b & 15c are section details of alternate details of a prefabricated
modular composite action panel supported by a steel wide flange beam at an
interior
support condition. FIG. 15b shows a configuration in which the timber portion
of the
prefabricated composite action panel is installed below the top of steel
elevation thereby
reducing overall structural depth. FIG. 15c is a detail showing the composite
action panel
running continuously over the interior steel support beam. Refer to FIG. 13b
for location
of interior support conditions in a multi-composite action panel modular
layout.
[00056]
FIG. 16a is a section detail showing an end support detail of a
prefabricated
modular composite action panel supported by a steel wide flange beam at an
edge support
condition as shown in section 16a in FIG. 13b.
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[0057]
FIG. 16b is an alternative section detail showing an end support detail of
a
prefabricated modular composite action panel supported by a steel wide flange
beam at an
edge support condition. Refer to FIG. 13b section 16a for location of section.
Similar to
the alternative shown in FIG. 15b, this alternative configuration is such that
the timber
portion of the prefabricated composite action panel is installed below the top
of steel
elevation thereby reducing overall structural depth.
[00058]
FIG. 17a is a section detail showing an end support detail of a
prefabricated
modular composite action panel supported by a cast-in-place concrete beam at
an interior
support condition. Refer to section cut 15a in FIG. 13b for section cut
locations.
[00059]
FIG. 17b is a section detail showing an end support detail of a
prefabricated
modular composite action panel supported by a cast-in-place concrete beam at
an edge
support condition. Refer to section cut 16a in FIG. 13b for section cut
locations.
[00060]
FIG 18 is a perspective view of a potential hoisting configuration of a
single
prefabricated modular composite action panel.
[00061]
FIG. 19a is a general flow chart outlining the primary steps and materials
involved in the fabrication and erection of a modular composite timber floor
system
consistent with principles disclosed herein.
[00062]
FIG. 19b is a flow chart outlining the fabrication process of a single
prefabricated modular composite action panel consistent with principles
disclosed herein.
[00063]
FIG. 19c is a flow chart outlining the erection process of a structural
floor
system using one or more prefabricated composite action panels consistent with
principles
disclosed herein.
[00064]
FIG. 20 is a perspective view showing a single bay of an exemplary
structural system and identifies the primary element types used in a typical
structural
system.
[00065]
FIG. 21a is a perspective view illustrating the primary components of a
prefabricated modular timber beam element.
[00066]
FIG. 21b is a perspective view illustrating the primary components of a
prefabricated modular timber column element.
[00067]
FIG. 21c is a perspective view illustrating the primary components of a
prefabricated modular timber wall element.
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DETAILED DESCRIPTION
[00068]
Reference will now be made in detail to one or more implementations in
accordance with a prefabricated modular composite action panel consistent with
the
principles disclosed herein as illustrated in the accompanying drawings. The
prefabricated
modular composite action panel, may be incorporated into a floor or roof
system of a
building or other structure and used to resist area loads as well as to
provide a continuous
diaphragm at each level of application. The modular nature of the composite
action panel
allows flexibility such that a system utilizing the composite action panel may
be tailored
to fit any building geometry with a series of repetitive composite action
panel elements
preferably connected as illustrated in the accompanying drawings and
description. The
prefabricated nature of the composite action panel allows composite action
panels to be
shop fabricated, improving construction tolerances, and increasing speed of
construction
while eliminating the need for separate tradesmen to field install slab
reinforcement.
[00069]
Exemplary embodiments of the composite action panel of this disclosure
and systems employing same are illustrated in the accompanying drawings and
description.
However, the composite action panel may be implemented such that any
combination of
the primary materials (timber, steel and concrete) presented herein may be
utilized at any
point during the lifespan of a structural system to achieve a structural floor
or roof system,
other systems as disclosed herein. A modular composite timber floor system
consistent
with principles disclosed herein enables the reduction or elimination of
temporary
formwork and shoring while utilizing traditional building materials to
increase speed of
construction and reduce overall building costs. Additional benefits of the
proposed
disclosure include but are not limited to: lightweight and stackable making
for easy
transportation and erection, introduces sequestered carbon into the project
thus improving
sustainable performance, and provides an attractive visual finish potentially
eliminating the
need for a hung ceiling.
[00070]
FIG 1 is a perspective view of an illustrative example of a single
composite
timber floor system employing one or more composite action panels consistent
with
principles disclosed herein. As seen in FIG. 1 the modular composite timber
floor system
panel includes a timber panel 10 connected to steel reinforcement 20 via
connectors 30
which form a composite action panel. Concrete 40 (shown in phantom for easier
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understanding) is cast on top of the composite action panel(s), encasing and
embedding all
of the steel reinforcement. In this exemplary description, the timber panel
10, rebar trusses
20 and connectors 30 are prefabricated and combined into one or more composite
action
panels and shipped to site. Once installed the one or more composite action
panels are
installed on site, and then the concrete 40 is cast in place creating a
monolithic floor system.
FIG. 2 illustrates this prefabricated composite action panel prior to
placement of concrete
40.
[00071]
The timber panel 10 illustrated in FIG. 1 shows an exemplary size and
shape
of timber panel, however it is possible to implement panels of any shape and
size in
accordance with principles of the present disclosure. Although the timber
panel 10,
illustrated in FIG. 1, shows a cross laminated timber profile with 3 ply
thickness, any
number of ply's may be used. The timber panel must be sufficiently strong to
act as part of
a composite concrete form. Alternate means of lamination are also possible
including, but
are not limited to, dowel laminated timber, nail laminated timber & glue
laminated timber
panels. In addition, as noted above, the timber can be made of natural or man-
made wood.
[00072]
In this illustrative example, the steel reinforcement 20 is composed of
deformed steel bars and round steel rods.
However, alternative types of steel
reinforcement can be used to achieve composite action between the other
materials (timber
& concrete 40). These alternative types include but are not limited to steel
plates,
perforated steel plates and rolled steel sections. Further this illustrative
example shows an
exemplary size and configuration of steel reinforcement, however steel
reinforcement 40
can be configured in a variety of ways to achieve the required strength and
serviceability
performance.
[00073]
FIG. 3 is an exploded perspective view of the illustrative example shown
in
FIG. 2. FIG. 3 shows the timber panel 10 at the base of the illustrative
assembly or
composite action panel. Connectors 30 allow for a structural connection
between the timber
panel 10 and the prefabricated rcbar trusses 21. In this illustrative example,
the connector
plate 30 is connected to the timber panel 10 via self-tapping lag screws 32,
as shown in
FIG ha-lie. This is just one potential method of connection between the timber
panel 10
and the connectors 30. Alternate connection techniques will be described in
more detail in
the following discussion (refer to FIGS. 12a-12f) The rebar trusses 21 are
welded to the
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connectors 30 at all points of contract. In this illustrative example, the
composite action
panel is designed and detailed as a 1-way system, meaning the composite action
panel
spans in the span direction or length of the rebar trusses (long direction in
the figure) and
is supported at both of its ends in the cross-span or transverse direction
(the short ends in
the figure). The rebar trusses 21 are configured to run parallel to this span
direction. By
connecting a series of rebar trusses 21 in parallel via the connectors 30 to
the timber panel
10, a prefabricated composite action panel is created. Transverse
reinforcement 22 is
provided in the direction perpendicular to the span. In this illustrative
example, transverse
reinforcement 22 is provided as additional reinforcement bars which are wire
tired in place
using standard construction techniques, however it is possible that the
transverse
reinforcement bars 22 are integrated into the rebar trusses 21 to contribute
to the composite
action panel's composite strength and allow for 2-way system applications.
[00074]
FIG. 4a is a perspective view of a single rebar truss 21 illustrated in
FIG. 3
and described above. The rebar truss 21 is a 3-dimensional truss that is made
up of one
straight continuous top deformed bar 21A, two inclined continuous diagonal
bars 21B
which are bent in a galloping fashion, two straight continuous bottom deformed
bars 21C,
two horizontal end support bars 21D (one at each end) and two vertical end
support bars
21E (one at each end). All bars are welded together at points of contact to
create a single
three-dimensional rebar truss 21.
[00075]
FIG. 4b is a perspective view of an explosion diagram of the components
described above in FIG. 4a. The inclined continuous diagonal bars 21B are
welded to the
top bar 21A and bottom bat 21C. Bottom bars 21C are welded to the horizontal
end support
bars 21D which are welded to the vertical end support bars 21E. The vertical
end support
bars 21E are also welded to the top bar 21A. As previously noted, this
represents but one
preferred rebar truss configuration. Other configurations may be implemented
consistent
with the principles of the present disclosure.
[00076]
FIG. 5a is a plan view of the prefabricated rebar truss 21 illustrated in
FIG.
4a. Sections 5b & 6c are used as reference for the sections shown in FIG. 5b &
6e.
[00077]
FIG 5b is an elevation view of the prefabricated rebar truss 21
illustrated
in FIG. 4a. Refer to FIG. 5a for location of the section 5a. This elevation
shows an example
of galloping configuration of the inclined diagonal bar 21B. As shown, the
galloping
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diagonal bar 21B has horizontal segments which occur at regular spacing at
both the top
and bottom of the truss allowing sufficient contact between the diagonal bar
21B and the
top and bottom bars 21A and 21C respectively. The horizontal segments of the
diagonal
bar 21B are shown in this preferred embodiment, but are not required as long
as sufficient
contact between the diagonal bars 21B and top and bottom bars (21A & 21C) is
achieved.
This truss profile is created from a continuous piece of round steel rod,
however truss
behavior may be achieved using an alternate configuration as previously noted.
Any truss
configuration which allows for composite action between the rebar cage 21 and
the timber
panel 10 would be consistent with the principles disclosed herein. Sections 6a
& 6b are
used as reference for the sections shown in FIG. 6a 8z 6b.
[00078]
FIG. 6a is a section view cut at a typical cross section of the
prefabricated
rebar truss 21 illustrated in FIG. 4a. Refer to FIG. 5b for location of
section. As shown in
this section, the top bar 21A is pinched between the two inclined diagonal
bars 21B, and a
weld is made between these two along this contact. Also shown in this section
is the
location of the bottom bar 21C relative to the inclined diagonal bar 21B.
[00079]
FIG. 6b is a section view cut at the end of the prefabricated rebar truss
21
illustrated in FIG. 4a. Refer to FIG. 5b for location of section. As shown in
this section,
the top bar 21A sits above the vertical end support bar 21E and the bottom
bars 21C sit
above the horizontal end support bar 21D. The horizontal end support bar 21D
runs interior
to the vertical end support bar 21E. Each of these bars are connected via
welds at the
locations of contact.
[00080]
FIG. 6c is a section view cut at the end looking perpendicular to the span
direction of the prefabricated rebar truss 21 illustrated in FIG. 4a. Refer to
FIG. 5a for
location of section. This section shows the relationship between the bottom
and top bars
21C & 21A respectively and the support bars (horizontal 8z vertical, 21D & 21E
respectively). Further, this section shows the horizontal segments of the
inclined diagonal
bars 21B as well as the termination of the diagonal bars 21B at the end of the
rebar truss
21.
[00081 ]
FIG 7 is a plan view of the illustrative composite action panel shown in
FIG. 2. This FIG. 7 shows how the prefabricated rebar truss 21 and the
transverse
reinforcement 22 are laid out on the timber panel 10 below. A series of rebar
trusses
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running in the direction of the span are placed in a parallel configuration
and equally spaced
across the width of the timber panel. Similarly, transverse reinforcement bars
22 running
perpendicular to the span are placed in a parallel configuration and equally
spaced across
the length of the timber panel.
[00082]
FIG. 8a & FIG. 8b are longitudinal and transverse section views,
respectively, of the composite action panel shown in FIG. 7. Refer to FIG. 7
for section cut
locations. FIG. 8a shows an exemplary distribution of transverse reinforcement
22 as well
as the elevation of the prefabricated rebar truss 21 as it relates to the
timber panel 10. FIG.
8b shows an exemplary distribution of prefabricated rebar trusses 21 across
the width of
the timber panel 10 as well as the elevation of the transverse reinforcement
22 relative to
the top bar 21A and bottom bar 21C. Refer to FIGS. 5 & 6 for details of the
rebar truss
assembly.
[00083]
FIG. 9 is a plan view of the connectors 30 laid out on the timber panel 10
as shown in the illustrative composite action panel shown in FIG. 2. As shown
in this
figure, the exemplary composite action panel has three steel connector plate
types. The
typical interior connector plates 31A are continuous strips of steel plate
which run
transverse to the composite action panel span and are located to ensure
contact between the
inclined diagonal bars 21B (refer to FIGS. 5a & 5b) and the interior connector
plate 31A.
This contact allows for welding between the interior connector plate 31A and
the inclined
diagonal bars 21C. The end connector plates 31B are located at both ends of
the composite
action panel. Similar to the interior connector plates 31A, the end connector
plates 31B are
continuous strips of steel plate which are positioned to ensure contact with
the inclined
diagonal bars 21B, allowing for weld between the end connector plates 31B and
the
inclined diagonal bars 21B. End connector plate 31B size may be adjusted to
prevent
seepage of wet concrete during the placement of concrete on site. The side
connector plate
31C is a single continuous strip of steel plate located on one side of the
timber panel 10.
The edge-most inclined diagonal bar 21B is welded to the side connector plate
31C.
[00084]
In this illustrative example, lag screw fasteners 32 are used to connect
the
connector plates 30 with the timber panel 10 Alternative connection types
include but are
not limited to those shown in FIG. 12a-12f.
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[00085]
FIG. 10a is a plan detail of a corner of the timber panel 10 and connector
plate 30 assembly. This detail shows the side connector plate 31C extending
beyond the
timber panel 10. This extension allows the connector plate to also function as
a pour stop
at the end and side connection. Refer to FIG. 13-16 for more detail on
composite action
panel end and side connections. It is also possible to extend the end
connector plate 31B
beyond the timber panel as required to accommodate the end connection detail,
refer to
FIG. 16a.
[00086]
FIG. 10b is a plan detail of a typical edge of the timber panel 10 and
connector plate 30 assembly. The prefabricated rebar trusses 21 have been
included in fine
line form in this detail to illustrate the overlap between these trusses 21
and the connectors
plates (interior 31A and edge 31C).
[00087]
FIG. ha is a section detail cut at the end of the illustrative composite
action
panel shown in FIG. 2 which is consistent with the current disclosure. Refer
to FIG. 9 for
section cut location. This detail shows the end connector plate 31B flush with
the timber
panel 10 at the end support condition. Refer to FIG. 13-16 for more detail on
composite
action panel end and side connections. Although this is used as an exemplary
configuration
of the end plate 31B, rebar truss 21 and timber panel 10, alternative
configurations are
possible which are consistent with principles disclosed herein. This detail
also shows the
lag screw fasteners 32 which connect the end connector plate 31B and the
interior
connector plate 31A to the timber panel. Alternative connection types include
but are not
limited to those shown in FIG. 12a-12f.
[00088]
FIGS. lib & 11c are additional section details cut through the
illustrative
composite action panel shown in FIG. 2 which is consistent with the current
disclosure.
Refer to FIG. 9 for section cut location. Similar to FIG. ha these section
details illustrate
the fasteners 32 used to connect the interior connector plates 31A to the
timber panel.
Further, FIG. lib shows the contact between the rebar truss 21 and the
interior connector
plate 31A. The rebar truss 21 and interior connector plate 31A are welded
together over
this contact length.
[00089]
FIGS. 12a-12f are isolated section details looking in the transverse
direction
of the illustrative panel shown in FIG 2. These details show alternative means
of
connections which allow for composite action between the rebar truss assembly
21 and the
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timber panel 10. Note, means of connecting the rebar truss assembly 21 to the
underlying
timber panel 10 include, but are not limited to those presented in FIGS. 12a-
12f.
[00090]
FIGS 12a shows lag screw fasteners 33A connecting the connector plates
30 to the timber panel 10. In this configuration, the rebar truss 21 is welded
to the connector
plate 30. These lag screw fasteners 33A may also be installed in an inclined
orientation as
shown in FIG. 12b.
[00091]
Alternate means of mechanical connections are shown in FIGS. 12c & 12d
which include nails 33B and a punched metal plate 33C. The punch metal plate
33C,
sometimes referred to as a spike plate, is a component typically used in the
construction of
timber trusses, but can also serve as a sufficient load transfer mechanism in
the current
disclosure. Connection between steel and timber components may also be via
epoxy
methods. This includes but is not limited to connecting the connector plates
30 directly to
the timber panel 10 via epoxy 33D, as well as connecting the rebar truss 21
directly to the
timber panel 10 via epoxy.
[00092]
FIG. 13a is a perspective view of an illustrative structural system using
structural steel for the beam (end 42 and side 43) and column 41 framing, and
a series of
the prefabricated modular composite action panels 50 (refer to FIG. 2) to
construct the floor
system. Composite action panels are shown representatively in this FIG. and
the detailed
steel trusses have not been included for clarity. As shown in this exemplary
system, the
modular floor system panels 50 are installed adjacent to one another and span
between end
support members 42. In addition to providing structural stability of the
system, side support
members are provided parallel to the longitudinal face of the prefabricated
modular
composite action panels 50 to act as edge support for the end composite action
panel.
[00093]
FIG. 13b is a plan view of the illustrative structural system shown in FIG
13a. This plan clearly illustrates the modular nature of the disclosed
composite action
panels. Prefabricated Modular composite action panels 50 can be shaped and
sized based
on the structural system geometry to allow repetition of the same module to
develop an
overall floor system. Shown in this figure is a system using structural steel
for framing
elements, however, additional systems include but are not limited to
reinforcement
concrete framing, per-cast reinforced concrete framing, pre-stressed
reinforced concrete
framing, timber framing and any combination of these framing types.
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[00094]
FIGS. 13a & 13b also illustrate the additional splice reinforcement
required
at the interface of adjacent composite action panels. Main splice
reinforcement bars 25A
and transverse splice reinforcement bars 25B are required at each interior end
and side of
the modular composite action panels 50 respectively. Hooked edge reinforcement
25C is
also required around the edges of the floor systems. These additional
reinforcement bars
can be installed at any point during the transportation and erection process
prior to the
placement of concrete.
[00095]
FIG. 14 is a section detail taken at the side connection between two
adjacent
modular composite action panels 50. Refer to FIG 13b for location of section
cut. This
detail shows an exemplary water stop mechanism which prevents the seepage of
concrete
through a potential seam 11 caused by erection tolerances. Although the detail
shown in
this example utilizes a thin strip of plywood 14 that may be field installed
to connect the
adjacent composite action panels and prevent the seepage of wet concrete,
alternative water
stopping mechanisms include but are not limited to, a thin gauge metal strip
(refer to side
connector plate 31C, FIG. 9), tape or a rubber gasket. One might also detail
the timber
panels 10 to have an offset top ply to allow for a natural overlap of the
timber panels as is
commonly done in construction using CLT panels as floor panels.
[00096]
FIG. 15a is a section detail showing an end support detail of a
prefabricated
modular composite action panel 50 supported by a steel wide flange beam at an
interior
support condition 41A. Refer to FIG. 13b for section cut locations. In this
illustrative detail
both adjacent timber panels 10 are bearing directly on the steel end support
beam flange
41A. The prefabricated modular composite action panels 50 are sized and
erected to ensure
composite beam action can be achieved between the end support member 41A and
the
concrete 40 via the steel shear stud 44. Additional main splice reinforcement
25A are
provided across the support line to achieve slab continuity. An erection strap
15 or
equivalent is required in this configuration to ensure stability of the
prefabricated modular
composite action panel 50 during the temporary condition, prior to the
placement of
concrete. Alternative means of providing temporary stability include but are
not limited to,
timber to steel bolted connections and timber to timber connections
[00097]
Alternative interior panel end support methods include but are not limited
to those shown in FIGS. 15b & 15c. As shown in FIG. 15b, the connection may be
made
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by direct bearing of the end connector plate 31B and the end support beam 41A.
The
connection may also be made by running a continuous timber panel 10 across the
top of
the support beam 41A as shown in FIG. 15c. In the case of the detail
illustrated in FIG.
15c, additional considerations are required to notch the timber panel 10 to
ensure composite
action between the support beam 41A and the concrete 40, if composite action
is desired.
[00098]
FIG. 16a is a section detail showing an end support detail of a
prefabricated
modular composite action panel 50 supported by a steel wide flange beam at an
edge
support condition 41A. Refer to FIG. 13b for section cut locations. Similar to
FIG. 16a,
the timber panel 10 is bearing directly on the steel end support beam flange
41A. Also,
similar to FIG 16a, the prefabricated modular composite action panels 50 are
sized to
ensure composite beam action can be achieved between the end support member
41A and
the concrete 40. The edge of slab top reinforcement 26A at this location is
hooked as per
typical reinforced concrete detailing standards, and edge of slab nosing bars
26B are
provided as shown in this exemplary detail. Refer to FIG. 15b description
above for
information on alternative exterior end support configurations shown in FIGS.
16b.
[00099]
FIG. 17a is a section detail showing an end support detail of a
prefabricated
modular composite action panel 50 supported by a reinforced concrete beam at
an interior
support condition 41B. Refer to FIG. 13b, section 15a for section cut
locations. As shown
in this detail, the timber panel 10 is supported by beam formwork 12 used to
form the
interior concrete end support member 41B. The potential performance of the
beam
formwork 12 includes, but is not limited to, temporary formwork which is
removed after
the curing of concrete, permanent formwork which is left in place for the
duration of the
structures lifespan or as a permanent integral part of the structural system
which is
composite with the concrete beam. The beam formwork may or may not require
additional
shoring 13 and still be consistent with the current disclosure. FIG. 16a is a
section detail
showing an end support detail of a prefabricated modular composite action
panel 50
supported by a steel wide flange beam at an edge support condition 41A. Refer
to FIG. 13b
for section cut locations.
[000 I 00]
Regarding the sequence of installation, in this illustrative example, the
beam
formwork 11 would be installed first, then the prefabricated modular composite
action
panel 50. Lastly the beam stirrups 27B, longitudinal bars 27A and main splice
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reinforcement 25A are installed. It is also possible for some of these
components to be
integrated together to increase speed of construction.
[000101]
FIG. 17b is a section detail showing an end support detail of a
prefabricated
modular composite action panel 50 supported by a reinforced concrete beam at
an edge
support condition 41B. Refer to FIG. 13b section 16a for section cut
locations. Refer to
FIG. 17a description for discussion on beam formwork 11 configuration and
erection
sequence. As shown in this section, the main splice bar 25A for an exterior
concrete end
support element 41B is hooked into the beam.
[000102]
FIG 18 is a perspective view of a potential hoisting configuration of a
single
prefabricated modular composite action panel 50. As shown in this figure, the
composite
action panel 50 can be lifted by 4 connection points 52B at which secondary
cables 52A
connect, and tie back to the primary cable 54. The present disclosure allows
for hoisting
directly from the rebar cage. Additional fasteners are provided as required at
hoist
connection points to ensure adequate withdrawal capacity is available.
Additional hoisting
hardware may be included on the prefabricated modular composite action panel
to increase
connection capacity as required. Although this figure only illustrates a
single composite
action panel being hoisted, it is possible to hoist multiple composite action
panels at a
single time.
[000103]
FIG. 19a is a general flow chart outlining the primary steps and materials
involved in the fabrication and erection of a modular composite timber floor
system
consistent with principles disclosed herein. As shown in this figure and
described in detail
above, the timber panel 10, connectors 30 and steel reinforcement elements
(rebar truss)
20 make up the prefabricated modular composite action panel 50. However, prior
to
fabrication of any composite action panel, detailed shop drawings of
individual composite
action panel pieces as well as the erection drawings must be generated to
establish the
geometry of each composite action panel to be fabricated. This detailing step
may be done
with traditional 2-dimensional shop drawings, or by using parametric 3-
dimensional
documentation tools. Once the composite action panel geometries are
established through
the documentation process, the composite action panels are fabricated FIG 19b
provides
a flow chart detailing a suitable fabrication process, preferably performed in
a shop or off-
site from where the composite action panels are to be installed. After the
composite action
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panels are shop fabricated, they can be shipped to the site where they are
erected based on
the erection plans. FIG. 19c provides a flow chart detailing an erection
process. Once
erected, concrete is placed (poured), resulting in a structural system, which
in this
illustrative embodiment is a monolithic floor or roof system.
[000104]
With continuing reference to Fig. 19A, in step Si, the detailed shop
drawings of individual composite action panel pieces as well as the erection
drawings are
generated to establish the geometry(i es) of each composite action panel to be
fabricated.
In step S2, the timber panel 10 and the steel reinforcement elements 20 are
secured to each
other by way of connectors 30, such as those described above. In step S3, the
prefabricated
composite action panel results. In step S4, the prefabricated composite action
panel is
transported to an erection site. In step S5, the prefabricated composite
action panel (and
typically others) is placed into position at the erection site, for example,
as a floor member,
wall member, or ceiling member and temporarily joined with other structural
components
as described above such as other composite action panels, and concrete is
poured into the
form. Once the concrete (or cementitious material) has cured, the additional
form members
are removed in step S6 and the result is an installed modular composite timber
and truss
panel, which in Fig. 19A is described as a floor panel as an example only.
[000105]
FIG. 19b is a flow chart outlining the fabrication process of a single
modular
timber floor system panel consistent with principles disclosed herein. As
shown in this
fabrication flowchart, each component of the prefabricated modular composite
action panel
has unique fabrication requirements at the front end of the process (reference
steps S3.1-
S3.3). Once each component is fabricated, they are combined to form a
composite action
panel. Depending on the connection methodology, the fabrication steps during
the
connection sequence vary, Refer to FIG. 12a-12f and the related description
above for and
understanding of these various connection types.
[000106]
With continuing reference to Fig. 19b, in step Si, the detailed shop
drawings of individual composite action panel pieces as well as the erection
drawings arc
generated to establish the geometry(ies) of each composite action panel to be
fabricated. In
steps S2.1, S2.2 & S2.3, raw materials are procured for fabrication of each
individual
component. In steps S3.1, S32, and S3.3, each composite action panel component
is
fabricated to the specified geometries per the individual piece drawings. The
timber panel
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can be fabricated using standard industry techniques. The connectors can be
fabricated by
cutting plate pieces to length/size and then drilling holes in the plates. The
reinforcement
elements (steel truss) can be fabricate by cutting steel bars to length,
bending the diagonal
bars into the galloping shape and then welding all of the bars together as
described above.
[000107]
In steps S4.1 and S4.2, additional prep work is performed on the timber
panel as required per the specified connection type. In this example, it is
determined if
epoxy connections are to be used. If yes, then the timber panel is either
routed to provide
pockets to receive the connection plates or ripped to provide dado grooves for
the
connection plates.
[000108]
In step SS the steel reinforcement elements (steel trusses) are connected
to
the connector plates based on the methods described above. In this embodiment,
they are
welded together. Alternatively, if the steel trusses are shipped individually
and the
connector plates are connected to the timber panel independent of the steel
truss, this step
can be performed later in the process, for example, in step S8.
[000109]
In step S6, the transverse reinforcement (transverse rebar) is installed.
Note,
if the steel trusses are shipped individually and the connector plate is
connected to the
timber panel independent of the steel truss, this step can be performed later
in the process,
for example in step S9. In steps S7.1, S7.2, S7.3 the connector plates are
attached to the
timber panel based on the selected method. In step S7.1, connector plates are
attached
using self-tapping lag screw. Alternatively or additionally, in step S7.2
connector plates
are attached using nails and minimal self-tapping screws. Alternatively or
additionally, in
step S7.3 the connector plates are attached to the timber panel using epoxy.
As can be
appreciated, typically, only one type of attachment method would be used, but,
depending
on the requirements and/or circumstances, two or more attachment method may be
used.
[000110]
As mentioned above, if the steel trusses are shipped/transported
individually, steps S8 and S9 can be performed. In step S8, the steel trusses
would be
welded to the connector plates. In step S9, the transvers rebar would be
attached.
[000111]
FIG. 19c is a flow chart outlining the erection process of a single
prefabricated modular timber floor system panel consistent with principles
disclosed
herein. As shown in this flowchart, the present disclosure may be implemented
in a
building or other structure that is constructed using a wide range of material
types.
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Depending on the base building material type, various construction techniques
may be
implemented to create a structurally stable system allowing installation of
panels one at a
time, or in groups. Depending on the end connection detailing, panels may
require
temporary connections to be made, thus ensuring stability of the system prior
to the
placement of concrete.
[000112]
The following is a basic description of an exemplary construction process
consistent with the flow chart provided in FIG. 19c which may be used to
construct a floor
slab system using this disclosure:
[000113]
In a step 10, a determination is made as to the type of building
structural
material to be employed. In this description, three types are shown: steel,
concrete, and
heavy timber. The type of building structure material impacts the way in which
the support
framing is erected and support details for the composite action panels.
[000114]
In step S11.1, steel framing is erected for steel structures. In step
S11.2, pre-
cast elements such as columns, walls, braces and beams are erected for pre-
cast concrete
buildings. Alternatively, in step S11.3 forms into which concrete is to be
poured are erected
for the structural elements such as columns, walls and braces. Ti step 11.4,
timber framing
is erected for timber buildings timber as the structural material.
[000115]
If the building structural material is non-precast concrete, i.e., cast-in-
place
concrete, following step S11.3, in step S12, the support framing is formed by
pouring
concrete into the forms erected in step S11.3 to create, e.g., the vertical
structural elements.
Support framing may be constructed using any commonly accepted building
materials and
techniques. This specification discloses flexible connection details allowing
the composite
action panels to be installed using a variety of support types. In step S13,
temporary or
permanent formwork for floor beams is install.
[000116]
In steps S14.1, S14.2, and S15 the prefabricated composite action panels
are
hoisted into place. In S14.1 plural panels are hoisted to a staging location
And then in
step S14.2, the composite action panels are distributed and placed in their
final locations.
Alternatively, in step S15, an individual composite action panel is hoisted
into place. The
exact location of a composite action panel depends on the modular layout of
all panels,
e.g., on a given floor, and is also dependent on the support type and
allowable construction
tolerances of the support.
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[000 i 17] In step S16, it is determined whether the rebar cage
will extend beyond end
of CLT. If the answer is no, then in step S17.1 the composite action panels
are secured in
place, with the requirements for securing the composite action panels being
based on end
connection type. If the answer is yes, then in step 17.2, splice reinforcement
and additional
edge reinforcement for the composite action panels are installed as noted
above. Typical
mild reinforcing steel bar is used for splices between adjacent panels,
however alternative
splice details which are accepted by the authority having jurisdiction for a
given project
may also be employed.
[000118] In step S18, concrete is poured and the composite
action panel steel
stiffening members are embedded in the concrete Shoring can be provided as
needed for
the composite action panels and/or support beams prior to the pouring of
concrete.
[000119] In step S19, any temporary formwork and shoring is
removed.
[000120] In step S20, protective layers from the timber panel
(i.e., that surface of the
timber panel that is to be left exposed) are removed. If the composite action
panels are
used in a flooring system, the timber can be left exposed to provide a timber
panel ceiling
for a lower floor.
[000121] FIG. 20 is a perspective view showing a single bay of
an exemplary
structural system 60 and identifies the primary element types used in a
typical structural
system. This FIG. 20, in combination with the FIGS. 21a-21c and the preceding
figures
will be used to describe how the modular composite action panel disclosed
herein can also
be applied to the other typical elements of a structural system. In this way,
it is possible
that the embodiment described in this disclosure be used to form the entire
structural
system of a building or individual elements apart from slab elements which
have been
described in detail through the previous figures.
[000122] The typical elements shown in this exemplary single bay
system are the slab
50A incorporating one or more composite action panels, beam elements 61,
column
elements 62, braces elements 63 and wall elements 64. Refer to the first
paragraph of the
detailed description portion of this specification for a description of slab
elements 50A
performance characteristics. Beam elements 61 are horizontal elements which
support the
slab 50A and are supported by column elements 62, wall elements 64 or other
beam
elements. Column element 62 and wall element 64 are vertical elements which
support slab
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element 50A and beam element 61 and transfer building loads to the foundation
system.
Brace elements 63 are diagonally oriented, and typically connected adjacent
vertical
elements, but can also connect beam elements to vertical elements.
[000123]
FIG. 21a is a perspective view illustrating the primary components of a
prefabricated modular timber beam element 61. Similar to the composite action
panels
described in detail above and illustrated in the earlier figures, the beam
element consists of
timber panels 10, connector elements 30, and steel reinforcement 61A. As with
the
composite action panels, the timber 10 and steel reinforcement elements 61A
are
prefabricated off site and joined together and then transported to an
installation site as a
modular package making for rapid and precise installation. The two elements,
timber 10
and steel reinforcement 61A can be made to act compositely by coupling them
with the
connector elements 30. Unlike the slab element 50A, the beam element 61 can
have three
outer sides of timber, creating a trough in which concrete can be placed on-
site. An
additional tie element 61B can be provided as required to stabilize the
vertical portions of
the beam element 61 in the temporary condition.
[000124]
FIG. 21b is a perspective view illustrating the primary components of a
prefabricated modular timber column element 62. This configuration is also
applicable for
the prefabricated modular timber column element 63. Similar to the previous
elements
described, the column 62 (and brace 63 of FIG. 20) consist of prefabricated
timber panels
joined with steel reinforcement 62A using connector elements 30. The column
and brace
elements are unique in that they have four outer sides of timber which form a
hollow tube.
Following erection, concrete is placed in the tube, creating a structural
element with
potential composite behavior consistent with the previous descriptions offered
in this
disclosure. Similar to the beam elements and consistent with standard
construction
practices, ties are provided which connect opposing timber faces to ensure
stability under
the hydrostatic pressure of wet concrete.
[000125]
FIG. 21c is a perspective view illustrating the primary components of a
prefabricated modular timber wall element 64. Wall elements 64 consist of
timber panels
10 prefabricated with steel reinforcement 64A via a connector element 30 on
the interior
face of each composite action panel. Two composite action panels can be
installed opposite
each other with stabilizing cross ties 64B, leaving space between the
composite action
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panels for concrete to be placed on-site. Each composite action panel can be
installed
separately, or a pair of composite action panels can be prefabricated together
and installed
as a double-sided wall form. The outer sides of the wall element will then be
made of
timber.
[000126]
The forgoing description of an implementation of the disclosure has been
present for the purpose of illustration and description. It is not exhaustive
and does not
limit the disclosure to the precise form disclosed. Modifications and
variations are possible
in light of the above teachings or may be acquired from practicing the
disclosure.
Accordingly, while various embodiments of the present disclosure may have been
described, it will be apparent to those of skill in the art that many more
embodiments and
implementations are possible that are within the scope of this disclosure.
Accordingly, the
present disclosure is not to be restricted except in light of the attached
claims and their
equivalents
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