Pre-cast concrete flooring systems and methods of use

Abstract

Various implementations include a corrugated concrete floor system that includes a plurality of elongated pre-cast concrete floor support units disposed in a horizontal arrangement relative to each other for each floor of a building. The concrete floor support units are disposed between floors of a multi-story building. The units define a plurality of supply air plenums and return air plenums that are arranged alternately in the sandwich space between each floor. The supply air plenums are in fluid communication with the building level above them, and the return air plenums are in fluid communication with the building level below them. By having the supply-air plenum and the return-air plenum share the volume occupied by concrete floor support units, the height of the sandwich space is reduced.

1 . A pre-cast concrete floor support system, comprising:
 at least a first elongated floor support unit and a second elongated floor support unit, each elongated floor support unit comprising:
 a first wall; 
 a second wall; 
 a third wall; 
 a first web extending between the first wall and the second wall; and 
 a second web extending between the first wall and the third wall, 
   wherein the second and third walls are coplanar and lie in a plane that is parallel and spaced apart from the first wall, the first and second webs are spaced apart from each other, and the first wall and the first and second webs define a channel therebetween; and   a distal edge of the third wall of the first elongated floor support unit abuts against a distal edge of the second wall of the second elongated floor support unit, wherein the distal edges of the second and third walls are spaced apart from the first and second webs, respectively,   wherein the channel defined by the first wall and the first and second webs of each elongated floor support unit is a first channel and faces a first vertical direction, and a second channel is defined by the third wall and the second web of the first elongated floor support unit and the abutting second wall and the first web of the second elongated floor support unit, the second channel faces a second vertical direction that is opposite from the first vertical direction.   
     
     
         2 . The pre-cast concrete floor support system of  claim 1 , wherein each elongated floor support unit further comprises a first flange and a second flange, the first flange extending from an intersection of the first wall and the first web in the plane of the first wall, and the second flange extending from an intersection of the first wall and the second web in the plane of the first wall. 
     
     
         3 . The pre-cast concrete floor support system of  claim 1 , wherein:
 the first wall of each elongated floor support unit includes a first surface and a second surface, the first and second surfaces being opposite and spaced apart from each other, the first surface facing the first vertical direction and the second surface facing the second vertical direction,   each of the first and second webs of each elongated floor support unit having a first surface and a second surface, the first and second surfaces of the webs being opposite and spaced apart from each other, wherein the first surfaces of the first and second webs and the first wall define the channel,   each of the second and third walls of each elongated floor support unit has a first surface that faces the first vertical direction and a second surface that is opposite and spaced apart from the first surface of each of the second and third walls and faces the second vertical direction, and   thermally insulating material is disposed on at least a portion of the first surfaces of the first and second webs and the first, second, and third walls.   
     
     
         4 .- 10 . (canceled) 
     
     
         11 . The pre-cast concrete floor support system of  claim 1 , wherein the second channel distributes supply air from a heating, ventilation, and air conditioning (HVAC) system for a second level of a building, and the first channel receives return air for the HVAC system from a first level of the building, the first level being vertically below and adjacent the second level. 
     
     
         12 . The pre-cast concrete floor support system of  claim 1 , wherein each elongated floor support unit has a first edge and a second edge, and first and second surfaces of each wall and web of each elongated floor support unit extending between the first edge and the second edge, wherein one of the first or second edges of the first channel is in fluid communication with at least one return air inlet for the HVAC system, and the return air flows through the first channel, and wherein one of the first or second edges of the second channel is in fluid communication with at least one supply air outlet for the HVAC system, and the supply air flows through the second channel. 
     
     
         13 . The pre-cast concrete floor support system of  claim 1 , wherein the first web and/or the second web of each elongated concrete floor support unit lies at an angle of between 90° and 135° to the first wall. 
     
     
         14 . (canceled) 
     
     
         15 . The pre-cast concrete floor support system of  claim 1 , wherein the concrete comprises pre-stressed tendons. 
     
     
         16 . The pre-cast concrete floor support system of  claim 2 , wherein each flange defines a plurality of recessed portions along a distal edge of each flange, the distal edge extending a first distance from the web from which the flange extends and each recessed portion having a distal edge that extends a second distance from the web from which the flange extends, the first distance being greater than the second distance, and wherein the distal edge of the second flange of the second elongated concrete floor support unit abuts the distal edge of the first flange of the first elongated concrete floor support unit, and the recessed portions defined by each edge align and define an opening through which supply air flows. 
     
     
         17 . The pre-cast concrete floor support system of  claim 2 , wherein each of the second wall and third wall defines a plurality of recessed portions along a distal edge of each of the second wall and the third wall, the distal edge extending a first distance from the web from which the second or third wall extends and each recessed portion having a distal edge that extends a second distance from the web from which the second or third wall extends, the first distance being greater than the second distance, and wherein the distal edge of the second wall of the second elongated concrete floor support unit abuts the distal edge of the first wall of the first elongated concrete floor support unit, and the recessed portions defined by each distal edge align and define an opening through which supply air flows. 
     
     
         18 . An elongated pre-cast concrete floor support unit, the floor support unit comprising:
 a first wall;   a second wall;   a third wall;   a first web extending between the first wall and the second wall; and   a second web extending between the first wall and the third wall,   wherein the second and third walls are coplanar and lie in a plane that is parallel and spaced apart from the first wall, the first and second webs are spaced apart from each other, and the first wall and the first and second webs define a channel therebetween.   
     
     
         19 . The floor support unit of  claim 18 , further comprising a first flange and a second flange, the first flange extending from an intersection of the first wall and the first web in the plane of the first wall, and the second flange extending from an intersection of the first wall and the second web in the plane of the first wall. 
     
     
         20 . The floor support unit of  claim 18 , wherein:
 the first wall includes a first surface and a second surface, the first and second surfaces being opposite and spaced apart from each other, the first surface facing a first vertical direction and the second surface facing a second vertical direction that is opposite from the first vertical direction,   each of the first and second webs having a first surface and a second surface, the first and second surfaces of the webs being opposite and spaced apart from each other, wherein the first surfaces of the first and second webs and the first wall define the channel,   each of the second and third walls has a first surface that faces the first vertical direction and a second surface that is opposite and spaced apart from the first surface of each of the second and third walls and faces the second vertical direction, and   thermally insulating material is disposed on at least a portion of the first surfaces of the first and second webs and the first, second, and third walls.   
     
     
         21 . The floor support unit of  claim 20 , wherein the thermally insulating material comprises at least one of a fiber reinforcing polymer material or sprayed foam insulation. 
     
     
         22 .- 25 . (canceled) 
     
     
         26 . The floor support unit of  claim 18 , wherein the unit has a first edge and a second edge, and first and second surfaces of each wall and web extend between the first edge and the second edge, wherein the first edge of the channel is in fluid communication with a return air duct for a heating, ventilation, and air conditioning (HVAC) system, and the return air is received through the channel. 
     
     
         27 . The floor support unit of  claim 18 , wherein the first web and/or the second web lies at an angle of between 90° and 135° to the first wall. 
     
     
         28 . (canceled) 
     
     
         29 . The floor support unit of  claim 18 , wherein the concrete comprises pre-stressed tendons. 
     
     
         30 . An elongated pre-cast concrete floor support unit, the elongated floor unit comprising:
 a first wall;   a second wall;   a third wall;   a fourth wall;   a first web extending between the first wall and the second wall;   a second web extending between the first wall and the third wall; and   a third web extending between the third wall and the fourth wall,   wherein the second and third walls are coplanar, the first and fourth walls are coplanar, the first, second, and third webs are spaced apart from each other, the second and third walls lie in a plane that is parallel and spaced apart from the first and fourth walls, the first and second webs and the first wall define a first channel therebetween, and the third wall and the second and third webs define a second channel therebetween, wherein the first channel opens in a first vertical direction, and the second channel opens in a second vertical direction that is opposite of the first vertical direction.   
     
     
         31 . The elongated pre-cast concrete floor support unit of  claim 30 , further comprising a first flange, a second flange, and a third flange, the first flange extending from an intersection of the first wall and the first web in the plane of the first wall, the second flange extending from an intersection of the first wall and the second web in the plane of the first wall, and the third flange extending from an intersection of the fourth wall with the third web in the plane of the fourth wall. 
     
     
         32 .- 48 . (canceled) 
     
     
         49 . The elongated pre-cast concrete floor support unit of  claim 30 , further comprising a fifth wall and a fourth web, the fifth wall being coplanar with the second and third walls, wherein fourth web is spaced apart from the first, second, and third webs, the fourth web extends between the fourth wall and the fifth wall, and the third and fourth webs and the fourth wall define a third channel therebetween that opens in the first vertical direction. 
     
     
         50 . (canceled) 
     
     
         51 . The elongated pre-cast concrete floor support unit of  claim 49 , further comprising a fourth flange, the fourth flange extending from an intersection of the fourth wall with the fourth web in the plane of the fourth wall. 
     
     
         52 . (canceled)