GB2595248A

GB2595248A - A kit of parts for assembling a castor deck

Info

Publication number: GB2595248A
Application number: GB2007380.5A
Authority: GB
Inventors: Hamilton Stephen
Original assignee: Air Tech Innovations Ltd
Current assignee: Air Tech Innovations Ltd
Priority date: 2020-05-19
Filing date: 2020-05-19
Publication date: 2021-11-24
Anticipated expiration: 2040-05-19
Also published as: GB202007380D0; GB2595248B

Abstract

A kit of parts for assembling a castor deck 100 for use in moving loads across a surface, for example when loading an aircraft hold with pallets and/or unit load devices (ULDs). The kit comprises a plurality of frame members 1, 2 which are configured to be joined to one another in a grid pattern to form a frame. A plurality of fixing elements such as self-tapping screws or bolts join the frame members and a plurality of support elements 4, including a rotatable load support element / castor (101, Fig 3), are configured to project above the load surface of the assembled frame to support and enable movement of a load on castor deck 100. A method of assembling a castor deck 100, and a castor deck assembled from the kit of parts are also provided. Frame members 1, 2 may have an inverted U-shaped cross section (see Fig 2) and between 5 and 25 support elements 4 may be provided per metre squared when the kit is constructed.

Description

A MT OF PARTS FOR ASSEMBLING A CASTOR DECK

The present invention relates to a kit of parts for assembling a castor deck, a castor deck and a method of assembling a castor deck. A castor deck is platform that is provided with rotatable elements, usually castor wheels, on an upper surface such that a load can be rotated or conveyed in any horizontal direction by moving across the surface of the deck. By way of a non-limiting example, a castor deck can be used for handling loads, for example when loading and unloading aircraft with payloads such as pallets and unit load devices (I_TLDs).

BACKGROUND

Castor decks for moving loads are known in the art. Typically, castor decks are made of metal and are welded together from component parts to form a permanent rigid structure. The finished castor decks are then transported to the location of use, for example an airport. Castor decks are generally very large to accommodate loads of various sizes and to provide low friction movement of loads in any direction when the load is placed on the surface of the castor deck. For example, castor decks typically have dimensions of 2.6m by 3.3m or larger, thus being larger than standard intermodal shipping containers which have an internal width of 2.352m to 2.489m. Therefore, existing castor decks are frequently too large to be transported in standard intermodal shipping containers.

A problem with existing castor decks is that they require non-standard containers to deliver 20 the assembled castor deck from the manufacturing site to the location of use. Non-standard containers can result in less efficient fuel usage and increased shipping costs.

It is an object of the present invention to provide a castor deck that mitigates one or more of the aforesaid problems.

SUMMARY OF THE INVENTION

Aspects of the present invention are set out in the accompanying independent and dependent claims. Combinations of features from the dependent claims may be combined with features of the independent claims as appropriate and not merely as explicitly set out in the claims.

According to one aspect of the invention, there is provided a kit of parts for assembling a castor deck, comprising a plurality of frame members, including a set of first frame members and a set of second frame members, which are configured to be joined to one another in a grid pattern to form a frame having a load surface; a plurality of fixing elements for joining the first frame members to the second frame members; and a plurality of support elements configured to be connected to the first frame members, wherein each support element includes a rotatable load support element configured to project above the load surface of the assembled frame to support and enable movement of a load on the castor deck.

An advantage of providing a kit of parts for assembling a castor deck is that the castor deck can be transported in an unassembled state and the parts can be transported in a smaller space than would be required to transport an assembled castor deck. Another advantage is provided by the kit facilitating the assembly of the castor deck at any preferred location. Further advantages of providing said kit of parts are reduced transportation costs as there is no need to use non-standard containers, and reduced fuel usage owing to the tighter packing and therefore less air resistance during transportation.

Optionally, each first frame member is elongate and substantially U-shaped in cross-section, and comprises a base member and a pair of opposed side walls that extend upwards from the base member. This formation provides strength and rigidity, while being 25 relatively light and simple to manufacture.

Optionally, the support elements are configured to be connected to base members of the first frame members, between the opposed side walls. This provides a stable foundation for the support elements.

Optionally, each second frame member is elongate and substantially inverted U-shaped in cross-section, and comprises a top member and a pair of opposed side walls that extend downwards from the top member. This formation provides strength and rigidity, while being relatively light and simple to manufacture.

The base members of the first frame members may be configured to be joined to the top members of the second frame members. This provides a strong, rigid structure for the frame.

Optionally, the set of first frame members are configured to be joined to the set of second frame members in a substantially perpendicular arrangement. in other words, the first frame and second frame members may be configured such that in the assembled castor deck the longitudinal axes of the first frame members and the second frame members are substantially perpendicular to one another.

The kit of parts optionally includes a plurality of top plates configured to be attached to the load surface of the frame The top plates provide additional rigidity to the assembled 15 castor deck and also provide a surface on which an operator (a person moving loads on the castor deck) can stand.

Each top plate may include a plurality of apertures configured such that the support elements protrude through the apertures in the assembled castor deck.

A plurality of mounting elements may attach the top plates to the first frame members. 20 This provides for easy assembly of the castor deck and a strong construction.

The plurality of top plates may comprise, for example, from 2 to 10 top plates, optionally from 3 to 8 top plates, optionally from 4 to 6 top plates. In a typical example, the castor deck includes four rectangular top plates, configured to be arranged in a square pattern. The top plates may comprise a perforated deck or a durbar checker plate. A perforated deck top plate is advantageous for outdoor use where it would be beneficial to allow rainwater to drain from the surface. A durbar checker plate is advantageous where it is required to improve grip, for example with respect to grip of a shoe on the surface, for example, indoors or in freezing or wet conditions. By way of example, there may be four top plates included in the kit of parts. By way of example, each of the top plates may be quadrilateral, in particular rectangular or square Optionally, each support element comprises a castor that includes a wheel, a wheel mount and a base structure, wherein the wheel is mounted on the wheel mount for rotation about a 5 wheel axis, and the wheel mount is mounted on the base structure for rotation about a swivel axis that is substantially perpendicular to the wheel axis Tn an embodiment, the wheel axis may be configured to be substantially horizontal in use, or parallel to the top deck of the assembled castor deck, and the swivel axis may be configured to be substantially vertical in use, or perpendicular to the top deck of the assembled castor deck. 10 Alternatively, each support element may comprise a ball bearing, a fixed castor or a wheel of any other suitable type.

Optionally, the fixing elements include self-tapping screws and/or self-tapping bolts. Self-tapping screws and/or bolts can provide structural integrity without the need for welding. Self-tapping screws and/or bolts also provide the advantage of enabling assembly the 15 castor deck using standard tools such as screwdrivers Optionally, the set of first frame members comprises from 4 to 30 first frame members, optionally from 6 to 20 first frame members, optionally from 10 to 15 first frame members. For example, in an embodiment there may be 13 first frame members. Optionally, the set of second frame members comprises from 2 to 10 second frame members, optionally from 3 to 8 second frame members, optionally from 4 to 6 second frame members. For example, in an embodiment there may be 4 second frame members.

The number and/or width of the first and second frame members may be varied according to the desired size, strength or stability of the castor deck. It should be understood that such variations do not deviate from the scope of the invention.

Optionally, the assembled frame has an upper surface and a lower surface, and the kit of parts is configured such that the height of the assembled frame, between the upper surface and the lower surface, is from 100mm to 200mm, optionally from 120mm to 150mm.

Optionally, the kit of parts may be configured such that the distribution density of the support elements of the assembled castor deck is from 5 to 25 support elements/m2, optionally from 10 to 20 support elements/m2, optionally from 12 to 18 support elements/m2. For example, in an embodiment the distribution density of the support elements may be 15 support elements/m2.

The distribution density of the support elements can be varied according to the expected 5 weight and dimensions of the load to be conveyed. For example, smaller and heavier loads will require a higher distribution density and larger or lighter loads can be conveyed over relatively a lower distribution density of support elements.

According to another aspect of the invention there is provided a castor deck comprising a frame having a load surface, the frame comprising a set of first frame members and a set of second frame members, which are joined to one another in a grid pattern; a plurality of fixing elements joining the first frame members to the second frame members; and a plurality of support elements connected to the first frame members, wherein each support element includes a rotatable load support element that projects above the load surface of the assembled frame to support and enable low friction movement of a load on the castor deck.

Optionally, each first frame member is elongate and substantially U-shaped in cross-section, and comprises a base member and a pair of opposed side walls that extend upwards from the base member.

Optionally, the support elements are connected to base members of the first frame 20 members, between the opposed side walls.

Optionally, each second frame member is elongate and substantially inverted U-shaped in cross-section, and comprises a top member and a pair of opposed side walls that extend downwards from the top member.

The base members of the first frame members may be joined to the top members of the 25 second frame members.

Optionally, the set of first frame members are joined to the set of second frame members in a substantially perpendicular arrangement.

The castor deck may comprise a plurality of top plates attached to the load surface of the frame Each top plate may include a plurality of apertures through which the support elements protrude.

A plurality of mounting elements may attach the top plates to the first frame members.

The plurality of top plates may comprise from 2 to 10 top plates, optionally from 3 to 8 top plates, optionally from 4 to 6 top plates. For example, there may be 4 top plates. The top plates may comprise durbar checker plates or perforated plates. The top plates may be quadrilateral in shape, for example square or rectangular.

Optionally, each support element comprises a castor that includes a wheel, a wheel mount and a base structure, wherein the wheel is mounted on the wheel mount for rotation about a wheel axis, and the wheel mount is mounted on the base structure for rotation about a swivel axis that is substantially perpendicular to the wheel axis Alternatively, each support element may comprise a ball bearing, a fixed castor or a wheel of any other suitable type.

The support elements may be rotatable about one or two axes. For example, if conveyance is only required in one direction, support elements with a single axis of rotation may be used to simplify the design Optionally, the fixing elements may include self-tapping screws and/or self-tapping bolts.

Optionally, the set of first frame members may comprise from 4 to 30 first frame members, 20 optionally from 6 to 20 first frame members, optionally from 10 to 15 first frame members. For example, in an embodiment there may be 13 first frame members.

Optionally, the set of second frame members comprises from 2 to 10 second frame members, optionally from 3 to 8 second frame members, optionally from 4 to 6 second frame members. For example, in an embodiment there may be 4 second frame members.

Optionally, the height of the frame, between the upper surface and the lower surface, may be from 100mm to 200mm, optionally from 120mm to 150mm.

Optionally, the distribution density of the support elements may be from 5 to 25 support elements/m2, optionally from 10 to 20 support elements/m2, optionally from 12 to 18 support elements/m2 For example, the distribution density may be 15 support elements/m2 The castor deck may optionally comprise a weighing station including one or more load 5 sensing cells in communication with a display for determining and displaying the load on the castor deck assembly.

The castor deck may optionally include finger stops or similar elements for restricting horizontal motion of a load, said finger stops being embedded in the top plates and being configured to be raised and lowered as required to prevent or allow movement of the load.

The castor deck may optionally include lift-up pallet stops at one or more peripheral edges of the castor deck for blocking or limiting the motion of a pallet or load on the castor deck. The pallet stops may be retractable to a withdrawn position below the surface of the castor deck, so that they only block or limit the motion of a load or pallet when raised.

The castor deck may optionally include at least one protection barrier and/or a litter skirt.

According to another aspect of the invention there is provided a method of assembling a castor deck, the method comprising providing a kit of parts as defined by any one of the preceding statements of invention, joining a set of first frame members to a set of second frame members in a grid pattern using a plurality of fixing elements to form a frame having a load surface; and connecting a plurality of support elements to the first frame members, wherein each support element includes a rotatable load support element, such that the rotatable load support elements project above the load surface of the assembled frame to support and enable low friction movement of a load on the castor deck.

The method may comprise attaching a plurality of top plates to the load surface of the frame.

The method may include attaching the top plates using fixing elements.

The method may include that the fixing elements are self-tapping screws and/or self-tapping bolts.

Each top plate may include a plurality of apertures, and the method may comprise arranging the top plates so that the support elements protrude through the apertures.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary detailed embodiments will now be described with reference to the 5 accompanying drawings, wherein: Figure 1 is an isometric view of a partially assembled castor deck without top plates; Figure 2 shows a close-up view of region "A" identified in Figure 1, showing a joint in the frame; Figure 3 shows a top plan view of a partially assembled castor deck without top plates; Figure 4 shows a side view of a castor deck from a direction parallel to the second frame members, Figure 5 shows a side view of a castor deck from a direction perpendicular to the second frame members; Figure 6 shows an isometric view of an assembled castor deck with top plates; 15 Figure 7 shows a top plan view of an assembled castor deck with top plates, and Figure 8 shows a side view of a castor deck elevated on support legs.

DETAILED DESCRIPTION OF THE EMBODIMENTS

A partially assembled castor deck 100 is shown in Figure 1. The castor deck 100 may be assembled from a kit of parts The castor deck 100 includes first frame members 2 and second frame members 1 forming a frame F. The second frame members 1 are assembled in a position beneath the first frame members 2. The first frame members 2 and second frame members 1 are assembled in a grid formation. The first frame members 2 and second frame members I are attached to one another by fixing elements. The first frame members 2 are elongate with a substantially U-shaped cross section. The second frame members 1 are elongate with a substantially inverted U-shaped cross section and flanged at the open end.

"U-shaped" as used herein refers to a structure comprising a base member and a pair of opposed side walls that extend upwards from the base member. For example, "U-shaped" may refer to a half-cylinder, or a tube with a quadrilateral cross-section open at one side. "Inverted U-shaped-as used herein refers to a similar structure comprising a top member and a pair of opposed side walls that extend downwards from the top member.

In the illustrated embodiment, the number of second frame members 1 is 4, however many different numbers of second frame members may be provided, depending on the desired size and/or strength of the castor deck. For example, the number of second frame members may be between 2 and 10.

In the illustrated embodiment, the number of first frame members 2 is 13, however, many different numbers of first frame members may be provided, depending on the desired size and/or strength of the castor deck. For example, the number of first frame members may be between 4 and 30.

In use, the castor deck 100 will support and enable horizontal motion of a load.

Accordingly, support elements 4 are provided, with a rotatable element exposed, on a load surface L of the castor deck, said load surface L being the upper surface when the castor deck is in use. The exposed rotatable element contacts an underside of a load and facilitates horizontal motion by rolling the load across a plurality of support elements. The support elements 4 are attached to the first frame members 2 and spaced at intervals across the grid forming an array of support elements. The support elements 4 project above the toad surface of the assembled frame to support and enable movement of a load on the castor deck 100.

The support elements 101 may be rotatable load support elements as shown in Figure 2. In this embodiment the rotatable load support elements 101 are castor wheels, which are 25 mounted with the wheel uppermost. However, alternative rotatable load support elements may be provided, as described below.

The rotatable load support elements 101 may be configured to rotate about two perpendicular axes. For example, if the support elements are castor wheels, the wheels may be configured to rotate about a wheel axis that is parallel to the load surface L of the castor deck and a swivel axis that is perpendicular to the load surface. In use the perpendicular axes may be a vertical axis and a horizontal axis. Alternatively, if the support elements are ball bearings, the balls may be configured to rotate about a two perpendicular axes that are each parallel to the load surface.

The rotatable load support elements provide substantially frictionless or low friction movement of a load placed on the load surface L of the castor deck in any direction, as well as rotation about a rotation axis that is perpendicular to the load surface.

The terms "frictionless" and "low friction" as used herein refer to situations where the resistance to movement of the load is substantially lower than the static friction between the load and a solid support surface, for example of steel. The actual level of friction will depend on the rolling resistance of the rotatable support elements and characteristics of the load, including the hardness and smoothness of the load surface that engages the rotatable support elements. Typically, where the load surface is relatively hard and smooth, the rotatable load support elements may provide a coefficient of friction of less than 0.1, or less than 0.05, or preferably less than 0.02.

Alternatively, one or more of the support elements 4 may comprise support elements, for example wheels, that are configured to rotate about only one axis, for example a horizontal axis, to permit movement of a load only in a specified direction during use.

The distribution density of the support elements over the load surface L may for example be between 4 to 25 support elements/m2. For example, there may be 15 castor wheels per metre squared. The distribution density of the support elements is preferably selected so that a load placed on the load surface is supported by a minimum of three support elements at all times, to ensure that the load is supported stably by contact with the upper surfaces of the castor wheels, and ensure that it is possible to transfer a load easily from a first set of rotatable support elements to another set of said support elements as the load is moved over the load surface of the castor deck. It is self-evident that the number of castor wheels can vary without deviating from the inventive concept.

The frame is provided with side rails 12 and end rails 10 that close off the space defined by the second frame members 1 at the perimeter of the castor deck 100 The side rails 12 and end rails 10 prevent material from getting caught in the frame as loads are transported, for example loose packaging. The first frame members 2, second frame members 1, side rails 12 and end rails 10 may comprise a metal such as steel. These components may be treated for corrosion resistance: for example they may be galvanised or powder coated.

The exemplary embodiment illustrated in Figure 1 also includes bolts 4 with washers 9, shown in exploded view, for attaching the first frame members 2 to the second frame members 1, by closure with the nuts 11. Bolts 4, washers 9 and nuts 11 also attach the side rails 12 and end rails 10 to the frame. In Figure 1 the nearest side rail 12 and nearest end rail 10 are shown in exploded view.

Figure 4 shows a side view of the castor deck 100 with the second frame members 1 shown from a longitudinal direction.

Figure 5 shows a side view of the castor deck showing the second frame members 1 extending in a transverse direction.

Figure 6 shows an embodiment of the castor deck 100 with top plates 102 attached to the upper surface of the frame. In this embodiment the top plates 102 comprise four rectangular plates, which are attached to the frame F by fixing elements such as self-tapping screws and/or bolts S. The castor wheels 101 may project above the upper surface of the top plates 102 to support a load on the load surface L of the castor deck.

Each top plate 102 may include a plurality of apertures A configured such that the support elements 101 protrude through the apertures in the assembled castor deck. The top plates 102 may comprise a perforated deck or a durbar checker plate. In the embodiment shown in Figure 6 the apertures A and the support elements 101 are arranged in a square grid pattern. They may however be arranged in numerous alternative patterns including, for example, diamond, triangular or hexagonal patterns.

A kit of parts for assembling a castor deck may include a plurality of frame members, including a set of first frame members and a set of second frame members, which are configured to be joined to one another in a grid pattern to form a frame having a load surface; a plurality of fixing elements for joining the first frame members to the second frame members; and a plurality of support elements configured to be connected to the first frame members, wherein each support element includes a rotatable load support element configured to project above the load surface of the assembled frame to support and enable movement of a load on the castor deck. Optionally, the kit of parts may also include a plurality of top plates 102 configured to be attached to the upper surface of the assembled frame.

Figure 7 shows a top plan view of the castor deck 100 with top plates 102 attached The castor wheels 101 may project above the upper surface of the top plates 102 through apertures A in the top plates. The top plates 102 are aligned and abut one another edge to edge such that substantially the entire surface of the frame F is covered by the top plates The top plates 102 may be of equal size or of complementary dimensions such that when assembled they substantially cover the upper surface of the frame Figure 2 shows a close-up view of the area "A" indicated in Figure 1. The second frame members 1 feature recesses 5 between the castor wheels 101 for receiving screws that may be, for example, hex socket countersunk screws. Mounting elements 3 may be included for mounting the top plates 102 to the second frame members 1. The mounting elements 3 are positioned between the castor wheels 101 in the internal void of the second frame members 1. The mounting element 3 is fixed by screws to an internal side of the first frame members 2.

Figure 3 shows a top view of the castor deck 100. As shown in Figure 2 the mounting 20 element 3 may be positioned between neighbouring castor wheels 101. As shown in Figure 3 the mounting elements 3 may be positioned at intervals on the side rails 12 and the end rails 10.

The top plates may be attached to an upper side of the mounting element 3 by fixing means such as self-tapping screws S. The mounting elements 3 may be, for example, angles such as a hot rolled steel angles or iron angles.

Figure 8 shows another embodiment of the castor deck 100. The castor deck 100 may include support legs 103 which raise the castor deck above the ground. The legs 103 may raise the castor deck to a height of 200mm to 650mm above the ground, for example 500mm.

The assembled castor deck may typically have a length from 2800mm to 3600mm and a width from 2000mm to 3000mm. In the example illustrated in the drawings, the assembled castor deck has a length of 3315mm and a width of 2600mm However, other sizes are also possible and are within the scope of the invention.

The kit of parts from which the castor deck is assembled includes first frame members 2, second frame members 1, top plates 102, support elements 101, end rails 10, side rails 12, and mounting elements 3. The kit of parts can therefore be used to assemble the castor deck described above and shown in the figures using bolts and/or screws. The kit of parts can be packed into a smaller space than the assembled castor deck thereby enabling easier and more efficient transport.

The kit of parts can be assembled into a castor deck 100 by a method of assembly. The method of assembly comprises providing a kit of parts, joining the first frame members 2 to the second frame members 1 in a grid pattern using a plurality of fixing elements to form a frame having a load surface; and connecting a plurality of support elements 101 to the first frame members 2, such that the support elements 101 project above the load surface of the assembled frame to support and enable substantially frictionless (low friction) movement of a load on the castor deck 100.

A further step in the method is attaching a plurality of top plates 102 to the load surface of the frame, wherein each top plate includes a plurality of apertures; and arranging the top plates 102 so that the support elements 101 protrude through the apertures. The top plates 102 may be attached to the frame F by fixing elements S. The fixing elements S may for example be self-tapping screws and/or self-tapping bolts.

Terms for components used herein should be given a broad interpretation that also encompasses equivalent functions and features. Descriptive terms should also be given the broadest possible interpretation; e.g, the term "comprising" as used in this specification means "consisting at least in part of' such that interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. The present description refers to embodiments with particular combinations of features, however, it is envisaged that further combinations and cross-combinations of compatible features between embodiments will be possible.

Claims

Claims: A kit of parts for assembling a castor deck, comprising: a plurality of frame members, including a set of first frame members and a set of second frame members, which are configured to be joined to one another in a grid pattern to form a frame having a load surface; a plurality of fixing elements for joining the first frame members to the second frame members; and a plurality of support elements configured to be connected to the first frame members, wherein each support element includes a rotatable load support element configured to project above the load surface of the assembled frame to support and enable movement of a load on the castor deck.
A kit of parts according to claim 1, wherein each first frame member is elongate and substantially U-shaped in cross-section, and comprises a base member and a pair of opposed side walls that extend upwards from the base member.
3. A kit of parts according to claim 2, wherein the support elements are configured to be connected to base members of the first frame members, between the opposed side walls.
A kit of parts according to any preceding claim, wherein each second frame member is elongate and substantially inverted U-shaped in cross-section, and comprises a top member and a pair of opposed side walls that extend downwards from the top member.
A kit of parts according to claim 4 when dependent on claim 2 or claim 3, wherein the base members of the first frame members are configured to be joined to the top members of the second frame members.
A kit of parts according to any preceding claim, wherein the set of first frame members are configured to be joined to the set of second frame members in a substantially perpendicular arrangement.
A kit of parts according to any preceding claim, including a plurality of top plates configured to be attached to the load surface of the frame.
A kit of parts according to claim 7, wherein each top plate includes a plurality of apertures configured such that the support elements protrude through the apertures in the assembled castor deck.
A kit of parts according to claim 7 or claim 8, including a plurality of mounting elements for attaching the top plates to the first frame members.
A kit of parts according to claim 7 or claim 8 or claim 9, wherein the plurality of top plates comprises from 2 to 10 top plates, optionally from 3 to 8 top plates, optionally from 4 to 6 top plates.
11. A kit of parts according to any preceding claim, wherein each support element comprises a castor that includes a wheel, a wheel mount and a base structure, wherein the wheel is mounted on the wheel mount for rotation about a wheel axis, and the wheel mount is mounted on the base structure for rotation about a swivel axis that is substantially perpendicular to the wheel axis.
12. A kit of parts according to any preceding claim, wherein the fixing elements include self-tapping screws and/or self-tapping bolts.
13. A kit of parts according to any preceding claim, wherein the set of first frame members comprises from 4 to 30 first frame members, optionally from 6 to 20 first frame members, optionally from 10 to 15 first frame members.
14. A kit of parts according to any preceding claim, wherein the set of second frame members comprises from 2 to 10 second frame members, optionally from 3 to 8 second frame members, optionally from 4 to 6 second frame members
15. A kit of parts according to any preceding claim, wherein the frame has an upper surface and a lower surface, and the first and second frame members are configured so that the height of the assembled frame between the upper surface and the lower surface, is from 100mm to 200mm, optionally from 120mm to 150mm.
16 A kit of parts according to any preceding claim, wherein the kit of parts is configured so that the distribution density of the support elements in the assembled castor deck is from 5 to 25 support elements/m2, optionally from 10 to 20 support elements/m2, optionally from 12 to 18 support elements/m2.
17. A castor deck comprising: a frame having a load surface, the frame comprising a set of first frame members and a set of second frame members, which are joined to one another in a grid pattern; a plurality of fixing elements joining the first frame members to the second frame members; and a plurality of support elements connected to the first frame members, wherein each support element includes a rotatable load support element that projects above the load surface of the assembled frame to support and enable low friction movement of a load on the castor deck.
18. A castor deck according to claim 17, further comprising a plurality of top plates attached to the load surface of the frame
19. A castor deck according to claim 18, wherein each top plate includes a plurality of apertures through which the support elements protrude.
20. A method of assembling a castor deck, the method comprising: providing a kit of parts as defined by any one of claims I_ to 16, joining a set of first frame members to a set of second frame members in a grid pattern using a plurality of fixing elements to form a frame having a load surface; and connecting a plurality of support elements to the first frame members, wherein each support element includes a rotatable load support element, such that the rotatable load support elements project above the load surface of the assembled frame to support and enable low friction movement of a load on the castor deck.
21. A method according to claim 20, further comprising attaching a plurality of top plates to the load surface of the frame.
22. A method according to claim 21, wherein each top plate includes a plurality of apertures, the method comprising arranging the top plates so that the support elements protrude through the apertures.
23. A method according to claims 21 or 22 wherein the top plates are attached using fixing elements
24. A method according to claim 23 wherein the fixing elements are self-tapping screws and/or self-tapping bolts.