Steel sheet floor support

Abstract

The utility model discloses a steel floor support plate, aims at solving traditional floor support plate rigidity strength is insufficient, steel consumption is big, construction is complicated and material utilization is low etc.

Description

Technical Field

[0001] This utility model relates to the field of engineering technology, specifically a steel plate floor decking that can be widely used in various engineering projects. Background Technology

[0002] In modern engineering, floor decking, as a crucial component of floor structures, directly impacts building safety, construction efficiency, and economy. Traditional floor decking, such as profiled steel sheet composite floor decking, while widely used in construction projects, has several limitations. Its stiffness and load-bearing capacity are relatively limited, making it difficult to meet the demands of complex building conditions such as large spans and heavy loads.

[0003] With the acceleration of urbanization and the innovation of building technology, the construction industry is showing a trend towards large-span, super high-rise, green and environmentally friendly, and industrialized construction. The emergence of large-span public buildings, high-rise commercial complexes, and industrial plants places higher demands on the mechanical properties, ease of construction, and environmental performance of floor decking. The popularization of green building concepts has prompted building materials to develop towards sustainability and low energy consumption, making traditional floor decking insufficient to meet the industry's development needs. Against this backdrop, the development of new high-performance floor decking has become an urgent need in the construction field.

[0004] Traditional steel floor decking includes profiled steel floor decking and steel truss floor decking. However, their stiffness and strength are insufficient to meet the requirements of existing buildings, resulting in a large number of secondary beams or the need for supports, and a large amount of steel consumption. Specific problems are as follows:

[0005] Corrugated steel floor decking is made by cold-pressing and bending steel plates thicker than 0.8mm into continuously bent decking. The bending of the steel plate provides the stiffness and strength to withstand vertical loads. It uses a large amount of steel and has a large plate thickness. If the steel plate is used for load-bearing purposes, it must be treated with fireproofing and rust prevention, which increases the cost. If it is not used for load-bearing purposes, the thick steel plate is wasted as a base plate.

[0006] Steel truss floor decking typically uses steel trusses welded to cold-pressed steel plates, usually around 0.5mm thick. These plates serve only as the bottom formwork for concrete pouring and do not bear any load. The steel truss consists of a single top chord reinforcement, two bottom chord reinforcements, and web members. The web members are connected to the ribs on the bottom slab by outward bending at the troughs. This type of floor decking has several problems: 1. Low stiffness and strength; smaller span without bracing for the same amount of steel. The top chord reinforcement has a 15mm protective layer, and the diameter of the top and bottom reinforcements is generally 10mm-12mm. The centroid of the top chord reinforcement is 20mm from the concrete surface. The bottom chord reinforcement also has a 15mm protective layer, and its centroid is also 20mm from the bottom surface. 1. For floor slabs with a thickness of approximately 120mm, the sacrificed centroid distance is relatively large, resulting in lower stiffness and strength of the truss floor deck. 2. The steel truss of the reinforced truss floor deck is densely packed, with a spacing of generally 200mm, and the spacing of the bottom chord reinforcement is only 100mm, resulting in a large amount of steel consumption and significant steel waste. Due to the thinness and weakness of the steel base plate, the spacing of the web members of the truss cannot be large, otherwise it will lead to the failure of the base plate strength between the truss web members. The traditional spacing of the web members of the reinforced truss at the base plate is 80mm, with a spacing of 200mm, and the maximum distance between web members is 120mm. If the truss spacing is increased, the distance between web members will increase, and the steel plate between the web members is prone to deformation and failure, resulting in safety risks and the risk of unevenness of the slab base in the later stages. 3. The upper chord of the truss of two longitudinally adjacent floor decks is broken and cannot be used as negative moment reinforcement, requiring the addition of reinforcement.

[0007] The patent document (CN 214614890 U) uses steel pipe for the top chord, and the connection between the web reinforcement and the steel pipe is achieved through four-point welding. The web members are bent outward at their troughs and then welded to the metal base plate to form the floor deck. Firstly, the connection between the web members and the top chord relies on point welding, making the connection between the top chord and the truss a weak point. Under heavy loads, the structural safety of the truss cannot be guaranteed. Secondly, the outward bending of the web members before connecting to the base plate limits the base plate's participation in load-bearing. When the base plate is under load, the web members undergo significant shear deformation due to bending, further reducing the base plate's contribution to truss performance. Finally, the centroid of the top chord is significantly farther from the bottom chord. Because the top chord uses steel pipe, with the same amount of steel, the centroid of the top chord is farther from the concrete surface and closer to the metal base plate, resulting in limited improvement in the stiffness of the floor deck and a limited increase in the span of the components.

[0008] While the use of flat tubes in the patent document (CN 119825071 A) slightly increases the spacing between the two web members compared to traditional steel trusses, the increased steel content due to the use of steel pipes or various types of steel limits the extent of this increase. This is detrimental to providing lateral bending strength for composite floor slabs, floor decks, and thin-bottom beams. The steel plates between floor deck trusses in truss combinations are prone to deformation, posing safety risks. The concrete base slab between thin-bottom composite slabs in truss combinations is prone to cracking. Using steel bars, steel pipes, or structural steel in the upper flange results in a smaller centroid distance between the upper flange section and the lower chord of the truss for the same cross-section, significantly reducing the truss's moment of inertia and thus lowering its bending strength and stiffness. This also leads to a smaller span for precast slabs and floor decks in truss combinations. Furthermore, the larger distance from the top surface of the poured concrete slab significantly reduces the utilization rate of the upper flange within the concrete slab, hindering the full utilization of material strength. In the literature, the troughs of the web members are connected to the steel plates, and the cold-bent parts of the steel plates have cold-bent protruding ribs. The shape of the ribs is relatively complex. The troughs of the web members are welded to the top surfaces of the protruding ribs, which is still a point-to-surface contact connection. The connection strength and reliability are very weak. In addition, the bent parts of the reinforcing bars serve as stress zones, which is not conducive to fully utilizing the role of the steel plates when the truss is under stress. Utility Model Content

[0009] (a) Purpose of the utility model

[0010] The purpose of this utility model is to overcome the defects of existing floor decking, such as poor coordination between steel plates and trusses, inability of steel plates to participate in overall stress, insufficient structural rigidity, excessive steel consumption, and high construction costs. It provides a steel plate floor decking and its implementation method that can achieve coordinated work of various components, significantly improve overall performance, save steel consumption, and facilitate construction. Utility Model Content

[0012] To achieve the above-mentioned technical objectives, this utility model provides the following technical solution:

[0013] A steel plate floor deck includes a wider upper flange (1), reinforcing bar web members (2), lower chord reinforcing bars (3), and a profiled thin-bottom steel sheet (4). The specific structures of each component are as follows:

[0014] 1. Wider upper wing edge (1)

[0015] Its minimum width is not less than 30mm, and it can adopt the following three structural forms, which are thin-walled upper flanges:

[0016] a. Modular structure: Composed of a top plate (5) and two side plates (6) in a V-shape, formed by bending a steel plate with a thickness of 0.8~3mm in one piece; the side plates (6) are 10~20mm wide and form a preset angle with the vertical axis; the opening edge of the V-shaped side plates (6) can be bent inward or outward according to the stress requirements to enhance the connection strength with other components. In this structure, the top plate is set on the top and away from the bottom plate. This design allows the centroid of the upper flange to be maximized from the bottom plate under limited conditions. In this way, the truss can achieve maximum strength and stiffness in a limited space and with the same amount of material. The V-shaped inclined structure can enhance the out-of-plane stability of the upper flange on the one hand, and facilitate the connection with the web members on the other hand, so that a reliable line-surface contact connection can be formed between the web members and the side plates, and then the connection operation can be carried out by low-cost resistance welding. At the same time, the opening edge is set as a structure that bends inward or outward. This bending structure further strengthens the stiffness of the upper flange and enhances its out-of-plane stability, thus ensuring that the upper chord between the web members will not experience instability failure. This is because when the truss is under stress, the upper flange is usually in a state of compression. If the moment of inertia of the upper flange section is too small and the slenderness ratio is too large, the material is very prone to local instability failure, and the bending design of the opening edge can precisely avoid this problem.

[0017] b. Steel plate structure: Thin steel plates with a thickness of not less than 1mm are used; longitudinal concave and convex ribs can be set at the transverse edge or transverse middle position of the thin steel plate to improve its own stiffness; the longitudinal concave and convex ribs are broken at the corresponding crest of the reinforcing bar web (2) to avoid interference with the reinforcing bar web (2), avoid the reduction of the transverse local stiffness of the flange, and affect the strength of the truss. For the thin steel plate that serves as the upper flange, its out-of-plane moment of inertia is relatively small. When the truss is under stress, the thin steel plate is under compression, and the slenderness ratio of the steel plate between the crests is very large, which makes it very easy to cause instability and failure. To solve this problem, concave and convex ribs are added to the steel plate between the crests. This design increases the moment of inertia of the steel plate, reduces the slenderness ratio of the steel plate, and thus improves the strength of the truss. It should be noted that since the web members have an inclination angle with the vertical axis, the web members will exert a certain pressure on the flange steel plate when under stress. If the ribs are installed along the entire length, the lateral compressive strength of the steel plate will be weakened, which will affect the strength of the truss. Therefore, the ribs are interrupted at the crests and only installed between the crests. This way, the ribs can enhance the performance of the steel plate while avoiding their adverse effect on the lateral compressive strength of the steel plate, thus ensuring the overall strength of the truss.

[0018] c. Trapezoidal steel pipe structure: The top and bottom surfaces of the steel pipe are parallel, the width of the top surface is smaller than the width of the bottom surface, and the left and right side plates (6) form a preset inclination angle with the vertical axis, which has good compressive strength. The steel pipes used in the structure have excellent characteristics. They have a good moment of inertia. When under stress, the slenderness ratio is small and the stability strength is large, which can effectively improve the strength of the truss. At the same time, the inclined setting of the left and right side plates is conducive to providing sufficient contact surface for the connection with the web members, thereby significantly increasing the connection reliability of the flange and web members, and further ensuring the overall stability and stress performance of the truss structure.

[0019] The wider upper flange (1) also has the following characteristics:

[0020] a. The distance between the upper surface of the top slab (5) and the upper surface after the concrete pouring is 10~20mm to ensure that the upper flange can effectively participate in the combined stress of the concrete. The closer the top slab of the upper flange is to the top surface of the concrete, the greater the distance between the upper flange and the bottom slab, and the higher the moment of inertia of the truss formed by the flange and the bottom slab, which can significantly improve the bending stiffness of the structure and increase the span of the members without bracing. At the same time, this closer distance allows the upper flange to better bear the tensile force on the concrete surface and prevent cracking at the top of the concrete. However, this distance needs to be controlled within a reasonable range: if the distance is less than 10mm, the concrete cover will be too thin and easily cause cracking; when the distance is greater than 20mm, it will have an adverse effect on the moment of inertia and the effective section height, resulting in the upper flange's performance not being fully utilized.

[0021] b. One or more connecting holes (8) can be set at both ends of the top plate (5). The distance between the end holes and the two ends of the top plate is 30~50mm, which is convenient for connecting with adjacent components. At the longitudinal break of the floor deck, in order to make the upper flanges of the floor decks at both ends overlap and connect with each other, steel bars or screws are threaded in the holes. After the concrete is poured, the force transmission connection of the upper flange can be realized, giving full play to the mechanical properties of the upper flange and saving more steel. The connection method can be that the top plates of the upper flanges of the longitudinally adjacent floor decks overlap each other, or a new connecting thin plate can be added. The connecting plate is connected to the upper flanges of the two truss floor decks respectively. Holes are also reserved on the connecting plate. The holes are aligned with the holes of the top plates of the upper flanges. Then, steel bars or screws are threaded in the holes. The longitudinal connection is usually at the support of the plate. After the concrete is poured, the floor slab will form a negative bending moment at the support. Connecting the upper flanges of adjacent plates with connectors can greatly reduce the use of connecting steel bars and give full play to the strength of the upper flange steel in the service state. In addition, to prevent temperature cracks in concrete floor slabs, continuous reinforcing bars need to be laid on the slab surface. If the upper flanges of longitudinally adjacent slabs are connected, the upper flange steel can be used as thermal stress relief steel after concrete pouring, thereby maximizing the role of the upper flange steel. During construction, the upper flange is under compression, which can improve the strength and stiffness of the truss and reduce the amount of support required; while in service, it can withstand the tensile force of the floor slab, making full use of the material properties.

[0022] c. The wider upper flange (1) extends beyond the edge of the profiled thin-bottom steel sheet (4) at least once, with the extra length being 100~500mm. At the longitudinal break in the floor decking, in order to connect the upper flanges of the floor decking at both ends, the upper flange of one end of the floor decking must cross the beam at the break. Generally, the beam is 200~300mm wide. If the length is too small, the flange top plate cannot be overlapped. If the length is too large, it wastes materials and is more difficult to manufacture.

[0023] d. The wider upper flange (1) can be bent downwards at both ends and welded to the profiled thin-bottom steel plate (4). The side plate (6) at the bend has a notch. The end of the floor deck where it rests on the beam or shear wall is often the part with the greatest shear force. Due to the influence of structural dimensions, the end truss web members of some floor decks cannot rest on the beam or shear wall, which can easily cause shear failure. This utility model adopts a thin-walled upper flange, which has the characteristic of being easy to bend. By simply bending the upper flange downwards and welding it to the bottom plate, the shear force of the truss can be transferred compared with the traditional method of welding a section of steel at the end. This design not only saves materials, but also simplifies the processing, reduces the amount of welding, and is more energy-efficient.

[0024] e. The surface of the top plate (5) of the wider upper flange (1) may be provided with at least one of the following: notches, indentations, transverse ribs, or longitudinal ribs. The upper flange is made of thin steel plate bent into shape. These structures can enhance the local yield bearing capacity of the thin steel plate. After the concrete is poured, the upper flange is very close to the top of the concrete, which can withstand the tension on the concrete surface and prevent the top of the concrete from cracking. Notches or indentations can also enhance the bond between the upper flange and the concrete, and make fuller use of the mechanical properties of the thin steel of the upper flange.

[0025] 2. Reinforcing bar web members (2)

[0026] A single steel bar is continuously bent into a wave shape and symmetrically arranged in two rows on the left and right; the web members (2) of the steel bar form a preset angle with the vertical axis. As a preferred option, straight sections are provided at the troughs or crests of the waves to facilitate welding and fixing.

[0027] a. When the wider upper flange (1) is a composite structure, the crest of the steel bar web member (2) is welded and fixed to the inner or outer side of the V-shaped side plate (6);

[0028] b. When the wider upper flange (1) is a trapezoidal steel pipe structure, the crest of the reinforcing bar web member (2) is welded and fixed to the outer side of the steel pipe side plate (6);

[0029] c. When the wider upper flange (1) is a steel plate structure, the top surface of the crest of the reinforcing bar web member (2) is welded and fixed to the bottom surface of the thin steel plate.

[0030] 3. Bottom chord reinforcement (3)

[0031] Parallel arrangement directly below the wider upper flange (1), welded and fixed to the trough of the steel web member (2), specifically connected to the inner side, outer side or bottom surface of the trough;

[0032] The bottom chord reinforcement (3) can be divided into upper bottom chord reinforcement (3-1) and lower bottom chord reinforcement (3-2); the upper bottom chord reinforcement (3-1) has a diameter of no more than 14 mm and is welded to the inner or outer side of the web reinforcement (2); the lower bottom chord reinforcement (3-2) has a diameter of no more than 6 mm and is welded to the bottom surface of the web reinforcement (2) and the profiled thin bottom steel plate (4) to form a double stress node. Increasing the lower bottom chord reinforcement is beneficial to improving the strength and stiffness of the truss. The lower bottom chord reinforcement is welded to the bottom surface of the web reinforcement trough, which maximizes the distance between the bottom chord and the upper flange, thereby increasing the moment of inertia of the truss. At the same time, the lower bottom chord is welded to the bottom plate to form a line-surface contact, which more effectively increases the reliability of the connection between the truss and the bottom plate.

[0033] 4. Profiled thin-bottom steel sheet (4)

[0034] Thin steel plate is cold-formed and its surface is pressed with multiple longitudinal ribs (7). The extension direction of the longitudinal ribs (7) is parallel to the wider upper flange (1) and is welded and fixed to the reinforcing bar web members (2).

[0035] The longitudinal rib (7) can adopt the following three structures:

[0036] a. Trapezoidal Ribs (Z-shaped Ribs): The ribs are symmetrical on both sides, forming a preset angle with the vertical axis. The rib height is not less than 50mm, with a larger longitudinal rib height. Multiple stiffening ribs can be pressed onto the rib sides. The stiffening ribs protrude from the surface of the profiled thin-bottom steel plate and are welded to the reinforcing bar web members to enhance shear resistance. The stiffening ribs can increase the local stiffness of the longitudinal rib's hypotenuse, and the welding of the protruding surface of the stiffening ribs to the web members makes it easier to penetrate the weld when the web plate is welded to the bottom plate due to the thin bottom plate thickness. With stiffening ribs, the weld points are not completely exposed, preventing the bottom plate from rusting and affecting the aesthetics later. The inclination angles of the two hypotenuses of the trapezoidal ribs are the same as those of the web members, forming a bent shape that is smaller at the top and larger at the bottom. This increases the strength of the thin-bottom steel plate and allows the web members to make full contact with the inclined weld. Unlike the point connection of conventional web member steel plates, the line-surface connection has a larger contact area and more reliable connection, which can fully utilize the strength of the steel bottom plate, thereby increasing the strength and stiffness of the truss floor deck. The trapezoidal ribs are relatively tall, which increases the rigidity of the base plate. The combination of the ribs and the truss provides both the rigidity of the upper flange combined with the base plate and the rigidity of the ribs, thus significantly increasing the rigidity of the floor deck and allowing for a larger span without bracing. Furthermore, because the trapezoidal ribs protrude at least 50mm, they can form a multi-ribbed plate after concrete pouring, reducing the amount of concrete and steel reinforcement required.

[0037] b. Closed-ended inverted triangular ribs: The rib height is no more than 15mm, providing good overall stability. The longitudinal ribs adopt closed triangles, ensuring a flat base plate. The weld points formed after welding the ribs to the web members are within the closed triangle, guaranteeing both the flatness and aesthetics of the base plate, and preventing rust spots due to the weld points being hidden within the closed triangle. The triangular ribs can be welded to the web members at the top or on the side. Welding to the side provides a larger contact area, further ensuring the connection strength between the web members and the base plate. The height of the triangular longitudinal ribs should not be too large, just enough to ensure connection with the web members. If it exceeds 15mm, the protective layer thickness of the lower chord reinforcement will not meet the specifications.

[0038] c. Stacked ribs: formed by multiple layers of bending, allowing structural parameters to be adjusted according to load requirements.

[0039] d. Transverse ribs can be pressed between the rib edges of adjacent longitudinal ribs (7). The extension direction of the transverse ribs is perpendicular to the longitudinal ribs (7) to improve the out-of-plane stiffness of the profiled thin bottom steel plate (4). The bottom plate is relatively thin, and the hypotenuse of the longitudinal ribs can increase the out-of-plane stiffness of the bottom plate. When the distance between the hypotenuses is large, the out-of-plane stiffness of the bottom plate is weak. Adding transverse ribs between the hypotenuses can improve the stiffness of the bottom plate between the ribs. When the top of the longitudinal rib is large, adding transverse ribs can also increase the out-of-plane local stiffness of the top plate of the longitudinal rib.

[0040] Key structural matching relationships

[0041] a. One or two longitudinal trapezoidal ribs can be set between the left and right rows of steel reinforcement web members (2). The height of the trapezoidal ribs is no more than 20mm, which is used to enhance the local structural stability.

[0042] b. The connection method between the reinforcing bar web member (2) and the longitudinal rib (7) is as follows: welded to the rib side of the trapezoidal rib and the closed inverted triangular rib; welded to the top of the closed inverted triangular rib and the stacked rib through the trough bottom.

[0043] c. The rib edges of the trapezoidal ribs, the rib edges of the closed inverted triangular ribs, the reinforcing bar web members (2), and the side plates (6) of the wider upper flange (1) are kept in the same angle with the vertical axis to ensure sufficient connection and uniform force transmission direction of each component and avoid stress concentration. The longitudinal ribs of the upper flange side plate and the cold-formed bottom plate are formed by cold-forming the upper flange and cold-formed steel plate with the same side angle. The upper flange and the bottom plate are connected together by the web members to form a truss floor deck. Compared with the traditional truss floor deck, the inertial distance between the upper flange and the profiled thin bottom steel plate is increased by more than 40%, which significantly improves the bending stiffness.

[0044] (III) Core Innovation Points

[0045] To address the problems of insufficient stiffness, large steel consumption, and poor connection reliability of traditional floor decking, the innovation of this utility model focuses on structural optimization and collaborative stress-bearing design, as detailed below:

[0046] 1. Innovative Upper Flange Structure

[0047] a. Adopting a thin-walled, wide-width design (minimum width ≥ 30mm), the distance between the centroid of the upper flange and the bottom plate is maximized through a combined, steel plate, or trapezoidal steel pipe structure, thereby increasing the truss moment of inertia by more than 20% with the same amount of material.

[0048] b. The distance between the top slab and the top surface of the concrete is controlled at 10~20mm, which ensures the thickness of the protective layer and allows the upper flange to directly participate in the tensile stress of the concrete, thus solving the problem of low utilization rate of the traditional upper flange.

[0049] c. The design of the opening edge bend and the figure-eight side plate enhances out-of-plane stability and enables line-to-surface contact welding between the web member and the side plate (replacing the traditional point connection), thus improving connection reliability.

[0050] 2. Optimization of web members and connections

[0051] a. The reinforcing bar web members are continuously bent in a wavy shape, with the inclination angle consistent with that of the longitudinal ribs of the upper flange side plate and the bottom plate, forming a full contact weld to avoid stress concentration.

[0052] b. The bottom chord reinforcement adopts a double-layer design (upper layer diameter ≤14mm, lower layer diameter ≤6mm), and is double-welded to the web trough and the bottom plate to strengthen the stress of the joint.

[0053] c. The longitudinal connection is achieved by lap joint of the upper flange + steel bar / screw connection, replacing the traditional additional steel reinforcement, realizing negative bending moment transfer and also serving as steel for temperature stress release.

[0054] 3. Innovation in base plate and rib structure

[0055] a. The profiled thin-bottom steel plate is equipped with trapezoidal ribs with a height of ≥50mm. The stiffening ribs on the rib sides are welded to the web members, which not only enhances the shear resistance but also avoids the exposed weld points from rusting.

[0056] b. The inclination angle of the trapezoidal rib is consistent with that of the web member, forming a "smaller at the top and larger at the bottom" shape, realizing the connection between the web member line and surface, which increases the contact area by more than 50% compared with the traditional point connection.

[0057] 4. Structural Combination Innovation

[0058] a. By combining a wider upper flange with a metal base plate, the traditional triangular truss is replaced with a trapezoidal truss, resulting in a better structural performance.

[0059] b. The original triangular spatial structure was changed to a quadrilateral box-shaped spatial structure, which significantly improved the overall stability, load-bearing capacity and deformation resistance of the structure, and further optimized the structural performance.

[0060] (iv) Bonus effect

[0061] Compared with the prior art, the present invention has the following significant advantages:

[0062] a. Significantly improved bending strength and stiffness of the floor decking: By using cold-formed upper flanges and cold-formed steel sheets to form the longitudinal ribs of the upper flange side plates and cold-formed bottom plates with consistent lateral inclination angles, and connecting the upper flange and bottom plate together with web members, a truss floor decking is formed. Compared to traditional truss floor decking, the distance of inertia between the upper flange and the profiled thin bottom steel sheet is increased by more than 20%, thus significantly improving bending stiffness.

[0063] b. Increased strength and reliability of the connection between the web members and the upper and lower flanges: In existing technologies, the web members are spot-welded to the upper and lower flanges, with the upper flange being a reinforcing bar or steel pipe, the lower flange being a steel plate, and the web members being reinforcing bars. This invention bends both the upper and lower flanges into inclined surfaces, allowing the web member reinforcing bars to be welded to these inclined surfaces. High-efficiency resistance welding can be used, changing the connection from spot welding to line-surface welding, resulting in higher welding strength and a more reliable connection, thus ensuring that the base plate participates in load-bearing.

[0064] c. For the same width of floor decking, the amount of truss used can be reduced, saving steel: This utility model unfolds steel into thin-walled steel plates, and then bends them into upper flanges with V-shaped side plates. With the same amount of steel used, the unfolded width of the steel is greater, and the distance between the troughs of the web members is larger. When the upper flange is combined with the thin steel base plate, the out-of-plane stiffness and strength of the truss are increased. The existing distance between the troughs of reinforcing bars and truss web members is about 80mm, and the distance between the troughs of steel pipe web members is 110mm. However, after unfolding the steel plate with the same flange steel, the distance between the troughs can be increased to 160mm, thereby reducing the number of trusses by about 30% in floor decking of the same width.

[0065] d. Saving on steel consumption in floor slabs: Concrete floor slab reinforcement consists of bottom and top bars. The bottom bars bear the mid-span bending moment, while the top bars bear the negative bending moment of the floor slab. Existing technology, due to the narrow truss width and dense arrangement, increases the number of bottom chord bars and web members, thus increasing steel consumption. Simultaneously, the top chord bars are interrupted at longitudinally adjacent points in the floor slab, failing to be fully utilized and requiring additional reinforcement at these points, further increasing steel consumption. This invention utilizes the narrow and thin characteristics of the upper slab by creating holes in it, allowing the upper flanges of longitudinally adjacent floor slabs to be mechanically connected through these holes. This fully utilizes the strength of the upper flange steel plates, reducing steel consumption.

[0066] e. After the floor slab is poured, the utilization rate of the upper flange steel increases: After the upper flange is unfolded, the distance from the centroid to the top of the poured floor slab decreases, which is more conducive to the strength of the upper flange. Furthermore, the increased contact area between the upper flange and the concrete improves the bond strength between the concrete and the upper flange, fully utilizing the strength of the upper flange. Especially in the composite floor slab or floor decking within the span beam, the utilization of the upper flange steel is maximized, reducing the amount of steel used.

[0067] f. The floor decking is simpler and more energy-efficient to manufacture, and has a lower cost: The thin-walled upper flange side plate and the longitudinal rib side of the bottom plate are in full contact with the web members, and resistance welding can be used to connect them, saving welding materials. Compared with the welding process of the upper flange of steel pipe, which requires gas shielded welding, it is simpler, more economical and efficient.

[0068] g. Excellent synergistic load-bearing performance: By setting the rib sides of the trapezoidal rib, the reinforcing bar web members (2), and the side plates (6) of the wider upper flange (1) to the same inclination angle, the angle matching of each component is realized, so that the profiled thin bottom steel plate (4) can participate in the overall load-bearing as the lower chord of the truss. This changes the status quo in traditional floor decking where the steel plate only plays an attachment role, and greatly improves the material utilization rate and overall load-bearing capacity.

[0069] h. Strong structural stability: The use of line-to-surface contact welding replaces the traditional point connection, significantly increasing the contact area between the reinforcing bar web members (2) and the longitudinal ribs (7) and the wider upper flange (1), greatly improving the connection strength and force transmission efficiency; at the same time, the double-layer setting of the lower chord reinforcing bars (3) and the arrangement of stiffening ribs further enhance the structure's resistance to deformation.

[0070] i. Convenient and efficient construction: Through standardized cold bending and automatic resistance welding processes, the industrial production of floor decking has been achieved, reducing human error; the precise matching design of each component simplifies the on-site installation process and improves construction efficiency. Attached Figure Description

[0071] Figure 1 This is a schematic diagram (figure-eight shape) of a thin-walled upper flange structure for a steel plate floor deck.

[0072] Figure 2 This is a schematic diagram of a thin-walled upper flange structure for a steel plate floor deck (the inner side of the V-shape).

[0073] Figure 3 This is a schematic diagram of a thin-walled upper flange structure for a steel plate floor deck (outer side of the V-shape).

[0074] Figure 4 This is a schematic diagram of a thin-walled upper flange structure for a steel plate floor deck (steel plate).

[0075] Figure 5 This is a schematic diagram of a thin-walled upper flange structure for a steel plate floor deck (the steel plate has concave and convex ribs in the middle).

[0076] Figure 6 This is a schematic diagram of a thin-walled upper flange structure for a steel plate floor deck (the steel plate has concave and convex ribs on its edge).

[0077] Figure 7 This is a schematic diagram of a thin-walled upper flange structure for a steel plate floor deck (the steel plate has bent ribs at the edge).

[0078] Figure 8 This is a schematic diagram of a thin-walled upper flange structure (trapezoidal tube) for a steel plate floor deck.

[0079] Figure 9 This is a schematic diagram of the reinforcing bar structure of a steel plate floor deck;

[0080] Figure 10 This is a schematic diagram of the reinforcing bar structure of a steel plate floor deck (horizontal bend at the trough).

[0081] Figure 11 This is a schematic diagram of the reinforcing bar structure of a steel plate floor deck (with horizontal bends at the crests).

[0082] Figure 12 This is a schematic diagram of the reinforcing bar structure of a steel plate floor deck (with horizontal bends at troughs and crests).

[0083] Figure 13 This is a schematic diagram of a truss structure for a steel plate floor deck (figure-eight upper chord, single lower chord).

[0084] Figure 14 This is a schematic diagram of a truss structure for a steel plate floor deck (upper chord, double lower chord).

[0085] Figure 15 This is a schematic diagram of a truss structure for a steel plate floor deck (with an outer folded edge upper chord and double lower chords).

[0086] Figure 16 A schematic diagram of a profiled thin-bottom steel plate structure for steel plate floor decking. Figure 1 ;

[0087] Figure 17 A schematic diagram of a profiled thin-bottom steel plate structure for steel plate floor decking. Figure 2 ;

[0088] Figure 18 A schematic diagram of a profiled thin-bottom steel plate structure for steel plate floor decking. Figure 3 ;

[0089] Figure 19 A schematic diagram of a profiled thin-bottom steel plate structure for steel plate floor decking. Figure 4 ;

[0090] Figure 20 This is a structural schematic diagram of a steel plate floor deck.

[0091] Figure 21 This is a structural schematic diagram of a steel plate floor deck.

[0092] Figure 22 This is a structural schematic diagram of a steel plate floor deck.

[0093] Figure 23 This is a structural schematic diagram of a steel plate floor deck.

[0094] Figure 24 This is a structural schematic diagram of a steel plate floor deck.

[0095] Figure 25 This is a structural schematic diagram of a steel plate floor deck.

[0096] Figure 26 This is a structural schematic diagram of a steel plate floor deck.

[0097] Figure 27 This is a schematic diagram of a longitudinal connection of a steel plate floor deck at a beam.

[0098] Figure 28 This is a front elevation diagram of a longitudinal connection of a steel plate floor deck at a beam.

[0099] Figure 29 A schematic diagram of an AA-section structure for longitudinal connection of steel plate floor decking at a beam;

[0100] Figure 30 This is a schematic diagram showing the inclination angles of the upper flange side plate, reinforcing bar web members, and longitudinal rib sides of a steel plate floor deck.

[0101] In the figure: 1. Thin-walled upper flange; 2. Reinforcing bar web; 3. Lower chord reinforcement; 3-1. Upper lower chord reinforcement; 3-2. Lower lower chord reinforcement; 4. Profiled thin bottom steel plate; 5. Top plate; 6. Side plate; 7. Longitudinal rib; 8. Connecting hole. Detailed Implementation

[0102] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0103] Example 1

[0104] Please refer to Figures 1-30. This utility model provides a technical solution: the steel plate floor deck includes a wider upper flange, reinforcing bar webs, lower chord reinforcing bars, and a profiled thin-bottom steel plate, with the specific structure as follows:

[0105] (1) Wider upper flange: Composed of a top plate and two side plates in a V-shape, made of steel plates with a thickness of 0.8~3mm bent in one piece, with a side plate width of 10~20mm. The edges of the V-shaped side plates are folded inward or outward. This design maximizes the expansion of the upper flange by bending the thin steel plate, thereby increasing the centroid position of the upper flange and increasing the moment of inertia and lateral stability of the truss. The width of the side plates covers the bending area of ​​the web members, and the connection in the middle is a straight bar, which can ensure the maximum stiffness of the axial force of the web members of the truss; the thickness of the upper flange meets the requirements of the expansion width and ensures sufficient thickness for connection with the web members (e.g., a 1.1mm thick upper flange, a top plate width of 50mm, a side plate width of 10mm, and a cross-sectional area of ​​77mm², equivalent to the cross-sectional area of ​​a 10mm diameter steel bar).

[0106] (2) Reinforcing bar web members: These are made of continuously bent reinforcing bars in a wavy shape, with the same inclination angle as the side plate along the vertical axis. The crests of the waves are welded to the side plate for fixation. This design achieves line-to-surface contact welding between the web members and the side plate, avoiding stress concentration and improving connection reliability.

[0107] (3) Bottom chord reinforcement: It is arranged parallel to the top of the profiled thin-bottom steel plate and welded and fixed above the trough of the reinforcement web. The bottom chord reinforcement also functions as the reinforcing steel of the concrete, which can improve the stiffness of the floor deck.

[0108] (4) Profiled thin bottom steel plate: It is formed by bending thin steel plate and pressing multiple longitudinal ribs parallel to the upper flange of thin wall on the surface. The inclination angle of the inclined rib side of the longitudinal rib is consistent with the inclination angle of the side plate and the reinforcing bar web, and is welded to the web.

[0109] The advantage of this embodiment is that:

[0110] The centroid distance between the top flange of the upper flange and the concrete slab surface is better (e.g., for a 1.1mm thick upper flange, the centroid distance from the concrete slab surface is 15mm, which is closer to the slab surface than the 20mm distance for a 10mm diameter steel bar). For a 100mm thick floor slab, the load-bearing capacity can be increased by about 10%.

[0111] The spacing between the bottom of the web members has been widened from the traditional 80mm to 150mm, and the number of trusses for a 600mm wide floor deck can be optimized from 3 to 2, reducing the amount of steel used.

[0112] In the existing technology, the minimum spacing of the bottom chord reinforcement bars of the three trusses is 100mm, which far exceeds the actual required spacing of 180mm for the floor slab, resulting in steel waste. In this embodiment, by reducing the number of trusses, the redundancy of the bottom chord reinforcement bars and web members can be avoided. At the same time, the longitudinal ribs of the profiled thin bottom steel plate are fully connected with the web members, allowing the bottom plate to participate in the stress, improving the overall stiffness and strength of the floor deck, and increasing the span without bracing.

[0113] Furthermore, the longitudinal ribs are trapezoidal ribs, and the rib edges are welded to the troughs of the web members (as shown in Figures 7, 8, 9, 11, 12, and 14).

[0114] When the trapezoidal ribs are small (as shown in Figures 7 and 14), the spacing between the web members is much larger than the rib width, and the two web members of the truss are welded to the outer edges of the two ribs respectively.

[0115] When the width of the upper side of the trapezoidal rib is the same as the distance between the troughs of the web members (as shown in Figures 8 and 11), the web members are welded to the two sides of the rib, which not only enhances the strength of the base plate and increases the span without bracing, but also reduces the length of the web members' reinforcement.

[0116] When the height of the trapezoidal rib is large (as shown in Figures 9 and 12), the base plate itself bends to form a certain rigidity, and the two troughs of the truss are welded to the top of the rib.

[0117] Compared to traditional large-wave bending floor decks (no truss, large thickness, high steel consumption), this embodiment combines profiled thin-bottom steel plates with thin-walled upper flange trusses, which saves steel consumption while improving mechanical properties, increasing span, and reducing the amount of cast-in-place concrete and the self-weight of the floor slab.

[0118] In addition, multiple stiffening ribs (transverse or longitudinal) can be pressed on both sides of the trapezoidal rib. The stiffening ribs protrude from the surface of the base plate and are welded to the web members (as shown in Figures 9 and 12).

[0119] Longitudinal stiffening ribs are used for trapezoidal ribs with low height to avoid exposed weld points that would affect the aesthetics of the base plate.

[0120] Transverse stiffeners are used for high-height trapezoidal ribs to enhance the lateral strength and local stability of the rib edges, while avoiding corrosion problems caused by exposed welds.

[0121] Transverse ribs (extending direction perpendicular to the longitudinal ribs) are pressed between the inclined sides of adjacent longitudinal ribs in the profiled thin steel sheet. Figure 7-15 This can improve the out-of-plane stiffness of the inter-rib bottom plate, and is especially suitable for scenarios with large diagonal distances, while also enhancing the local stiffness of the longitudinal rib top plate.

[0122] The distance between the top surface of the upper flange of the slab and the finished concrete surface should be controlled between 10 and 20 mm. If the distance is too close (<10 mm), the concrete cover will be too thin and prone to cracking; if it is too far (>20 mm), it will affect the moment of inertia and effective section height, reducing the performance of the upper flange. This distance setting can significantly improve the stiffness of the floor deck and the load-bearing capacity and crack resistance of the upper flange after concrete pouring.

[0123] Example 2

[0124] The design is basically the same as in Example 1, except that the wider upper flange (1) is made of 2 mm thick steel plate with a width of 50 mm and a longitudinal rib that bulges upward at the center of the transverse direction. The reinforcing bar web has a straight section at the crest, and the longitudinal rib is broken at the corresponding position of the crest. The lower chord reinforcing bar (3) can be divided into upper lower chord reinforcing bar (3-1) and lower lower chord reinforcing bar (3-2); the upper lower chord reinforcing bar (3-1) has a diameter of no more than 14 mm and is welded to the inner or outer side of the reinforcing bar web (2); the lower lower chord reinforcing bar (3-2) has a diameter of no more than 6 mm and is welded to the bottom surface of the reinforcing bar web (2) and the profiled thin bottom steel plate (4) to form a double stress node.

[0125] Example 3

[0126] The design is basically the same as in Example 1, except that the wider upper flange (1) is made of a trapezoidal steel pipe with a thickness of 1 mm and a width of 50 mm at the top. The steel plate has an upwardly protruding longitudinal rib at the transverse center. The reinforcing bar web has a straight section at the crest, and the longitudinal rib at the corresponding position of the crest is broken.

[0127] Example 4

[0128] The invention is basically the same as that in Example 1, except that: the upper flange top plate has one or more connecting holes at both ends, the holes are 30-50mm away from the ends of the top plate, and the thin-walled upper flange extends 100-500mm beyond the ends of the profiled thin bottom steel plate (as shown in Figures 11-14 and 16-18).

[0129] Floor decking typically spans 1-3 beams. When spanning beams, the upper flange can bear negative bending moments, making the floor decking a continuous slab, increasing the span between beams and utilizing the upper flange to bear the negative bending moments above the floor slab. However, when the floor decking is interrupted at a beam, traditional techniques require additional reinforcement at the top of the beam, failing to utilize the strength of the upper flange. This embodiment solves this problem through the following design:

[0130] The upper flange adopts a steel plate unfolding design, with holes at the end of the top plate. The upper flange top plates of the longitudinally adjacent floor decks overlap each other. After the holes overlap, steel bars or bolts are inserted. After the concrete is poured, the upper flange is connected to transmit force, giving full play to its mechanical properties and saving steel.

[0131] The connection method can be to directly overlap the top plate of the upper flange, or to add a connecting plate (the connecting plate has holes aligned with the upper flange, through which steel bars or screws are inserted).

[0132] The extra-long portion of the upper flange (100~500mm) needs to cross the beam (usually the beam width is 200~300mm) to ensure effective overlap of the upper flanges on the floor decks at both ends.

[0133] Example 5

[0134] It is basically the same as Example 1, except that: the two ends of the wider upper flange are bent downward and welded to the profiled thin bottom steel plate, and the side plate at the bend has a notch (as shown in Figure 15).

[0135] The shear force is greatest at the ends of the floor deck where it rests against beams or shear walls. Due to structural size limitations, some end truss web members cannot be placed on supports, making them prone to shear failure. Traditional techniques solve this by welding vertical web members, which is a complex process. This embodiment utilizes the easily bendable characteristic of the thin-walled upper flange, directly bending it downwards and welding it to the base plate to achieve shear force transfer. This approach offers advantages such as material saving, simplified processing, reduced welding, and energy efficiency.

[0136] The side panels have notches at the bends to release bending stress, prevent irregular deformation of the upper flange, and ensure bending accuracy.

[0137] Example 6

[0138] It is basically the same as Example 1, except that the top plate surface of the thin-walled upper flange is provided with at least one of the following: grooves, indentations, transverse ribs or longitudinal ribs.

[0139] The upper flange is made of thin steel plate bent into shape. The surface structure described above can enhance the local yield strength of the thin steel plate. After the concrete is poured, the upper flange, being close to the concrete surface, can withstand surface tension and prevent cracking. At the same time, the scoring or indentation can enhance the adhesion between the upper flange and the concrete, fully utilizing the mechanical properties of the thin-walled steel.

[0140] Example 7

[0141] It is basically the same as Example 1, except that the longitudinal rib is a closed triangular rib with a height of no more than 15mm, and is welded to the trough of the web member (as shown in Figures 10 and 13).

[0142] The closed triangular rib design ensures a flat base plate, with weld points hidden within the closed opening, enhancing the base plate's aesthetics and preventing corrosion. It can be welded to the web members via the rib top or the rib side (side welding provides a larger contact area and higher connection strength). The triangular rib height is controlled within 15mm to meet the protective layer thickness requirements for the lower chord reinforcement (exceeding 15mm does not comply with specifications).

[0143] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A steel deck panel, characterized by Comprising: a wider upper flange (1), the overall minimum width of which is not less than 30 mm; a steel web member (2), which is formed by continuously bending steel bars into a wavy shape, consists of left and right rows, and forms an inclination angle with a vertical axis; a lower chord steel bar (3), which is arranged in parallel below the wider upper flange (1) and is welded and fixed to the inner side, outer side or bottom surface at the trough of the steel web member (2); a profiled thin bottom steel plate (4), which is formed by bending a thin steel plate, with a plurality of longitudinal ribs (7) parallel to the wider upper flange (1) pressed on the surface, and the longitudinal ribs (7) are welded to the steel web member (2).

2. The steel plate floor decking according to claim 1, characterized in that: the longitudinal rib (7) is any one of the following structures a. trapezoidal ribs, with rib sides symmetrical left and right, and the rib sides form an inclination angle with a vertical axis; b. closed inverted triangular ribs, the height of which is not greater than 15 mm; c. stacked ribs.

3. A steel deck sheet according to claim 2, characterized in that: The height of the trapezoidal rib is not less than 50 mm.

4. A steel deck sheet according to claim 3, characterized in that: A plurality of stiffening ribs are pressed on both rib sides of the trapezoidal rib.

5. A steel deck sheet according to claim 1, characterized in that: One or two longitudinal trapezoidal ribs are arranged between the left and right rows of the steel web member (2), and the height of the trapezoidal ribs is not greater than 20 mm.

6. A steel deck sheet according to claim 1, characterized in that: When the longitudinal rib (7) is a longitudinal rib or a closed triangular rib, the steel web member (2) is welded to the rib side of the longitudinal rib (7).

7. A steel deck sheet according to claim 1, characterized in that: When the longitudinal rib (7) is a stacked rib or a closed triangular rib, the trough bottom of the steel web member (2) is welded to the top of the longitudinal rib (7).

8. A steel deck sheet according to claim 1, characterized in that: Transverse ribs are pressed between adjacent rib sides of the longitudinal ribs (7) on the profiled thin bottom steel plate (4), and the extension direction of the transverse ribs is perpendicular to the longitudinal ribs (7).

9. The steel plate floor decking according to claim 1, characterized in that: the wider upper flange (1) is any one of the following structures it is composed of a top plate (5) and two side plates (6) in a splayed shape, formed by bending a steel plate with a thickness of 0.8~3 mm, the width of the side plate (6) is 10~20 mm, and the side plate (6) forms an inclination angle with a vertical axis; a thin steel plate, the thickness of which is not less than 1 mm; a trapezoidal steel pipe, the top surface and the bottom surface of which are parallel, the width of the top surface is smaller than that of the bottom surface, and there are left and right side plates (6), the side plates (6) form an inclination angle with a vertical axis.

10. A steel deck sheet according to claim 9, characterized in that: When the wider upper flange (1) is composed of a top plate (5) and two side plates (6) in a splayed shape, the opening edges of the two side plates (6) are bent inward or outward.

11. A steel deck sheet according to claim 9, characterized in that: When the wider upper flange (1) is a thin steel plate, longitudinal concave-convex ribs are provided at the transverse edge or the transverse middle of the thin steel plate.

12. A steel deck sheet according to claim 11, characterized in that: The longitudinal concave-convex ribs are broken at the position corresponding to the wave crest of the steel web member (2).

13. A steel deck sheet according to claim 1, characterized in that: The inclination angles of the rib side of the longitudinal rib (7), the steel web member (2) and the side plate of the wider upper flange (1) relative to the vertical axis are consistent.

14. A steel deck sheet according to claim 1, characterized in that: There is a straight section bending at the trough or crest of the steel web member (2).

15. A steel deck sheet according to claim 9, characterized in that: When the wider upper flange (1) is composed of a top plate (5) and two side plates (6) in a splayed shape, the wave crest of the steel web member (2) is welded to the inner side or outer side of the two side plates (6).

16. A steel deck sheet according to claim 9, characterized in that: When the wider upper flange (1) is a trapezoidal steel pipe, the wave crest of the steel web member (2) is welded to the outer side of the side plate (6) of the trapezoidal steel pipe.

17. A steel deck sheet according to claim 9, characterized in that: When the wider upper flange (1) is a thin steel plate, the top surface of the wave crest of the steel web member (2) is welded to the bottom surface of the thin steel plate.

18. A steel deck sheet according to claim 1, characterized by: The lower chord reinforcement (3) is divided into upper lower chord reinforcement (3-1) and lower lower chord reinforcement (3-2).

19. A steel deck plate according to claim 18, characterized in that: The upper lower chord steel bar (3-1) is welded to the inner or outer side of the steel bar web (2), and the lower lower chord steel bar (3-2) is welded to the bottom surface of the steel bar web (2) and the profiled thin bottom steel plate (4).

20. A steel deck sheet according to claim 18, characterized in that: The diameter of the upper lower chord reinforcement (3-1) is no greater than 14mm; the diameter of the lower lower chord reinforcement (3-2) is no greater than 6mm.

21. A steel deck sheet according to claim 1, characterized in that: The upper surface of the wider upper flange (1) is 10-20 mm away from the upper surface after the concrete is poured.

22. A steel deck sheet according to claim 1, characterized in that: The wider upper flange (1) has one or more connecting holes (8) at both ends.

23. A steel deck sheet according to claim 1, characterized in that: The wider upper flange (1) extends beyond the end edge of the profiled thin bottom steel plate (4) at least once.

24. A steel deck sheet according to claim 1, characterized in that: The wider upper flange (1) is bent downward at both ends and welded to the profiled thin bottom steel plate (4), and the side plate (6) at the bend has a notch.

25. A steel deck sheet according to claim 1, characterized in that: The surface of the wider upper flange (1) is provided with at least one of the following: engravings, embossings, transverse ribs, or longitudinal ribs.

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