Structural Floor and Roof Joists

Abstract

A floor includes structural floor joist that includes a flange and tabs punched out of the flange (forming holes in the flange). Flooring material of the floor that extrudes through at least one of the holes is bonded to some of the tabs and the flange of the structural floor joist, forming a bonded composite assembly of the structural floor joist and the forming material, that has a centroid that is located in or near the forming material, placing some of the forming material in compression and placing at least 90% of the structural floor joist in tension.

1 . An apparatus comprising:
 a forming material; and   a member having:
 a flange having a central longitudinal axis; and 
 a web that extends from the flange; 
 a plurality of tabs punched out of the flange, forming a hole for each of the plurality of tabs, yielding a plurality of holes, 
   wherein a portion of the forming material extrudes through at least one of the holes and the portion of the forming material is bonded to the forming material to the tabs and the flange of the member, forming a bonded composite assembly of the member and the forming material,   wherein the bonded composite assembly having a centroid that is located in or near the forming material, placing 100% or near or about 100% of the forming material in compression and placing at least 90% of the member in tension.   
     
     
         2 . The apparatus of  claim 1 , wherein the centroid of the bonded composite assembly is located at a bottom plane of the forming material. 
     
     
         3 . The apparatus of  claim 2 , wherein the centroid of the bonded composite assembly is located at the middle of the flange and between the web and the flange return. 
     
     
         4 . The apparatus of  claim 1 , wherein each of the plurality of tabs comprise:
 a tab leg that is substantially planar and is connected to the flange at one end of the tab leg of each of the plurality of tabs and that projects outwardly from the flange at an angle of less than 90 degrees to the flange; and   a tab foot extending from the tab leg of each of the plurality of tabs and curving in a direction that is (i) toward a plane extending perpendicular to the central longitudinal axis through the one end of the tab leg of each of the plurality of tabs and (ii) away from a hole in the flange created by the tab being punched out of the flange,
 wherein the hole is defined by a base side and a top side, the base side has a greater length than the top side and the tab leg of each of the plurality of tabs the extends from the base side, 
 wherein the tabs of each of the plurality of the member comprises a first tab and a second tab, 
 wherein one of the first tab and the second tab of each member being a lateral tab and the other of the first and second tabs of each member being a longitudinal tab; 
 a total surface area of the holes created by the tabs is greater than about 10% of the total surface area of the flange; and 
   wherein the tabs of the member and a structural mesh is embedded in the forming material with the tab foot of each tab curving in the direction that is away from the respective hole in the respective flange created by the tab punched out of the respective flange and with the webs not embedded in the forming material.   
     
     
         5 . The apparatus of  claim 4  being pre-cast and further comprising:
 at least one lifting anchor embedded in the forming material. 
 
     
     
         6 . The apparatus of  claim 5  being pre-cast and further comprising:
 the at least one lifting anchor being embedded in the structurally reinforced forming material. 
 
     
     
         7 . The apparatus of  claim 5 , wherein the end of the tab leg of each lateral tab that is connected to the respective flange is substantially perpendicular to the end of the tab leg of each longitudinal tab that is connected to the respective flange. 
     
     
         8 . The apparatus of  claim 4 , wherein the member further comprises:
 16 gage in thickness.   
     
     
         9 . The apparatus of  claim 8 , wherein the member further comprises:
 a tensile strength of 50 ksi.   
     
     
         10 . An apparatus comprising:
 a plurality of members, each of the plurality of members comprising:
 a forming material; 
 a flange having a central longitudinal axis; and 
 a web extending from the flange; and 
 a plurality of tabs punched out of the flange, forming a hole for each of the plurality of tabs, forming a plurality of holes, 
   wherein a portion of the forming material extrudes through at least one of the holes and the portion of the forming material is bonded to the forming material to the tabs and the flange of the member, forming a bonded composite assembly of the member and the forming material, that has a centroid that is located in or near the forming material, placing 100% or near or about 100% of the forming material in compression and placing at least 90% of the member in tension.   
     
     
         11 . The apparatus of  claim 10 , wherein the centroid is located at a bottom plane of the forming material. 
     
     
         12 . The apparatus of  claim 11 , wherein the centroid is located above the middle of the web. 
     
     
         13 . The apparatus of  claim 12 , wherein each of the tabs comprise:
 a tab leg that is connected to the flange at one end of the tab leg and that projects outwardly from the flange at an angle of less than 90 degrees to the flange; and   a tab foot extending from the tab leg and curving in a direction that is (i) toward a plane extending perpendicular to the central longitudinal axis through the one end of the tab leg and (ii) away from a hole in the flange created by the tab being punched out of the flange,   wherein the hole is defined by a base side and a top side, the base side has a greater length than the top side and the tab leg the extends from the base side,   wherein the tabs of each of the plurality of the members comprises a first tab and a second tab,   wherein one of the first tab and the second tab of each floor member being a lateral tab and the other of the first and second tab of each member being a longitudinal tab;   a total surface area of the holes created by the tabs is greater than about 10% of the total surface area of the flange; and   wherein the tabs of the plurality of members and a structural mesh are embedded with the tab foot of each tab curving in the direction that is away from the respective hole in the respective flange created by the tab punched out of the respective flange.   
     
     
         14 . The apparatus of  claim 13 , wherein the end of the tab leg of each lateral tab that is connected to the respective flange is substantially perpendicular to the end of the tab leg of each longitudinal tab that is connected to the respective flange. 
     
     
         15 . The apparatus of  claim 13 , wherein each of the plurality of members further comprise:
 16 gage in thickness.   
     
     
         15 . (canceled) 
     
     
         16 . The apparatus of  claim 13 , wherein the each tab leg is substantially planar. 
     
     
         17 . The apparatus of  claim 13 , wherein the tabs of the plurality of member and a structural mesh are embedded in forming material. 
     
     
         18 . The apparatus of  claim 17  being pre-cast and wherein the tabs are embedded in structurally reinforced forming material. 
     
     
         19 . The apparatus of  claim 18  being pre-cast and further comprising:
 at least one lifting anchor is embedded in the forming material with the plurality of member and the structural mesh. 
 
     
     
         20 . The apparatus of  claim 10 , wherein the forming material further comprises microfibers. 
     
     
         21 - 120 . (canceled) 
     
     
         121 . A monolithic structure comprising:
 a floor having:
 a first web; 
 a first top flange extending from a top of the first web; and 
 a first tab attached to, or extending from, the first top flange. 
   a roof having:
 a second web; 
 a second top flange extending from a top of the second web; and 
 a second tab attached to, or extending from, the second top flange. 
   
     
     
         122 . The monolithic structure of  claim 121 , wherein the monolithic structure has a first mid-point between the first top flange and a bottom of the first web, wherein a first centroid being located above the first mid-point, the first centroid being an first equilibrium point of a first compression area of the floor and a first tension area of the floor, the first tension area being below the first centroid and the first compression area being above the first centroid; and wherein the monolithic structure has a second mid-point between the second top flange and a bottom of the second web, wherein a second centroid being located above the second mid-point, the second centroid being an second equilibrium point of a second compression area of the floor and a second tension area of the floor, the second tension area being below the second centroid and the second compression area being above the second centroid. 
     
     
         123 . The monolithic structure of  claim 122  further comprising:
 a first deck on the top of the first top flange, the first deck having a hole, the first tab protruding through the hole in the first deck; 
 a first forming material on the top of the first deck; 
 a second deck on the top of the second top flange, the second deck having a hole, the second tab protruding through the hole in the second deck; and 
 a second forming material on the top of the second deck, 
 wherein the first web, the first top flange and the first tab comprise a first member, 
 wherein a portion of the first forming material solidifies around the first tab and the portion of the first forming material is bonded to the first tab, forming a first bonded composite assembly of the first member, the first deck and the first forming material, 
 wherein the second web, the second top flange and the second tab comprise a second member, 
 wherein a portion of the second forming material solidifies around the second tab and the portion of the second forming material is bonded to the second tab, forming a second bonded composite assembly of the second member, the second deck and the second forming material. 
 
     
     
         124 - 130 . (canceled) 
     
     
         131 . The monolithic structure of  claim 123 , wherein the first tab is attached to the first top flange through the first deck via a first attachment apparatus, and the first attachment apparatus does not leave an open hole in the first top flange and the first attachment apparatus does not leave an open hole in the first deck, and wherein the second tab is attached to the second top flange through the second deck via a second attachment apparatus, and the second attachment apparatus does not leave an open hole in the second top flange and the second attachment apparatus does not leave an open hole in the second deck. 
     
     
         132 . The monolithic structure of  claim 131 , wherein the attachment apparatus is selected from the group consisting of screws, welds or pop-rivets, wherein the attachment apparatus is selected from the group consisting of screws, welds or pop-rivets. 
     
     
         133 - 138 . (canceled)