Deck plate assembly and installation method for same

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

Deck plate assembly and installation method thereof

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

[0002] Deck plates are known as a rational material for the underlayment of externally insulated dry roof construction methods that do not require concrete pouring, as they can be weighed down and shorten construction time. Furthermore, composite deck slabs, which are formed by integrating deck plates with concrete, are widely used as a standard floor material for steel-framed buildings due to their ease of construction and cost (see, for example, Patent Document 1). Composite deck slabs and roof underlayment deck plates often require ceiling finishing.

[0003] Japanese Patent Application Laid-Open No. 2020-41348

[0004] At construction sites, ceiling finishing as described above is dangerous because it involves working overhead, and it is not easy to improve the accuracy of the work.

[0005] The present invention has been made in consideration of the above-mentioned problems, and aims to improve deck plates to improve safety and accuracy during construction, and to provide a rational installation method for the improved deck plates.

[0006] One embodiment of 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 equal to the unit width of the deck plate, wherein the deck plate comprises a first fitting portion formed by bending an end of the deck plate into a curved hook shape, and a second fitting portion formed in a hook shape that is curved upside down from the first fitting portion, the first fitting portion being provided on one of the ends of the deck plate in the short direction so as to be recessed relative to the end of the decorative material provided on the underside of the deck plate, and the second fitting portion being provided on the other end of the deck plate in the short direction so as to protrude relative to the end of the decorative material provided on the underside of the deck plate, and the first fitting portion and the second fitting portion are formed so that when two adjacent deck plate assemblies are fitted together, the undersides of the decorative materials provided on each are approximately flush.

[0007] As a result, the decorative material clearly defines the unit width of the deck plate assembly in the short direction, and the decorative material can also serve as an adjustment guide for the play that occurs between the first and second mating portions that are mated in the short direction.As a result, it is not necessary to carefully plan the construction of the deck plate to ensure the unit width is as designed.

[0008] It is also preferable that the end of the decorative material provided on the first fitting portion side extends beyond the first fitting portion in the lateral direction.

[0009] This makes it possible to prevent concrete slag from leaking from gaps between the decorative materials when concrete is poured onto the deck plate, improving the aesthetic appearance of the underside of the deck plate.

[0010] It is also preferable that a joint for fitting two contacting decorative materials together be provided on the side surface of the end portion in the lateral direction of the decorative material.

[0011] This allows for a strong fit between deck plate assemblies, which improves construction and aesthetic functionality by preventing concrete sludge leakage and defining the overall shape of the laid deck plate assembly, and contributes to further improvements in structural performance, fire resistance, and livability.

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

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

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

[0015] This makes it possible to eliminate ceiling finishing work, which involves dangerous upward work, by combining it with deck plate installation, and also prevents the deck plate assembly from falling, allowing for precise installation work.

[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 accuracy of the installation work.

[0017] Fig. 1 is a perspective view showing a deck plate assembly with a unit width; Fig. 2 is a cross-sectional view of a deck plate assembly with a ceiling finish; (a) to (d) are views showing a method of installing the deck plate assembly; Fig. 2 is a cross-sectional view in the short side direction of two mated deck plate assemblies; Fig. 3 is a cross-sectional view in the short side direction of two mated deck plate assemblies according to another embodiment;

[0018] Hereinafter, several embodiments of the present invention will be described with reference to the drawings. Note that in the following description, the drawings are schematic, and the dimensional relationships and ratios of the elements may differ from the actual ones. The dimensional relationships and ratios may differ between the drawings.

[0019] FIG. 1 is a perspective view of a deck plate assembly 1 according to one 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, for example, roll-forming a thin steel plate that has been subjected to a surface treatment such as zinc plating. The deck plate 10 does not necessarily have to be subjected to a surface treatment such as plating. The deck plate 10 has a plurality of alternating peaks 11 and valleys 13 extending in the longitudinal direction L, and adjacent peaks 11 and valleys 13 are connected by inclined portions 15, thereby forming a continuous wave shape in the transverse direction W. As shown in FIG. 2 , when the deck plate assembly 1 is bridged between a support beam B1 and another adjacent support beam B2 (hereinafter also referred to as the "bridged state"), the peaks 11 are flat, plate-like portions located above the top surfaces of the support beams B1 and B2 and extending in the longitudinal direction L. The valley portions 13 are parallel or approximately parallel to the peak portions 11 and are formed flat. In the spanning state, the valley portions 13 of the deck plate 10 arranged outermost in the short direction W, which contacts the support beams B1, B2, are placed on each of the support beams B1, B2. The inclined portions 15 are portions that connect the peak portions 11 and the valley portions 13 and are plate-shaped portions that extend in the longitudinal direction L. The inclined portions 15 extend obliquely from the side edges of the peak portions 11 toward the side edges of the valley portions 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 per unit width X in the short-side direction W, and is formed in a wave-like shape in a cross section along the short-side direction W. Note that, depending on the dimension of the deck plate assembly 1 in the short-side direction W, one or three or more peaks 11 may be provided on the deck plate 10 of one unit width X. Furthermore, at least a portion of the valleys 13 is provided at both ends of the deck plate 10 in the short-side direction W, and when the deck plate assembly 1 is connected to other deck plate assemblies 1 in the short-side direction W, the connection portions between the deck plate assemblies 1 function as the valleys 13. Furthermore, the deck plate assembly 1 may be end-closed (hereinafter also referred to as "enclosing") at both ends in the longitudinal direction L.

[0021] A decorative material 20 is provided on the underside of the deck plate 10. For example, the decorative material 20 is fastened to the deck plate 10 at intervals of 300 to 600 mm in the short direction and at intervals of 300 to 1500 mm in the long direction, thereby stably fixing the deck plate 10 and the decorative material 20. The decorative material 20 is, for example, a wooden board formed into a board shape, and is fixed to the underside of the valley portion 13 using screws or the like. When the decorative material 20 is a wooden board, it may be not only sawn lumber, but also wood materials such as laminated lumber or engineered wood such as LVL, which has been treated with chemicals or added with resin to improve strength, fire resistance / flame retardancy, or both, or may be wood that has improved resistance to mold and decay fungi. When the decorative material 20 is made of wood, ２This also contributes to environmental considerations, such as stock savings, and to improving the living environment by absorbing moisture and sound. The decorative material 20 can be attached to the deck plate 10 by any method, including adhesives and other means, and is not limited to screws. The decorative material 20 does not necessarily have to be attached so as to be in direct contact with the underside of the valley portion 13 of the deck plate 10; it may be attached at a distance from the underside of the valley portion 13 of the deck plate 10 via a member such as a pipe or steel material. In other words, the decorative material 20 of the deck plate assembly 1 may be attached directly or indirectly to the underside of the deck plate 10 by any means. The decorative material 20 may be a decorative finishing material that covers the underside of the deck plate assembly 1 exposed to the floor directly below between the support beams B1 and B2 when the deck plate assembly 1 is placed on the support beams B, improving its appearance.

[0022] The deck plate 10 further includes a first fitting portion 21 formed by bending the end of the valley portion 13 to form a curved, hook-like shape, and a second fitting portion 22 formed by bending the end of the valley portion 13 upside down relative to the first fitting portion 21. The first fitting portion 21 is provided at one end of the deck plate 10 in the short direction W so as to be recessed relative to the end of the decorative material 20 provided on the underside of the deck plate 10, and the second fitting portion 22 is provided at the other end of the deck plate 10 in the short direction W so as to protrude relative to the end of the decorative material 20 provided on the underside of the deck plate 10. Therefore, the end of the decorative material 20 provided on the first fitting portion 21 side extends further in the short direction than the first fitting portion 21. The first fitting portion 21 and the second fitting portion 22 are formed so that the undersides of the respective decorative materials 20 are substantially flush when two deck plate assemblies 1 are fitted together, as described below. The first fitting portion 21 is provided at one of the ends of the deck plate 10 in the short direction W so as to protrude relative to the end of the decorative material 20 provided on the underside of the deck plate 10, and the second fitting portion 22 may be provided at the other end of the deck plate 10 in the short direction W so as to retract relative to the end of the decorative material 20 provided on the underside 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] According to one advantageous embodiment, a decorative member 20 having 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 the deck plate assembly 1 having this configuration is installed at a construction site, the decorative member 20 also serves as an adjustment guide for the inherent play between the first and second mating portions 21 and 22 in the transverse direction W, eliminating the need to carefully plan the construction of the deck plate assembly 1 to ensure the unit width is consistent with the design. This allows for efficient and precise work during overhead ceiling finishing work. Furthermore, the decorative member 20 can be appropriately positioned between the support beams B1 and B2 in the transverse direction W on which the deck plate 10 rests.

[0024] In addition, although not shown in the figure, in order to further strengthen the connection between the decorative materials 20, a joint such as a joint for fitting two contacting decorative materials 20 together can be provided on the side of the end portion in the short direction W of the decorative material 20.

[0025] In the case where the deck plate 10 is a deck formed of peaks 11 and valleys 13 extending in the longitudinal direction, as in this embodiment, any equipment such as air conditioning equipment, fire extinguishing equipment, or wiring equipment may be provided in the space formed between the peaks 11 and the decorative material 20 of the deck plate 10. In this way, by storing equipment that was conventionally often exposed on the underside of the deck plate assembly 1 inside the deck plate assembly 1, the aesthetic appearance of the entire deck plate assembly 1 is improved and the space in the ceiling can be used more efficiently.

[0026] According to another embodiment, the deck plate 10 is not limited to a deck plate formed from the peaks 11 and valleys 13 as described above, but may also be a flat deck plate in which ribs are formed on a flat plate, or a reinforced deck plate to which a reinforcing bar truss is attached.

[0027] 3(a) to 3(d) are diagrams illustrating a construction method for laying two deck plate assemblies 1A and 1B according to this embodiment. As shown in FIG. 2, for the first deck plate assembly 1 (the leftmost deck plate 10 in FIG. 2), the width of the decorative material 20 is preferably shortened by 50 mm so that, for example, a 50 mm width of the deck plate can be placed on the support beam B1. With one end of the first deck plate assembly 1A supported by the support beam B1, the end 23B of the decorative material 20B of the second deck plate assembly 1B, which is located on the second mating portion 22B side, is placed on the end 23A of the decorative material 20A of the first deck plate assembly 1A, which is located on the first mating portion 21A side, as shown in FIG. 3(a). Next, as shown in FIG. 3( b), the end 23B of the decorative material 20B of the second deck plate assembly 1B is tilted around a lower corner 25B of the end 23B until the side of the end 23B contacts the first mating portion 21A of the first deck plate 10A. The angle of tilt can be set appropriately depending on the shape and position of the mating portions 21A, 22B, the thickness of the decorative materials 20A, 20B, etc. With the second deck plate assembly 1B sufficiently tilted, as shown in FIG. 3( c), the lower corner 25B of the end 23B of the decorative material 20B is shifted to the edge 24A of the end 23A of the decorative material 20A of the first deck plate assembly 1A. Eventually, as shown in FIG. 3( d), the end 23B of the second deck plate assembly 1B disengages from the end 23A of the first deck plate assembly 1A. This brings the first mating portion 21A of the first deck plate 10A into contact with the second mating portion 22B of the second deck plate 10B. Then, with the mating portions in contact, the second deck plate assembly 1B is pivoted downward relative to the first deck plate assembly 1A, thereby mating the first mating portion 21A with the second mating portion 22B. This allows the first deck plate assembly 1A and the second deck plate assembly 1B to be laid so that the undersides of the decorative materials 20A, 20B are flush with each other. Finally, flashing 20'' is separately installed in areas 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 portions can be used as installation references, making deck plate installation more accurate and efficient than with a single deck. This allows for easier installation of deck plate assemblies and eliminates the need for overhead work. Furthermore, by matching the unit width of the decorative material and the deck plate, even if there is play between the first and second fitting portions of adjacent deck plates, the play between the adjacent decorative materials can be eliminated after the deck plate assembly is installed. This eliminates the need for error adjustment during installation and improves the aesthetic appearance of the finished product. Furthermore, when assembling the second deck plate assembly 1B to the first deck plate assembly 1A, the second deck plate assembly 1B can be placed on the decorative material 20A of the first deck plate assembly 1A to support part of its weight, thereby reducing the workload and preventing unintended detachment of the second deck plate assembly 1B. This allows for safe installation.

[0029] At the construction site, after the deck plate assembly 1 is laid, concrete is poured onto the top surface of the deck plate assembly 1 and the concrete is allowed to solidify integrally, thereby forming a deck composite slab.

[0030] In the first embodiment, when concrete is poured onto the upper surfaces of the deck plate assemblies 1A, 1B after the deck plate assemblies 1A, 1B are laid, concrete slag C may slip through the gap between the first fitting portion 21A and the second fitting portion 22B and leak out from the joint between the two adjacent decorative materials 20A, 20B, as shown in Figure 4. This may significantly impair the aesthetic appearance of the decorative materials 20A, 20B, and ultimately the entire underside of the deck plate assemblies 1A, 1B.

[0031] Therefore, in an improved embodiment, as shown in Figure 5, the decorative material 20A is fixed to the deck plate so that the end 23A of the decorative material 20A extends a distance D in the short direction beyond the first mating portion 21A. Alternatively, the end 23A may be recessed, for example, by the distance D toward the 10A side beyond the first mating portion 21A. According to this embodiment, when the two deck plate assemblies 1A, 1B are mated, the position at which the ends of the decorative materials 20A, 20B contact each other can be separated by the distance D toward the second mating portion 22B in the short direction W from the position at which the first mating portion 21A and the second mating portion 22B are mated. In this case, even if concrete slag C slips through the gap between the first fitting portion 21A and the second fitting portion 22B, the gap D is provided up to the position where the decorative materials 20A, 20B contact each other, preventing the concrete slag C from leaking out of the joints between the decorative materials 20. This improves the aesthetic appearance of the undersides of the deck plate assemblies 1A, 1B. The gap D may be determined appropriately taking into consideration the fluidity of the concrete slag C, etc.

[0032] In this embodiment, the second deck plate assembly 1B can also be arranged adjacent to the first deck plate assembly 1A in the same order as shown in FIG.

[0033] In this embodiment, because the second fitting portion 22B protrudes significantly from the decorative material, there is no need to shorten the width of the first decorative material 20' of the deck plate assembly installation, as shown in Figure 2. Therefore, the width of the decorative material 20 provided on all deck plate assemblies 1 can be unified to the same dimension as the unit width X of the deck plate, which is advantageous in terms of manufacturing and on-site management.

[0034] According to another advantageous embodiment, the rigidity of the decorative material 20 allows the camber and flatness of the cross section of the horizontal bending to be planned for the deck plate 10, which is prone to deformation due to being made of thin steel. That is, by appropriately selecting the rigidity and shape of the decorative material 20, the overall shape of the 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, costly measures that would otherwise be required to increase the plate thickness, height, install shoring, or increase the amount of concrete due to insufficient performance of the deck plate 10 alone can be omitted. Furthermore, it is also possible to improve the living environment by improving sound and vibration insulation, moisture and sound absorption, and normalizing the air quality.

[0035] For example, when concrete is poured onto the top surface of the deck plate assembly 1, the weight of the concrete can cause the entire deck plate assembly 1 to bend downward. In anticipation of this, the decorative material 20 can be given a quantitative camber, which is a warp in the longitudinal direction of the deck plate, to mitigate the curvature caused by the weight of the concrete. Quantitative camber can be achieved by adjusting the rigidity, dimensions, and joints of the decorative material 20.

[0036] REFERENCE SIGNS LIST 1 Deck plate assembly 1A First deck plate assembly 1B Second deck plate assembly 10, 10A, 10B Deck plate 11 Peak portion 13 Valley portion 15 Inclined portion 20, 20A, 20B Decorative material 21, 21A First fitting portion 22, 22B Second fitting portion 23A, 23B End of decorative material 24A Edge of end of decorative material 25B Lower corner of end of decorative material C Concrete sludge B1, B2 Support beam D Spacing L Longitudinal direction W Shortitudinal direction X Unit width

Claims

1. A deck plate assembly comprising a deck plate and a decorative material provided on the lower surface of the deck plate and having a unit width equal to the unit width of the deck plate, wherein the deck plate includes a first fitting portion formed in a hook shape in which the deck plate is bent and warped upward, and a second fitting portion formed in a hook shape that is warped in the opposite direction to the first fitting portion; the first fitting portion is provided at one end of the deck plate in the short side direction so as to be retracted with respect to the end of the decorative material provided on the lower surface of the deck plate, and the second fitting portion is provided at the other end of the deck plate in the short side direction so as to protrude with respect to the end of the decorative material provided on the lower surface of the deck plate; and the first fitting portion and the second fitting portion are formed such that when two adjacent deck plate assemblies are fitted, the lower surfaces of the decorative materials provided thereon are substantially flush.

2. A deck plate assembly comprising a deck plate and a decorative material provided on the lower surface of the deck plate and having a unit width equal to the unit width of the deck plate, wherein the deck plate includes a first fitting portion formed in a hook shape in which the deck plate is bent and warped upward, and a second fitting portion formed in a hook shape that is warped in the opposite direction to the first fitting portion; the first fitting portion is provided at one end of the deck plate in the short side direction so as to protrude with respect to the end of the decorative material provided on the lower surface of the deck plate, and the second fitting portion is provided at the other end of the deck plate in the short side direction so as to be retracted with respect to the end of the decorative material provided on the lower surface of the deck plate; and the first fitting portion and the second fitting portion are formed such that when two adjacent deck plate assemblies are fitted, the lower surfaces of the decorative materials provided thereon are substantially flush.

3. A deck plate assembly comprising a deck plate and a decorative material provided on the lower surface of the deck plate and having a unit width equal to the unit width of the deck plate, wherein the deck plate includes a first fitting portion formed in a hook shape in which the deck plate is bent and warped upward, and a second fitting portion formed in a hook shape that is warped 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 on the same plane in the height direction as the end of the decorative material provided on the lower surface of the deck plate. The second fitting portion is provided on the other end of the deck plate in the short direction on the same plane in the height direction as the end of the decorative material provided on the lower surface of the deck plate. The first fitting portion and the second fitting portion are formed such that when two adjacent deck plate assemblies are fitted, the lower surfaces of the decorative materials provided on each of them are substantially flush. Deck plate assembly.

4. The deck plate assembly according to claim 1, wherein the end of the decorative material on the side of the first fitting portion extends in the short direction beyond the first fitting portion.

5. The deck plate assembly according to claim 2, wherein the end of the decorative material on the side of the second fitting portion extends in the short direction beyond the second fitting portion.

6. The deck plate assembly according to claim 1, wherein a joint for fitting two adjacent decorative materials is provided on the side surface of the end of the decorative material in the short direction.

7. The deck plate assembly according to claim 1, wherein the deck plate is a deck plate formed from ridges and valleys extending in the longitudinal direction, a flat deck plate having ribs formed on a flat plate portion, or a reinforced deck plate with a reinforcing bar attached.

8. When the deck plate is a deck plate formed from ridges and valleys extending in the longitudinal direction, building equipment or electrical equipment such as air conditioning equipment, fire fighting equipment, or wiring equipment is provided between the ridges of the deck plate and the decorative material. The deck plate assembly according to claim 7, characterized in that.

9. A method of installing two adjacent deck plate assemblies according to any one of claims 1, 4, 6 to 8, comprising: placing an end portion of the decorative material on the second fitting portion side of one deck plate assembly on an end portion of the decorative material on the first fitting portion side of the other deck plate assembly; tilting the end portion of the decorative material on the second fitting portion side about a lower corner of the end portion until a side surface of the end portion contacts the first fitting portion; shifting a lower corner of the end portion of the decorative material on the second fitting portion side to an edge of the end portion of the decorative material on the first fitting portion side; and pivoting the one deck plate assembly downward with respect to the other deck plate assembly with the first fitting portion and the second fitting portion in contact with each other.

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