Apparatus and Method for Forming an Elevated Deck

Abstract

An system and method for forming an elevated deck and support beam within a structure enables the pouring of one or a succession of superposed decks above a surface such as a floor, the ground or other supporting surface. The system includes a plurality of profiles which alone or in combination define concrete-receiving reservoirs for forming poured in place support beams, with the elevated deck being poured contemporaneously therewith for support on the beams. The profiles include first and second preferably divergent sidewalls which are connected by middle member which serves as a base or bridge between the sidewalls. The profiles are complementally configured to nest with one another to provide a span across structural walls, and may be provided with complementally configured end caps.

1 . A profile for use in forming an elevated deck and support beam structure, the profile comprising: 
 a. a first end wall;    b. a second end wall; and    c. a middle section including: 
 i. a first side wall connected to said first end wall;  
 ii. a second side wall connected to said second end wall; and  
 iii. a substantially planar wall connecting said first and second side walls, said substantially planar wall and said side walls forming a reservoir between said first and second end walls.  
   
   
   
       2 . The profile as recited in  claim 1 , wherein said planar wall extends parallel to said first and second end walls.  
   
   
       3 . The profile as recited in  claim 1 , wherein said first end wall includes: 
 a. a first section; and    b. a second section connected to said first section and forming a step or lip therebetween.    
   
   
       4 . The profile as recited in  claim 3 , wherein said second end wall is a substantially flat planar member.  
   
   
       5 . The profile as recited in  claim 4 , wherein said flat planar member has a thickness substantially equal to a thickness of said first section thereby forming a level surface when placed adjacent thereto.  
   
   
       6 . The profile as recited in  claim 3 , wherein said second end wall includes: 
 a. a first section; and    b. a second section connected to said first section and forming a step or lip therebetween.    
   
   
       7 . The profile as recited in  claim 1 , wherein said reservoir is able to receive a reservoir of a further profile for storage thereof.  
   
   
       8 . The profile as recited in  claim 1 , wherein said profile is re-useable.  
   
   
       9 . An insert for providing structural support to an elevated deck and support beam of a structure, said insert comprising: 
 a. a support structure extending a width of the support beam and defining a conduit therethrough;    b. a support post extending from said support structure; and    c. an attachment strip connected to an end of said support post opposite said support structure and positioned at a base of the support beam for securing at least one of boards and panels to said support beam.    
   
   
       10 . The insert as recited in  claim 9 , wherein said conduit is able to receive at least one of wires, pipes and plumbing therethrough.  
   
   
       11 . The insert as recited in  claim 9 , wherein said support post extends substantially from a mid-point of said support structure.  
   
   
       12 . The insert as recited in  claim 9 , wherein said insert comprises a first angled support post extending on a first side of said support post between said support structure and said attachment strip and a second angled support post extending on a second side of said support post opposite said first side between said support structure and said attachment strip.  
   
   
       13 . The insert as recited in  claim 9 , further comprising at least one stabilizing bar extending perpendicular to said structural support and along a length of the support beam.  
   
   
       14 . The insert as recited in  claim 13 , wherein said at least one stabilizing bar extends parallel to said attachment strip.  
   
   
       15 . The insert as recited in  claim 13 , wherein said at least one stabilizing bar is positioned adjacent said structural support on a side of said insert opposite said attachment strip.  
   
   
       16 . A method for forming an elevated deck and support beams of a structure including the activities of: 
 a. placing shoring beams between a first pair of opposing side walls along a length of a structure;    b. positioning a plurality of beam holders at predetermined intervals aligned along the length of a second pair of opposing walls of the structure;    c. positioning a reservoir presented by a plurality of profiles including a first end wall and a second end wall connected via a middle section forming the reservoir within respective ones of the plurality of beam holders, the first end wall of each profile being received by a stepped section of the second end wall of an adjacent profile to form a level surface therebetween;    d. further positioning a plurality of form profiles adjacent on another along the width of the structure and aligned with a further shoring beams creating a further row of form profiles;    e. aligning the reservoirs of adjacent profiles to provide respective reservoirs extending the width of the structure;    f. pouring concrete within each of the reservoirs and atop the profiles creating a level deck;    g. removing each of the shoring beams; and    h. disengaging the profiles from the beams and deck.    
   
   
       17 . The method as recited in  claim 16 , wherein prior to said activity of pouring concrete, further comprising the activity of positioning a structural insert within the respective one of the aligned reservoirs along the width of the structure, the structural insert including at least one structural support defining a conduit extending between the walls of the reservoir, a support post extending from the structural support and an attachment strip connected to the support post at an end opposite the structural support.  
   
   
       18 . The method as recited in  claim 17 , wherein said activity of disengaging the profiles further revealing the attachment strip extending alone the base of the beam.  
   
   
       19 . The method as recited in  claim 18 , further comprising the activity of securing at least one of panels and boards to the securing strip thereby covering.  
   
   
       20 . The method as recited in  claim 16 , further comprising the activity of stacking a profile within the reservoir of a further profile.  
   
   
       21 . The method as recited in  claim 17 , further comprising the activity of positioning at least one framing member atop at least one of said shoring beams, and said step of positioning said form profiles includes positioning and connecting the plurality of form profiles around said framing member and to said framing member and said step of pouring concrete includes pouring concrete around the at least one framing member.  
   
   
       22 . The method as recited in  claim 21 , further comprising the activity of inserting at least one of wiring, piping and plumbing through the aligned conduits along the length of the structure.  
   
   
       23 . The method as recited in  claim 16 , wherein the form profiles include a first end wall extending from an edge of a first divergent side wall and a second end wall extending from an edge of a second divergent side wall opposite said first divergent side wall, said first and second end walls extending parallel to said connecting member, said first and second end walls including a plurality of apertures along the length of at least some of said form profiles, and further comprising the activities of at least one of: 
 connecting longitudinally adjacent form profiles to one another between their respective first and second ends via fasteners received through aligned apertures, and    connecting at least one jump rail to adjacent form profiles for supporting said rows of profiles, the jump rail being formed as a substantially planar member having a plurality of spaced apertures extending along a length of the jump rail.    
   
   
       24 . The method as recited in  claim 16 , wherein prior to said activity of positioning profiles, the method comprises the activity of positioning an end cap in spanning relationship across the opposing side walls, the end cap including a pair of opposed, divergent side walls and having a connecting member connecting the side walls and an end panel enclosing at least one end of the end cap, and wherein said activity of positioning profiles includes positioning at least one of the profiles atop the end cap.  
   
   
       25 . The method as recited in  claim 16 , wherein the profile is modified and includes first end wall and the second end wall each having stepped sections and further comprising the activity of positioning modified profiles adjacent one another thereby leaving an opening the formed deck.  
   
   
       26 . A system for use in forming a deck and beam support structure of cementatious materials elevated above a supporting surface, said system comprising: 
 a plurality of elongated profiles having a longitudinal axis extending longitudinally from a first end to a second end, one of said plurality of profiles being oriented in substantially parallel alignment to another of said plurality of profiles, the profiles each including a pair of opposed, divergent side walls and a connecting member, the profiles each having a normally lower surface and a cementatious material receiving surface, the side walls of the aligned profiles presenting at least one reservoir for receiving flowable cementatious material for forming a beam;    a shoring member for supporting the profiles in an elevated condition above a supporting surface.    
   
   
       27 . The system as recited in  claim 26 , wherein said reservoir is positioned between the side walls of at least one of said plurality of profiles.  
   
   
       28 . The system as recited in  claim 26 , wherein said reservoir is positioned between two opposing side walls of two adjacent profiles of said plurality of profiles.  
   
   
       29 . The system as recited in  claim 26 , wherein said profiles further comprise: 
 a first end wall extending from an edge of a first divergent side wall; and    a second end wall extending from an edge of a second divergent side wall opposite said first divergent side wall, said first and second end walls extending parallel to said connecting member.    
   
   
       30 . The system as recited in  claim 28 , wherein said first and second end walls include at least one aperture extending therethrough.  
   
   
       31 . The system as recited in  claim 31 , further comprising: 
 at least one jump rail having a plurality of apertures spaced along a length of the jump rail; and    a plurality of fasteners for releaseably securing said at least one jump rail to said plurality of adjacent profiles oriented in substantially parallel relationship to one another, wherein a respective aperture of said at least one jump rail is aligned with said apertures in said first and second end walls, and wherein said fasteners are selectively received through the aligned apertures of said jump rail and a respective one of said first and second end walls for releaseably securing said at least one jump rail to a plurality of profiles to provide support therefore.    
   
   
       32 . The system as recited in  claim 26 , further comprising a framing member for defining an area of the deck to remain unfilled with cementations material, and wherein said plurality of profiles are selectively positionable around said framing member.  
   
   
       33 . The system as recited in  claim 32 , further comprising step-shaped connectors having an offset section connecting first and second connector sections, and further including at least one connection aperture extending through each of said first and second connector sections for releaseably securing said profiles to said framing member.  
   
   
       34 . The system as recited in  claim 26 , further comprising a plurality of support bars selectively positioned within a conduit between parallel adjacent profiles.  
   
   
       35 . The system as recited in  claim 28 , further comprising an insert selectively receivable within said reservoirs extending between said first end and said second end for providing structural support to the deck and beam.  
   
   
       36 . The system as recited in  claim 35 , wherein said insert comprises: 
 a. a support structure extending a width of the support beam and defining a conduit therethrough; and    b. at least one support bar extending along longitudinally between said first and second end.    
   
   
       37 . The system as recited in  claim 36 , wherein said channel is adapted to receive at least one of wires, pipes and plumbing therethrough.  
   
   
       38 . The system as recited in  claim 26 , further comprising at least one board positioned at a base of said reservoir and between opposing side walls of adjacent profiles.  
   
   
       39 . The system as recited in  claim 37 , wherein said at least one board is adapted for connection to at least one of boards and panels thereto.  
   
   
       40 . The system as recited in  claim 29 , further comprising at least one extension board selectively positioned to rest atop said first end wall of a first profile and said second end wall of an adjacent profile.  
   
   
       41 . The system as recited in  claim 29 , further comprising mounting apertures extending through said first and second end walls and positioned at opposing distal ends of at least some of said profiles, said mounting apertures being sized and positioned to receive fasteners therethrough for mounting said profiles to additional, complementally configured profiles.  
   
   
       42 . The system as recited in  claim 26 , further comprising an end cap including a pair of opposed, divergent side walls and having a connecting member connecting the side walls and an end panel enclosing at least one end of the end cap, said end cap being complementally configured to at least one of said profiles for mounting to and enclosing a first end of said at least one of said profiles.  
   
   
       43 . The system as recited in  claim 26 , further comprising a wedge configured for selective positioning between a respective profile and a deck or support beam formed thereby and for releasing said profile from the formed deck upon hardening of the cementatious material.  
   
   
       44 . The system as recited in  claim 26 , wherein one of said plurality of profiles complementally configured with another of said plurality of profiles for positioning in longitudinally overlapping relationship wherein said divergent first and second side walls of said one profile engage the corresponding divergent first and second side walls of the another profile when arranged in overlapping or nested relationship.  
   
   
       46 . A system as recited in  claim 26 , wherein said plurality of profiles each include a pair of open ends for permitting nesting or overlapping of two similarly configured profiles.  
   
   
       47 . A system as recited in  claim 46 , including at least one end cap having a pair of side walls and a bridge presenting a cross-sectional configuration complemental to at least one of said plurality of profiles, said end cap further including at least one closed end having an end panel substantially extending between said pair of side walls.  
   
   
       48 . A system as recited in  claim 26 , including at least one elongated member extending beneath said plurality of profiles, connected thereto, and oriented transverse to the longitudinal axis of said plurality of profiles.  
   
   
       49 . A system as recited in  claim 48 , wherein said elongated member includes a plurality of aligned openings, and further including respective pins extending through at least said one and said other of said profiles and through said openings in said elongated member for connecting said profiles to said elongated member.  
   
   
       50 . A system as recited in  claim 26 , including further respective complementally configured profiles aligned with each of said plurality of profiles and positioned along said longitudinal axis in overlapping relationship to respective ones of said plurality of profiles.  
   
   
       51 . A system as set forth in  claim 26 , including a tubular member extending across said reservoir.  
   
   
       52 . A system as set forth in  claim 26 , including an elongated reinforcing member positioned in said reservoir to extend substantially parallel to said longitudinal axis of said profile.  
   
   
       53 . A system as set forth in  claim 26 , including a plurality of brackets connecting respective ones of said plurality of profiles to a framing member extending upwardly from said brackets and between two laterally spaced profiles, said framing member defining a barrier to the entry of concrete in order to provide a passage through the deck and beam support structure to be formed of cementatious material.  
   
   
       54 . A system as set forth in  claim 27 , further including a board positioned in said reservoir between said reservoir-defining side walls of adjacent profiles and atop said profiles, said board being oriented and configured to inhibit the passage of cementations material between said adjacent profiles.  
   
   
       55 . A system for forming an elevated deck and support beam within a structure comprising a plurality of profiles, said plurality of profiles each including a first end wall, a second end wall and a middle section connecting said first end wall and said second end wall forming a reservoir therein, said plurality of profiles are aligned and positioned adjacent one another along each of a length of the structure and a width of the structure, wherein respective first end walls of ones of said plurality of lengthwise aligned profiles are received by second end walls of lengthwise adjacent profiles to form a level surface and reservoirs of widthwise aligned profiles are aligned to form a reservoir extending across the width of the structure for forming support beams.  
   
   
       56 . The system as recited in  claim 55 , wherein said first end wall is a stepped section and said second end wall is a substantially planar member.  
   
   
       57 . The system as recited in  claim 56 , wherein said substantial planar member is receivable in said stepped section thereby creating a level surface therebetween.  
   
   
       58 . The system as recited in  claim 55 , further comprising an extension leg for receipt by either of said first end wall and said second end wall for extending a distance between adjacent profiles to equal to a length of said extension leg.  
   
   
       59 . The system as recited in  claim 58 , wherein said extension leg has a thickness substantially equal to a thickness of each of said first end wall and said second end wall.  
   
   
       60 . The system as recited in  claim 55 , further comprising a plurality of inserts selectively receivable within reservoirs and extending a width of the support beam and defining a conduit therethrough.  
   
   
       61 . The system as recited in  claim 60 , wherein said conduit is able to receive at least one of wires, pipes and plumbing therethrough.  
   
   
       62 . The system as recited in  claim 55 , further comprising a plurality of beam holders positioned at predetermined intervals along a length of opposing structural walls for receiving respective reservoirs of said profiles therein.  
   
   
       63 . The system as recited in  claim 55 , further comprising a plurality of shoring beams supported by a plurality of adjustable shores extending along the length of the structure and parallel with opposing structural walls for supporting said plurality of profiles within the structure.  
   
   
       64 . The system as recited in  claim 55 , wherein upon hardening of the concrete, said profile is selectively removable from said structure for later re-use.  
   
   
       65 . A method of forming an elevated deck and beam support structure above a surface and extending between at least two spaced, opposing upright walls of a structure, said method comprising the steps of: 
 providing a plurality of shoring members extending upwardly from said surface;    providing a plurality of elongated profiles each having generally divergent side walls and a panel member connecting the side walls to each other;    orienting said plurality of profiles to be supported by said shoring members whereby at least one of said plurality of profiles is substantially parallel to another of said profiles and substantially in a common horizontal plane;    flowing cementations material into at least one beam-defining reservoir defined by the side walls of one or more of said plurality of profiles and atop said panel members to form a generally unitary deck and beam support structure located in elevated relationship to said surface;    allowing said cementatious material to cure to a self-sustaining condition; and    removing said shoring members and said plurality of profiles from an underside of said deck and beam support structure.    
   
   
       66 . A method as set forth in  claim 65 , wherein said step of removing said plurality of profiles includes the step of moving one of said divergent side walls of a profile away from the other of said divergent side walls of the profile.  
   
   
       67 . A method as set forth in  claim 65 , wherein said step of removing said plurality of profiles includes the step of moving one of said divergent side walls of a profile toward the other divergent side wall of the panel.