Deck Plate

The present invention relates to a deck plate.

To construct a floor slab, a roof, and a rooftop slab of a building structure, a deck plate is widely used. The deck plate is disposed to be bridged between beams, and both ends of the deck plate are fixed to upper surfaces of the beams. After the deck plate is fixed, concrete is placed on the deck plate. When the concrete is solidified, a floor structure, a roof, or a rooftop structure is constructed.

The deck plate is formed by bending a metal plate by roll forming or the like. Ribs for enhancing rigidity are provided on the deck plate, and protruding streak portions protruding toward the ribs are provided on slab supporting portions provided between the ribs (for example, see Patent Literature 1).

After being manufactured in a factory, a predetermined number of deck plates as described above are tied with a band and shipped. The deck plates include the ribs. Therefore, when the deck plates are stacked in the same direction, a volume is increased, and the number of deck plates to be stacked is limited. Therefore, deck plates in a pair are stacked while being turned upside down relative to each other, and a plurality of pairs of stacked deck plates are stacked and tied with the band (hereinafter, referred to as package).

However, when deck platesandin a pair are stacked as illustrated in, ribsof one deck platecontact recessed streak portionsof the other deck plate, and ribsof the other deck platecontact recessed streak portionsof the one deck platein some cases. In this case, contact areas between the ribsand the recessed streak portionsand contact areas between the ribsand the recessed streak portionsare small to cause an unstable state. When the deck platesandare tied with a band, the deck plateandare bent with contact parts as fulcrums. In addition, the whole of the package is in an unstable shape. Thus, the package does not stand by itself and easily falls over.

It is an object of the present invention, which has been made in consideration of the above-described problem, to provide a technique for stacking deck plates in a stable state.

To solve the above-described problem, according to an aspect of the present invention, a deck plate is formed of a metal plate and includes plane portions and ribs provided alternately and continuously. Bottom surfaces of the ribs and contact parts of the plane portions contacting the bottom surfaces of the ribs when deck plates in a pair are stacked while being turned upside down relative to each other are formed in complementary shapes.

The bottom surfaces of the ribs and the contact parts are each preferably formed in a plane shape.

When the deck plates in a pair are stacked while being turned upside down relative to each other, the entire bottom surfaces of the ribs preferably contact the contact parts.

Each of the plane portions preferably includes protruding streak portions protruding toward one of surfaces. The bottom surfaces of the ribs contacting the protruding streak portions when the deck plates in a pair are stacked while being turned upside down relative to each other are preferably formed in shapes complementary to the protruding streak portions.

When the deck plates in a pair are stacked while being turned upside down relative to each other, the entire bottom surfaces of the ribs preferably contact the protruding streak portions.

Each of the plane portions preferably includes protruding streak portions protruding toward one of surfaces. The protruding streak portions contacting each other when a plurality of pairs of deck plates stacked while being turned upside down relative to each other are stacked are preferably formed in complementary shapes.

When the plurality of pairs of deck plates stacked while being turned upside down relative to each other are stacked, entire regions of the protruding streak portions of one deck plate preferably contact the protruding streak portions of another deck plate.

The protruding streak portions preferably include first protruding streak portions protruding toward a surface on which the ribs are provided on the plane portions, and second protruding streak portions protruding toward a surface opposite to the surface on which the ribs are provided on the plane portions.

The deck plates in a pair are preferably stacked while being turned upside down relative to each other, to minimize a height and a width in a transverse direction.

According to the aspect of the present invention, it is possible to stack the deck plates in the stable state.

Some embodiments of the present invention are described below with reference to drawings. In the following description, the drawings are schematic, and it should be noted that a relationship between dimensions of elements, ratios of the elements, and the like are different from actual ones. The size relationship or ratio may also be partly different among the drawings.

A configuration of a deck plate according to a first embodiment is described with reference toto.is a perspective view of the deck plate.is a cross-sectional view taken along line A-A of the deck plate illustrated in.is an enlarged cross-sectional view of a protruding streak portion illustrated in.is a cross-sectional view illustrating a state where the deck plates illustrated inare stacked.

As illustrated into, a deck plateserves as a form for concrete placed to construct a floor structure (or roof or rooftop structure) of a building structure.

As illustrated in, the deck plateis bridged between beams facing each other. One end of the deck plateis placed on one of the beams and is fixed to the beam by welding or the like, and another end is placed on the other beam and is fixed to the other beam by welding or the like. More specifically, the beams are each made of, for example, an H-section steel, and the ends of the deck plateare placed on and fixed to flange portions of the H-section steels forming the respective beams.

As illustrated inand, the deck plateis formed of a thin steel plate subjected to or not subjected to surface treatment such as galvanization. The deck plateis manufactured by, for example, roll-forming a flat steel plate by a roll forming machine. The deck plateis bent at a plurality of positions by the roll forming machine. The deck platepreferably has a thickness of 0.6 mm to 2.3 mm.

The deck plateincludes, for example, two ribsand, plane portions, protruding streak portions, a locked portion, and end-closed portions.

As illustrated in, the ribis formed by bending the steel plate. The ribincludes a bent partbent toward one of surfaces of the steel plate, a straight partthat is continuous from the bent partand in which a surface direction extends in a direction orthogonal to the plane portions, a folded-back partthat is continuous from the straight partand is folded back by being bent a plurality of times, a straight partthat is continuous from the folded-back partand in which a surface direction extends along the straight part, and a bent partthat is continuous from the straight partand is bent toward the plane portions.

Each of the bent partand the bent partis formed such that a bending radius R is about 3 mm to about 10 mm, for example, about 6 mm. This is because bending processing by roll forming is relatively easily performable, and to prevent a recess formed between the bent partsandfrom being increased more than necessary to cause a waste of concrete.

The straight partand the straight partare formed such that a surface of the straight partand a surface of the straight partcontact each other, and are coupled by swaging or the like. This prevents the straight partand the straight partfrom separating from each other.

The folded-back partis formed to have a substantially triangular shape in a cross-sectional view, and is folded back such that a start point and an end point are adjacent to each other and the straight partand the straight partcontact each other. The folded-back partis formed such that a bottom surface partcorresponding to a bottom surface of the ribhas one flat plane.

As illustrated in, the ribis formed by bending the steel plate. The ribincludes a bent partbent toward one of surfaces of the steel plate, a straight partthat is continuous from the bent partand in which a surface direction extends in the direction orthogonal to the plane portions, a folded-back partthat is continuous from the straight partand is folded back by being bent a plurality of times, a straight partthat is continuous from the folded-back partand in which a surface direction extends along the straight part, an inclined partthat is continuous from the straight partand is obliquely inclined toward the plane portionsin a direction separating from the straight part, a straight partthat is continuous from the inclined partand in which a surface direction extends along the straight part, and a bent partthat is continuous from the straight partand is bent toward the plane portions.

Each of the bent partand the bent partis formed such that a bending radius R is about 3 mm to about 10 mm, for example, about 6 mm. This is because bending processing by roll forming is relatively easily performable, and to prevent a recess formed between the bent partsandfrom being increased more than necessary to cause a waste of concrete.

The straight partand the straight partare formed such that a surface of the straight partand a surface of the straight partcontact each other, and are coupled by swaging or the like. This prevents the straight partand the straight partfrom separating from each other.

The folded-back partis formed to have a substantially triangular shape in a cross-sectional view, and is folded back such that a start point and an end point are adjacent to each other and the straight partand straight partcontact each other. The folded-back partis formed such that a bottom surface partcorresponding to a bottom surface of the ribhas one flat plane. The bottom surface partof the folded-back partis formed to be positioned on the plane same as the bottom surface partof the folded-back part.

The inclined partis to form a gap between the straight partand the straight part. The inclined partenables insertion of the locked portionwith the gap formed between the straight partand the straight partas a reception portionfor the locked portion.

The deck plateincludes, for example, the two ribsand. The riband the ribare provided with an interval (distance between centers) of 180 mm to 220 mm along a width direction (transverse direction) of the deck plate. More specifically, a length L of the deck platein the width direction is 360 mm to 440 mm. The ribis provided such that a distance Lfrom one end of the deck platein the width direction to a center of the rib(center of ribis boundary surface on which straight partand straight partcontact each other) becomes 180 mm to 220 mm. The ribis provided such that a distance Lfrom the center of the ribto a center of the rib(center of ribis boundary surface on which straight partand straight partcontact each other) becomes 180 mm to 220 mm. In other words, the ribis provided near a center of the deck platein the width direction, and the ribis provided near an end of the deck platein the width direction. The distance Land the distance Lare preferably equal to each other, and for example, each of the distances Land Lis 200 mm, and the length L is 400 mm.

The ribsandare provided to extend along a length direction (longitudinal direction) of the deck plate. In other words, the ribsandare provided continuously from the one end to the other end along a direction in which the deck plateis bridged between beams.

Each of the ribsandis preferably formed such that a height H from a lower end to an upper end (upper surface) of each plane portionis 50 mm to 150 mm, and is formed, for example, such that the height H is 100 mm.

As illustrated in, the plane portionsare mainly portions where the ribsandare not provided in the deck plate, and are planes mainly receiving a load of the placed concrete. The plane portionsare provided adjacent to the ribsandin the transverse direction of the deck plate. In other words, in the deck plate, the ribsandand the plane portionsare alternately provided. In the deck plate, the plane portionsare provided on the same plane.

As illustrated in, deck platesandin a pair are stacked while being turned upside down relative to each other so as to minimize a height and a width in the transverse direction by bringing the ribof the deck plateand the ribof the deck plateclose to each other as much as possible (for example, until any portions of deck platesandcontact each other). Contact partsandof the plane portions(surfaces of plane portions on rib side) of one of the deck plates contacting the bottom surface partsandof the ribsandof the other deck plate at that time are formed in shapes complementary to the bottom surface partsandof the ribsand. More specifically, as illustrated inand, since the bottom surface partsandof the ribsandare each formed in one flat plane shape, the contact partsandare also each formed in a plane shape having one flat surface. The contact partsandare provided on the plane same as the plane portions. In other words, the contact partsandare parts where no protruding streak portionsare provided. Therefore, when the deck platesandin a pair are stacked while being turned upside down relative to each other so as to minimize the height and the width in the transverse direction, the entire bottom surface partsandof the ribsandof the one deck plate contact the contact partsandof the plane portionsof the other deck plate. At this time, the surface direction of the bottom surface partsandof the ribsandand the surface direction of the contact partsandof the plane portionsare parallel to each other, and are present on the substantially same plane along the transverse direction of the deck plate.

As illustrated in, each of the protruding streak portionsis formed by bending the steel plate. The protruding streak portionsare formed to protrude toward the surfaces of the plane portionson which the ribsandare provided. Thus, the plane portionsare planes in which flat parts and valley parts (ridge parts as viewed from opposite side) are alternately continued.

The plurality of protruding streak portionsare provided side by side along the transverse direction of the deck plate. For example, two protruding streak portionsare provided on each of the plane portions. Depending on a width of each of the protruding streak portions, for example, the number of protruding streak portionsis preferably 1 to 5 on each of the plane portions. The protruding streak portionsare provided to extend along the longitudinal direction of the deck plate.

As illustrated in, each of the protruding streak portionsis preferably formed such that a width B along the transverse direction of the deck plateis 20 mm to 30 mm, a height h (length from lower surface of each plane portionto outer surface of portion most protruding from ringsandside) is 3 mm to 8 mm. Each of the protruding streak portionsis formed such that a valley partformed at a center in the width direction is deepest, and includes inclined surfaceshaving the same inclination on both dies of the valley partin the width direction. Each of the protruding streak portionsis preferably formed such that a bending radius R of each of bent parts(boundary parts with respective plane portionsand valley part) at which a metal plate is bent is 3 mm to 6 mm.

The locked portionis provided at one end of the deck plate. The locked portionis an end part of the steel material bent at a substantially right angle from the adjacent plane portion, and is provided to extend along the height direction of the ribsand. When the deck platesare coupled, the locked portionof one of the deck platesis inserted into the reception portionprovided on the ribof the other deck plate. When the deck platesare coupled, the deck platesare superimposed such that a part of the plane portionsof the one deck plateis placed on an upper surface of an extending portionof the other deck plate, and the locked portionof the one deck plateis inserted into the reception portionof the other deck plate. The extending portionis provided continuously from the bent partof the riband extends along the plane portions.

It is sufficient for the locked portionto have a height enough to be locked to the reception portion. Further, based on the premise that leakage of the placed concrete is prevented, the deck platesmay be coupled by superimposition of the plane portions, joining by welding, or fastening tools such as screws, without forming the locked portion.

Further, it is sufficient for the reception portionto receive the locked portion.

As illustrated in, the end-closed portionsare provided at both ends of the deck platein the length direction (longitudinal direction). The end-closed portionsare formed by crushing both ends of the riband the ribin a direction orthogonal to the surface of the deck plate. Thus, in the riband the rib, the end-closed portionsat the both ends are each formed to have a crushed cross-section, and the other portions sandwiched between the end-closed portionsare each formed to have a substantially triangular shape in a cross-sectional view. As a result, the both ends of the riband the ribare lower in height than the other portions, and accordingly the both ends of the riband ribcan be placed on upper surfaces of the flange portions of the beams. Each of the end-closed portionsis formed to have a length along the extending direction of the riband the ribgreater than a length placed on the upper surface of the flange portion of the corresponding beam.

When the manufactured deck plateis shipped, a plurality of pairs of stacked deck platesandare stacked and tied with a band to form a package.

is a cross-sectional view illustrating a state where the deck platesandin a pair are stacked while being turned upside down relative to each other so as to minimize the height and the width in the transverse direction.

In the state illustrated in, one deck plateis disposed such that the ribsandare directed downward, whereas the other deck plateis disposed such that the ribsandare directed upward. The deck platesandin a pair are stacked while being turned upside down relative to each other so as to minimize the height and the width in the transverse direction by bringing the ribof the deck plateand the ribof the deck plateclose to each other as much as possible (for example, until any portions of deck platesandcontact each other).

The bottom surface partof the ribof the other deck plateis in surface contact with the contact partof the one deck plate, and the bottom surface partof the ribof the other deck plateis in surface contact with the contact partof the one deck plate

The bottom surface partof the ribof the one deck plateis in surface contact with the contact partof the one deck plate, and the bottom surface partof the ribof the one deck plateis in surface contact with the contact partof the other deck plate

In the state illustrated in, the contact areas of the plane portionsand the ribsandof the deck platesandin a pair are large, and the heights of the deck platesandin a pair are equal to each other. Thus, a stable state is established.