Precast composite floor panel with integrated joist and method of manufacturing same

Abstract

A fiber reinforced floor panel usable in a building comprised of a joist and at least one boot whereby the boot is fixedly connected to an end of the steel joist; a planar section comprised of reinforcing members, whereby a deflection strength of the planar section is higher than a deflection strength of a planar section without the reinforcing members; and a reinforcing material covering whereby the at least one boot and the steel joist are not completely surrounded by the reinforcing material covering.

1 . A panel usable as a floor or a roof in a building structure comprised of: 
 an elongate joist having a vertical web and a side orthogonal to said web; and    a cementitious material comprising a planar section;    whereby an edge of the joist is embedded in the cementitious material and the vertical web extends away therefrom;    the vertical web is comprised of a plurality of through openings through which said cementitious material extends.    
   
   
       2 . The panel as recited in  claim 1  wherein the cementitious material includes fibers dispersed therein.  
   
   
       3 . The panel as recited in  claim 1  wherein a horizontal plane is disposed on an edge of the joist opposite the embedded edge of the joist.  
   
   
       4 . The panel as recited in  claim 3 , whereby a lip is disposed on an unattached edge of the horizontal plane and extends toward the cementitious material.  
   
   
       5 . The panel as recited in  claim 1 , wherein the joist is comprised of steel.  
   
   
       6 . The panel as recited in  claim 2 , wherein the fibers are glass fibers.  
   
   
       7 . The panel as recited in  claim 2 , wherein the fiber reinforced cementitious is cast whereby the planar section is formed.  
   
   
       8 . A fiber reinforced floor panel usable in a building structure comprised of: 
 a joist; and    a fiber reinforced cementitious material comprising a planar section;    wherein the joist is comprised of an elongate member having a vertical side and first and second horizontal sides such that the joist has a C-shaped cross-section and whereby a boot is fixedly connected to at least an end of the joist;    wherein the boot is comprised of a heel and a toe; and    whereby the heel and the toe fixedly engage the fiber reinforced cementitious material.    
   
   
       9 . The fiber reinforced panel as recited in  claim 8  wherein the boot has a first side and a second side, and a front and a back end, whereby the front end is shorter in height than the back end.  
   
   
       10 . The fiber reinforced panel as recited in  claim 9  wherein the first and second sides are disposed at a distance from each other that is at least as large as a largest width of the first and second horizontal sides of the joist and whereby a joist receiving slot is formed therebetween.  
   
   
       11 . The fiber reinforced panel as recited in  claim 9  wherein the boot is further comprised of a reinforcing rod.  
   
   
       12 . The fiber reinforced panel as recited in  claim 8  wherein the boot is further comprised of the cementitious material.  
   
   
       13 . The reinforced panel as recited in  claim 10  wherein the joist matingly engages the boot in the joist receiving slot.  
   
   
       14 . The fiber reinforced floor panel as recited in  claim 9  wherein the joist is held in fixed communication with the planar section by at least the boot.  
   
   
       15 . The fiber reinforced floor panel as recited in  claim 8 , wherein the joist is comprised of steel.  
   
   
       16 . The fiber reinforced floor panel as recited in  claim 8 , wherein the fibers are glass fibers.  
   
   
       17 . The fiber reinforced floor panel as recited in  claim 8 , wherein the fiber reinforced cementitious is cast whereby the planar section is formed.  
   
   
       18 . A method of manufacturing a panel comprised of the steps of: 
 placing a first boot and a second boot at a predetermined distance from each other; and    placing a first end of the light-gage steel joist in the first boot and a second end of the light-gage steel joist in the second boot to form a joist assembly;    positioning the joist assembly in a mold;    depositing a cementitious material in the mold so that at least a portion of the joist assembly is surrounded thereby;    curing the fiber reinforced cementitious material thereby fixedly securing the joist assembly therein.    
   
   
       19 . The method as recited in  claim 18  further comprising providing through-holes in the joist.  
   
   
       20 . The method as recited in  claim 19  further comprising causing the cementitious material to flow through the through holes in the joist before curing.  
   
   
       21 . A lightweight structural panel, comprising: 
 an elongate joist having a vertical web and a side orthogonal to the vertical web,    said vertical web and side each having a plurality of through-holes disposed therein;    a fiber reinforced cementitious material cast in cooperative engagement around said side and a portion of said web and extended through ones of said through holes in each of said side and said web so as to fixedly look said joist in relation to said cementitious material.    
   
   
       22 . A lightweight structural panel as recited in  claim 21 , said joist having a cross-section profile of one of a C-, L-, I-, T-, and a rectangle.  
   
   
       23 . A lightweight structural panel as recited in  claim 21 , further comprising a boot disposed on each end of said joist.  
   
   
       24 . A lightweight structural panel as recited in  claim 23 , each boot comprising: 
 a pocket having a pair of spaced apart walls, said joist being disposed therebetween;    a foot connected between corresponding edges of said spaced apart walls; and    a through hole in said foot and portions of said spaced apart walls.    
   
   
       25 . A lightweight structural panel as recited in  claim 24 , each boot further comprising a column connected between said spaced apart walls, said column extended from said foot to a side of said walls opposite said foot.  
   
   
       26 . A lightweight structural panel as recited in  claim 25 , said column further comprising a reinforcing member disposed therein extending from said foot to said side of said walls opposite said foot.  
   
   
       27 . A method of making a lightweight structural panel comprising: 
 providing a mold in the shape of the structural panel;    placing a joist in said mold, said joist having a vertical web and a side orthogonal thereto; and    placing a cementitious slurry in said mold, said cementitious slurry incorporating therein said side and a portion of said vertical web of said joist.    
   
   
       28 . A method of making a lightweight structural panel as recited in  claim 27  further comprising: 
 providing a plurality of through holes in each of said side and said web of said joist.    
   
   
       29 . A method of making a lightweight structural panel as recited in  claim 28 , further comprising placing said cementitious slurry through ones of said through holes.  
   
   
       30 . A method of making a lightweight structural panel as recited in  claim 27 , further comprising curing said cementitious slurry.  
   
   
       31 . A method of making a lightweight structural panel as recited in  claim 27 , further comprising placing a pair of boots in said mold and disposing ends of said joist in said boots.  
   
   
       32 . A method of making a lightweight structural panel as recited in  claim 31 , further comprising providing said boots with through-holes.  
   
   
       33 . A method of making a lightweight structural panel as recited in  claim 32 , further comprising placing said cementitious material through said through holes in said boots.