WO2007141380A1

WO2007141380A1 - Intermediate floor

Info

Publication number: WO2007141380A1
Application number: PCT/FI2007/050314
Authority: WO
Inventors: Marko Moisio
Original assignee: Rautaruukki Oyj
Priority date: 2006-06-02
Filing date: 2007-05-31
Publication date: 2007-12-13
Also published as: FI20065376L; FI20065376A0

Abstract

The invention relates to an intermediate floor comprising one or more composite plate structures, which together with concrete form a supporting slab-like intermediate floor. The composite plate structure in turn comprises an elongated profile plate (2) having a first and a second side edge (4, 6), a first and a second end, an upper surface (16) and a lower surface (18), and two or more longitudinal corrugations extending between the first and the second end and providing the upper surface with downward extending grooves (8) and the lower surface with upward extending grooves (10). The composite plate structure further comprises a composite plate (12) mounted to the upper surface (16) of the profile plate (2) and comprising one or more ridges (14) extending substantially in parallel with the corrugations.

Description

INTERMEDIATE FLOOR

BACKGROUND OF THE INVENTION

[0001] The invention relates to an intermediate floor according to the preamble of claim 1 and particularly to an intermediate floor comprising one or more composite plate structures that together with concrete form a supporting slab-like intermediate floor, the composite plate structure comprising an elongated profile plate having a first and a second side edge, a first and a second end, an upper surface and a lower surface, and two or more longitudinal corrugations extending between the first and the second end and providing the upper surface with downward extending grooves and the lower surface with upward extending grooves.

[0002] According to the prior art, intermediate floors often have cellular structures, in which concrete and steel plates together form a self- supporting slab-like composite structure. This type of composite structure generally comprises a profile plate and possibly one or more other plates attached to the profile plate, a plural number of such plates being often attached to one another on the width of the slab. The profile plates are corrugated, the corrugations thus providing the upper surface of the profile plate with grooves extending downward and the lower surface with grooves extending upward. The upper or lower surface of the profile plates may also be provided with additional plates, known as composite plates, which strengthen and support the profile plates. Further, the plate structure described above is provided with a concrete surface that forms the coating on the intermediate floor.

[0003] A problem with the prior art intermediate floor described above is that the stiffness and bearing properties of this type of composite structure are not always optimal in a desired direction. It is therefore not possible to obtain an intermediate floor with desired properties for example in the longitudinal direction of the profile plate corrugations and/or in a direction transverse thereto.

BRIEF DISCLOSURE OF THE INVENTION

[0004] It is therefore an object of the invention to provide an intermediate floor in which the above problems are solved. The object of the invention is achieved by an intermediate floor characterized in that the composite plate structure further comprises a composite plate mounted to the upper sur- face of the corrugated metal plate and comprising one or more ridges that extend substantially in parallel with the corrugations.

[0005] The preferred embodiments of the invention are disclosed in the dependent claims.

[0006] The invention is based on forming an intermediate floor comprising one or more profile plates adjacently attached to each other, the plates having a first and a second side edge, a first and a second end, an upper surface and a lower surface, and two or more longitudinal corrugations extending between the first and the second end and providing the upper surface with downward extending grooves and the lower surface with upward extending grooves. The upper surface of at least one of these profile plates is provided with a composite plate mounted or fastened thereto and preferably extending substantially across the entire width and length of the upper surface. This composite plate further comprises ridges extending in parallel with the corrugations of the profile plate. The ridges are preferably aligned so that they extend upward at the base of the upward extending corrugations of the profile plate. The composite plate may comprise one or more ridges, a plural number of ridges may be provided at upward extending corrugations. Ridges may also be provided at downward extending corrugations. Moreover, the dimensions of the ridges and their cross-sectional shape may be selected to be suitable for each particular application.

[0007] An advantage of the method and system of the invention is that compared with the prior art, composite plate ridges extending parallel with the corrugations of the profile plate increase the rigidity of the cellular structure in the direction of the profile plate corrugations. In addition, the cross-section of the ridges in the composite plate may be formed such that a good adhesion to the surface concrete to be applied onto the profile plate is achieved.

BRIEF DISCLOSURE OF THE FIGURES

[0008] In the following the invention will be described in greater detail with reference to the preferred embodiments and the accompanying drawing, in which

Figure 1 is a schematic view of an embodiment of the invention.

DETAILED DISCLOSURE OF THE INVENTION

[0009] Figure 1 shows a cross-sectional view of an embodiment of an intermediate floor of the invention. According to Figure 1 , the intermediate floor comprises a profile plate 2, which in turn comprises a first and a second side edge 4, 6, a first and a second end, an upper surface 16 and a lower surface 18, and two or more longitudinal corrugations extending between the first and the second end and providing the upper surface 16 thereof with downward extending grooves 8 and the lower surface 18 thereof with upward extending grooves 10. One profile plate 2 of this type preferably comprises two or more corrugations or grooves 8, 10. In the embodiment of Figure 1 the profile plate 2 comprises two grooves 8 extending downward and three grooves 10 extending upward. The cross-sectional shape and dimensions of the grooves 8, 10, and thereby those of the profile plate 2, may vary as required by each particular application. In other words, the cross-sectional profile of the profile plate 2 may vary according to a particular application and/or purpose of use.

[0010] The intermediate floor may comprise two or more profile plates 2 adjacently attached to each other at the side edges 4, 6. In that case the side edges of adjacent profile plates 2 are made to overlap at least partly, and they may be fastened together mechanically, for example by means of bolts or screws, or by means of laser welding, for example. Their overlapping may be achieved for example as shown in Figure 1 , in which case the side edge of one profile plate extends underneath the other one and further upward for a portion into one of its upward extending grooves 10. In the case of Figure 1 the joint between the adjacent plates is arranged to the lower surface 18 of the profile plates 2, the adjacent profile plates 2 thus being arranged to form together a downward extending groove 26 at one joint. This downward extending groove 26 formed at one joint between adjacent profile plates may be at least partly filled with pre-concreting. This pre-concreting may comprise applying low-density concrete, or some other corresponding concreting operation. Alternatively, the groove 26 may be filled with surface concrete later, in connection with surface concreting. In Figure 1 the side edges 4 and 6 of the profile plate 2 are bent to produce a fold forming a bonding to enhance the attachment or locking of the profile plate 2 with the concrete of the groove 26. In addition to the fold, or instead of it, the side edge 4, 6 may have attached to it a gripping member, which may be any piece enhancing attachment to the concrete. Correspondingly, the side edge of an adjacent profile plate may comprise a fold 5 extending into an upward extending groove 10 of the profile plate 2, as shown in Figure 1. The pre-concrete applied into the groove 26, or any other similar concreting that fills the groove 26, may be provided with a post- tension strand 24 that may be tensioned after the concreting.

[0011] According to the invention, and as shown in Figure 1 , the upper surface 16 of the profile plate 2 is provided with a composite plate 12 attached thereto and preferably extending on the length and width of the profile plate. In this context the composite plate 12 refers to a plate comprising formulations, such as grooves, protrusions or depressions, enhancing its attachment to concrete. Such grooves, protrusions or depressions may be even several millimetres deep, whereby shearing forces in the composite structure thus produced are transferred by these patterns/shapes. The composite plate 12 may be attached to the profile plate 2 mechanically by means of bolts or screws, or by means of laser welding, for example, although other fastening means and methods may also be used. In addition, the side edges of the composite plate may extend for a portion of the surface of the profile plate 2 into the groove 26, in which case the composite plate 12 may be fastened to the profile plate 2 also at these side edges extending into the groove 26. The composite plate 12 is provided with ridges 14, which in this context refer to any wave-like or corrugated form. The ridges 14 protrude upward from the surface of the composite plate 12 and away from the profile plate 2, extending substantially in parallel with the corrugations of the profile plate 2, as shown in Figure 1. The composite plate 12 may have one or more ridges 14, and they may have any cross- sectional shape. For example, the ridges 14 may have the cross-sectional shape of a rectangular prism, semi-circle, curve, triangle or some other polygon or a part of a polygon. In Figure 1 the ridges 14 have an upward broadening trapedoizal shape.

[0012] The ridges 14 are preferably produced into the composite plate 12 at predetermined, regular intervals, although alternatively they may be at irregular intervals as well. In addition, the distance between the ridges 14 may be adjusted according to the profile plate used. In that case, as shown in Figure 1 , the composite plate 12 may comprise one or more ridges 14 at each upward extending groove 10. The bottoms of the upward extending grooves 10 in particular are arranged to form the upper surface 16 of the profile plate, in which case the ridge and/or ridges 14 in the composite plate 12 are arranged at the location of the bottoms of the upward extending grooves 10. However, it is to be noted that one or more ridges of the composite plate 12 may also be placed at downward extending grooves 8 and/or at the location of the bottom of the downward extending grooves 8, the bottom forming the lower surface 18 of the profile plate 2. Further, the composite plate 12 may comprise additional ridges extending transverse to the direction of the corrugations in the profile plate 2, for example between the ridges 14 parallel with the corrugations.

[0013] The profile plate 2 may also be provided with an under plate 20 attached to the lower surface 18 of the profile plate 2 mechanically by screws or bolts, or by means of laser welding, for example, or by some other suitable means. The under plate 20 may extend between the side edges 4, 6 of one profile plate 2 or, as shown in the alternative of Figure 1 , it may extend from one joint between adjacent profile plates 2 to the next joint. In that case the under plate 20 has an additional effect of attaching adjacent profile plates 2 together. The side edges of the under plate 20 of Figure 1 are provided with a fold 22 extending across the overlapping area formed at the joint between two adjacent profile plates 2 and possibly all the way into the bottom of the groove, as shown in Figure 1. In that case the lower plate 20 may be fastened also to this adjacent profile plate at a joint 23, which further enhances the composite effect of the structure. The attachment may be carried out mechanically or by welding, for example, in which case the joint between the under plate 20 and the profile plate 2 is on the upper surface 16 of the profile plate 2. The under plate 20 may also be provided with ridges similar to those in the composite plate 12, the ridges extending in parallel with the corrugations of the profile plate 2. In that case the ridges may be made to extend at the downward extending grooves 8, for example, similarly as the ridges 14. Alternatively, corrugations of the under plate 20 may extend perpendicularly and transversally to the corrugations of the profile plate 12, whereby they produce transverse rigidity in relation to the composite plate 12.

[0014] As described above, the profile plate 2 and the composite plate 12, possibly also the under plate 20, form a composite plate structure that together with concrete forms a supporting slab-like intermediate floor that may be further supported onto the beams of a building. The intermediate floor is thus produced by applying onto the composite plate structure a surface concrete which is preferably made hard. In the Figure, the broken line between the grooves 26 and the surface concrete 28 depicts the interface between a possible pre-concrete and the surface concrete. Naturally the pre-concreting may also be left out, in which case the surface concrete is applied also into the grooves 26. The ridges 14 in the composite plate 12 may be shaped to enable a good bonding with and locking to the surface concrete. Hence the trapezoidal ridges 14 of Figure 1 , for example, lock the composite plate 12 and thereby also the composite plate structure to the surface concrete 28. A preferred solution for the ridges 14 is the dovetail shape shown in Figure 1. In addition to this dovetail shape, the upper surface of the ridge 14 is preferably provided with patterns, such as recesses or protrusions, transverse to the longitudinal direction of the ridge. A ridge may be provided with a plural number of such transverse patterns one after the other in the longitudinal direction thereof. It is to be noted that such patterns on the upper surface of a ridge may also be produced, in a similar manner, onto the upper surface of ridges of some other shape.

[0015] As shown in Figure 1 , between the profile plate 2 and the composite plate 12 on one hand and the profile plate and the under plate 20 on the other hand empty spaces are left in the grooves 8 and 10. Such empty spaces may serve as installation spaces, for example, for electricity, ventilation, illumination installations, or the like. It is also to be noted that in specific applications the plates 2, 12 and 20 may have such a width that sufficiently broad plate is not available off the shelf. In that case the profile plate 2 and/or the composite plate 12 and/or the under plate 20 may be formed of two or more plates joined together. The joint may be produced by means of welding, for example.

[0016] A further aspect to be noted is that the intermediate floor of the invention may be produced as a precast structure comprising one or more composite plate structures as described above, with a composite plate mounted onto a profile plate. These elements are then placed side by side to form the intermediate floor.

[0017] It is apparent to a person skilled in the art that as technology advances the basic idea of the invention may be implemented in various ways. The invention and its embodiments are therefore not restricted to the above examples, but may vary within the scope of the claims.

Claims

1. An intermediate floor comprising one or more composite plate structures that together with concrete (28) form a supporting slab-like intermediate floor, the composite plate structure comprising an elongated profile plate (2) having a first and a second side edge (4, 6), a first and a second end, an upper surface (16) and a lower surface (18) and two or more longitudinal corrugations extending between the first and the second end and providing the upper surface with downward extending grooves (8) and the lower surface with upward extending grooves (10), characterized in that the composite plate structure further comprises a composite plate (12) mounted to the upper surface (6) of the profile plate (2) and comprising one or more ridges (14) extending substantially in parallel with the corrugations.

2. An intermediate floor according to claim 1, characterized in that the composite plate (12) comprises one or more ridges (14) at each upward extending groove (10).

3. An intermediate floor according to claim 1 or 2, characterized in that the bottoms of the upward extending grooves (10) are arranged to form the upper surface (16) of the profile plate (2), the ridge and/or ridges (14) of the composite plate (12) being produced at the bottoms of the upward extending grooves (10).

4. An intermediate floor according to any one of claims 1 to 3, characterized in that the ridges (14) protrude upwards from the surface of the composite plate (12).

5. An intermediate floor according to any one of claims 1 to 4, characterized in that the ridges (14) have a cross-sectional shape of a trapezoid.

6. An intermediate floor according to any one of claims 1 to 4, characterized in that the grooves (14) have a cross-sectional shape of a rectangular prism, semi-circle, curve, triangle or some other polygon or a part of a polygon.

7. An intermediate floor according to any one of claims 1 to 6, characterized in that the composite plate structure further comprises an under plate (20) mounted to the under surface of the profile plate (2).

8. An intermediate floor according to claim 7, characterized in that the under plate (20) comprises one or more corrugations extending substantially in parallel with the waves.

9. An intermediate floor according to any one of claims 1 to 6, characterized in that the intermediate floor comprises two or more profile plates (2) attached to each other at their side edges (4, 6).

10. An intermediate floor according to claim 9, characterized in that at least some of the profile plates (2) comprise a composite plate (12) and/or an under plate (20).

11. An intermediate floor according to claim 9 or 10, characterize d in that the joint between adjacent profile plates (2) is arranged to the lower surface (18) of the profile plates (2), whereby adjacent profile plates (2) are arranged to form together a downward extending groove (26) at the joint.

12. An intermediate floor according to claim 11, characterized in that the downward extending groove (26) formed at one joint between two adjacent profile plates (2) is at least partly filled by pre-concreting.

13. An intermediate floor according to claim 12, characterized in that the pre-concreting contains a post-tension strand (24) that may be tensioned after the concreting.

14. An intermediate floor according to claim 12 or 13, characterized in that the first and/or the second side edge (4, 6) of the profile plate (2) comprises a fold for locking the profile plate to the applied pre- concrete.

15. An intermediate floor according to any one of claims 1 to 14, characterized in that the intermediate floor further comprises a surface concrete (28) onto the profile plate (2) and/or the composite plate (12).

16. An intermediate floor according to any one of claims 1 to 14, characterized in that the side edge of the under plate (20) of the profile plate (2) extends into the bottom of the upward extending groove of an adjacent profile plate and to the upper surface of this profile plate, where it is attached to an adjacent profile plate at a joint (23).

17. An intermediate floor according to any one of claims 1 to 16, characterized in that the profile plate (2) and/or the composite plate (12) and/or the under plate (20) are formed of two or more parts welded together,

18. An intermediate floor according to any one of claims 1 to 16, characterized in that the composite plate structures are formed as multielement structures.