Method of manufacturing deck plate

Abstract

To provide a method of manufacturing a deck plate capable of securing a prescribed cross-sectional performance without increasing a unit weight.SOLUTION: A manufacturing method of a deck plate 1 in one embodiment includes an aperture formation process for widening a slit 40 disposed in a zigzag fashion on a steel plate and forming an aperture 4. A slit formation process for forming the slit 40 on the steel plate may further be included before the aperture formation process. A bending process for bending the steel plate into a prescribed shape may be also included, and the slit 40 on the steel plate that is bent may be widened to form the aperture 4 during the aperture formation process.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a deck plate.

Background Art

[0002] The deck plate is used as a flat deck for a concrete formwork, and is also used as a composite slab integrally with concrete. For example, Patent Documents 1 and 2 disclose technologies related to deck plates.

[0003] The flat deck of Patent Document 1 is a flat deck in which a steel plate is roll-formed and a flat portion and a leg rib are alternately continuous in the width direction. The flat portion includes a first flat portion near one end in the width direction and a second flat portion other than the first flat portion.

[0004] The deck plate of Patent Document 2 is a deck plate for a concrete slab that is bent from a steel plate and formed into a rectangular shape in plan view, and includes a rectangular flat slab support portion that supports the lower surface of the concrete slab, and a reinforcing rib that projects in the out-of-plane direction from one side of the slab support portion along the longitudinal direction.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0006] As in the disclosed technologies of Patent Documents 1 and 2, ribs are formed to improve the cross-sectional performance of the deck plate. For example, in the deck plate for a flat deck, generally a rib with a height of 75 mm is used. However, in recent years, in order to cope with longer spans, deck plates having ribs with a height of 90 to 100 mm, which is higher than 75 mm, have also begun to be commercially available.

[0007] Generally, when improving the cross-sectional performance of the deck plate, it is effective to increase the height of the rib. However, the deck plate is usually manufactured by cold roll forming, in which a thin plate coil is passed between a plurality of rollers arranged in a row and continuously bent to be processed into a predetermined cross-sectional shape. Therefore, in order to manufacture a deck plate having a rib height higher than that of the conventional one, a wider thin plate coil than the conventional one and a new dedicated facility (roll forming machine) for processing this wide coil are required.

[0008] In this way, in order to manufacture a deck plate having a rib height or a deck plate width length different from the existing ones in order to ensure a predetermined cross-sectional performance, a dedicated roll forming machine is required for each cross-sectional shape, so a large-scale equipment investment is required. Therefore, at present, it is often the case that the plate thickness is increased to cope with it. However, when the plate thickness is increased, the weight per unit area increases, resulting in a cost increase and a decrease in workability. For this reason, a deck plate having a predetermined cross-sectional performance without increasing the unit weight is required.

[0009] Therefore, the present invention has been devised in view of the above-described circumstances, and an object thereof is to provide a method for manufacturing a deck plate capable of ensuring a predetermined cross-sectional performance without increasing the unit weight.

Means for Solving the Problems

[0010] The method for manufacturing a deck plate according to the present invention is characterized by including an opening forming step of expanding slits arranged in a staggered pattern in a steel plate to form openings.

Effects of the Invention

[0011] According to the present invention, it is possible to provide a method for manufacturing a deck plate that can ensure a predetermined cross-sectional performance without increasing the unit weight.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments for carrying out a deck plate and a method for manufacturing a deck plate to which the present invention is applied will be described in detail with reference to the drawings.

[0014] <First Embodiment: Deck Plate 1> As shown in FIG. 1, both ends in the longitudinal direction of the deck plate 1 are placed on a pair of H-shaped steel beams 8. The deck plate 1 is used as a flat deck for a concrete formwork. Concrete (not shown) is placed on the deck plate 1 to construct a deck slab.

[0015] The deck slab is a member that constitutes the floor of a building and constitutes an example of a building structure. The deck slab is formed by a deck plate and concrete. Examples of deck slabs include a deck composite slab, a deck composite slab, etc. A deck composite slab includes a deck plate and concrete placed on the deck plate. The deck composite slab has a structure in which concrete resists the compressive force generated in the slab and the deck plate resists the tensile force generated in the slab. A deck composite slab includes a deck plate, concrete placed on the deck plate, and tensile reinforcement. The deck composite slab has a structure in which concrete resists the compressive force generated in the slab and the tensile reinforcement resists the tensile force generated in the slab.

[0016] As shown in FIGS. 2(a) and 2(b), the deck plate 1 includes a flat plate portion 2 having a flat plate shape, and a plurality of ribs 3 protruding from the flat plate portion 2 along the longitudinal direction. Openings 4 are formed in the ribs 3 of the deck plate 1 in a staggered arrangement in the longitudinal direction of the deck plate 1. Thereby, the deck plate 1 can secure a predetermined cross-sectional performance without increasing the unit weight. Note that the openings 4 arranged in a staggered pattern in the longitudinal direction may be formed in at least one of the flat plate portion 2 and the ribs 3.

[0017] The flat plate portion 2 is formed in a rectangular shape in plan view. The flat plate portion 2 has an embossed portion 21 formed by embossing, and a bent portion 22 formed by bending one end portion in the short side direction (width direction) of the deck plate 1 in the protruding direction of the rib 3. The bent portion 22 in one deck plate 1 can be inserted between a pair of rising plate portions 31, 31 that are in contact with each other in another deck plate 1. Thereby, a plurality of deck plates 1 can be arranged and connected in the width direction. Although the embossed portion 21 is shown in FIG. 2(a), the description of the embossed portion 21 is omitted in other figures (FIGS. 1, 2(b), 3) of the first embodiment.

[0018] The rib 3 protrudes downward. In the example shown in FIG. 1, the rib 3 is not embedded in the concrete.

[0019] The rib 3 has a pair of rising plate portions 31, 31 that rise from the flat plate portion 2 and are in contact with each other, and a reinforcing portion 32 formed by bending the tips of the pair of rising plate portions 31, 31. The opening 4 is formed in the rising plate portion 31. The reinforcing portion 32 is formed by bending, for example, into a triangular cross-sectional shape. The rib 3 has an end closure portion 5 in which both end portions in the longitudinal direction of the deck plate 1 are crushed and closed in the vertical direction by end closure processing.

[0020] As shown in Fig. 2(b), the opening 4 is formed in three steps on the rising plate portion 31. The opening 4 is composed of triangular openings 4 arranged in the upper and lower stages and a rhombic opening 4 arranged in the middle stage. The triangular openings 4 and the rhombic openings 4 are arranged with their longitudinal positions shifted from each other and arranged side by side in the longitudinal direction of the deck plate 1.

[0021] Both end closure portions 5 at both ends in the longitudinal direction of the deck plate 1 are placed on the beam member 8. When construction is carried out using the deck plate 1, the operator will work on the flat plate portion 2 of the deck plate 1. Since the load of the operator does not directly act on the rib 3, the opening 4 will not shrink or will hardly shrink.

[0022] <First Embodiment: Manufacturing Method of Deck Plate 1> Next, an example of the manufacturing method of the deck plate 1 will be described. The manufacturing method of the deck plate 1 includes a slit forming step, a bending step, and an opening forming step.

[0023] First, in the slit forming step, using a roll forming machine, the steel sheet wound in a coil shape is unwound into a flat steel sheet, and slits are formed in a staggered pattern on the flat steel sheet. The slits are formed at the positions where the ribs 3 of the steel sheet will be formed in the subsequent bending step.

[0024] In the slit forming step, an embossed portion 21 may be formed at the location that will be bent into the flat plate portion 2 of the flat steel sheet. In the slit forming step, other necessary pre-notch processing may also be performed.

[0025] Then, as shown in Fig. 3(a), in the bending process, using a roll forming machine, a flat steel plate with slits formed is bent to form a predetermined cross-section. In the bending process, the steel plate is bent to form a flat plate portion 2 in a flat shape and a plurality of ribs 3 protruding along the longitudinal direction from the flat plate portion 2. In the bending process, slits 40 are formed in the ribs 3. The longitudinal direction of the slits 40 is formed along the extending direction of the ribs 3. In the bending process, the flat steel plate is bent to form a rising plate portion 31 and a reinforcing portion 32. Also, in the bending process, the steel plate is cut to a predetermined length, and end closure portions 5 are formed at both longitudinal ends of the ribs 3.

[0026] Then, as shown in Fig. 3(b), in the opening forming process, the slits 40 arranged in a staggered pattern in the ribs 3 are expanded in the short direction (width direction) of the slits 40 to form openings 4. The height of the ribs 3 can be adjusted according to the size of the openings 4 formed in the opening forming process. The size of the openings 4 can also be adjusted by the width dimension of the slits 40 formed in the slit forming process. Since the height of the ribs 3 can be adjusted, a plurality of types of deck plates 1 having a predetermined cross-sectional shape can be manufactured from one type of coiled steel plate.

[0027] Thus, an example of the manufacturing method of the deck plate 1 is completed. In the present invention, after the slit forming process, the opening forming process may be performed, and the bending process may be, for example, before the slit forming process or after the opening forming process.

[0028] In this embodiment, the ribs 3 are formed with openings 4 arranged in a staggered pattern in the longitudinal direction. Thereby, the height of the ribs 3 can be adjusted according to the size of the openings 4 in the deck plate 1. For this reason, the deck plate 1 can ensure a predetermined cross-sectional performance without increasing the unit weight.

[0029] In this embodiment, an opening forming step is provided in which the slits 40 arranged in a staggered pattern on the steel plate are expanded to form the opening 4. Thereby, the deck plate 1 capable of adjusting the height of the rib 3 can be manufactured according to the size of the opening 4. For this reason, the deck plate 1 can secure a predetermined cross-sectional performance without increasing the unit weight.

[0030] Also, in this embodiment, an opening forming step is provided in which the slits 40 arranged in a staggered pattern on the steel plate are expanded to form the opening 4. Thereby, a plurality of types of deck plates 1 having a predetermined cross-sectional shape can be manufactured from one type of coiled steel plate. For this reason, if there is equipment for forming the slits 40 and the openings 4, large-scale equipment investment for manufacturing deck plates with a predetermined cross-sectional shape is not required, and manufacturing can also be performed using existing equipment.

[0031] In this embodiment, before the opening forming step, a slit forming step of forming slits in the steel plate is further provided. Thereby, the width, length, etc. of the slits can be adjusted. For this reason, it becomes easier to further manufacture the deck plate 1 having a predetermined cross-sectional performance.

[0032] In this embodiment, in the bending process, the steel plate is bent to form a flat plate portion 2 in a flat plate shape and a plurality of ribs 3 protruding along the longitudinal direction from the flat plate portion, and in the opening forming step, the slits formed in at least one of the flat plate portion 2 and the rib 3 are expanded to form the opening 4. Thereby, the opening 4 can be formed in at least one of the flat plate portion 2 and the rib 3.

[0033] In addition, in the deck plate 1 shown in FIG. 1, the rib 3 protrudes downward and is used as a flat deck that is not embedded in the concrete. Although not shown, in the deck plate 1, the rib 3 may be arranged so as to protrude upward. In this case, the rib 3 is embedded in the concrete, and the deck plate 1 is used as a composite slab.

[0034] <Second Embodiment: Deck Plate 1> Next, the deck plate 1 in the second embodiment will be described. Hereinafter, the description of the same configuration as that of the first embodiment will be omitted as appropriate. As shown in Fig. 4(a), in the second embodiment, the shape of the reinforcing portion 32 is different from that of the first embodiment.

[0035] The rib 3 has a pair of rising plate portions 31, 31 that rise from the flat plate portion 2 and are in contact with each other, and a reinforcing portion 32 in which the tips of the pair of rising plate portions 31, 31 are bent. An opening 4 is formed in the rising plate portion 31. The rib 3 is formed by bending, for example, into a T-shaped cross section by the pair of rising plate portions 31, 31 and the reinforcing portion 32.

[0036] <Third Embodiment: Deck Plate 1> Next, the deck plate 1 in the third embodiment will be described. As shown in Fig. 4(b), in the third embodiment, the shape of the reinforcing portion 32 is different from that of the first embodiment.

[0037] The rib 3 has a pair of rising plate portions 31, 31 that rise from the flat plate portion 2 and are in contact with each other, and a reinforcing portion 32 in which the tips of the pair of rising plate portions 31, 31 are bent. An opening 4 is formed in the rising plate portion 31. The rib 3 is formed by bending, for example, into an L-shaped cross section by the pair of rising plate portions 31, 31 and the reinforcing portion 32.

[0038] <Fourth Embodiment: Deck Plate 1> Next, the deck plate 1 in the fourth embodiment will be described. As shown in Fig. 5, in the fourth embodiment, the number of steps of the opening 4 is different from that of the first embodiment.

[0039] The opening 4 is formed in five steps on the rising plate portion 31. The opening 4 is composed of triangular openings 4 arranged in the upper and lower stages and three-stage rhombic openings 4 arranged in the middle stage. Among the three-stage rhombic openings 4, the upper and lower rhombic openings 4 of the triangular openings 4 are arranged with their longitudinal arrangements shifted from each other and arranged side by side in the longitudinal direction of the deck plate 1. Among the three-stage rhombic openings 4, the middle rhombic openings 4 of the triangular openings 4 are arranged with the same longitudinal arrangement and arranged side by side in the longitudinal direction of the deck plate 1.

[0040] In this embodiment, since the number of steps of the opening 4 is arranged in five steps in the vertical direction, the degree of freedom in adjusting the height of the rib 3 is higher than that in the case of three steps in the vertical direction.

[0041] <Fifth Embodiment: Deck Plate 1> Next, the deck plate 1 in the fifth embodiment will be described. As shown in FIG. 6, the fifth embodiment is different from the first embodiment in that the opening 4 is formed in the flat plate portion 2.

[0042] The deck plate 1 has openings 4 formed in a staggered pattern in the longitudinal direction in the flat plate portion 2. Thereby, the deck plate 1 can secure a predetermined cross-sectional performance without increasing the unit weight. Note that the openings 4 formed in a staggered pattern in the longitudinal direction may be formed in at least one of the flat plate portion 2 and the rib 3.

[0043] When placing concrete on the deck plate 1 in which the opening 4 is formed in the flat plate portion 2, it is preferable to lay a sheet material such as a refractory sheet or a non-woven fabric on the flat plate portion 2. Thereby, leakage of concrete from the opening 4 can be prevented.

[0044] <Fifth Embodiment: Manufacturing Method of Deck Plate 1> Next, an example of the manufacturing method of the deck plate 1 will be described. The manufacturing method of the deck plate 1 includes a slit forming step, a bending step, and an opening forming step.

[0045] First, in the slit forming step, using a roll forming machine, the steel sheet wound in a coil shape is unwound to form a flat steel sheet, and slits are formed in the flat steel sheet in a staggered pattern. The slits are formed at positions where the flat portion 2 of the steel sheet is to be formed in the subsequent bending step.

[0046] Then, in the bending step, using a roll forming machine, the flat steel sheet with slits formed is bent to form a predetermined cross-section. In the bending step, the steel sheet is bent to form a flat flat portion 2 and a plurality of ribs 3 protruding along the longitudinal direction from the flat portion 2. In the bending step, a slit 40 is formed in the flat portion 2. The longitudinal direction of the slit 40 is formed along the extending direction of the rib 3. Also, in the bending step, the steel sheet is cut to a predetermined length, and end closure portions 5 are formed at both ends in the longitudinal direction of the rib 3.

[0047] Then, in the opening forming step, the slits 40 arranged in a staggered pattern in the flat portion 2 are expanded in the width direction of the slits 40 to form openings 4. The width of the flat portion 2 can be adjusted according to the size of the openings 4 formed in the opening forming step. The size of the openings 4 can also be adjusted by the width dimension of the slits 40 formed in the slit forming step. Since the width of the flat portion 2 can be adjusted, a plurality of types of deck plates 1 having a predetermined cross-sectional shape can be manufactured from one type of coiled steel sheet.

[0048] In this embodiment, the flat portion 2 has openings 4 arranged in a staggered pattern in the longitudinal direction. Thereby, the width of the flat portion 2 of the deck plate 1 can be adjusted according to the size of the openings 4. For this reason, the deck plate 1 can ensure a predetermined cross-sectional performance without increasing the unit weight.

[0049] In this embodiment, an opening forming step is provided in which the slits 40 arranged in a staggered pattern in the steel sheet are expanded to form openings 4. Thereby, a deck plate 1 whose width of the flat portion 2 can be adjusted according to the size of the openings 4 can be manufactured. For this reason, the deck plate 1 can ensure a predetermined cross-sectional performance without increasing the unit weight.

[0050] In addition, in the present embodiment, an opening forming step is provided in which slits 40 arranged in a staggered pattern on the steel plate are expanded to form an opening 4. As a result, a plurality of types of deck plates 1 having a predetermined cross-sectional shape can be manufactured from one type of coiled steel plate. Therefore, if there is equipment for forming the slits 40 and the opening 4, large-scale equipment investment for manufacturing a deck plate with a predetermined cross-sectional shape is not required, and it can also be manufactured using existing equipment.

[0051] <Sixth Embodiment: Deck Plate 1> Next, the deck plate 1 in the sixth embodiment will be described. As shown in FIG. 7, in the sixth embodiment, the rib 3 has an engaging portion 33 and an engaging portion 34, which is different from the first embodiment.

[0052] Both ends of the deck plate 1 in the longitudinal direction are placed on a pair of H-shaped steel girders 8. The deck plate 1 is used as a composite slab on which concrete is placed. Concrete (not shown) is placed on the deck plate 1.

[0053] As shown in FIG. 8(a), the deck plate 1 includes a flat plate portion 2 having a flat plate shape, and a plurality of ribs 3 protruding from the flat plate portion 2 along the longitudinal direction. Openings 4 arranged in a staggered pattern in the longitudinal direction of the deck plate 1 are formed in the ribs 3 of the deck plate 1. As a result, the deck plate 1 can ensure a predetermined cross-sectional performance without increasing the unit weight. Note that the openings 4 arranged in a staggered pattern in the longitudinal direction may be formed in at least one of the flat plate portion 2 and the ribs 3.

[0054] The flat plate portion 2 is formed in a rectangular shape in plan view. The flat plate portion 2 is formed in a trapezoidal cross-sectional shape and has a trapezoidal protrusion 23 extending along the longitudinal direction.

[0055] The rib 3 protrudes upward. In the example shown in FIG. 7, the rib 3 is to be embedded in the concrete. Although not shown, the rib 3 may have an end closure portion 5 in which both ends in the longitudinal direction are crushed in the vertical direction and closed by end closure processing.

[0056] The rib 3 disposed at the center in the width direction of the deck plate 1 has a pair of rising plate portions 31, 31 that rise from the flat plate portion 2 and are in contact with each other, and a reinforcing portion 32 formed by bending the tips of the pair of rising plate portions 31, 31. An opening 4 is formed in the rising plate portion 31. The reinforcing portion 32 is formed, for example, by being bent into a triangular cross-sectional shape.

[0057] The rib 3 disposed at one end in the width direction of the deck plate 1 has a rising plate portion 31 that rises from the flat plate portion 2 and an engaging portion 33 formed at the tip of the rising plate portion 31. The engaging portion 33 has a first bent portion 33a bent toward the center in the width direction and a second bent portion 33b bent from the tip of the first bent portion 33a toward the flat plate portion 2 side. A protrusion 35 extending along the longitudinal direction is formed on the rising plate portion 31 of the rib 3 disposed at one end in the width direction of the deck plate 1.

[0058] The rib 3 disposed at the other end in the width direction of the deck plate 1 has a rising plate portion 31 that rises from the flat plate portion 2 and an engaging portion 34 formed at the tip of the rising plate portion 31. The engaging portion 34 in one deck plate 1 can engage with the engaging portion 33 in another deck plate 1. Thereby, a plurality of deck plates 1 can be arranged side by side and connected in the width direction. The engaging portion 34 has a first bent portion 34a bent toward the center in the width direction, a second bent portion 34b bent from the tip of the first bent portion 34a along the flat plate portion 2, a third bent portion 34c bent from the tip of the second bent portion 34b toward the rising plate portion 31, and a fourth bent portion 34d further bent from the tip of the third bent portion 34c.

[0059] As shown in FIG. 8(b), the opening 4 is formed in three stages in the rising plate portion 31. The opening 4 is composed of a triangular opening 4 disposed in the upper and lower stages and a rhombic opening 4 disposed in the middle stage. The triangular opening 4 and the rhombic opening 4 are arranged side by side in the longitudinal direction of the deck plate 1 with their arrangements shifted from each other in the longitudinal direction.

[0060] The deck plate 1 has both longitudinal ends placed on the beam member 8. When construction is carried out using the deck plate 1, the operator will work on the flat plate portion 2 of the deck plate 1. Since the load of the operator does not directly act on the rib 3, the opening 4 will not shrink or will hardly shrink.

[0061] <Sixth Embodiment: Manufacturing Method of Deck Plate 1> Next, an example of the manufacturing method of the deck plate 1 will be described. The manufacturing method of the deck plate 1 includes a slit forming step, a bending step, and an opening forming step.

[0062] The slit forming step is the same as that of the first embodiment.

[0063] Then, in the bending step, using a roll forming machine, the flat steel plate with slits formed is bent to form a predetermined cross-section. In the bending step, the steel plate is bent to form a flat plate portion 2 in a flat shape and a plurality of ribs 3 protruding along the longitudinal direction from the flat plate portion 2. In the bending step, slits 40 are formed in the rib 3. The longitudinal direction of the slit 40 is formed along the extending direction of the rib 3. Also, in the bending step, the steel plate is cut to a predetermined length. In the bending step, the flat steel plate is bent to form a rising plate portion 31, a reinforcing portion 32, an engaging portion 33, and an engaging portion 34.

[0064] The opening forming step is the same as that of the first embodiment.

[0065] Thus, an example of the manufacturing method of the deck plate 1 is completed.

[0066] In this embodiment, the rib 3 in which the opening 4 is formed is embedded in the concrete. The opening 4 can ensure adhesion with the concrete. Therefore, integration with the concrete can be achieved. Also, since the opening 4 is formed in the rib 3, embossing for ensuring adhesion with the concrete is not required for the rib 3.

[0067] Here, in the concrete placed on the deck plate 1, there may be embedded pipes such as electrical wiring. In a normal deck plate, when arranging the embedded pipe in the direction crossing the vertical ribs, the thickness of the concrete placed on the deck plate is increased, and the embedded pipe is arranged in the thickened portion above the vertical ribs. In this regard, in the present embodiment, the rib 3 in which the opening 4 is formed is embedded in the concrete. Thereby, an embedded pipe such as electrical wiring can be arranged so as to penetrate the opening 4. For this reason, the thickness of the concrete placed on the deck plate 1 can be made thinner.

[0068] In addition, in the deck plate 1 shown in FIG. 7, the rib 3 projects upward and is used as a composite slab embedded in the concrete. Although not shown, in the deck plate 1, the rib 3 may be arranged so as to project downward. In this case, the rib 3 is not embedded in the concrete, and the deck plate 1 is used as a flat deck for the formwork of the concrete.

[0069] <Seventh Embodiment: Deck Plate 1> Next, the deck plate 1 in the seventh embodiment will be described. As shown in FIGS. 9(a) and 9(b), the seventh embodiment is different from the above-described embodiments in that the deck plate 1 has a peak portion 61, a valley portion 62, and an inclined portion 63.

[0070] Concrete (not shown) is placed on the deck plate 1. The deck plate 1 is used as a composite slab integrated with the concrete.

[0071] As shown in Fig. 9(a), the deck plate 1 has a ridge portion 61, a valley portion 62, and an inclined portion 63 that connects the ridge portion 61 and the valley portion 62. Openings 4 are formed in the inclined portion 63 of the deck plate 1 in a staggered pattern in the longitudinal direction of the deck plate 1. Thereby, the deck plate 1 can secure a predetermined cross-sectional performance without increasing the unit weight. Note that the openings 4 arranged in a staggered pattern in the longitudinal direction may be formed in at least any one of the ridge portion 61, the valley portion 62, and the inclined portion 63. The deck plate 1 has two ridge portions 61. On both sides of the ridge portion 61 of the deck plate 1, the inclined portions 63 are continuous, and the valley portion 62 is continuous with the inclined portion 63. The deck plate 1 is formed in a corrugated shape with a trapezoidal cross-section.

[0072] The ridge portion 61 and the valley portion 62 are formed in a flat plate shape that is rectangular in plan view. The ridge portion 61 has a groove 61a in the center in the width direction to improve rigidity. The valley portion 62 has a protrusion 62a in the center in the width direction to improve rigidity. An engaging portion 64 is formed in the valley portion 62 on one end side in the width direction of the deck plate 1, and an engaging portion 65 is formed in the valley portion 62 on the other end side in the width direction of the deck plate 1. The engaging portion 64 of one deck plate 1 is engaged with the engaging portion 65 of the other deck plate 1. Thereby, a plurality of deck plates 1 can be arranged side by side and connected in the width direction. The inclined portion 63 has a stepped portion 63a, and this stepped portion 63a can ensure adhesion to the placed concrete.

[0073] As shown in Fig. 9(b), the openings 4 are formed in three stages in the inclined portion 63. The openings 4 are composed of triangular openings 4 arranged in the upper and lower stages and rhombic openings 4 arranged in the middle stage. The triangular openings 4 and the rhombic openings 4 are arranged with their longitudinal arrangements shifted from each other and arranged side by side in the longitudinal direction of the deck plate 1.

[0074] When placing concrete on the deck plate 1 in which the openings 4 are formed in the inclined portion 63, it is preferable to lay a sheet material such as a refractory sheet or a non-woven fabric on the inclined portion 63. Thereby, leakage of concrete from the openings 4 can be prevented.

[0075] <Seventh Embodiment: Manufacturing Method of Deck Plate 1> Next, an example of the manufacturing method of the deck plate 1 will be described. The manufacturing method of the deck plate 1 includes a slit forming step, a bending step, and an opening forming step.

[0076] First, in the slit forming step, using a roll forming machine, the steel sheet wound in a coil shape is unwound to form a flat steel sheet, and slits are formed in the flat steel sheet so as to be staggeredly arranged. The slits are formed at positions where the inclined portions 63 of the steel sheet are formed in the subsequent bending step.

[0077] Then, as shown in FIG. 10(a), in the bending step, using a roll forming machine, the flat steel sheet with slits formed is bent to form a predetermined cross-section. In the bending step, the steel sheet is bent to form a peak portion 61, a valley portion 62, and an inclined portion 63 where the peak portion 61 and the valley portion 62 are continuous. In the bending step, slits 40 are formed in the inclined portion 63. The longitudinal direction of the slits 40 is formed along the extending direction of the inclined portion 63.

[0078] Then, as shown in FIG. 10(b), in the opening forming step, the slits 40 arranged staggeredly in the inclined portion 63 are expanded in the width direction of the slits 40 to form openings 4. The height of the inclined portion 63 can be adjusted according to the size of the openings 4 formed in the opening forming step. The size of the openings 4 can also be adjusted by the width dimension of the slits 40 formed in the slit forming step. Since the height of the inclined portion 63 can be adjusted, a plurality of types of deck plates 1 having a predetermined cross-sectional shape can be manufactured from one type of coiled steel sheet.

[0079] Thus, an example of the manufacturing method of the deck plate 1 is completed.

[0080] In this embodiment, in the inclined portion 63, openings 4 arranged staggeredly in the longitudinal direction are formed. Thereby, the deck plate 1 can adjust the height of the inclined portion 63 according to the size of the openings 4. For this reason, the deck plate 1 can ensure a predetermined cross-sectional performance without increasing the unit weight.

[0081] In this embodiment, an opening forming step of forming an opening 4 by expanding slits 40 arranged in a staggered pattern on a steel plate is provided. Thereby, a deck plate 1 capable of adjusting the height of the rib 3 according to the size of the opening 4 can be manufactured. For this reason, the deck plate 1 can secure a predetermined cross-sectional performance without increasing the unit weight.

[0082] Also, in this embodiment, an opening forming step of forming an opening 4 by expanding slits 40 arranged in a staggered pattern on a steel plate is provided. Thereby, a plurality of types of deck plates 1 having a predetermined cross-sectional shape can be manufactured from one type of coiled steel plate. For this reason, if there is equipment for forming the slits 40 and the openings 4, a large-scale equipment investment for manufacturing a deck plate with a predetermined cross-sectional shape is not required, and it can also be manufactured using existing equipment.

[0083] In this embodiment, before the opening forming step, a slit forming step of forming slits in the steel plate is further provided. Thereby, the width, length, etc. of the slits can be adjusted. For this reason, it becomes easier to manufacture the deck plate 1 having a predetermined cross-sectional performance.

[0084] In this embodiment, in the bending process, the steel plate is bent to form a peak portion 61, a valley portion 62, and an inclined portion 63 where the peak portion 61 and the valley portion 62 are continuous. In the opening forming step, the opening 4 is formed by expanding the slits formed in at least any one of the peak portion 61, the valley portion 62, and the inclined portion 63. Thereby, the opening 4 can be formed in at least any one of the peak portion 61, the valley portion 62, and the inclined portion 63.

[0085] <Eighth Embodiment: Deck Plate 1> Next, the deck plate 1 in the eighth embodiment will be described. As shown in Fig. 11(a), the eighth embodiment is different from the seventh embodiment in that the deck plate 1 has an opening 4 in the peak portion 61.

[0086] The deck plate 1 has openings 4 formed in a staggered pattern in the longitudinal direction on the ridge portions 61. The openings 4 are formed, for example, on both sides in the width direction with a groove 61a interposed therebetween.

[0087] <Eighth Embodiment: Manufacturing Method of Deck Plate 1> First, in the slit forming step, using a roll forming machine, the coiled steel sheet is unwound into a flat steel sheet, and slits are formed in the flat steel sheet so as to be arranged in a staggered pattern. The slits are formed at positions where the ridge portions 61 of the steel sheet are to be formed in the subsequent bending step.

[0088] Then, in the bending step, using a roll forming machine, the flat steel sheet with slits formed is bent to form a predetermined cross-section. In the bending step, the steel sheet is bent to form a ridge portion 61, a valley portion 62, and an inclined portion 63 where the ridge portion 61 and the valley portion 62 are continuous. In the bending step, a slit 40 is formed in the ridge portion 61. The longitudinal direction of the slit 40 is formed along the extending direction of the ridge portion 61.

[0089] Then, in the opening forming step, the slits 40 arranged in a staggered pattern in the ridge portion 61 are expanded in the width direction of the slits 40 to form the openings 4. The width of the ridge portion 61 can be adjusted according to the size of the openings 4 formed in the opening forming step. The size of the openings 4 can also be adjusted by the width dimension of the slits 40 formed in the slit forming step. Since the width of the ridge portion 61 can be adjusted, a plurality of types of deck plates 1 having a predetermined cross-sectional shape can be manufactured from one type of coiled steel sheet.

[0090] In this embodiment, the ridge portion 61 has openings 4 formed in a staggered pattern in the longitudinal direction. Thereby, the deck plate 1 can adjust the width of the ridge portion 61 according to the size of the openings 4. For this reason, the deck plate 1 can ensure a predetermined cross-sectional performance without increasing the unit weight.

[0091] When placing concrete on the deck plate 1 in which the opening 4 is formed in the ridge portion 61, it is preferable to lay a sheet material such as a refractory sheet or a non-woven fabric on the ridge portion 61. Thereby, leakage of concrete from the opening 4 can be prevented.

[0092] <Embodiment 9: Deck Plate 1> Next, the deck plate 1 in the ninth embodiment will be described. As shown in Fig. 11(b), the ninth embodiment is different from the seventh embodiment in that the deck plate 1 has an opening 4 in the trough portion 62.

[0093] The deck plate 1 has openings 4 formed in a staggered pattern in the longitudinal direction in the trough portion 62. The openings 4 are formed on both sides in the width direction, for example, sandwiching the protrusion 62a.

[0094] <Embodiment 9: Manufacturing Method of Deck Plate 1> First, in the slit forming process, using a roll forming machine, the steel sheet wound in a coil shape is unwound into a flat steel sheet, and slits are formed so as to be arranged in a staggered pattern on the flat steel sheet. The slits are formed at positions where the trough portions 62 of the steel sheet are formed in the subsequent bending process.

[0095] Then, in the bending process, using a roll forming machine, the flat steel sheet with slits formed is bent into a predetermined cross-section. In the bending process, the steel sheet is bent to form the ridge portion 61, the trough portion 62, and the inclined portion 63 where the ridge portion 61 and the trough portion 62 are continuous. In the bending process, a slit 40 is formed in the trough portion 62. The longitudinal direction of the slit 40 is formed along the extending direction of the trough portion 62.

[0096] Then, in the opening formation step, the slits 40 arranged in a staggered pattern in the valley portion 62 are expanded in the width direction of the slits 40 to form the openings 4. The width of the valley portion 62 can be adjusted according to the size of the openings 4 formed in the opening formation step. The size of the openings 4 can also be adjusted by the width dimension of the slits 40 formed in the slit formation step. Since the width of the valley portion 62 can be adjusted, a plurality of types of deck plates 1 having a predetermined cross-sectional shape can be manufactured from one type of coiled steel sheet.

[0097] In the present embodiment, the openings 4 are formed in a staggered pattern in the longitudinal direction in the valley portion 62. Thereby, the deck plate 1 can adjust the width of the valley portion 62 according to the size of the openings 4. For this reason, the deck plate 1 can secure a predetermined cross-sectional performance without increasing the unit weight.

[0098] When placing concrete on the deck plate 1 in which the openings 4 are formed in the valley portion 62, it is preferable to lay a sheet material such as a refractory sheet or a non-woven fabric on the valley portion 62. Thereby, leakage of concrete from the openings 4 can be prevented.

[0099] <Tenth Embodiment: Deck Plate 1> Next, the deck plate 1 in the tenth embodiment will be described. As shown in FIG. 12, the tenth embodiment is different from the seventh embodiment in that the deck plate 1 has one peak portion 61.

[0100] The deck plate 1 has one peak portion 61, inclined portions 63 are connected to both sides of the peak portion 61, and valley portions 62 are connected to the inclined portions 63. Even in this case, the openings 4 arranged in a staggered pattern in the longitudinal direction may be formed in at least any one of the peak portion 61, the valley portion 62, and the inclined portion 63. The deck plate 1 is formed in a corrugated shape with a trapezoidal cross section.

[0101] The embodiments of the present invention have been described above. However, these embodiments are presented as examples and are not intended to limit the scope of the invention. Furthermore, the present invention can be implemented in various novel forms in addition to the above embodiments. Therefore, the above embodiments can be variously omitted, replaced, and modified without departing from the gist of the present invention. Such novel forms and modifications are included in the scope and gist of the present invention, and are also included in the scope of the invention described in the claims and the scope of equivalents of the invention described in the claims.

Explanation of Reference Numerals

[0102] 1: Deck plate 2: Flat plate portion 21: Embossed portion 22: Bent portion 23: Trapezoidal protrusion 3: Rib 31: Upright plate portion 32: Reinforcing portion 33: Engaging portion 34: Engaging portion 35: Protrusion 4: Opening 40: Slit 5: End closure portion 61: Ridge portion 61a: Groove 62: Valley portion 62a: Protrusion 63: Inclined portion 63a: Step portion 64: Engaging portion 65: Engaging portion 8: Beam member

Claims

1. Comprising an opening forming step of expanding slits arranged in a staggered pattern on a steel plate to form an opening A method for manufacturing a deck plate, characterized in that.

2. Before the opening forming step, further comprising a slit forming step of forming the slits on the steel plate The method for manufacturing a deck plate according to claim 1, characterized in that.

3. Further comprising a bending step of bending the steel plate into a predetermined shape, In the opening forming step, expanding the slits in the bent steel plate to form the opening The method for manufacturing a deck plate according to claim 2, characterized in that.

4. In the bending step, the steel plate is bent to form a flat plate portion and a plurality of ribs protruding longitudinally from the flat plate portion, In the opening forming step, expanding the slits formed in at least one of the flat plate portion and the ribs to form the opening The method for manufacturing a deck plate according to claim 3, characterized in that.

5. In the bending step, the steel plate is bent to form a peak portion, a valley portion, and an inclined portion connecting the peak portion and the valley portion, In the opening forming step, expanding the slits formed in at least one of the peak portion, the valley portion, and the inclined portion to form the opening The method for manufacturing a deck plate according to claim 3, characterized in that.

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