WO2007085076A1

WO2007085076A1 - A composite floor apparatus and a method of making and using same with building supports

Info

Publication number: WO2007085076A1
Application number: PCT/CA2007/000090
Authority: WO
Inventors: Waldemar H. Greiner
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-01-24
Filing date: 2007-01-24
Publication date: 2007-08-02
Anticipated expiration: 2008-07-24

Abstract

A composite floor apparatus includes trusses, a floor pan, and concrete. Each truss has longitudinally spaced projections extending inwardly or outwardly from its sides, and has a cambered deflection that is flattened in use. The pan has notches, each receiving part of a truss, with the projections unobstructed above the pan. The concrete has an upper surface, a lower surface engaging the upper surface of the pan, and inside portions securely engaging the projections. The concrete encases the projections m bonded relation, so as to resist longitudinal movement relative to the trusses. When the upper surface of the concrete supports a floor load, notional top and bottom portions of the apparatus are in compression and tension, respectively, with a neutral axis therebetween. The neutral axis is positioned beneath a substantial portion of the concrete, which contributes to the strength and stiffness of the apparatus.

Description

A COMPOSITE FLOOR APPARATUS AND A METHOD OF MAKING AND USING SAME WITH BUILDING SUPPORTS

FIELD OF THE INVENTION

[0001] The present invertion relates to a floor apparatus and method, and more particularly, to a metal and concrete composite floor apparatus and a method of making and using same with building supports .

BACKGROUND OF THE INVENTION

[0002] In the construction industry for buildings (including commercial and high rise buildings, among others) , it may often have been necessary and/or desirable to utilize floor systems that span significant distances between building supports. Moreover, it may frequently be necessary and/or desirable to support a floor system only about its periphery. Prior art floor systems may have been generally unsatisfactory in achieving the distances required, and/or they may have been limited, inter alia, by the weight of any flooring components (e.g., concrete) that heretofore may not have contributed to the strength and/or stiffness of the floor system. That is, it will typically be necessary for a floor system to be able to withstand substantial loading -- including the mass of the floor itself -- across these significant spanning distances. Preferably, though not achieved in the prior art, these wide spans between building supports might actually help to support the floor systems against collapse.

[0003] It may heretofore have been necessary and/or desirable to utilize floor systems that span significant distances between building supports, so as to maximize useful square footage. This aspect is one which may have, and/or may yet, become increasingly important with increasing real-estate costs.

[0004] Any prior art f Loor systems which may have included systems or networks of steel trusses together with concrete (i.e., poured and/or formed for placement thereabove) may not have provided for the concrete and the trusses to work together so as to jointly contribute to the strength and/or stiffness of the floor. Instead, the concrete in prior art floor systems has generally acted much the same as a dead weight, without making any significant structural contribution to the strength of the floor. As such, prior art concrete and steel truss floor systems may heretofore only have been able to achieve spans of moderate length between adjacent building supports .

[0005] To recap and improve upon the foregoing, and as may be appreciated by persons having ordinary skill m the art that, in prior art truss-based floor systems, the strength of the trusses themselves may have contributed the vast majority of the strength to the entire floor system. Indeed, one of the largest loads borne by prior art floor systems may have been the weight of the nonstructural components of the system itself. In floor systems including concrete, the majority of the system's weight may be due to the presence of the concrete. That is, in prior art floor systems, the concrete component thereof may typically have provided little, if any, strength to the system (i.e., m terms of the load- bearing capacity thereof) . Rather, the concrete in prior art floor systems may have primarily served to provide a rigid surface over which other flooring materials (e.g., carpet, hardwood) may be laid and/or installed.

[0006] Any prior art floor systems that may have included concrete, as a component thereof, may also have been disadvantageous insofar as they may have required precise manual positioning of concrete-forming members and/or floor pans within these systems, so as to facilitate the pouring and curing of concrete into a desired shape. As prior art floor systems may not typically have been particularly adapted for use with concrete forming members and/or floor pans, any such prior art concrete forming members and/or floor pans may typically have required custom integration into each different type of floor system. [0007] It may also have been necessary and/or desirable, in the prior art, to fix and/or support the concrete forming members and/or floor pans relative to the rest of the floor system, such that they might together (or so that the concrete forming member and/or floor pan might on its own) withstand and properly support the additional weight of any concrete which might be poured therein. Moreover, once the concrete cured, it may heretofore have been typically necessary and/or desirable to remove these prior art concrete forming members and/or floor pans from the floor systems, thereby necessitating the expendituie of a significant amount of additional time and labor.

[0008] Additionally, prior art floor systems may have been disadvantageous insofar as they may have required a laborious and/or time-consuming assembly of numerous components.

[0009] Insofar as concrete in a floor system may be subjected to tensile (and/or other) stresses once installed, it may be necessary and/or desirable to reinforce the concrete in such a floor system, so as to prevent and/or reduce the risk of cracking.

[0010] It is thus an object of this invention to obviate or mitigate at least one of the above mentioned disadvantages of the prior art. SUMMARY OF THE INVENTION

[0011] In accordance with the present invention there is disclosed a composite floor apparatus for use with building support members to operatively support a floor load. The apparatus includes a plurality of elongate trusses, a first floor pan, and hardened concrete. Each of the trusses has at least two support portions longitudinally spaced from one another. The support portions are adapted to operatively engage and transfer the load to the building support members. Neighboring ones of the trusses are spaced from one another in a substantially transverse direction. Each of the elongate trusses has substantially planar outer side surfaces shaped to define a plurality of longitudinally spaced projecting portions. Each of the projecting portions extends from the outer side surfaces m a respective first direction. Each respective first direction is selected from the group consisting of an inward-extending direction and an outward-extending direction. Each of the trusses is fabricated to define a cambered deflection that is substantially flattened in an operative configuration. The first floor pan has an upper pan surface and an underside portion that is shaped to define one or more notches therethrough. The notches are spaced from one another in the substantially transverse direction. Each of the notches receives a portion of a respective one of the trusses. The floor pan is substantially secured to the aforesaid respective one of the trusses. At least two exposed ones of the projecting portions

- b - lie in substantially unobstructed relation above at least a portion of the floor pan. The hardened concrete has an upper concrete surface, a lower concrete surface, and inside portions. The lower concrete surface engages the upper pan surface. The inside portions securely engage the exposed ones of the projecting portions. As such, the concrete substantially encases, in bonded relation, the exposed ones of the projecting portions on each of the trussses, so as to substantially resist longitudinal movement of the concrete relative to each of the trusses. In a loaded configuration, the upper concrete surface operatively supports the floor load, such that a notional top portion of ^he apparatus is in compression and a notional bottom portion of the apparatus is in tension, with a neutral axis being defined therebetween. The neutral axis is positioned beneath a substantial portion of the concrete. As such, the aforesaid substantial portion of the concrete is situated substantially within the notional top portion, in such a way that it contributes to a strength and stiffness of the composite floor apparatus .

[0012] According to one aspect of a preferred embodiment of the invention, the trusses may preferably, but need not necessarily, have an open web design and are constructed substantially from a steel material. [0013] According to one aspect of a preferred embodiment of the invention, the steel material may preferably, but need not necessarily, include a ligh^~ gauge steel material.

[0014] According to one aspect of a preferred embodiment of the invention, each of the trusses may preferably, but need not necessarily, include a top chord, a bottom chord, and/or a plurality of web members. Each of the web members may preferably, but need not necessarily, extend between the top chord and the bottom chord.

[0015] According to one aspect of a preferred embodiment of the invention, each bottom chord and/or each top chord may preferably, but need not necessarily, be substantially constructed from a roll- formed light gauge steel material.

[0016] According to one aspect of a preferred embodiment of the invention, each top chord and/or each bottom chord may preferably, but need not necessarily, have a hat-shaped profile. The top chord may preferably, but need not necessarily, be oriented so as to define a downward facing interior portion. The bottom chord may preferably, but need not necessarily, be oriented to define an upward facing interior portion.

[0017] According to one aspect of a preferred embodiment of the invention, the web members may preferably, but need not necessarily, extend from the downward fac xng interior portion of the top chord to the upward facing interior portion of the bottom chord.

[0018] According to one aspect of a preferred embodiment of the invention, the projecting portions, extending from the outer side surfaces, are provided on each top chord of each of the trusses.

[0019] According to one aspect of a preferred embodiment of the invention, the first direction may preferably, but need not necessarily, be the aforesaid mward-extendmg direction. As such, each of the projecting portions may preferably, but need not necessarily, define a top chord depression formed m the top chord, with the inside portions of the concrete preferably, but not necessarily, substantially encasing each top chord depression.

[0020] According to one aspect of a preferred embodiment of the invention, each top chord depression may preferably, but need not necessarily, be shaped by stamping the outer side surfaces.

[0021] According to one aspect of a preferred embodiment of the invention, each of the notches of the floor pan may preferably, but need not necessarily, receive a respective one of the top chords. At least two exposed ones of the projecting portions on each of the top chords may preferably, but need not necessarily, lie in substantially unobstructed relation preferably, but not necessarily, above at least a portion of the floor pan. The inside portions may preferably, but need not necessarily, securely engage the exposed ones of the projecting portions on each of the top chords. The concrete may preferably, but need not necessarily, substantially encase in bonded relation, the exposed ones of the projecting portions on each of the top chords.

[0022] According to one aspect of a preferred embodiment of the invention, the at least two exposed ones may preferably, but need not necessarily, include at least first and second pairs of the exposed ones of the projecting portions. The first and second pairs may preferably, but need not necessarily, be longitudinally spaced from one another. Each of the pairs may preferably, but need not necessarily, include first and second ones of the exposed ones of the projecting portions. The first and second ones of each of the pairs may preferably, but need not necessarily, extend from opposing ones of the outer side surfaces.

[0023] According to one aspect of a preferred embodiment of the invention, the floor pan may preferably, but need not necessarily, be shaped to define a lower surface portion and an upper surface portion. The lower surface portion may preferably, but need not necessarily, be situated substantially beneath the exposed ones of the projecting portions. The upper surface portion may preferably, but need not necessarily, be situated substantially above each top chord. The upper surface portion may preferably, but need not necessarily, be generally situated above the top chord by a set-off dimension m a substantially upward direction.

[0024] According to one aspect of a preferred embodiment of the invention, the set-off dimension may preferably, but need not necessarily, be substantially m the order of about 3/4 inches.

[0025] According to one aspect of a preferred embodiment of the invention, the upper surface portion may preferably, but need not necessarily, be shaped to define a cavity portion that substantially bridges the set-off dimension to substantially engage the top chord.

[0026] According to one aspect of a preferred embodiment of the invention, the floor pan may preferably, but need not necessarily, be substantially secured to the top chord by fasteners extending through the cavity portion.

[0027] According to one aspect of a preferred embodiment of the invention, the floor pan LS shaped to define a lower surface portion, an upper surface portion, and a substantially planar substantially upright portion extending therebetween. The lower surface portion is situated substantially beneath the exposed ones of the projecting portions. The upper surface portion is situated substantially above each top chord. The upright portion is shaped to define a plurality of transversely spaced embossed portions. Each of the embossed portions extends from the upright portion in a respective second direction. Each respective second direction is selected from the group consisting of an mward-extendmg pan direction and an outward-extending pan direction. The inside portions of the concrete substantially encase, m bonded relation, the embossed portions on the floor pan, so as to substantially resist transverse movement of the concrete relative to the floor pan .

[0028] According to one aspect of a preferred embodiment of the invention, the second direction is the mward-extendmg pan direction, such that each of the embossed portions defines a pan depression formed m the floor pan, and such that the inside portions of the concrete substantially encase each pan depression.

[0029] According to one aspect of a preferred embodiment of the invention, each pan depression is shaped by stamping the upright portion.

[0030] According to one aspect of a preferred embodiment of the invention, the apparatus may preferably, but need not necessarily, also include a second floor pan. The first floor pan may preferably, but need not necessarily, have a projecting edge portion. The second floor pan may preferably, but need not necessarily, have a mating socket pan edge portion. The projecting edge portion of the first floor pan may preferably, but need not necessarily, securely engage the mating socket pan edge portion of the second floor pan.

[0031] According to one aspect of a preferred embodiment of the invention, the projecting edge portion of the first floor pan may preferably, but need not necessarily, engage the socket pan edge portion of the second floor pan in substantially locking and sealed relation .

[0032] According to one aspect of a preferred embodiment of the invention, the apparatus may preferably, but need not necessarily, also include a wall stud connection member adapted to operativey engage and securely transfer loads to the building support members. The first floor pan may preferably, but need not necessarily, have a projecting edge portion. The wall stud connection member may preferably, but need not necessarily, have a mating socket wall edge portion. The projecting edge portion may preferably, but need not necessarily, securely engage the mating socket wall edge portion of the wall stud.

[0033] According to one aspect of a preferred embodiment of the invention, the projecting edge portion of the first floor pan may preferably, but need not necessarily, engage the socket wall edge portion in substantially locking and sealed relation.

[0034] According to one aspect of a preferred embodiment of the invention, the floor pan may preferably, but need not necessarily, be shaped to define a lower surface portion and an upper surface portion. The lower surface portion may preferably, but need not necessarily, be situated substantially beneath the exposed ones of the projecting portions. The upper surface portion may preferably, but need not necessarily, be situated substantially above each of the trusses. The hardened concrete may preferably, but need not necessarily, have a thickness, above the upper surface portion, of at least about 2.5 xnches.

[0035] According to one aspect of a preferred embodiment of the invention, the thickness of the hardened concrete may preferably, but need not necessarily, be substantially in the order of about 3.5 inches .

[0036] According to one aspect of a preferred embodiment of the invention, the hardened concrete may preferably, but need not necessarily, be embedded with one or more reinforcing members therein. The reinforcing members may preferably, but need not necessarily, be selected from the group consisting of wire mesh and reinforcing steel bars. [0037] According to one aspect of a preferred embodiment of the invention, a truss spacing on-center distance between adjacent ones of the trusses may preferably, but need not necessarily, be substantially between about 32 inches and about 96 inches.

[0038] According to one aspect of a preferred embodiment of the invention, in the loaded configuration, the neutral axis may preferably, but need not necessarily, be positioned substantially beneath the lower concrete surface.

[0039] In accordance with the present invention there is also disclosed a method of forming a composite floor apparatus for use with building support members and concrete. The method includes a chord forming step, a web forming step, and a floor pan forming step. In the chord forminςj step, a plurality of top chords and bottom chords are roll-formed by passing first elongate sheets of light gauge steel material through a series of roll-forming chord tool sets. Passage of the first elongate sheets through each successive one of the chord tool sets progressively forms the top chords and the bottom chords. In the chord forming step, each of the top chords and the bottom chords is roll-formed so that a chord profile of each of the top chords and the bottom chords defines a substantially "U"-shaped chord portion that includes two substantially planar chord side portions extending substantially at right angles from opposing ends of a substantially planar central chord base portion. The chord side portions define a web-receiving aperture therebetween. In the chord forming step, a plurality of longitudinally spaced top chord depressions are stamped in the chord side portions of each of the top chords. In the web forming step, a plurality of web members are roll-formed by passing second elongate sheets of light gauge steel material through a series of roll- forming web tool sets. Passage of the second elongate sheets through each successive one of the web tool sets progressively forms the web members. In the floor pan forming step, a floor pan is roll-formed by passing a third elongate sheet of light gauge steel material through a series of roll-forming floor pan tool sets. Passage of the third elongate sheet through each successive one of the floor pan tool sets progressively forms the floor pan, such that the floor pan has an underside portion that defines a plurality of notches that are transversely spaced from one another. Each of the web members is adapted to be operatively secured between one of the top chords and one of the bottom chords to form elongate trusses. The trusses are securable on the building support members. The trusses are adapted to be nested and secured within the notches of the floor pan, such that at least two exposed ones of the top chord depressions lie in substantially unobstructed relation above at least a portion of the floor pan. The floor pan and the exposed ones of the top chord depressions are adapted to operatively support the concrete thereon. The exposed ones of the top chord depressions are substantially encased, in bonded relation, by the concrete, so as to substantially resist longitudinal movement of the concrete relative to each of the tiusses.

[0040] According to one aspect of a preferred embodiment of the invention, the method may preferably, but need not necessarily, also include a floor pan sheet forming step, before the floor pan forming step, of forming the plurality of the third elongate sheets with a plurality of opposed notch pairs along transverse edges thereof. Each of the opposed notch pairs may preferably, but need not necessarily, correspond to one of the notches which are defined by the underside portion of the floor pan after the floor pan forming step .

[0041] According to one aspect of a preferred embodiment of the invention, m the floor pan sheet forming step, neighboring ones of the opposed notch pairs may preferably, but need not necessarily, be spaced by a truss spacing on-center distance that is substantially between about 32 inches and about 96 inches.

[0042] According to one aspect of a preferred embodiment of the invention, in the chord forming step, each of the top chords and the bottom chords may preferably, but need not necessarily, be roll- formed so that the chord profile of each of the top chords and the bottom chords additionally defines two substantially "L"-shaped chord portions. Each of the "L"-shaped chord portions may preferably, but need not necessarily, include a substantially planar first chord segment and a substantially planar second chord segment. The first chord segment may preferably, but need not necessarily, extend in a substantially outward direction and substantially at right angles from a respective one of the chord side portions. The second chord segment may preferably, but need not necessarily, extend substantially at right angles from the first chord segment. The web-receiving aperture of each of the bottom chords may preferably, but need not necessarily, operatively face in a substantially upward direction. The web-receiving aperture of each of the top chords may preferably, but need not necessarily, operatively face in a substantially downward direction. Each of the web members may preferably, but need not necessarily, be operatively adapted to extend into each web-receiving aperture, and to be secured to each "U"-shaped chord portion, of each of the top chords and the bottom chords.

[0043] According to one aspect of a preferred embodiment of the invention, in the web forming step, each of the web members may preferably, but need not necessarily, be roll-formed so that a web profile of each of the web members defines a substantially ^reshaped web portion.

[0044] According to one aspect of a preferred embodiment of the invention, in the web forming step, the "C"-shaped web portion may preferably, but need not necessarily, be roll-formed to include a substantially planar central web base portion and two substantially "L"-shaped web side portions. Each of the web side portions may preferably, but need not necessarily, include a substantially planar first web segment and a substantially planar second web segment. The first web segment may preferably, but need not necessarily, extend substantially at right angles from one respective end of the web base portion. The second web segment may preferably, but need not necessarily, extend in a substantially inward direction and substantially at right angles from the first web segment.

[0045] In accordance with the present invention there is additionally disclosed a method of forming a composite floor apparatus on building support members. The method includes a truss assembling step, a truss supporting step after the truss assembling step, a floor pan assembling step, and a concrete pouring step after the floor pan assembling step. In the truss assembling step, a plurality of elongate trusses is assembled, each having two support portions longitudinally spaced from one another. Each of the trusses is assembled by locating and securing a plurality of roll- formed web members between a roll-formed top chord and a roll-formed bottom chord. In the truss supporting step, the support portions of the trusses are located and secured on the building support members. In the floor pan assembling step, the trusses are nested and secured within a plurality of notches transversely spaced along a roll-formed floor pan, such that at least two exposed ones of the top chord depressions lie m substantially unobstructed relation above at least a portion of the floor pan. In the concrete pouring step, concrete is poured over the floor pan and over the exposed ones of the top chord depressions, such that the exposed ones of the top chord depressions are substantially encased, m bonded relation, by the concrete, so as to substantially resist longitudinal movement of the concrete relative to each of the trusses.

[0046] According to one aspect of a preferred embodiment of the invention, after the concrete pouring step, a notional top portion of the apparatus may preferably, but need not necessarily, be m compression and a notional bottom portion of the apparatus may preferably, but need not necessarily, be m tension, with a neutral axis being defined therebetween. The neutral axis may preferably, but need not necessarily, be positioned beneath a substantial portion of the concrete. As such, the substantial portion of the concrete may preferably, but need not necessarily, be situated substantially within the notional top portion -- preferably, but not necessarily, so as to contribute to a strength and stiffness of the composite floor apparatus.

[0047] According to one aspect of a preferred embodiment of the invention, m the floor pan assembling step, neighboring ones of the trusses may preferably, but need not necessarily, be spaced m a substantially transverse direction by a truss spacing on-center distance that is substantially between about 32 inches and about 96 inches .

[0048] According to one aspect of a preferred embodiment of the invention, before the floor pan assembling step, the floor pan may preferably, but need not necessarily, be provided with cavity portions substantially adjacent to the notches. In the floor pan assembling step, fasteners may preferably, but need not necessarily, be extended through the cavity portions to securely engage each top chord.

[0049] Thus, the apparatus or method according to the invention obviates or mitigates at least one of the above-mentioned disadvantages of the prior art.

[0050] Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter of which is briefly described hereinbelow. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 of the drawings appended hereto is a perspective view, in partial section, cf a composite floor apparatus according to a preferred embodiment of the invention, shown in use with building support members;

[0052] Figure 2 of the drawings is a side perspective view of two floor pans of the apparatus shown m Figure 1;

[0053] Figure 3 is a side view, m partial section, of the apparatus of Figure 1, shown m use with a building support member;

[0054] Figure 4 is an enlarged view of a portion of the apparatus of Figure 3, showing notional top and bottom portions thereof, m tension compression and tension respectively;

[0055] Figure 5 is a top front perspective view of a top chord of the apparatus shown in Figure 1;

[0056] Figure 6 is an enlarged view of encircled area 6 of Figure 5;

[0057] Figure 7 is a bottom front perspective view of a bottom chord of the apparatus shown an Figure 1; 0058 ] Figure 8 i s an enlarged view of encircled area 8 of Figure

7 ;

[0059] Figure 9 is a top perspective view of one of the web members of the apparatus shown in Figure 1 ;

[0060] Figure 10 is a sectional view of the apparatus along sight line 10-10 of Figure 1;

[0061] Figure 11 is a sectional view of the apparatus along sight line 11-11 of Figure 1;

[0062] Figure 12 is a side perspective view, in partial section, of a top chord and two floor pans of the apparatus shown in Figure 1;

[0063] Figure 13 is a side perspective view, in partial section, of a floor pan, a top chord, and connection member the apparatus of Figure 1, shown in use with building support members;

[0064] Figure 14 is a perspective view, in partial section, of a composite floor apparatus according to an alternate embodiment of the invention, shown in use with building support members and a ceiling covering; and [0065] Figure 15 of the; drawings appended hereto is a perspective view, in partial section, of a composite floor apparatus according to the invention, shown in use with a variety of building support members .

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0066] Now, with reference to the drawings, there is shown in Figure 1 a composite floor apparatus 30 in use with building support members 20 to the operatively support a floor load (not shown) . The apparatus 30 includes a plurality of elongate trusses 32, a plurality of floor pans 100,200 (including first and second floor pans, 100 and 200 respectively), and hardened concrete 130.

[0067] As best seen in Figures 1 and 3, each of the trusses 32 has at least two support portions 34, which are longitudinally spaced from one another. The support portions 34 are adapted to operatively engage and transfer the load (not shown) to the building support members 20. Neighboring ones of the trusses 32 are spaced from one another in a substantially transverse direction (as indicated generally by arrow "B" in Figure 1) . As best shown in Figure 1, adjacent trusses 32 are preferably spaced, on center, from one another by a truss spacing on-center distance (as indicated generally by dimension "K") that is, preferably, substantially between about 32 inches and about 96 inches. [0068] As best seen in Figures 3 and 4, each of the elongate trusses 32 has substantially planar outer side surfaces 36 that are shaped to define a plurality of longitudinally spaced projecting portions 68. Preferably, and as best seen in Figure 1, each of the trusses 32 includes a top chord 60, a bottom chord 160, and a plurality of web members 40 extending between the top and bottom chords 60,160.

[0069] As best seen in Figures 5 to 8, each top chord 60 and each bottom chord 160 has a hat-shaped profile (alternately hereinafter referred to as the "chord profile"), 62 and 162 respectively. The top chord 60 is oriented so as to define a downward-facing interior portion 76, and the bottom chord 160 is oriented to define an upward- facing interior portion 176. The chord profile 62,162 of each of the top chords 60 and the bottom chords 160 includes a substantially "U"- shaped chord portion 64,164 and two substantially "L"-shaped chord portions 78,78, 178,178. The "U"-shaped chord portion 64,164 includes two substantially planar chord side portions 66, 66, 166, 166 extending substantially at right angles from opposing ends 74,74, 174,174 of a substantially planar central chord base portion 72,172. The chord side portions 66,66, 166,166 define the interior portion (alternately hereinafter referred to as the "web-receiving aperture") 76,176 therebetween. [0070] Each of the "L"-shaped chord portions 78,178 includes a substantially planar first chord segment 80,180 and a substantially planar second chord segment 82,182. The first chord segment 80,180 extends in an outward-extending truss direction (as indicated generally by arrows "F" in each of Figures 5 to 8, and as alternately hereinafter referred to as a "substantially outward direction") and substantially at right angles from a respective one of the chord side portions 66,166. The second chord segment 82,182 extends substantially at right angles from the first chord segment 80,180.

[0071] As shown in Figures 3 to 6, each of the projecting portions 68 extends, in a respective first direction, from one outer side surface 36 of the truss 32 (as best seen in Figures 3 and 4) . Most preferably, two of the side surfaces 36 are situated on each top chord 60, preferably opposing one another on each of the side portions 66,66 of the top chord 60, such that the projecting portions 68 extend therefrom in the first direction (as best seen in Figures 5 and 6) . Each respective first direction is selected from the group consisting of an inward-extending truss direction (as indicated generally by arrows "E" in Figures 5 and 6) and the outward-extending truss direction "F". Preferably, and best seen in Figure 6, the first direction is the inward-extending truss direction "E" (and, as such, the two terms are hereinafter used interchangeably) . As such, each of the projecting portions 68 defines a top chord depression (with the two terms hereinafter being used interchangeably) . Each top chord depression 68 is pieferably shaped by stamping the outer side surfaces 36 of the truss 32.

[0072] Preferably, the web members 40 extend from the downward facing interior portion 76 of the top chord 60 to the upward facing interior portion 176 of the bottom chord 160. Each of the web members has a web profile (as best seen in Figure 9) that includes a substantially "C"-shaped web portion 44. The "C"-shaped web portion 44 includes a substantially planar central web base portion 46 and two substantially "L"-shaped web side portions 50. Each of the web side portions 50 includes a substantially planar first web segment 52 and a substantially planar second web segment 54. The first web segment 52 extends substantially at right angles from one respective end 48 of the web base portion 46. The second web segment 54 extends m the mward-extendmg truss direction "E" (alternately hereinafter referred to as the "substantially inward direction") and substantially at right angles ϊ rom an end portion 53 of the first web segment 52. The web members 40 may be fastened in place between the top and bottom chords 60,160 by fasteners (not shown) extending through web securing apertures 55 formed in each end of each first web segment 52.

[0073] Each of the trusses 32 is preferably fabricated to define a cambered deflection (not shown) that is substantially flattened m an operative configuration (as best seen in Figures 3 and 4) . [0074] Each floor pan 100,200 has an upper pan surface 102 and an underside portion 104 that has one or more notches 106 formed therethrough. Each floor pan 100,200 also has a lower surface portion 108, an upper surface portion 110, and a substantially planar and substantially upright portion 114 that extends therebetween.

[0075] As best seen in Figure 1, the notches 106 are spaced from one another in the substantially transverse direction "B" by the truss spacing on-center distance "K". Each of the notches 106 has a notch width (as indicated generally by dimension "L" m Figure 2) which is sized to be at least as wide (in the transverse direction "B") as the central chord base portion 72 of the top chord 60. In fact, each of the notches 106 receives a portion of a respective one of the trusses 32. More preferably, and as best seen m Figures 3, 12 and 13, each of the notches 106 of each floor pan 100,200 receives a respective one of the top chords 60. The upper surface portion 110 of each floor pan 100,200 is situated substantially above each top chord 60 by a set-off dimension (as indicated generally by dimension ^NXH" m Figure 2) in a substantially upward direction (as indicated generally by arrow "C"). The set-off dimension "H" is preferably substantially in the order of about 3/4 inches. As best seen in Figure 2, the upper surface portion 110 includes a cavity portion 112 that substantially bridges the set-off dimension "H" to substant ially engage the top chord 60 (as best seen in Figures 3-4 and 11) . Each floor pan 100,200 is substantially secured to the aforesaid respective one of the trusses 32. Preferably, each floor pan 300,200 is substantially secured to the top chord 60 by fasteners (not shown) extending through each cavity portion 112 into the top chord 60.

[0076] The upright portion 114 is shaped to define a plurality of transversely spaced (in the transverse direction "B") embossed portions 116. Each of the embossed portions 116 extends from the upright portion 114 in a respective second direction - i.e., either an mward-extendmg pan direction (as indicated generally by arrows "G" m Figure 2) or an outward-extending pan direction (i.e., a direction generally opposed to the mward-extendmg pan direction "G") . Preferably, and as best seen m Figure 2, the second direction is the mward-extendmg pan direction "G" (with the two terms being hereinafter used interchangeably) . As such, each of the embossed portions 116 defines a pan depression (with the two terms hereinafter being used interchangeably) that is formed m each floor pan 100,200. Each pan depression 116 may be shaped by stamping the upright portion 114 of the floor pans 100,200.

[0077] With each top chord 60 extending through one of the notches 106, and as best seen in Figures 1 and 3-4, at least two exposed ones 70 of the projecting portions 68 (on each top chord 60) lie in substantially unobstructed relation above at least a portion of the floor pan 100,200. Preferably, the lower surface portion 108 of the floor pan 100,200 is situated substantially beneath the exposed ones

70 of the projecting portions 68.

[0078] The at least two exposed ones 70 of the projecting portions 68 preferably include, as wil] be appreciated from the drawings (and as best seen m Figures 1, 5-6 and 10), four or more exposed ones 70 - i.e., two longitudinally spaced pairs 70,70, 70,70 of exposed ones 70, with each such pair 70,70 including exposed ones 70 on both side portions 66,66 of the top chord 60. That is, the at least two exposed ones 70 comprise at least a first pair 70,70 and a second pair 70,70 of said exposed ones 70 of the projecting portions 68. The first pair 70,70 and the second pair 70,70 are longitudinally spaced from one another. Each pair 70,70 includes a first exposed one 70 and a second exposed one 70 of the projecting portions 68. The first one 70 and the second one 70 of each such pair 70,70 extend from opposing ones of the outer side surfaces 36,36.

[0079] The apparatus 30 may include first and second floor pans, 100 and 200 respectively, secuiely engaging one another. Preferably, and as best seen in Figure 4, the first floor pan 100 has a projecting edge portion 120, and the second floor pan 200 has a mating socket pan edge portion 218. The projecting edge portion 120 of the first floor pan 100 securely engages the mating socket pan edge portion 218 of the second floor pan 200 in substantially locking and sealed relation. Similarly, and as best seen in Figure 2, the second floor pan 200 has a projecting edge portion 220, and the first floor pan 100 has a mating socket pan edge portion 118. The projecting edge portion 220 of the second floor pan 200 securely engages the mating socket pan edge portion 118 of the first floor pan 100 in substantially locking and sealed relation.

[0080] Preferably, and as best seen in Figures 3 and 13, the apparatus 30 also includes a wall stud connection member 300 that is adapted to operatively engage and securely transfer the load (not shown) to the building support members 20. As shown in Figures 3 and 13, the wall stud connection member 300 may fit over one or more of the building support members 20, where it may also be securely interposed between the support portions 34 of the trusses 32 and the building support members 20. Preferably, the projecting edge portion 120 of the first floor pan 100 may engage a mating socket wall edge portion 318 of the wall stud connection member 300 in substantially locking and sealed relation.

[0081] As best seen in Figures 10 and 11, the hardened concrete 130 has an upper concrete surface 132, a lower concrete surface 134, and inside portions 136. The lower concrete surface 134 engages the upper pan surface 102. As best seen in Figures 10 and 11, the inside portions 136 securely engage the exposed ones 70 of the projecting portions 68 and the embossed portions 116 on the floor pan 100. In this manner, and as best seen in Figure 10, the concrete 130 substantially encases, m bonded relation, the exposed ones 70 of the projecting portions 68 on each of the trusses 32, so as to substantially resist longitudinal movement (m the direction generally indicated by arrow "A" in Figures 1 and 5-6) between the concrete 130 and each of the trusses 32. That is, as best seen m Figure 10, the inside portions 136 of the concrete 130 preferably substantially encase the exposed top chord depressions 68 on each of the top chords 60. As best seen in Figure 11, the concrete 130 also substantially encases, in bonded relation, the embossed portions 116 on the floor pan 100, so a∑ to substantially resist transverse movement (m the transverse direction "B") of the concrete 130 relative to the floor pan 100. That is, as best seen in Figure 11, the inside portions 136 of the concrete 130 preferably substantially encase each pan depression 116.

[0082] The hardened concrete 130 preferably has a thickness (as indicated generally by dimension "J" m Figure 3), above the upper surface portion 110 of the floor pans 100,200, of at least about 2.5 inches. More preferably, the thickness "J" of the hardened concrete 130 is substantially m the order of about 3.5 inches. The hardened concrete 130 is preferably embedded with reinforcing members (not shown) therein. The reinforcing members preferably include wire mesh

(not shown) . In some cases, the reinforcing members may include reinforcing steel bars (not shown) . Among other things, the use of the reinforcing members may help to reinforce the concrete 130, so as to prevent and/or reduce the risk of cracking, when it may be subjected to tensile (and/or other) stresses after being installed.

[0083] In a loaded configuration, and as may be best appreciated from a consideration of Figure 4, the upper concrete surface 132 operatively supports the floor load (not shown) , such that a notional top portion 140 of the apparatus 30 is in compression, and such that a notional bottom portion 142 of the apparatus 30 is in tension, with a neutral axis (as indicated generally by axis "N" m Figure 4) being defined therebetween. The neutral axis "N" is positioned beneath a substantial portion 138 of the concrete 130, with only a smaller remainder 139 of the concrete 130 lying below the neutral axis "N". Preferably, m the loaded configuration, the neutral axis "N" is positioned substantially beneath at least a portion of the lower concrete surface 134. In some embodiments according to the invention (and though not shown m the drawings), in the loaded configuration, the neutral axis "N" may be positioned substantially beneath a substantial entirety of the lower concrete surface 134. As such, the aforesaid substantial portion 138 of the concrete 130 is situated substantially within the notional top portion 140, in such a way that it contributes to a strength and stiffness of the composite floor apparatus 30. If the neutral axis "N" is alternately positioned beneath the substantial entirety of the lower concrete surface 134, then the entirety 138,139 of the concrete 130 would be situated substantially within the notional top portion 140, such that all of it may then contribute to the strength and stiffness of the composite floor apparatus 30.

[0084] Δn alternate embodiment of the apparatus 30' is shown in Figure 14 m use with a ceiling covering 24 that is attached to the building support member 20 by a ceiling support 22 thereof. In this alternate embodiment, the apparatus 30' includes an alternate floor pan 100' which is twice as wide (in the longitudinal direction "A") as the floor pans 100,200 which are shown in the preceding drawings. Additionally, the alternate floor pan 100' is notably provided without the cavity portion 112. In the alternate embodiment of the apparatus 30' which is shown in Figure 14, there is also provided a lower truss retaining member 170 which extends m the transverse direction "B" between adjacent bottom chords 160, securing them to one another.

[0085] Figure 15 shows the apparatus 30, in a partial cutaway view (and without the concrete 130), in use with a variety of building support members 20, 20', 20". The top chords 60 are shown supported on building support members 20, which are themselves supported on other building support members 20' , which are in turn supported on still further building support members 20". In this manner, the floor loads (not shown) may be structurally and safely transferred from the apparatus 30 to the appropriate supports 20, 20', 20". [0086] Preferably, the trusses 32 -- including each bottom chord

160, top chord 60 and web member 40 - have an open web design. Preferably, the trusses 32 -- including each bottom chord L60, top chord 60 and web member 40 -- are constructed substantially from a steel material. The steel material is preferably a roll-formed light gauge steel material.

[0087] The present invention also includes a method of forming metal components of the apparatus 30 for use with concrete 130 and the building support members 20. The method includes a chord forming step, a web forming step, a floor pan sheet forming step, and a floor pan forming step.

[0088] In the chord forming step, a plurality of the top chords 60 and the bottom chords 160 are roll-formed by passing first elongate sheets (not shown) of light gauge steel material through a series of roll-forming chord tool sets (not shown) . Passage of the first elongate sheets through each successive one of the chord tool sets progressively forms the top chords 60 and the bottom chords 160 to have the aforesaid chord profile 62,162. In the chord forming step, the aforesaid plurality of longitudinally spaced top chord depressions 68 are stamped in the chord side portions 66 of each of the top chords 60. [0089] In the web forming step, a plurality of the web members 40 are roll-formed by passing second elongate sheets (not shown) of light gauge steel material through a series of roll-forming web tool sets (not shown) . Passage of the second elongate sheets through each successive one of the web tool sets progressively forms the web members 40 to have the aforementioned substantially "C"-shaped web portion 44.

[0090] In the floor pan sheet forming step, a third elongate sheet (not shown) is formed with a plurality of opposed notch pairs (not shown) along transverse edges thereof. Neighboring ones of the opposed notch pairs are preferably spaced from one another by the aforesaid truss spacing on-center distance "K".

[0091] In the floor pan forming step, at least one floor pan 100 is roll-formed by passing the third elongate sheet (not shown) of light gauge steel material through a series of roll-forming floor pan tool sets (not shown) . Passage of the third elongate sheet through each successive one of the floor pan tool sets progressively forms the floor pan 100. The notches 106 in the underside portion of the floor pan correspond to the opposed notch pairs (not shown) which were formed during the floor pan sheet forming step.

[0092] After forming the web members 40 and the top and bottom chords 60,160 as aforesaid, each of the web members 40 may be operatively secured between one of the top chords 60 and one of the bottom chords 160 to form the elongate trusses 32. More specifically, each of the web members 40 operatively extends into each web-receiving aperture 76,176, and is secured to each "U"-shaped chord portion 64,164, of each of the top chords 60 and the bottom chords 160. Thereafter, the trusses 32 are securable on the building support members 20, with the web-receiving aperture 176 of each of the bottom chords 160 operatively facing in the substantially upward direction "C", and with the web-receiving aperture 76 of each of the top chords 60 operatively facing in a substantially downward direction "D".

[0093] Similarly, after forming the trusses 32 and the floor pan 100 as aforesaid, the trusses 32 may be nested and secured within the notches 106 of the floor pan 100, such that the at least two (and, as aforesaid, preferably four or more) exposed ones 70 of the top chord depressions 68 lie in substantially unobstructed relation above at least a portion of the floor pan 100.

[0094] Thereafter, the floor pan 100 and the exposed ones 70 of the top chord depressions 68 may operatively support the concrete 130 thereon. In pouring the concrete 130 over the floor pan 100 and each top chord 60, the exposed ones 70 of the top chord depressions 68 are substantially encased, in bonded relation, by the concrete 130. As such, the bonding between the concrete 130 and the top chord depressions 68 helps the concrete 130 to substantially resist longitudinal movement relative to each of the trusses 32.

[0095] More particularly, the present invention also includes a method of assembling and using the apparatus 30 with building support members 20. This method includes a truss assembling step, a truss supporting step after the truss assembling step, a floor pan assembling step, and a concrete pouring step after the floor pan assembling step.

[0096] In the truss assembling step, the elongate trusses 32 are assembled, each having two support portions 34 longitudinally spaced

(in the longitudinal direction "A") from one another. Each of the trusses 32 is assembled by locating and securing the roll-formed web members 40 between the roll-formed top and bottom chords 60,160.

[0097] In the truss supporting step, the support portions 34 of the trusses 32 are located and secured on the building support members 20 (in one of the general arrangements which are described in greater detail hereinabove) .

[0098] Before the floor pan assembling step, the floor pan 100 is provided, in the aforesaid manner, with the cavity portions 112 substantially adjacent to the notches 106. [0099] In the floor pan assembling step, the trusses 32 are nested and secured within the notches 106 transversely spaced (in the transverse direction "B") along the roll-formed floor pan 100, such that the at least two (and, as aforesaid, preferably four or more) exposed ones 70 of the top chord depressions 68 lie in substantially unobstructed relation above at least a portion of the floor pan 100. Neighboring ones of the trusses 32,32 are spaced in the substantially transverse direction "B" by the truss spacing on-center distance "K". Fasteners (not shown) are extended through the cavity portions 112 to securely engage each top chord 60.

[0100] In the concrete pouring step, concrete 130 is poured over the floor pan 100 and over the exposed ones 70 of the top chord depressions 68. In this manner, the exposed ones 70 of the top chord depressions 68 are substantially encased, in bonded relation, by the concrete 130, so as to substantially resist longitudinal movement of the concrete 130 relative to each of the trusses 32.

[0101] After the concrete pouring step, the notional top portion 140 will be that portion of the apparatus 30 which is in compression, and the notional bottom portion 142 will be that portion of the apparatus 30 which is in tension. The neutral axis "N" is deimed as the axis (and/or plane) between the notional top and bottom portions 140,142. Preferably, and as aforesaid, the neutral axis "N" is positioned beneath the substantial portion 138 of the concrete 130, such that same is situated substantially within the notional top portion 140, and such that same contributes to the strength and stiffness of the composite floor apparatus 30.

[0102] From all of the foregoing, it will be appreciated that use of the apparatus 30 and methods according to the invention may find utility and industrial appl Lcation m the construction industry for buildings (including commercial and high rise buildings, among others) . More specifically, the use of the apparatus 30 and methods according to the invention may facilitate the provision of floor systems that span significant distances between building supports 20 (such as, for example, flooi systems which are supported on Ly about their periphery). Floor systems which include the apparatus 30, and/or which are manufactured and/or assembled according to the methods of the invention, may be generally satisfactory in achieving the distances required, without being substantially limited by the weight of certain flooring components (e.g., concrete) that may now contribute to the strength and/or stiffness of the floor system. As such, floor systems produced according to invention may now be able to withstand substantial loading -- including the mass of the floor itself -- across these significant spanning distances. Moreover, these wide spans between building supports 20 may now actually help to support the floor systems against collapse. In this manner, floor systems that span significant distances between building supports 20 may help to maximize useful square footage and/or minimize real- estate costs.

[0103] Additionally, the use of the apparatus 30 and methods according to the invention ma^ provide for the concrete 130 and the trusses 32 to work together so as to jointly contribute to the strength and/or stiffness of the floor. Similarly, the apparatus 30 and methods according to the invention may avoid any tendency, m the prior art, for the concrete 130 to act as a dead weight - and instead, it may afford the concrete 130 an opportunity to make a significant structural contribution to the strength of the floor. In this manner, concrete and steel truss floor systems may be provided which are able to span beyond the moderate lengths (between adjacent building supports 20) that were achieved in the prior art. Now, with the aid of the present invention, the strength of the trusses 32 may no longer be the only, nor perhaps even a major, contributor to the strength of the entire floor system. Rather, the invention may permit a prior substantially non-structural component (i.e., concrete) to substantially contribute to the strength (i.e., the load-bearing capacity) of flooring systems, whilst still providing a rigid surface over which other flooring materials (e.g., carpet, hardwood) may be laid and/or installed.

[0104] The invention may provide a further advantage in floor systems, insofar as the concrete 130 may no longer require precise manual positioning of concrete-forming members and/or floor pans

100,200 within these systems. Rather, the pouring and curing of the concrete 130 into a desired shape in a floor system may be simpLy and efficiently enabled by the use of the floor pans 100,200 according to the invention. The floor pans 100,200 are particularly adapted for use with such systems (i.e., without requiring custom integration of concrete forming members into each different type of floor system) . The floor pans 100,200 may be i^~eadily fixed and/or supported relative to the rest of the floor system, such that they might help to withstand and properly support the additional weight of any concrete 130 which may be poured therein. It is no longer necessary to remove the floor pans 100,200 from the floor systems after the concrete 130 has been poured, thereby potentially reducing the expenditure of time and/or labor which may be involved.

[0105] It should also be appreciated, by persons having ordinary skill in the art, that the apparatus 30 and methods according to the invention may, as a whole, be efficiently installed and/or empLoyed, with a reduced amount of labor and/or time being involved in assembling the components.

[0106] In view of all of the above, it will be appreciated that the invention obviates and/or mitigates at least one of the disadvantages of the prior art. [0107] Various other modifications and alterations may be used m the design and manufacture of the apparatus 30 and method according to the present invention without departing from the spirit and scope of the invention, which is limited only by the accompanying claims.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY ORPRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A composite floor apparatus for use with building support members to operatively support a floor load, said apparatus comprising : a) a plurality of elongate trusses, each having at ] east two support portions longitudinally spaced from one another, with said support portions adapted to operatively engage and transfer the load to the building support members, with neighboring ones of said trusses spaced from one another in a substantially transverse direction, and with each of said trusses having substantially planar outer side surfaces shaped to define a plurality of longitudinally spaced projecting portions, with each of said projecting portions extending from said outer side surfaces in a respective first direction, with each said respective first direction being selected from the group consisting of an mward-extendmg truss direction and an outward-extending truss direction, with each of said trusses fabricated to define a cambered deflection that is substantially flattened in an operative configuration; b) a first floor pan having an upper pan surface, and an underside portion that is shaped to define a plurality of notches therethrough, with said notches being spaced from one another in said substantially transverse direction, with each of said notches receiving a portion of a respective one of said trusses, and with said floor pan being substantially secured to said respective one of said trusses, such that at least two exposed ones of said projecting portions lie m substantially unobstructed relation above at least a portion of said floor pan; and c) hardened concrete having an upper concrete surface, a lower concrete surface, and inside portions, with said lower concrete surface engaging said upper pan surface, with said inside portions securely engaging said exposed ones of said projecting portions, such that said concrete substantially encases, in bonded relation, said exposed ones of said projecting portions on each of said trussses, so as to substantially resist longitudinal movement of said concrete relative to each of said trusses; wherein m a loaded configuration, said upper concrete surface operatively supports said floor load, such that a notional top portion of said apparatus is m compression and a notional bottom portion of said apparatus is in tension, with a neutral axis being defined therebetween, with said neutral axis being positioned beneath a substantial portion of said concrete, such that said substantial portion of said concrete is situated substantially within said notional top portion so as to contribute to a strength and stiffness of said composite floor apparatus.

2. A composite floor apparatus according to claim 1, wherein said trusses have an open web design and are constructed substantially from a steel material.

3. A composite floor apparatus according to claim 2, wherein said steel material comprises a light gauge steel material.

4. A composite floor apparatus according to one of claims 1 and 2, wherein each of said trusses comprises a top chord, a bottom chord, and a plurality of web members, with each of said web members extending between said top chord and said bottom chord.

5. A composite floor apparatus according to claim 4, wherein each of said bottom chord and said top chord is substantially constructed from a roll-formed light gauge steel material.

6. A composite floor apparatus according to one of claims 4 and 5, wherein each of said top chord and bottom chord has a hat-shaped profile, with said top chord oriented so as to define a downward- facing interior portion, and with said bottom chord oriented to define an upward-facing interior portion.

7. A composite floor apparatus according to claim 6, wherein said web members extend from said downward-facing interior portion of said top chord to said upward-facing interior portion of said bottom chord .

8. A composite floor apparatus according to one of claims 4 to 7, wherein said projecting portions, extending from said outer side surfaces, are provided on each said top chord of each of said trusses .

9. A composite floor apparatus according to claim 8, wherein said first direction is said inward-extending truss direction, such that each of said projecting portions defines a top chord depression formed in said top chord, and such that said inside portions of said concrete substantially encase each said top chord depression.

10. A composite floor apparatus according to claim 9, wherein each said top chord depression is shaped by stamping said outer side surfaces .

11. A composite floor apparatus according to one of claims 8 to 10, wherein each of said notches of said floor pan receives a respective one said top chord, such that said at least two exposed ones of said projecting portions on each said top chord lie in said substantially unobstructed relation above said at least a portion of said floor pan, with said inside portions securely engaging, and said concrete substantially encasing in said bonded relation, said exposed ones of said projecting portions on each said top chord.

12. A composite floor apparatus according to claim 11, wherein said at least two exposed ones comprise at least first and second pairs of said exposed ones of said projecting portions, with said first and second pairs being longitudinally spaced from one another, and with each of said pairs including first and second ones of said exposed ones of said projecting portions, with said first and second ones of each of said pairs extending from opposing ones of said outer side surfaces.

13. A composite floor apparatus according to one of claims 11 and 12, wherein said floor pan is shaped to define a lower surface portion and an upper surface portion, with said lower surface portion being situated substantially beneath said exposed ones of said projecting portions, and with said upper surface portion being situated substantially above each said top chord, with said upper surface portion being generally situated above said top chord by a set-off dimension m a substantially upward direction.

14. A composite floor apparatus according to claim 13, wherein said set-off dimension is substantially in the order of about 3/4 inches.

15. A composite floor apparatus according to one of claims 13 and 14, wherein said upper surface portion is shaped to define a cavity portion that substantially bridges said set-off dimension to substantially engage said top chord.

16. A composite floor apparatus according to claim 15, wherein said floor pan is substantially secured to said top chord by fasteners extending through said cavity portion into said top chord.

17. A composite floor apparatus according to one of claims 1 to 12, wherein said floor pan is shaped to define a lower surface portion, an upper surface portion, and a substantially planar substantially upright portion extending therebetween, with said lower surface portion being situated substantially beneath said exposed ones of said projecting portions, and with said upper surface portion being situated substantially above each said top chord, wherein said upright portion is shaped to define a plurality of transversely spaced embossed portions, with each of said embossed portions extending from said upright portion in a respective second direction, with each said respective second direction being selected from the group consisting of an inward-extending pan direction and an outward-extending pan direction, and wherein said inside portions of said concrete substantially encase, in said bonded relation, said embossed portions on said floor pan, so as to substantially resist transverse movement of said concrete relative to said floor pan.

18. A composite floor apparatus according to claim 17, wherein said second direction is said inward-extending pan direction, such that each of said embossed portions defines a pan depression formed in said floor pan, and such that said inside portions of said concrete substantially encase each said pan depression.

19. A composite floor apparatus according to claim 18, wherein each said pan depression is shaped by stamping said upright portion.

20. A composite floor apparatus according to one of claims 1 to 19, further comprising a second floor pan, with said first floor pan having a projecting edge portion, with said second floor pan having a mating socket pan edge portion, and with said projecting edge portion of said first floor pan securely engaging said mating socket pan edge portion.

21. A composite floor apparatus according to claim 20, wherein wherein said projecting edge portion of said first floor pan engages said socket pan edge portion of said second floor pan in substantially locking and sealed relation.

22. A composite floor apparatus according to one of claims 1 to 19, further comprising a wall stud connection member adapted to operatively engage and securely transfer the load to the building support members, with said first floor pan having a projecting edge portion, with said wall stud connection member having a mating socket wall edge portion, and with said projecting edge portion securely engaging said mating socket wall edge portion.

23. A composite floor apparatus according to claim 22, wherein said projecting edge portion of said first floor pan engages said socket wall edge portion in substantially locking and sealed relation.

24. A composite floor apparatus according to one of claims 1 to 12, wherein said floor pan is shaped to define a lower surface portion and an upper surface portion, with said lower surface portion being situated substantially beneath said exposed ones of said projecting portions, and with said upper surface portion being situated substantially above each of said trusses, and wherein said hardened concrete has a thickness, above said upper surface portion, of at least about 2.5 inches.

25. A composite floor apparatus according to claim 24, wherein said thickness of said hardened concrete is substantially m the order of about 3.5 inches.

26. A composite floor apparatus according to one of claims 1 to 25, wherein said hardened concrete is embedded with one or more reinforcing members therein, with said reinforcing members being selected from the group consisting of wire mesh and reinforcing steel bars.

27. A composite floor apparatus according to one of claims 1 to 26, wherein a truss spacing on-center distance, between adjacent ones of said trusses, is substantially between about 32 inches and about 96 inches .

28. A composite floor apparatus according to one of claims 1 to 27, wherein in said loaded configuration, said neutral axis is positioned substantially beneath said lower concrete surface.

29. A method of forming a composite floor apparatus for use with building support members and concrete, said method comprising the steps of: a chord forming step of roll-forming a plurality of top chords and bottom chords by passing first elongate sheets of light gauge steel material through a series of roll-forming chord tool sets, with passage of said first elongate sheets through each successive one of the chord tool sets progressively forming said top chords and said bottom chords; wherein in said chord forming step, each of said top chords and said bottom chords is roll-formed so that a chord profile of each of said top chords and said bottom chords defines a substantially "U"-shaped chord portion that includes two substantially planar chord side portions extending substantially at right angles from opposing ends of a substantially planar central chord base portion, with said chord side portions defining a web- receivmg aperture therebetween; and wherein in said chord forming step, a plurality of longitudinally spaced top chord depressions are stamped in said chord side portions of each of said top chords; a web forming step of roll-forming a plurality of web members by passing second elongate sheets of light gauge steel material through a series of roll-forming web tool sets, with passage of said second elongate sheets through each successive one of the web tool sets progressively forming said web members; and a floor pan forming step of roll-forming a floor pan by passing a third elongate sheet of light gauge steel material through a series of roll-forming floor pan tool sets, with passage of said third elongate sheet through each successive one of the floor pan tool sets progressively forming said floor pan, such that said floor pan has an underside portion that defines a plurality of notches that are transversely spaced from one another; wherein each of said web members is adapted to be operatively secured between one of said top chords and one of said bottom chords to form elongate trusses, with said trusses securable on the building support members, wherein said trusses are adapted to be nested and secured within said notches of said floor pan, such that at least two exposed ones of said top chord depressions lie in substantially unobstructed relation above at least a portion of said floor pan, and wherein said floor pan and said exposed ones of said top chord depressions are adapted to operatively support said concrete thereon, with said exposed ones of said top chord depressions being substantially encased, in bonded relation, by said concrete, so as to substantially resist longitudinal movement of said concrete relative to each of said trusses.

_ CO —

30. A method according to claim 29, further comprising a floor pan sheet forming step, before said floor pan forming step, of forming said third elongate sheet with a plurality of opposed notch pairs along transverse edges thereof, with each of said opposed notch pairs corresponding to one of said notches defined by said underside portion of said floor pan following said floor pan forming step.

31. An apparatus accordmq to claim 30, wherein m said floor pan sheet forming step, neighboring ones of said opposed notch pairs are spaced by a truss spacing cn-center distance that is substantially between about 32 inches and about 96 inches.

32. A method according to one of claims 29 to 31, wherein in said chord forming step, each of said top chords and said bottom chords is roll-formed so that said chord profile of each of said top chords and said bottom chords additionally defines two substantially "reshaped chord portions, each of said ^xvL"-shaped chord portions including a substantially planar first chord segment that extends in a substantially outward direction and substantially at right angles from a respective one of said chord side portions, and a substantially planar second chord segment that extends substantially at right angles from said first chord segment; and wherein said web-receivmg aperture of each of said bottom chords operatively faces in a substantially upward direction and said web-receivmg aperture of each of said top chords operatively faces xn a substantially downward direction, with each of said web members being operatively adapted to extend into each said web- receivmg aperture, and to be secured to each said "U"-shaped chord portion, of each of said top chords and said bottom chords.

33. A method according to one of claims 30 to 32, wherein in said web forming step, each of said web members is roll-formed so that a web profile of each of said web members defines a substantially ^reshaped web portion.

34. A method according to claim 33, wherein m said web forming step, said "C"-shaped web portion is roll-formed to include a substantially planar central web base portion and two substantially "L"-shaped web side portions, with each of said web side portions including a substantially planar first web segment that extends substantially at right angles from one respective end of said web base portion, and a substantially planar second web segment that extends m a substantially inward direction and substantially at right angles from said first web segment.

35. A method of forming a composite floor apparatus on building support members, said method comprising the steps of: a truss assembling step of assembling a plurality of e Longate trusses, each having two support portions longitudinally spaced from one another, and each being assembled by locating and securing a plurality of roll-formed web members between a roll-formed bottom chord and a roll-formed top chord having a plurality of longitudinally spaced top chord depressions stamped in chord side portions thereof; a truss supporting step, after said truss assembling step, of locating and securing said support portions of said trusses on the building support members; a floor pan assembling step of nesting and securing said trusses within a plurality of notches transversely spaced along a roll-formed floor pan, such that at least two exposed ones of said top chord depressions lie in substantially unobstructed relation above at least a portion of said floor pan; and a concrete pouring step, after said floor pan assembling step, of pouring concrete over said floor pan and over said exposed ones of said top chord depressions, such that said exposed ones of said top chord depressions are substantially encased, in bonded relation, by said concrete, so as to substantially resist longitudinal movement of said concrete relative to each of said trusses.

36. A method according to claim 35, wherein after said concrete pouring step, a notional top portion of said apparatus is in compression and a notional bottom portion of said apparatus is in tension, with a neutral axis being defined therebetween, with said neutral axis being positioned beneath a substantial portion of said concrete, such that said substantial portion of said concrete is situated substantially within said notional top portion so as to contribute to a strength and stiffness of said composite; floor apparatus .

37. A method according to one of claims 35 and 36, wherein in said floor pan assembling step, neighboring ones of said trusses are spaced in a substantially transverse direction by a truss spacing on-center distance that is substantially between about 32 inches and about 96 inches.

38. A method according to one of claims 35 to 37, wherein before said floor pan assembling step, said floor pan is provided with cavity portions substantially adjacent to said notches, and wherein in said floor pan assembling step, fasteners are extended through said cavity portions to securely engage each said top chord.