Deck plate

Abstract

To provide a deck plate capable of securing a prescribed cross-sectional performance without increasing a unit weight.SOLUTION: A deck plate 1 in one embodiment is a deck plate 1 including a crest 61, a valley 62 and a ramp 63 continuous to the crest 61 and the valley 62, and is characterized by apertures 4 disposed in a zigzag fashion in a longer direction, formed on the ramp 63. The deck plate 1 is used as a deck plate for a composite slab, and is integrated with concrete installed on the deck plate 1.SELECTED DRAWING: Figure 9

Description

Technical Field

[0001] The present invention relates to 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 and continuously formed 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] Ribs are formed to improve the cross-sectional performance of the deck plate, like the disclosed technologies in Patent Documents 1 and 2. For example, in the case of a deck plate for a flat deck, generally a rib with a height of 75 mm is used. In recent years, however, 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 started 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 plurality of slats are continuously bent between rollers arranged in a row from a thin plate coil to be processed into a predetermined cross-sectional shape. Therefore, in order to manufacture a deck plate with a rib height higher than before, a wider thin plate coil than before and new dedicated equipment (roll forming machine) for processing this wider coil are required.

[0008] In order to ensure such a predetermined cross-sectional performance, in order to manufacture a deck plate with a rib height or deck plate width length different from the existing ones, 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, causing an increase in cost and a decrease in workability. For this reason, a deck plate having a predetermined cross-sectional performance without increasing the unit weight is demanded.

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

Means for Solving the Problem

[0010] The deck plate according to the present invention is a deck plate having a ridge portion, a groove portion, and an inclined portion connecting the ridge portion and the groove portion, wherein openings are formed in at least any one of the ridge portion, the groove portion, and the inclined portion in a staggered arrangement in the longitudinal direction.

Advantages of the Invention

[0011] According to the present invention, it is possible to provide a deck plate that can secure 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 the 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 beam members 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, and a deck slab is constructed.

[0015] A deck slab is a member that constitutes the floor of a building and forms an example of a building structure. The deck slab is formed by a deck plate and concrete. Examples of deck slabs include deck composite slabs, deck composite slabs, 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 the 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 decoding slab has a structure in which the 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 projecting 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 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 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 in the projecting direction of the rib 3 at one end in the short direction (width direction) of the deck plate 1. The bent portion 22 in one deck plate 1 can be inserted between a pair of rising plate portions 31, 31 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 projects 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. An opening 4 is formed in the rising plate portion 31. The reinforcing portion 32 is formed by bending, for example, into a triangular cross-section. The rib 3 has an end closure portion 5 in which both longitudinal ends 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 stages in the rising plate portion 31. The opening 4 is composed of a triangular opening 4 arranged in the upper and lower stages and a rhombic opening 4 arranged 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.

[0021] Both end closure portions 5 at both longitudinal ends of the deck plate 1 are placed on the beam material 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 the flat steel sheet so as to be arranged in a staggered pattern. The slits are formed at 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 a location to be bent as the flat portion 2 in the flat steel plate. In the slit forming step, other necessary pre-notch processing may be performed.

[0025] Then, as shown in Fig. 3(a), 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 flat portion 2 and a plurality of ribs 3 protruding along the longitudinal direction from the flat portion 2. In the bending step, 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 step, the flat steel plate is bent to form a rising plate portion 31 and a reinforcing portion 32. Also, in the bending step, 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 step, 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 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 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 step, the opening forming step may be performed, and the bending step may be, for example, before the slit forming step or after the opening forming step.

[0028] In the present 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 secure 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, a large-scale equipment investment for manufacturing a deck plate having a predetermined cross-sectional shape is not required, and it can also be manufactured 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 and a plurality of ribs 3 protruding from the flat plate portion along the longitudinal direction. 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 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 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 in 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 in 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 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 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 in 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 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 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 in the first embodiment.

[0039] The opening 4 is formed in five stages 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 opening 4 of the triangular openings 4 has the same longitudinal arrangement and is arranged side by side in the longitudinal direction of the deck plate 1.

[0040] In this embodiment, since the number of stages of the opening 4 is arranged in five stages 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 stages 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, in the fifth embodiment, it 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 on 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 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 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 longitudinal ends 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 is formed with openings 4 arranged in a staggered pattern in the longitudinal direction. Thereby, the deck plate 1 can adjust the width of the flat portion 2 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.

[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 the 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 secure 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 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.

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

[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. 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.

[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 end portions 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 by bending, for example, into a triangular cross-section 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. The rib 3 disposed at one end in the width direction of the deck plate 1 has a protrusion 35 formed along the longitudinal direction on the rising plate portion 31.

[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 on the rising plate portion 31. The opening 4 is composed of triangular openings 4 disposed in the upper and lower stages and a rhombic opening 4 disposed in the middle stage. The triangular openings 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] And 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 cases where buried pipes such as electrical wiring are buried. In a normal deck plate, when arranging a buried pipe in a direction crossing the vertical ribs, the thickness of the concrete placed on the deck plate is increased, and the buried 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 buried in the concrete. Thereby, a buried 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 buried 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 buried in the concrete, and the deck plate 1 is used as a flat deck for a concrete formwork.

[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 groove portion 62, and an inclined portion 63 that is continuous with the ridge portion 61 and the groove 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 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 any one of the ridge portion 61, the groove portion 62, and the inclined portion 63. The deck plate 1 has two ridge portions 61. The inclined portions 63 are continuous with both sides of the ridge portion 61, and the groove 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 groove 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 groove portion 62 has a protrusion 62a in the center in the width direction to improve rigidity. An engaging portion 64 is formed in the groove portion 62 on one end side in the width direction of the deck plate 1, and an engaging portion 65 is formed in the groove 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 the 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 positions shifted in the longitudinal direction and are 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: Method for Manufacturing Deck Plate 1> Next, an example of the method for manufacturing the deck plate 1 will be described. The method for manufacturing 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 into 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 in a staggered manner 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 method for manufacturing the deck plate 1 is completed.

[0080] In this embodiment, the inclined portion 63 is formed with openings 4 arranged in a staggered manner in the longitudinal direction. Thereby, the height of the inclined portion 63 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.

[0081] 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 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 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, a large-scale equipment investment for manufacturing a deck plate having 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 slits formed in at least any one of the peak portion 61, the valley portion 62, and the inclined portion 63 are expanded to form the opening 4. 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 to form 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, for example, on both sides in the width direction with the protrusion 62a interposed therebetween.

[0094] <Embodiment 9: 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 trough portions 62 of the steel sheet are formed in the subsequent bending step.

[0095] 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 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 step, 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 forming 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 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 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 this 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 continuous on both sides of the peak portion 61, and valley portions 62 are continuous on 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. A deck plate having a peak portion, a valley portion, and an inclined portion connecting the peak portion and the valley portion, wherein openings arranged in a staggered pattern in the longitudinal direction are formed in at least one of the peak portion, the valley portion, and the inclined portion. The deck plate is characterized by this.

2. The inclined portion is characterized by having the openings formed therein. The deck plate according to Claim 1, characterized by this.

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