How to install the deck plate assembly

Abstract

The present invention improves a deck plate in order to attain higher levels of safety and precision during construction, and provides a rational method for installing the improved deck plate.　The present invention is a deck plate assembly comprising a deck plate and a decorative material provided on the underside of the deck plate and having a unit width that is equal to the unit width of the deck plate. The deck plate comprises: a first fitting part formed into a hooked shape bowing upward from the underside of the deck plate; and a second fitting part formed into a hooked shape bowing upside down relative to the first fitting part, wherein the first fitting part is provided on one end of the deck plate in the transverse direction so as to sink down toward an end of the decorative material on the underside of the deck plate, the second fitting part is provided on the other end of the deck plate in the transverse direction so as to project up from the end of the decorative material on the underside of the deck plate, and the first and second fitting parts are formed such that when two adjacent deck plates are mated together, the undersides of the respectively provided decorative materials are substantially flush with one another.

Description

Technical Field

[0001] The present invention relates to a deck plate assembly and a method for installing the same.

Background Art

[0002] Deck plates are known as a reasonable material that can shorten the construction period by measurement in the base of the external insulation dry construction method roof without placing concrete. In addition, a deck composite slab formed by integrating a deck plate and concrete has spread as a standard floor material for steel frame buildings because of its excellent workability and cost (see, for example, Patent Document 1). The deck composite slab and the roof base deck plate often require ceiling finishing.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] At a construction site, the above-mentioned ceiling finishing involves upward work, which is dangerous and it is not easy to improve the construction accuracy.

[0005] The present invention has been made in view of the above problems, and an object thereof is to improve a deck plate in order to improve safety and accuracy during construction, and further to provide a reasonable installation method for the improved deck plate.

Means for Solving the Problems

[0006] One embodiment of the present invention is a deck plate assembly comprising a deck plate and a decorative material provided on the lower surface of the deck plate having a unit width equal to the unit width of the deck plate, wherein the deck plate comprises a first fitting portion formed in a curved hook shape by bending the end of the deck plate and a second fitting portion formed in a hook shape that is curved in the opposite direction to the first fitting portion, wherein the first fitting portion is provided on one end of the deck plate in the short direction so as to retract into the end of the decorative material provided on the lower surface of the deck plate, and the second fitting portion is provided on the other end of the deck plate in the short direction so as to protrude into the end of the decorative material provided on the lower surface of the deck plate, wherein the first fitting portion and the second fitting portion are formed so that when two adjacent deck plate assemblies are fitted together, the lower surfaces of the decorative materials provided on each are substantially flush.

[0007] According to this, the decorative material clearly defines the unit width of the deck plate assembly in the short direction. As a result, the decorative material can also serve as an adjustment guide for the play that occurs between the first and second fitting parts that are fitted together in the short direction. Consequently, the effort required to carefully plan the construction of the deck plates to ensure the unit width is as designed is eliminated.

[0008] Furthermore, it is preferable that the end of the decorative material provided on the first fitting portion side extends in the shorter direction than the first fitting portion.

[0009] According to this, when concrete is poured onto a deck plate, leakage of concrete slurry from the gaps between decorative materials can be suppressed, improving the aesthetic appearance of the underside of the deck plate.

[0010] Furthermore, it is preferable that a joint for fitting together two contacting decorative materials is provided on the side surface of the end of the decorative material in the short direction.

[0011] This allows for a secure fit between deck plate assemblies, improving functionality in terms of construction and aesthetics, such as suppressing concrete slurry leakage and defining the overall shape of the laid deck plate assemblies, as well as contributing to further improvements in structural performance, fire resistance, and habitability.

[0012] Furthermore, the deck plate may be a deck plate formed from peaks and valleys extending in the longitudinal direction, a flat deck plate with ribs formed on the flat portion, or a reinforced deck plate with a reinforced truss attached.

[0013] Furthermore, if the deck plate is formed from peaks and valleys extending in the longitudinal direction, building equipment such as air conditioning equipment, fire extinguishing equipment, or wiring equipment, as well as electrical equipment, may be installed between the peaks of the deck plate and the decorative material.

[0014] A further embodiment of the present invention is a method for installing two adjacent deck plate assemblies, comprising the steps of: placing the end of the decorative material on the second fitting side of one deck plate assembly on the end of the decorative material on the first fitting side of the other deck plate assembly; tilting the end of the decorative material on the second fitting side around its lower corner until the side surface of the end contacts the first fitting; shifting the lower corner of the end of the decorative material on the second fitting side to the edge of the end of the decorative material on the first fitting side; and pivoting the one deck plate assembly downward relative to the other deck plate assembly while the first fitting and the second fitting are in contact.

[0015] According to this method, ceiling finishing work, which involves dangerous upward work, can be omitted by combining it with deck plate installation, and the deck plate assembly will not fall, allowing for precise installation work. [Effects of the Invention]

[0016] According to the present invention, the deck plate assembly can be laid and the ceiling finished simultaneously in a safe and efficient manner, thereby improving the precision of the installation work. [Brief explanation of the drawing]

[0017] [Figure 1] This is a perspective view showing a deck plate assembly with a single unit width. [Figure 2] This is a cross-sectional view of a deck plate assembly with a ceiling finish. [Figure 3] Figures (a) to (d) show the installation method of the deck plate assembly. [Figure 4] This is a cross-sectional view of the two fitted deck plate assemblies in the short direction. [Figure 5] This is a cross-sectional view in the short direction of a fitted assembly of two deck plates according to another embodiment. [Modes for carrying out the invention]

[0018] Several embodiments of the present invention will be described below with reference to the drawings. It should be noted that the drawings are schematic, and the dimensional relationships and ratios of the elements may differ from reality. Even between drawings, there may be differences in dimensional relationships and ratios.

[0019] FIG. 1 is a perspective view of a deck plate assembly 1 according to an embodiment of the present invention. The deck plate assembly 1 includes a deck plate 10 and a decorative material 20. The deck plate 10 is a corrugated steel plate formed by roll-forming a thin steel plate having a surface treatment such as zinc plating. Note that the deck plate 10 may not be subjected to a surface treatment such as plating. The deck plate 10 has a structure in which a plurality of ridges 11 and valleys 13 extending in the longitudinal direction L are alternately formed, and adjacent ridges 11 and valleys 13 are connected by inclined portions 15, whereby the ridges 11 and valleys 13 form a continuous corrugated shape in the short direction W. As shown in FIG. 2, the ridge 11 is a flat portion located above the upper surfaces of the support beams B1 and B2 in a state where the deck plate assembly 1 is bridged between the support beam B1 and another adjacent support beam B2 (hereinafter, also referred to as a "bridged state"), and is a plate-like portion extending in the longitudinal direction L. The valley 13 is parallel or substantially parallel to the ridge 11 and is a flat portion. In the bridged state, the valleys 13 of the deck plate 10 disposed on the outermost side in the short direction W and contacting the support beams B1 and B2 are placed on the support beams B1 and B2, respectively. The inclined portion 15 is a portion connecting the ridge 11 and the valley 13 and is a plate-like portion extending in the longitudinal direction L. The inclined portion 15 extends obliquely from the side edge of the ridge 11 toward the side edge of the valley 13 in the short direction W.

[0020] The deck plate 10 has, for example, two peaks 11, one valley 13, and two pairs of inclined portions 15 in a unit width X in the short direction W, and is formed in a corrugated shape in cross-section along the short direction W. Depending on the dimensions of the deck plate assembly 1 in the short direction W, one or more peaks 11 may be provided on a deck plate 10 of a unit width X. In addition, at least a portion of the valley 13 is provided at both ends of the deck plate 10 in the short direction W, and when the deck plate assembly 1 is connected to another deck plate assembly 1 in the short direction W, the connection portion between the deck plate assemblies 1 functions as a valley 13. Furthermore, the deck plate assembly 1 may be end-closed (hereinafter also referred to as "enclosure processing") at both ends in the longitudinal direction L.

[0021] On the lower surface side of the deck plate 10, a decorative material 20 is provided. For example, by fastening the decorative material 20 to the deck plate 10 at a pitch of 300 to 600 mm in the short direction and 300 to 1500 mm in the length direction, the deck plate 10 and the decorative material 20 are stably fixed. The decorative material 20 is, for example, a wooden board formed in a plate shape and is fixed to the lower surface side of the trough portion 13 using screws or the like. When the decorative material 20 is a wooden board, it may be not only sawn timber but also a so-called engineered wood such as laminated wood, LVL, etc. obtained by improving strength or fire resistance / flame retardant performance, or both, by adding a woody material, for example, a chemical treatment or a resin, or may be one with improved resistance to mold and decay fungi. When the decorative material 20 is formed from wood, consideration for the environment such as the CO2 stock effect and improvement of the living environment such as moisture absorption and sound absorption can be achieved at the same time. Also, regarding the attachment of the decorative material 20 to the deck plate 10, it is not limited to screws, and it may be attached by an adhesive or other means, and the attachment method is not limited. Also, the decorative material 20 is not limited to the case where it is attached so as to directly contact the lower surface of the trough portion 13 of the deck plate 10, and the decorative material 20 may be attached at a distance from the lower surface of the trough portion 13 of the deck plate 10 via members such as pipes and steel materials. That is, the deck plate assembly 1 only needs to have the decorative material 20 directly or indirectly attached to the lower surface side of the deck plate 10 by some means. The decorative material 20 may be a design finishing material that covers the lower surface of the deck plate assembly 1 exposed to the lower floor from between the support beams B1 and B2 and improves the appearance when the deck plate assembly 1 is placed on the support beam B.

[0022] The deck plate 10 is further formed with a first fitting portion 21, which is a curved hook shape formed by bending the end of the valley portion 13, and a second fitting portion 22, which is a hook shape formed in the opposite direction to the first fitting portion 21. The first fitting portion 21 is provided on one end of the deck plate 10 in the short direction W, so as to retract into the end of the decorative material 20 provided on the lower surface of the deck plate 10, and the second fitting portion 22 is provided on the other end of the deck plate 10 in the short direction W, so as to protrude into the end of the decorative material 20 provided on the lower surface of the deck plate 10. Therefore, the end of the decorative material 20 provided on the side of the first fitting portion 21 extends in the short direction more than the first fitting portion 21. The first fitting portion 21 and the second fitting portion 22 are formed so that when two deck plate assemblies 1 are fitted together, as will be described later, the lower surfaces of the respective decorative materials 20 are substantially flush. The first fitting portion 21 is provided on one end of the deck plate 10 in the short direction W, so as to protrude from the end of the decorative material 20 provided on the lower surface of the deck plate 10, and the second fitting portion 22 may be provided on the other end of the deck plate 10 in the short direction W, so as to retract from the end of the decorative material 20 provided on the lower surface of the deck plate 10, or the end of the deck plate 10 and the end of the decorative material 20 may be on the same plane in the height direction.

[0023] In one advantageous embodiment, a decorative material 20 with a unit width equal to the unit width X of the deck plate 10 is pre-assembled to the underside of the deck plate 10 at a factory or the like. When a deck plate assembly 1 with such a configuration is installed at a construction site, the decorative material 20 also serves as an adjustment guide for the play that inherently occurs between the first fitting part 21 and the second fitting part that are fitted together in the short-side direction W. This eliminates the need to carefully plan the construction of the deck plate assembly 1 to ensure the unit width is as designed. Therefore, efficient and precise work becomes possible when working upwards during ceiling finishing work. Furthermore, the decorative material 20 can be fitted with appropriate dimensions between the support beams B1 and B2 in the short-side direction W on which the deck plate 10 rests.

[0024] Furthermore, although not shown in the diagram, in order to further strengthen the connection between the decorative materials 20, joints such as connections for fitting two contacting decorative materials 20 can be provided on the side surface of the end of the decorative material 20 in the short direction W.

[0025] As in this embodiment, if the deck plate 10 is a deck formed from ridges 11 and valleys 13 extending in the longitudinal direction, any equipment such as air conditioning equipment, fire extinguishing equipment, or wiring equipment may be installed in the space formed between the ridges 11 of the deck plate 10 and the decorative material 20. In this way, by housing equipment that was conventionally often exposed on the lower surface of the deck plate assembly 1 within the deck plate assembly 1, the overall aesthetic appearance of the deck plate assembly 1 is improved, and the ceiling space can be used efficiently.

[0026] According to another embodiment, the deck plate 10 is not limited to a deck plate formed from the ridges 11 and valleys 13 described above, but may also be a flat deck plate with ribs formed on a flat board, or a reinforced deck plate with a reinforced truss attached.

[0027] Figures 3(a) to 3(d) show the construction method for laying the two deck plate assemblies 1A and 1B according to this embodiment. As shown in Figure 2, for the first deck plate assembly 1 (the leftmost deck plate 10 in Figure 2) 20', it is preferable to shorten the width of the decorative material 20 by 50 mm so that, for example, 50 mm of the width of the deck plate rests on the support beam B1. With one end of the first deck plate assembly 1A supported by the support beam B1, as shown in Figure 3(a), the end 23B of the decorative material 20B in the second deck plate assembly 1B on the side of the second fitting portion 22B is placed on the end 23A of the decorative material 20A in the first deck plate assembly 1A on the side of the first fitting portion 21A. Next, as shown in Figure 3(b), the end portion 23B of the decorative material 20B of the second deck plate assembly 1B is tilted around its lower corner 25B until the side surface of the end portion 23B contacts the first fitting portion 21A of the first deck plate 10A. The angle of this tilt can be appropriately set according to the shape and position of the fitting portions 21A and 22B, the thickness of the decorative materials 20A and 20B, etc. With the second deck plate assembly 1B sufficiently tilted, as shown in Figure 3(c), the lower corner 25B of the end portion 23B of the decorative material 20B is slid to the edge 24A of the end portion 23A of the decorative material 20A of the first deck plate assembly 1A, until eventually the end portion 23B of the second deck plate assembly 1B detaches from the end portion 23A of the first deck plate assembly 1A, as shown in Figure 3(d). As a result, the first fitting portion 21A of the first deck plate 10A comes into contact with the second fitting portion 22B of the second deck plate 10B. Then, with the fitting portions in contact, the second deck plate assembly 1B is pivoted downward relative to the first deck plate assembly 1A, causing the first fitting portion 21A and the second fitting portion 22B to engage. In this way, the first deck plate assembly 1A and the second deck plate assembly 1B can be laid so that the undersides of the decorative materials 20A and 20B are flush. Finally, flashing 20'' is installed separately in places where the unit width of the deck plate assembly does not match the width of the ceiling (see Figure 2).

[0028] As described above, by applying the method according to this embodiment, the fitting portion can be used as a reference for installation, so that the deck plate laying work can be made more accurate and efficient than when the deck is laid alone, the deck plate assembly can be laid easily, and ceiling finishing work that involves working upwards can be omitted. In addition, by matching the unit width of the decorative material and the deck plate, even if there is play between the first fitting portion and the second fitting portion of adjacent deck plates, the play between adjacent decorative materials can be eliminated after the deck plate assembly is installed, thereby eliminating the need to adjust for construction errors and improving the finished appearance. Furthermore, when combining the second deck plate assembly 1B with the first deck plate assembly 1A, the decorative material 20A of the first deck plate assembly 1A can bear part of the weight of the second deck plate assembly 1B, thereby reducing the workload and preventing the second deck plate assembly 1B from unintentionally falling off. Thus, the work can be performed safely.

[0029] At a construction site, after laying the deck plate assembly 1, concrete can be poured onto the top surface of the deck plate assembly 1 and allowed to solidify integrally to form a deck composite slab.

[0030] In the first embodiment, when concrete is poured onto the top surface of the deck plate assemblies 1A and 1B after they have been laid, as shown in Figure 4, the concrete slurry C may seep through the gap between the first fitting part 21A and the second fitting part 22B and leak out from the joint between the two adjacent decorative materials 20A and 20B. This can significantly impair the aesthetic appearance of the decorative materials 20A and 20B, and consequently the entire underside of the deck plate assemblies 1A and 1B.

[0031] Therefore, in the improved embodiment, as shown in Figure 5, the decorative material 20A is fixed to the deck plate such that the end portion 23A of the decorative material 20A extends in the shorter direction by a distance D from the first fitting portion 21A. Alternatively, the end portion 23A may be retracted by a distance D from the first fitting portion 21A towards the 10A side. According to this embodiment, when the two deck plate assemblies 1A and 1B are fitted together, the position where the ends of the decorative materials 20A and 20B contact each other can be spaced apart by a distance D in the shorter direction W towards the second fitting portion 22B side, relative to the position where the first fitting portion 21A and the second fitting portion 22B are fitted together. In this case, even if the concrete slurry C were to slip through the gap between the first fitting portion 21A and the second fitting portion 22B, a gap D is provided between the decorative materials 20A and 20B, thus preventing the concrete slurry C from leaking out of the joints between the decorative materials 20. This improves the aesthetic appearance of the underside of the deck plate assemblies 1A and 1B. The gap D can be determined appropriately, taking into consideration the fluidity of the concrete slurry C, etc.

[0032] In this embodiment as well, it is possible to arrange the second deck plate assembly 1B adjacent to the first deck plate assembly 1A in the same order as shown in Figure 3.

[0033] In this embodiment, since the second fitting portion 22B protrudes significantly from the decorative material, it becomes unnecessary to shorten the width of the first decorative material 20' when laying the deck plate assembly, as shown in Figure 2. Therefore, the width of the decorative material 20 provided on all deck plate assemblies 1 can be standardized to the same dimension as the unit width X of the deck plate, which offers advantages in terms of manufacturing and on-site management.

[0034] In another advantageous embodiment, the rigidity of the decorative material 20 allows for the planned setting of camber and flatness of the lateral curvature cross-section for the deck plate 10, which is prone to deformation due to being made of thin steel plate. In other words, by appropriately selecting the rigidity and shape of the decorative material 20, the shape of the entire deck plate assembly 1 can be precisely designed and constructed. In other words, the properties of the decorative material 20 can be appropriately selected depending on how the shape of the deck plate assembly 1 is designed. Furthermore, by adding the rigidity and strength of the decorative material 20 to the deck plate 10, it becomes possible to omit costly measures that would have been necessary if the deck plate 10 alone had insufficient performance, such as increasing the plate thickness, raising the height, installing shoring, or increasing the amount of concrete. It also becomes possible to improve the living environment by improving sound insulation and vibration performance, moisture absorption and sound absorption performance, and normalizing the air.

[0035] For example, when concrete is poured onto the top surface of deck plate assembly 1, the weight of the concrete may cause the entire deck plate assembly 1 to curve downwards. Anticipating this, by deliberately and quantitatively applying camber, which is the curvature in the longitudinal direction of the deck plate, to the decorative material 20, the curvature caused by the weight of the concrete can be mitigated. Applying camber quantitatively can be achieved by devising the rigidity, dimensions, and joints of the decorative material 20. [Explanation of Symbols]

[0036] 1. Deck Plate Assembly 1A First Deck Plate Assembly 1B Second Deck Plate Assembly 10, 10A, 10B Deck Plates 11 Yamabe 13 Tanibe 15 Slope 20, 20A, 20B decorative materials 21, 21A First mating part 22, 22B Second mating section 23A, 23B End of decorative material 24A Edge of decorative material 25B Lower corner of the edge of the decorative material C Concrete slurry B1, B2 support beam D interval L Longitudinal direction W (short direction) X unit width

Claims

[Claim 1] A method for installing two adjacent deck plate assemblies, The deck plate assembly comprises a deck plate and a decorative material provided on the lower surface of the deck plate, having a unit width equal to the unit width of the deck plate. The deck plate comprises a first fitting portion formed in a hook shape by bending the deck plate and curving upwards, and a second fitting portion formed in a hook shape that is curved in the opposite direction to the first fitting portion. The first fitting portion is provided on one end of the deck plate in the short direction so as to retract into the end of the decorative material provided on the lower surface of the deck plate, and the second fitting portion is provided on the other end of the deck plate in the short direction so as to protrude into the end of the decorative material provided on the lower surface of the deck plate. The first and second fitting portions are formed such that when two adjacent deck plate assemblies are fitted together, the lower surfaces of the decorative materials provided on each are substantially flush. The step of placing the end of the decorative material on the second fitting side of one deck plate assembly on the end of the decorative material on the first fitting side of the other deck plate assembly, The step of tilting the end of the decorative material on the second fitting side, with the lower corner of the end as the axis, until the side surface of the end contacts the first fitting portion, The steps include shifting the lower corner of the end of the decorative material on the second fitting side to the edge of the end of the decorative material on the first fitting side, With the first fitting portion and the second fitting portion in contact, the first deck plate assembly is pivoted downward relative to the other deck plate assembly. A method characterized by including the following.

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