Pre-assembled Decking Panel and Strut Assembly for Data Centers
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Solution Overview
Problem
The installation process for data center ceilings and roofs is time-consuming and labor-intensive, prone to errors, due to the need for attaching structural support hardware to joists after decking and insulation or concrete installation.
Innovation Solution
Pre-assembled decking panel and strut assemblies, where elongated struts are integrated with decking panels, allowing hanging systems to be directly attached, eliminating the need for additional hardware and reducing water penetration risks by positioning junctions at peaks rather than valleys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If decking panels are installed on joists and structural support hardware is attached separately in the field, then the installation process can be completed, but the process becomes time-consuming, labor-intensive and prone to installation errors
Solution Approach 1:
The patent combines the decking panel and strut assembly into a single pre-assembled unit. The strut is integrated with the decking panel through formed extensions that create attachment features, eliminating the need for separate installation of structural support hardware. This merging of components directly addresses the contradiction by reducing installation time and complexity while maintaining structural integrity.
Solution Approach 2:
The strut assembly is pre-assembled and pre-positioned relative to the decking panel before delivery to the installation site. The attachment features are pre-formed on the decking panel, allowing the strut to be quickly connected without field fabrication or complex alignment procedures. This preliminary action resolves the contradiction by eliminating time-consuming field assembly steps.
2Reliability
If spaced struts and beam clamps are attached to joists after decking installation, then hanging systems can be supported, but the process is labor intensive and can lead to installation errors
Solution Approach 1:
The decking panel and strut assembly are merged into a single unit with pre-formed attachment features. The strut is positioned and secured to the decking panel during manufacturing, ensuring precise alignment and secure connection. This eliminates field installation errors while maintaining ease of operation, as the pre-assembled unit requires simple connection to the joist.
Solution Approach 2:
The decking panel includes self-contained attachment features (formed extensions with holes) that are integral to the panel structure. These features automatically provide the necessary mounting points for the strut, eliminating the need for separate hardware attachment procedures. This self-service approach improves both reliability and ease of operation.
3Adaptability or versatility
If the decking creates space between joist and upper insulation assembly, then the decking functions as a form for concrete or supports insulation, but additional structural hardware is required to support hanging systems
Solution Approach 1:
The integrated decking panel and strut assembly performs multiple functions: it maintains the required space between the joist and upper insulation assembly, provides structural support for hanging systems through the integrated strut, and offers attachment points for both purposes. This multi-functionality eliminates the need for separate hardware while maintaining adaptability for different ceiling configurations.
Solution Approach 2:
The structural support function and decking function are merged into a single assembly. The strut is formed as an integral part of the decking panel structure, allowing the same component to provide both spacing and structural support. This reduces hardware requirements while maintaining versatility for different installation scenarios.
Data Source
AI summary
A pre-assembled decking panel and strut assembly for data center ceilings and roofs including a decking panel that is a sheet metal in a shape of a wave and an elongated strut member configured such that hanging systems can be attached to the elongated strut member. The peaks and valleys of the decking panel and the strut member extend in a first direction and are spaced in parallel in a second direction perpendicular to the first direction. A top wall of the strut member is affixed to a peak of the decking panel.