DEMOUNTABLE MODULAR DECK

Abstract: The present invention provides a modular metal frame car park (9) formed from a plurality of interlocking adjacent rectangular deck sheets (2) which are supported in an elevated position by a lattice framework (7). The lattice framework (7) is formed from a plurality of interconnected vertical pillars (3) and horizontal beams (8). The horizontal beams (8) have an I-shaped cross section. The deck sheets (2) have an upper load bearing surface and a lower support surface, adjacent ends of the sheets being placed on the horizontal beams (8). The car park (9) also includes an exit ramp (6), an entry ramp (4) and stairs for pedestrian access.

Description: DEMOUNTABLE MODULAR DECK This invention relates to a demountable modular deck. The term demountable modular deck used herein includes any demountable load bearing platform, including a demountable deck for a modular metal frame car park, a modular metal frame jetty, a modular exhibition platform, a modular stage and a boat deck, for example. Demountable modular decks are well known in the field of modular metal frame car parks. Modular metal frame car parks are particularly suitable for providing raised temporary car parking spaces and for increasing the capacity of existing ground level parking sites, quickly and at low capital cost. A known type of modular metal frame car park is disclosed in European Patent EP-B-0 364 414. EP-B-0 364 414 describes a raised car park which is capable of erection on uneven or unlevelled ground. The car park described in EP-B-0 364 414 includes a plurality of adjacent decking sheets which are supported at the corners by height adjustable pillars wherein the car park is reinforced against horizontal loads and impacts via a plurality of ties and/or struts. The decking sheets are preferably laminated from corrugated iron sheet and epoxy coated plywood panels with the latter providing the upper surface. A significant problem arises in the design of metal frame modular car parks because they should be sufficiently lightweight to be readily transported to and assembled on a construction site and yet sufficiently strong to support heavy bending loads due to vehicle weight. In this respect, there is an ongoing requirement for a decking sheet which has a higher strength to weight ratio. The car park decking sheets are also preferably maintenance free, corrosion resistant, transportable, easily storable and re-usable and when assembled the joints must be impermeable. Due to the impermeability of the decking sheets another consideration in the design of metal frame modular car parks is the drainage of surface water from the car park deck - 2 - surface. French Patent Application FR-A-2 740 489 describes a modular metal frame car park in which the car park deck comprises a plurality of cambered deck sheets each having a series of peripheral inter-connecting drainage channels. The inter-connecting channels are load bearing and support the cambered deck sheets. A drawback with this arrangement is that if the car park deck surface is cambered, it can be unpleasant for drivers to park their cars. Furthermore, on heavily cambered surfaces pedestrians may easily lose their balance and parked motorcycles may topple over. A further consideration in the design of metal frame modular car parks is their ease of assembly and disassembly. In known modular metal frame car parks, car park deck sheets are simply bolted to the supporting framework. Accordingly, the bolt holes on the deck sheet and the supporting framework must be aligned before the construction workers thread the bolts from the deck sheet side through the aligned holes. The bolts must then be secured from the supporting framework side. This can be time consuming since the bolt holes can be difficult to align and the construction worker assembling the car park deck must access the bolt from both sides of the deck sheet. Another problem with known fixing arrangements is that the bolt holes in the deck sheets can let surface water through causing corrosion to the decking and structure and drainage to vehicles below. An object of the present invention is to provide a demountable modular deck which has a higher strength to weight ratio than hitherto known demountable modular deck designs. Another object of the present invention is to provide a demountable modular deck which avoids a cambered deck surface for surface water drainage . A further object of the present invention is to provide a demountable modular deck which is readily connectable to a raised deck support. According to a first aspect of the invention there is provided a demountable modular deck comprising a plurality of load bearing deck sheets, and a plurality of elongate members - 3 - for releasable engagement with said deck sheets, each of said deck sheets defining a series of adjacent peaks and furrows, and wherein said elongate members are located substantially within the furrows to provide a substantially flat load bearing surface of said deck sheets. The deck sheets have a high bending stiffness relative to a flat sheet of similar weight and in this respect are able to carry higher bending loads and thereby support more weight . In this way the deck has a high strength to weight ratio. Preferably, the elongate members have a cross-section which is oversized relative to the cross-section of the troughs. Accordingly, the elongate members extend upward of the furrows to provide a series of raised ridges in the substantially load bearing surface. In this way point loads on the deck sheets are substantially avoided since any load on the flat load bearing surface acts predominantly on the elongate members. In this respect the elongate members distribute the loads evenly on the deck sheets. This avoids high local stresses in the deck sheets. Conveniently, the peaks and furrows each have a truncated V-shaped cross-section and the elongate members have a complementary C-shaped cross-section for interfitting engagement with the truncated V-shaped cross-section of the furrows. The truncated V-shaped cross-section of the peaks and furrows and the complementary C-shaped cross-section of elongate members provide for improved traction and load distribution throughout the deck. It is to be understood that the definition of the term truncated V-shaped cross-section used herein includes generally U-shaped cross-sections which have a substantially flat base portion and a pair of outwardly inclined side portions, and the definition of the term C-shaped cross-section used herein includes generally U-shaped cross- sections having a substantially flat base portion and a pair of inwardly inclined side portions. In preferred embodiments, the furrows are each provided with engagement means on opposite inclined sides thereof for engagement with the interfitting elongate member located therein. This ensures that the load on the elongate members is evenly transferred to the deck sheets. Preferably, the peaks are each provided with engagement means on opposite inclined sides thereof for engagement with releasable connection means for connection to a deck support. In this way the deck sheets can be connected to the deck support from a support surface of the deck sheets. This can reduce the time required to connect the deck sheets to the deck support. This also obviates the need for holes in the deck sheet for connection to the raised car park deck support and facilitates dismantling and reuse of the decking. Conveniently, the engagement means are provided by ribs or protrusions in the inclined sides. In this way the engagement means can be integrally formed in the deck sheets during manufacture. In preferred embodiments, at least one side edge of the deck sheets is provided with a flange for overlapping engagement with the flange of an adjoining deck sheet. In this way the structural integrity of the assembled deck can be improved. Preferably each elongate member has a textured surface on the load bearing surface thereof. Conveniently the texturing comprises substantially linear protrusions parallel to the longest side of the elongate member . In a preferred embodiment the texturing comprises substantially linear protrusions perpendicular to the longest side of the elongate member. The textured surface improves traction, traps grime to darken the surface and minimises glare. Conveniently, at least one of the ends of the elongate members defines an obtuse angle with respect to the load bearing surface . In this way, surface water on the deck can drain into the furrows through drainage gaps defined between opposing ends of adj acent elongate members . The drainage gaps are formed so as not to allow the passage of stones therethrough. The gaps also allow for thermal expansion of the elongate members. Preferably, a plurality of interconnected conduits are located within the peaks. In this way a fluid can be passed through the conduits for solar energy recovery in warm weather conditions and/or to prevent icing of the deck and ramps in cold weather. Heating of the fluid is enhanced if the conduits are formed from a material which is provided with sufficiently dark colour to absorb and retain heat. The conduits can be produced from a flexible material . According to a second aspect of the invention there is provided a demountable modular deck comprising a plurality of deck sheets for releasable connection with a deck support, each of said deck sheets having at least one corrugation provided with engagement means on an internal side of the corrugation, and releasable connection means for engagement with said engagement means for clamping said sheet to the deck support. This allows the deck to be readily assembled and disassembled. Preferably, the releasable connection means includes a generally rectangular plate rotatably mounted on a bolt for movement between a first position in which the plate engages the engagement means and a second position in which the plate is disengaged from the engagement means, the plate being lockable in said engaging position by tensioning the bolt. Conveniently, the bolt is a hook bolt. In preferred embodiments, said engagement means is provided by a pair of projections on opposing sides of said corrugation. According to a third aspect of the invention there is provided a demountable modular deck comprising a plurality of adjacent deck sheets and plurality of deck supports for supporting the deck sheets in an elevated position, the deck supports being located at a rear edge of the deck sheets, at - 6 - least two of the deck sheets being spaced apart to define a gap between their respective adjoining edges, the gap being spanned by a drainage channel which is supported on one of its sides by a deck support located along the edge of one of the deck sheets and along its other side by a deck support located along the edge of the other deck sheet . This allows surface water to be drained from the deck sheets into a drainage channel which can be supported in a non- load bearing manner between the edges of the deck sheets . Preferably, the channel has a generally U-shaped cross-section and a pair of flanges on opposite sides thereof for engaging the deck supports. In this way the drainage channel can be positioned on the deck supports without being connected thereto. Conveniently, the side flanges are each located between a respective deck sheet and deck support . The channel can thus be restrained between the deck sheets and the deck supports . In preferred embodiments, the deck sheets are provided with surface drainage means for discharge into said drainage channel . In this way full drainage of the deck can be achieved. According to a fourth aspect of the invention there is provided a demountable modular deck comprising a plurality of deck sheets, and a plurality of elongate members for releasable engagement with said deck sheets defining a series of adjacent peaks and furrows, wherein said elongate members are located within the furrow to provide a substantially flat load bearing surface of said deck sheets; wherein at least one peak and/or furrow in each deck sheet is provided with a conduit to enable thermal transfer between the deck sheet and fluid in the conduit . The conduits allow fluid to circulate around the peaks. In this way a fluid can be passed through the conduits for solar energy recovery in warm weather conditions and to prevent icing of the deck and ramps in cold weather. Heating of the fluid is enhanced if the conduits are formed from a material - 7 - which is provided with sufficiently dark colour to absorb and retain heat from the sun. The conduits can be produced from a flexible material . Preferably, the conduit is continuous. Conveniently, several conduits may be interconnected. In a preferred embodiment a major proportion of said deck sheets include conduits provided in the deck sheets. Accordingly the fluid can circulate around the conduits. According to a fifth aspect of the present invention there is provided a modular car park including a demountable modular deck according to any of the preceding aspects of the invention. According to a sixth aspect of the present invention there is provided a kit comprising a demountable modular deck including a plurality of deck sheets, and a plurality of elongate members for releasable engagement with said deck sheets, each of said deck sheets defining a series of adjacent peaks and furrows, and wherein said elongate members are for location within the furrows to provide a substantially flat support surface on one side of said deck sheets. The invention will now be described by way of example only with reference to the accompanying drawings in which: - Figure 1 is a schematic view of a modular metal frame car park to which the present invention is applied; Figure 2 is a schematic plan view of part of a car park deck of the modular metal car park of Figure 1; Figure 3 is a section view along line 1-1 in Figure 2 showing a part of the car park deck and a part of a car park deck support ; Figure 4 is a section view similar to Figure 3 showing an alternative arrangement for fixing the car park deck to the car park deck support ; and Figure 5 is a section view along line 2-2 in Figure 2 showing part of the deck and the car park deck support . In Figure 1 there is shown a modular metal frame car park 9 formed from a plurality of interlocking adjacent rectangular deck sheets 2 which are supported in an elevated position by - 8 - deck supports for example a lattice framework 7. The lattice framework 7 is formed from a plurality of interconnected vertical pillars 3 and horizontal beams 8. The horizontal beams 8 have an I shaped cross-section. The deck sheets 2 have an upper load bearing surface and a lower support surface, adjacent ends of the sheets being placed for support on the horizontal beams 8. The car park 9 also includes an exit ramp 6, an entry ramp 4 and stairs (not shown) for pedestrian access. With reference to Figure 2, a pair of deck sheets 2 are supported on horizontal beams 8 and placed adjacent each other in order that a gap 13 is defined therebetween. In Figure 3 it is shown that the deck sheets 2 have a generally corrugated cross-section with a peak 20 and a furrow 44. The peak 20 and furrow 44 have generally truncated V- shaped cross-sections so that each are provided with a flat portion 40 and 32, respectively. The flat portion 40 has a plurality of substantially linear protrusions which provide texture thereto. Interposed between flat portion 40 and flat portion 32 there is provided a side portion 38. The side portions 38 are inclined so that the angle between the side portions 38 and the flat portions 40 and 32 is obtuse. The side portions 38 are provided with projections in the form of elongate ribs 39 and 29. Rib 39 extends into the area defined by the furrow 44 and is provided in the upper region of the side portion 38. Rib 29 extends into the area defined by the peak and is provided in the lower region of the side portion 38. Adjacent deck sheets 2 are interlocked along their elongate edges by truncating the side portion 38 to form outer side portions 27 and 28. The first outer side portion 27 is truncated below the elongate rib 39 whereas the second outer side portion 28 is truncated above the elongate rib 29. Accordingly, the truncated end of side portion 28 interfits with the elongate rib 39 thus interlocking the adjacent deck sheets 2. An elongate member 26 which has a generally C shaped - 9 - cross-section is located in each of the furrows 44 to provide a substantially flat load bearing surface 1. The elongate member 26 is provided with a flat portion 56 and side portions 42. The length and the inclination of the side portions 42 is 5 such that the side portions 42 engage with the ribs 39 provided on each side portion 38 of the furrow 44. However, the length of the side portions 42 is relatively longer than the distance between the flat portion 40 and the rib 39, thus the flat portion 56 is slightly raised in respect to the flat portions 10 40. Accordingly, the load acting on the elongate members 26 due to vehicle weight is evenly distributed from the elongate member 26 to the deck sheet 12. The surface of flat portion 40 is textured with a plurality of linear protrusions parallel and perpendicular to 15 the longest side of elongate member 26. Each end of the elongate member 26 is splay cut. Accordingly, the abutting ends of two elongate members 26 defined a V-shape in the cross-section thereby defining a drainage gap therebetween. In this respect, any water on the 20 load bearing surface will drain off the elongate member 26 into the drainage gap and through to the furrow 44. An enclosed conduit 21 formed from a flexible black plastics material is located on the underside of each of the flat portions 40 of the peaks 20. The plastics material is 25 sufficiently resilient to withstand tearing. The conduits 21 are interconnected to provide a network of fluid flow passages on the underside of peaks of the deck sheets 2. The conduits 21 are releasably attached to the deck sheets 2 by resilient elongate clips 41 which engage with the rib 39 and hold the 30 conduit with the flat portion 40. In hot weather, the fluid flowing through the conduits 21 will be substantially cooler than the temperature of the load bearing surface 1 and therefore heat will be transferred from the load bearing surface 1 to the conduit . The warm water can 35 then be supplied, for example, directly or indirectly to a steam power or electrical generation plant; spare heating; or a hot water supply. In cool weather, the fluid can be warmed - 10 - in order that it will transfer heat to the load bearing surface 1 thus preventing the load bearing surface 1 becoming icy. The heat transfer can be enhanced by the using black materials for the upper surface of the deck sheets and elongate members. Abutting deck sheets 2 are supported on the horizontal beam 8. A compressible strip 31 is provided between the horizontal beam 8 and the deck sheets 2 so that the flat portions 32 of the deck sheets engage with the compressible strip 31. The compressible strip 31 can be waterproof, have a mechanical vibration damping function, a sound reducing function and an electrical insulation function to prevent electrolytic action between the deck sheets 2 and the horizontal beam 8. The deck sheets 2 are secured to the horizontal beam 8 by means of a rectangular securing plate 46 with elongate aperture 47, through which the shaft of a hook bolt 37 is used to secure the plate 46 to the horizontal beam 8. The securing plate 46 has a length substantially equal to the width of the peak 40 at the upper surface of the ribs 29 whereas a width of the securing plate is substantially less than the width of the peak at the upper surface of the ribs 29. Accordingly, the securing plate 46 can be engaged and disengaged by rotation of the securing plate 46 in the peak. The hook bolt 37 is tensioned by a nut 36 and a cranked plate 35 which engages a flange portion 33 of the horizontal beam 8. A castellated or compressible washer 34 is provided between the cranked plate 35 and nut 36 to prevent loosening by vibration. The tension in the hook bolt 37 clamps the securing plate 46 against the projections 29 and holds the deck sheet 2 in position. In an alternative arrangement shown in Figure 4, the hook bolt 37 is replaced by a linear bolt 61 which has a threaded portion 64. The threaded portion 64 engages with a complementary threaded portion 62 which is provided in the aperture 60 of the securing plate 63. The linear bolt 61 is tensioned by rotation about its axis in the aperture 60. Tension in the linear bolt 61 clamps the securing plate 63 - 11 - against the ribs 29 and holds the sheet in position. With reference to Figure 5, each end of the deck sheet 2 is splay cut and opposing deck sheets are spaced apart. The gap 13 between the adjacent deck sheets 2 is spanned by a channel 66 located on the support bearing surface 45. The channel 66 has a generally U-shaped cross-section with a flange 65 at both sides. The flanges 65 are located between the support bearing surface 45 and the horizontal beam 8 adjacent the compressible strip 31. A gap 67 is provided between the flanges 65 and the support bearing surface 45 by the compressible strip 31. Accordingly, the channel 66 is not load bearing. The channel 66 extends along the length of the abutting ends 11 to provide a means for catching surface water from the deck sheets 2. In this respect, the channels 66 will capture water directly from the deck sheets 2 and indirectly from the deck sheets 2 via the furrows 44. The channel will discharge the water into perimeter gutters (not shown) . Accordingly, the car park 9 is impermeable and the area below the deck sheets may also be used for parking or as a dry storage area. It will be understood that the illustrated embodiment described herein shows an application of the invention in one form only for the purposes of illustration. In practice the invention may be applied to many different configurations the detailed embodiments being straightforward to those skilled in the art to implement. For example the invention is not restricted to the specific shape of the corrugations shown in the drawings. Additionally, the deck sheets need not be rectangular, for example, they could be square. Furthermore, the conduits could be continuous instead of interconnecting. In this case, it is important that the conduits are formed from a plastics material which is sufficiently resilient to allow the conduits to be continuous. Other forms of connecting devices could be used to connect the deck sheets to the support frame, such connecting devices being well known to those in the art. Moreover the invention is not limited to modular metal - 12 - frame car parks . The demountable modular deck could be used for jetties, exhibition platforms, stages and boat decks, for example. It will be understood also that the present invention could include embodiments having more than one deck such as a multi-level car park.

Claims: - 13 - CLAIMS 1. A demountable modular deck comprising a plurality of load bearing deck sheets, and a plurality of elongate members for releasable engagement with said deck sheets, each of said deck sheets defining a series of adjacent peaks and furrows; wherein said elongate members are located substantially within the furrows to provide a substantially flat load bearing surface of said deck sheets. 2. A demountable modular deck according to claim 1 wherein the elongate members have a cross-section which is oversized relative to the cross-section of the troughs. 3. A demountable modular deck according to claims 1 or 2 wherein the peaks and furrows each have a truncated V-shaped cross-section and the elongate members have a complementary C- shaped cross-section for interfitting engagement with the truncated V-shaped cross-section of the furrows. 4. A demountable modular deck according to claim 3 wherein the furrows are each provided with engagement means on opposite inclined sides thereof for engagement with the interfitting elongate member located therein. 5. A demountable modular deck according to claims 3 or 4 wherein the peaks are each provided with engagement means on opposite inclined sides thereof for engagement with releasable connection means for connection to a deck support. 6. A demountable modular deck according to claims 4 or 5 wherein the engagement means are provided by ribs or protrusions in the inclined sides. 7. A demountable modular deck according to any preceding claim wherein at least one side edge of the deck sheets is provided - 14 - with a flange for overlapping engagement with the flange of an adjoining deck sheet. 8. A demountable modular deck according to any preceding claim 5 wherein each elongate member has a textured surface on the load bearing surface thereof . 9. A demountable modular deck according to claim 8 wherein the texturing comprises substantially linear protrusions 10 parallel to the longest side of the elongate member. 10. A demountable modular deck according to either claim 8 or 9 wherein the texturing comprises substantially linear protrusions perpendicular to the longest side of the elongate 15 member. 11. A demountable modular deck according to any preceding claim wherein at least one of the ends of the elongate member defines an obtuse angle with respect to the load bearing surface. 20 12. A demountable modular deck according to any preceding claim wherein a plurality of interconnected conduits are located within the peaks . 25 13. A demountable modular deck comprising a plurality of deck sheets for releasable connection with a deck support, each of said sheets having at least one corrugation provided with engagement means on an internal side of the corrugation, and releasable connection means for engagement with said engagement 30 means for clamping said sheet to the deck support. 14. A demountable modular deck according to claim 13 wherein the releasable connection means includes a generally rectangular plate rotatably mounted on a bolt for movement 35 between a first position in which the plate engages the engagement means and a second position in which the plate is disengaged from the engagement means, the plate being lockable - 15 - in said engaging position by tensioning the bolt. 15. A demountable modular deck according to claim 14 wherein the bolt is a hook bolt. 16. A demountable modular deck according to any one of claims 11 to 13 wherein said engagement means is provided by a pair of projections on opposing sides of said corrugation. 17. A demountable modular deck comprising a plurality of adjacent deck sheets and plurality of deck supports for supporting the deck sheets in an elevated position, the deck supports being located at a rear edge of the deck sheets, at least two of the deck sheets being spaced apart to define a gap between their respective adjoining edges, the gap being spanned by a drainage channel which is supported on one of its sides by a deck support located along the edge of one of the deck sheets and along its other side by a deck support located along the edge of the other deck sheet . 18. A demountable modular deck according to claim 17 wherein the channel has a generally U-shaped cross-section and a pair of flanges on opposite sides thereof for engaging the deck supports . 19. A demountable modular deck according to claim 18 wherein the side flanges are each located between a respective deck sheet and deck support . 20. A demountable modular deck according to any of claims 17 to 19 wherein the deck sheets are provided with surface drainage means for discharge into said drainage channel . 21. A demountable modular deck comprising a plurality of deck sheets, and a plurality of elongate members for releasable engagement with said deck sheets defining a series of adjacent peaks and furrows, wherein said elongate members are located - 16 - within the furrow to provide a substantially flat load bearing surface of said deck sheets; wherein at least one peak and/or furrow in each deck sheet is provided with a conduit to enable thermal transfer between the deck sheet and fluid in the 5 conduit. 22. A demountable modular deck according to claim 21 wherein the conduit is continuous. 10 23. A demountable modular deck according to either claim 21 or 22 wherein several conduits may be interconnected. 24. A demountable modular deck according to any of claims 21 to 23 wherein a major proportion of said deck sheets include 15 conduits provided in the deck sheets. 25. A modular car park including a demountable modular deck according to any preceding claim. 20 26. A kit comprising a demountable modular deck including a plurality of deck sheets, and a plurality of elongate members for releasable engagement with said deck sheets, each of said deck sheets defining a series of adjacent peaks and furrows, and wherein said elongate members are for location within the 25 furrows to provide a substantially flat support surface on one side of said deck sheets. 27. A demountable modular deck substantially as herein described and/or with reference to the accompanying drawings. 30 28 . A modular car park substantially as herein described and/or with reference to the accompanying drawings .

Inventors: SELIG AUBREY, STERN DAVID, SELIG, AUBREY, STERN, DAVID
Applicants: SELIG AUBREY, STERN DAVID, SELIG, AUBREY, STERN, DAVID
Application year: 1999
Main classification: E04H6
IPC codes: E04B5, E04D13, E04H6