Rugged Next Generation Composite False Deck System For Lightweight, Fire & Shock-Proof Elevated Open Spaces

Navy elevated deck structures utilize lightweight, fire-resistant composite deck tiles for walking surfaces. Current Nomex-cored glass/phenolic sandwich baseline panels are expensive, need special edge treatments after cutting to shape, and are frequently damaged by chipping at their thin edges. KaZaK has identified attractive pultrudable alternatives that can be used for the next generation of tough, inexpensive deck tiles. KaZaK designs will meet or exceed current system requirements, including weight and FST. Our designs will not require edge treatments when cut, will be considerably more resistant to the types of damage that destroy the current panels, and will permit panels to be repaired while underway and/or pier-side. KaZaK will also investigate alternative tile-to-sub-frame attachment schemes to meet shock requirements and improve below-deck access for ship system maintenance. KaZaK’s Phase I endeavors will focus on design, fabrication and testing of prototype deck panel hardware intended as a part-for-part replacement of existing DDG Nomex sandwich deck panels. Phase I panels will be designed to mount to the existing aluminum substructure. Some consideration in Phase I will also be given to redesign of an optimized substructure for the next generation panel system that will be developed in Phase II.BENEFITS: Military and commercial applications of elevated deck tiles that are lightweight, structurally stiff and fire resistant have enormous potential. Navy ships utilize elevated deck systems to permit communication, electrical and HVAC systems to run underneath the false deck. This practice is repeated throughout the Navy fleet. In addition, Navy and commercial ship joiner bulkheads, built in accommodations and moveable dividers are all markets for a tough, fire resistant and lightweight composite panels. The Army would be interested in these panels for portable shelters to support housing, medical, and storage facilities. In addition, these large composite panels could be used in the commercial construction market providing fire resistant cubicles, room dividers and nonstructural wall partitions.