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Comflor Decking New PDF
Comflor Decking New PDF
Introduction
Corus is one of the world’s leading Corus International is the specialist Our deep decks span between beams
steel suppliers, formed in 1999 by the supply chain management business with typical unpropped spans extending
merger of British Steel and Koninklijke unit with annual sales of 8 million tonnes to 6 metres and propped spans to
Hoogovens. Combining international of steel and a worldwide network of 9 metres. The deck is contained within
expertise with local customer service, offices. We are continually expanding the beam depth, which provides a very
the Corus brand represents quality our reach and evaluating new markets shallow floor zone. The shape of the
and strength, providing innovative for which a presence would bring local deck profiles allow for service
solutions to a wide variety of sectors advantage. Our scope of supply integration and the whole system
worldwide. Corus became a subsidiary extends across the full range of steel provides inherent fire resistance.
of Tata Steel in April 2007, leading to products, but our commercial teams
the creation of the world’s fifth largest specialise through retaining sector- The overall service we provide covers
steel producer. With a combined specific focus. Within this model, our design and detailing advice and supply
presence in 50 countries, Tata Steel teams have also developed relationships of decking systems coupled with
including Corus has 84,000 employees with third-party sources in order to offer logistical, technical, finance and
across six continents and a pro forma a more flexible solution. According to documentation support. As such,
crude steel production of 27 million our ISO 9001:2000 quality system, we Corus International is in an excellent
tonnes in 2007. The combined turnover only procure from companies with position to offer tailored decking
of Corus and Tata Steel stood at audited quality systems. In addition, solutions to projects around the world,
US$24.8 billion in 2006. we have stockholding facilities in North as proven by a long and successful
America, Europe, the Middle East and track record of supplying these products
the Far East. to customers globally.
02
Introduction
03
ComFlor 46
ComFlor 46
Shallow composite profile
Typical unpropped span 2.6m – 3.3m
04
ComFlor 46
ComFlor 46 design information
1.5 hrs 130 A193 2.4 2.4 2.7 2.7 2.7 2.3
and deck
No temporary props
Please refer to
145 A252 2.5 2.5 2.5 2.9 2.9 2.6 page 20 for span
2 hrs 200 A393 2.2 2.2 2.2 2.5 2.5 2.5 table parameters.
240 A393 2.0 2.0 2.0 2.3 2.3 2.3
Design notes
Deck material expected 0.5% minimum percentage Technical services
Corus Galvatite, hot dip zinc coated steel reinforcement should be used over the Corus International offers a comprehensive
EN 10326-S280GD+Z275 or equivalent. supports and 2% elsewhere to control advisory service on design of composite
Guaranteed minimum yield stress 280N/mm2. cracking. For further information refer to SCI flooring, which is available to all specifiers
Minimum zinc coating mass 275g/m2 total AD150. Mesh top cover must be a minimum and users. Should queries arise which are
both sides. of 15mm, and a maximum of 30mm. Mesh not covered by this literature or by the
laps are to be 300mm for A142 mesh and ComFlor software, please contact us.
Anti-crack mesh 400mm for A193, A252 and A393 mesh.
BS 5950: Part 4 currently recommends that Details of full design, load spans and
anticrack mesh should comprise 0.1% of slab Fire profile performance can be found by using
area. The Eurocode 4 recommendation is that For details of the performance of composite the ComFlor software CD. Your free copy
anticrack mesh should comprise 0.2% of slab slabs comprising ComFlor 46 decking in can be found on the inside back cover of
area for unpropped spans and 0.4% of slab simplified design cases or for full fire this publication.
area for propped spans. Where forklift truck engineering, refer to the ComFlor software.
(or other similar concentrated loading) is
05
ComFlor 51
ComFlor 51
Shallow composite profile
Typical unpropped span 2.5m – 3.6m
06
ComFlor 51
ComFlor 51 design information
105 0.096 2.26 2.21 1.79 1.69 1. Deck and beam deflection (i.e. ponding)
110 0.101 2.37 2.32 1.88 1.78 is not allowed for in the table.
115 0.106 2.49 2.44 1.97 1.87 2. Deck and mesh weight is not included
120 0.111 2.61 2.55 2.07 1.96 in the weight of concrete figures.
125 0.116 2.73 2.67 2.16 2.04 3. Density of concrete is taken as:
130 0.121 2.84 2.78 2.25 2.13 Normal weight (wet) 2400 kg/m3
150 0.141 3.32 3.25 2.62 2.49 Normal weight (dry) 2350 kg/m3
200 0.191 4.49 4.40 3.56 3.37 Lightweight (wet) 1900 kg/m3
240 0.231 5.43 5.32 4.30 4.08 Lightweight (dry) 1800 kg/m3
1.5 hrs 110 A142 2.7 2.7 2.2 3.1 3.0 2.4
and deck
No temporary props
Please refer to
125 A193 3.1 3.0 2.3 3.4 3.2 2.5 page 20 for span
2 hrs 200 A393 2.6 2.6 2.6 3.0 3.0 3.0 table parameters.
240 A393 2.4 2.4 2.4 2.8 2.8 2.8
Design notes
Deck material expected 0.5% minimum percentage Technical services
Corus Galvatite, hot dip zinc coated steel reinforcement should be used over the Corus International offers a comprehensive
EN 10326-S350GD+Z275 or equivalent. supports and 2% elsewhere to control advisory service on design of composite
Guaranteed minimum yield stress 350N/mm2. cracking. For further information refer to SCI flooring, which is available to all specifiers
Minimum zinc coating mass 275g/m2 total AD150. Mesh top cover must be a minimum and users. Should queries arise which are not
both sides. of 15mm, and a maximum of 30mm. Mesh covered by this literature or by the ComFlor
laps are to be 300mm for A142 mesh and software, please contact us.
Anti-crack mesh 400mm for A193, A252 and A393 mesh.
BS 5950: Part 4 currently recommends that Details of full design, load spans and
anticrack mesh should comprise 0.1% of Fire profile performance can be found by using
slab area. The Eurocode 4 recommendation For details of the performance of composite the ComFlor software CD. Your free copy
is that anticrack mesh should comprise 0.2% slabs comprising ComFlor 51 decking in can be found on the inside back cover of
of slab area for unpropped spans and 0.4% simplified design cases or for full fire this publication.
of slab area for propped spans. Where forklift engineering, refer to the ComFlor software.
truck (or other similar concentrated loading) is
07
ComFlor 60
ComFlor 60
Shallow composite profile
Typical unpropped span 3.0m – 4.4m
08
ComFlor 60
ComFlor 60 design information
140 A193 3.5 3.5 2.6 4.1 3.6 2.7 Please refer to
1.5 hrs
170 A252 3.2 3.2 3.2 4.1 4.1 3.3 page 20 for span
150 A193 3.4 3.0 2.3 3.5 3.1 2.4 table parameters.
2 hrs
180 A252 3.1 3.1 2.8 4.1 3.9 2.9
Design notes
Deck material percentage reinforcement should be used Technical services
Corus Galvatite, hot dip zinc coated steel over the supports and 2% elsewhere to Corus International offers a comprehensive
EN10326-S350GD+Z275 or equivalent. control cracking. For further information refer advisory service on design of composite
Guaranteed minimum yield stress 350N/mm2. to SCI AD150. Mesh top cover must be a flooring, which is available to all specifiers
Minimum zinc coating mass 275g/m2 total minimum of 15mm, and a maximum of and users. Should queries arise which are not
both sides. 30mm. Mesh laps are to be 300mm for covered by this literature or by the ComFlor
A142 mesh and 400mm for A193, A252 software, please contact us.
Anti-crack mesh and A393 mesh.
BS 5950: Part 4 currently recommends that Details of full design, load spans and
anti-crack mesh should comprise 0.1% of Fire profile performance can be found by using
slab area. The Eurocode 4 recommendation For details of the performance of composite the ComFlor software CD. Your free copy
is that anti-crack mesh should comprise slabs comprising ComFlor 60 decking in can be found on the inside back cover of
0.2% of slab area for unpropped spans and simplified design cases or for full fire this publication.
0.4% of slab area for propped spans. Where engineering, refer to the ComFlor software.
forklift truck (or other similar concentrated
loading) is expected 0.5% minimum
09
ComFlor 80
ComFlor 80
Shallow composite profile
Typical unpropped span 3.8m – 5.1m
ComFlor 80 is the next generation of profiled steel composite decks; it is the only 80mm
profile utilising the higher grade 450 steel and available in Colorcoat®.
The large corner curvature detail provides a very efficient profile. In conjunction with the
higher grade of steel, it ensures typical unpropped spans of 4.4m simply supported and in
the continuous condition, spans of 5.1m can be achieved.
The large spans achievable mean less structural steel is used and this provides savings in the
overall construction cost, which also offers more scope to architects and engineers in the
design process.
10
ComFlor 80
ComFlor 80 design information
180 300 120
15
95
80
35 50 35
15.8 17.2
ComFlor 80 composite slab – volume and weight 90 180 120
150 A393 4.2 4.0 3.0 4.8 4.1 3.1 Please refer to
1.5 hrs
180 A393 3.8 3.8 3.5 4.7 4.7 3.6 page 20 for span
160 A393 4.1 3.6 2.7 4.2 3.6 2.8 table parameters.
2 hrs
190 A393 3.7 3.7 3.1 4.7 4.2 3.2
Design notes
Deck material expected 0.5% minimum percentage Technical services
Corus Galvatite, hot dip zinc coated steel reinforcement should be used over the Corus International offers a comprehensive
EN 10326-S450GD+Z275 or equivalent. supports and 2% elsewhere to control advisory service on design of composite
Guaranteed minimum yield stress up to cracking. For further information refer to SCI flooring, which is available to all specifiers
450N/mm2. Minimum zinc coating mass AD150. Mesh top cover must be a minimum and users. Should queries arise which are not
275g/m2 total both sides. of 15mm and a maximum of 30mm. Mesh covered by this literature or by the ComFlor
laps are to be 300mm for A142 mesh and software, please contact us.
Anti-crack mesh 400mm for A193, A252 and A393 mesh.
BS 5950: Part 4 currently recommends that Details of full design, load spans and
anticrack mesh should comprise 0.1% of slab Fire profile performance can be found by using
area. The Eurocode 4 recommendation is that For details of the performance of composite the ComFlor software CD. Your free copy
anticrack mesh should comprise 0.2% of slabs comprising ComFlor 80 decking in can be found on the inside back cover of
slab area for unpropped spans and 0.4% simplified design cases or for full fire this publication.
of slab area for propped spans. Where forklift engineering, refer to the ComFlor software.
truck (or other similar concentrated loading) is
11
Shallow composite floor decks Design information
Design information
Composite floor decking design is generally dictated by the construction stage condition, the load and span required for
service and the fire resistance required for the slab. The deck design is also influenced by the composite beam design.
Design parameters Anti-crack mesh which provides valid mesh sizing and
• Fire rating – dictates minimum slab FibreFlor can be used to replace anti detailing for specific crack width control.
depth. crack mesh. Where mesh is used, BS5950: Where forklifts are to be used also refer to
• Concrete type – also dictates minimum Part 4 recommends that it comprises Steel Construction Institute advisory note
slab depth and influences unpropped 0.1% of slab area. The Eurocode 4 ‘AD 150, Composite Floors – Wheel Loads
deck span. recommendation is that anti-crack mesh from Forklifts’. Both publications are
• Deck span – (unpropped) usually should comprise 0.2% of slab area for available from our Technical Department.
dictates general beam spacing. unpropped spans and 0.4% of slab area
• Slab span – (propped deck) dictates for propped spans. Reduced mesh
maximum beam spacing.
1.2m 1.2m 1.2m 1.2m
In slabs subject to line loads, the mesh
Two stage design should comprise 0.4% of the cross-
All Composite Floors must be considered sectional area of the concrete topping,
Support Support Support
in two stages. propped and unpropped. Beam Beam Beam
• Wet concrete and construction load –
carried by deck alone. These limits ensure adequate crack control Diagram showing full mesh area over supports
• Cured concrete – carried by composite in visually exposed applications (0.5mm
slab. maximum crack width). The mesh Where EC4 mesh rules are used, as
reinforcement should be positioned at a recommended by Steel Construction
General design aims maximum of 30mm from the top surface. Institute and Corus, the full stipulated
Generally designers prefer to reduce Elsewhere, 0.1% reinforcement may be mesh applies to the slab 1.2m either side
the requirement to provide temporary used to distribute local loads on the slab of every support. Outside of this, i.e. in
propping and so the span and slab depth (or 0.2% to EC4). the midspan area, the mesh area may be
required governs the deck selection. Fire halved (to 0.2% for propped and 0.1%
requirements usually dictate slab depth. Mesh laps are to be 300mm for A142 for unpropped construction), provided
For most applications, the imposed load mesh and 400mm for A193, A252 and there are no concentrated loads, openings
on the slab will not limit the design. A393. etc. to be considered. Also the reduced
midspan mesh must be checked for
Quick reference and full design Forklift trucks adequacy under fire, for the rating
The combination of this manual and Where forklift truck (or other similar required.
ComFlor software makes both quick concentrated loading) is expected 0.5%
reference and full design easy. Indicative minimum percentage reinforcement should Bar reinforcement
design may be carried out from the printed be used over the supports and 0.2% The Axis Distance of bar reinforcement
tables, however the software greatly elsewhere to control cracking. For further defines the distance from the bottom of
increases the scope available to the information refer to SCI AD150. the ribs to the centre of the bar, which has
Design Engineer and allows the engineer a minimum value of 25mm, and a
to print a full set of calculations. Exposed floors maximum value of the profile height.
Composite floors are usually covered by Where used, bar reinforcement is placed
British standards and Eurocodes finishes, flooring or a computer floor; and at one bar per profile trough.
The Software user is offered a choice to because cracking is not visible, light top
design to either BS5950 Parts 4 and 3 or reinforcement is adequate, typically 0.1% Transverse reinforcement
to Eurocode 4. The quick reference tables of the gross cross sectional area. However Corus composite floor decks contribute
are designed to BS5950 Part 4, with the where the composite slab is to be left to transverse reinforcement of the
important exception of the mesh uncovered, e.g. for power trowelled floor composite beam, provided that the decking
recommendations. finishes, cracking, particularly over the is either continuous across the top flange of
beams, may not be adequately controlled the steel beam or alternatively that it is
by the light mesh usually provided. The welded to the steel beam by stud shear
cracking has no structural significance, but connectors. For further information refer to
the appearance of it, and the possibility of BS5950:Part 3: Section 3.1.Clause 5.6.4.
the crack edge breakdown under traffic,
may be perceived as a problem. In this
case, refer to Concrete Society publication.
‘Cracking In Composite Concrete /
Corrugated Metal Decking Floors Slabs’
12
Design information Shallow composite floor decks
Concrete choice Fire design methods account the deflection should not
Lightweight concrete (LWC) uses There are two requirements for fire design: exceed the span/130 or 30mm overall.
artificially produced aggregate such as • Bending resistance in fire conditions. The quick reference tables do take
expanded pulverised fuel ash pellets. • Minimum slab depth for insulation ponding into account, if deflection exceeds
LWC leads to considerable advantages in purposes. Ds/10, or Le/180, and thus use span/130
improved fire performance, reduced slab or 30mm as a deflection limit.
depth, longer unpropped spans and The capacity of the composite slab in fire
reduced dead load. However, LWC is not may be calculated using either the Simple It is recommended that the prop width
readily available in some parts of the Method or the Fire Engineering Method. should not be less than 100mm otherwise
country. Normal weight concrete uses a The simple method will be the most the deck may mark slightly at prop lines.
natural aggregate and is widely available. economic. The fire engineering method
should be used for design to Eurocodes. Vibration
The strength of the concrete must meet The dynamic sensitivity of the composite
the requirements for strength for the The Simple Method: The Simple Method slab should be checked in accordance
composite slab and shall not be less than may be used for simply supported decks with the Steel Construction Institute
25N/mm2 for LWC or 30N/mm2 for NWC. or for decks continuous over one or more publication P076: Design guide on the
Similarly, the maximum value of concrete internal supports. The capacity vibration of floors. The natural frequency
strength shall not be taken as greater than assessment in fire is based on a single or is calculated using the selfweight of the
40N/mm2 for LWC or 50N/mm2 for NWC. double layer of standard mesh. Any bar slab, ceiling and services, screed and
reinforcement is ignored. 10% imposed loads, representing the
The modular ratio defines the ratio of the permanent loads and the floor. In the
elastic modulus of steel to concrete, as The Fire Engineering Method: The Fire absence of more appropriate information,
modified for creep in the concrete. Engineering Method is of general the natural frequency of the composite
application. The capacity assessment in slab should not exceed 5Hz for normal
In design to BS5950 and BS8110, the fire is based on a single or double layer of office, industrial or domestic usage.
cube strength is used (in N/mm2). In design standard mesh at the top and one bar in Conversely, for dance floor type
to EC3, the cylinder strength is used (in each concrete rib. For the shallow decks, applications or for floors supporting
N/mm2). The concrete grade (C30/37) the program assumes the bar is positioned sensitive machinery, the limit may need
defines the (cylinder/cube strength) to EC3. just below the top of the steel deck. to be set higher.
Concrete density Shallow composite floors generally use For design to the Eurocodes, the loads
Density kg/m3 the simplified fire design method which considered for the vibration check are
Wet Dry Modular ratio utilises the anti-crack mesh as fire increased using the psi-factor for imposed
LWC 1900 1800 15 reinforcement. Increased load span loads (typically 0.5). The natural frequency
NWC 2400 2350 10 capability under fire may be realised by limit may be reduced to 4Hz, because of
including bar reinforcement and using this higher load, used in the calculation.
In the absence of more precise the fire engineering method of design.
information, the following assumptions Loads and load arrangement
may be made: The wet density is used in Deflection limits Loading information would normally
the design of the profiled steel sheets and Deflection Limits would normally be be agreed with the clients. Reference
the dry density, in the design of the agreed with the client. In the absence should also be made to BS 6399 and
composite slab. of more appropriate information, the to EC1.
following limits should be adopted:
Fire design Construction stage Factored loads are considered at the
Fire insulation Le/130 (but not greater than 30mm) ultimate limit state and unfactored
The fire insulation requirements of BS Imposed load deflection loads at the serviceability limit state.
5950: Part 8, must be satisfied and are Le/350 (but not greater than 20mm) Unfactored loads are also considered
taken into account in the tables and design Total load deflection in fire conditions.
software. Le/250 (but not greater than 30mm)
According to BS5950 Part 4, ponding, Partial factors are taken from BS5950,
Span/depth ratio resulting from the deflection of the decking EC3 and EC4.
Slab span to depth ratio is limited to a is only taken into account if the
maximum of 30 for lightweight concrete construction stage deflection exceeds Loads considered at the construction
and 35 for normal weight concrete. Ds/10. Le is the effective span of the deck stage consist of the slab self weight and
and Ds is the slab overall depth (excluding the basic construction load. The basic
Shear connectors in fire situation non-structural screeds). construction load is taken as 1.5 kN/m2
If shear connectors are provided, any or 4.5/Lp (whichever is greater), where
catenary forces transferred from the slab The deflection under construction load Lp is the span of the profiled steel sheets
to the support beams can be ignored should not exceed the span/180 or 20mm between effective supports in metres.
within the fire resistance periods quoted. overall, whichever is the lesser, when the For multi span unpropped construction,
ponding of the concrete slab is not taken the basic construction load of 1.5 kN/m2
into account. Where ponding is taken into is considered over the one span only.
13
Shallow composite floor decks Design information
Large
Openings greater than 700mm square –
should be trimmed with additional
permanent steelwork back to the support
beams. Opening
Opening rules
Where W = width of opening across the
span of the deck.
1. The distance between the opening and
unsupported edge must be greater than
500mm or W, whichever is the greater.
2. Openings must not be closer together
than 1.5W (of the largest opening) or
300mm, whichever is the greater. If they Extra bars in troughs
are closer they must be considered as
one opening.
3. Not more than 1⁄4 width of any bay
Centre line Transverse reinforced Centre line
is to be removed by openings. of floor beam concrete beam strip of floor beam
4. Not more than 1⁄4 width of deck span
d o /2
is to be removed by openings.
Effective span of
do transverse beam
Where these rules are not satisfied, the strips = 1.5d o
Deck span
openings must be fully trimmed with
support steelwork. d o /2
side of the beam centre line), the beam Load paths and beam strips around medium
resistance should be checked assuming an to large openings
appropriately reduced effective breadth
of slab.
14
Design information Shallow composite floor decks
Crushing Crushing
The methods of connection between slab
and beam is generally by means of through
deck welding of 19mm diameter shear
studs of varying height, which are fixed to
the beam after the decking has been laid.
Top flange of beam Force applied to slab
Shear stud specification
19mm x 95mm studs are used with CF46, Centre welding of shear-connectors
CF51 and CF60.
19mm x 125mm studs are used with CF80.
Headed studs Through deck welded stud reduction factor k – see note 1 below
When deck profile ribs are running BS5950 Part 3 Centre placed, Unfavourably placed
perpendicular to the steel beam i.e. favourably placed or studs
compositely connected to the composite offset placed studs (2)
slab, the capacity of headed studs should 1 stud/rib 2 studs/rib 1 stud/rib 2 studs/rib
be taken as their capacity in a solid slab CF46 and CF51 1.00 0.80 1.00 0.80
but multiplied by the reduction factor “k”. CF60 1.00 0.80 N/A* N/A*
The calculation method for “k” differs CF80 (125mm stud) 0.80 0.56 N/A* N/A*
between BS5950 Part 3 and Eurocode 4. *CF60 and 80 profile ensures centre placed studs.
Design guide
The Steel Construction Institute/Metal
Cladding and Roofing Manufacturers
Association P300 “Composite Slabs
and Beams using Steel Decking: Best
Practice for Design and Construction”
is recommended by Corus for further
reference.
Central studs
*76mm = 4d for 19mm studs
*76mm
min
Note 1
At the time of print, the stud reduction factors
in BS5950 Part 3 and in the National Annex 25mm min, edge of stud to edge of beam
for EC4 are subject to review, please check
with our Technical Department to see if these
figures are still current.
15
Shallow composite floor decks Construction details
Construction details
Plan view of typical floor layout Deck notation
F75
to Setting Out 6-1000
Point (s.o.p.) 2107
of decking Y = distance (mm)
Beam first sheet. Indicates bay Floor Phase Bundle
member from centreline of tie
which requires member to edge of level number
centreline temporary slab (perpendicular
propping. to deck span)
94
Y F75
Steel stud
Edge trim
Restraint Restraint
strap strap
at 600mm
centres Timber
Reinforcement bearer
as specified
Temporary
CF 80 25 min See typical plan for prop
Floor decking dimension ‘X’, & ‘Y’
Universal beam
16
Construction details Shallow composite floor decks
Restraint straps at
600mm centres
CF 80
Dimension ‘X’ required
CF 80 Floor decking
Maximum cantilever Floor decking
500mm, greater to extend to Studs in pairs or
cantilevers require edge trim staggered where a
temporary props and butt joint occurs
additional reinforcement
or steelwork brackets Universal beam Universal beam Deck to be butt
connected to the jointed over
Universal beam centreline of beam
X Beam centres
CF 80 Floor decking
Edge trim to centreline of beam
CF 80 Floor decking
to centreline of beam
17
Shallow composite floor decks Construction details
Restraint strap
Stud on centreline
of beam Steel stud
Edge trim CF51 Floor decking Edge trim CF51 Floor decking
to extend to edge trim to centreline of beam
Restraint
CF 80 strap
Edge trim Floor
Steel stud decking
18
Construction details Shallow composite floor decks
Restraint strap
CE100 edge
trim leaving
room for
25mm
Korkpak joint
CF51 Floor decking Edge trim to align with CF80 Floor decking with
to extend to edge edge of wall 75mm (minimum) bearing
trim onto wall
Universal beam
10mm min
19
Shallow composite floor decks Sitework
Sitework
Deck fixing
Immediately after laying, the deck must Fixing information for shallow decking
be fixed through its trough to the top of To steel Heavy duty powder actuated fixings – Hilti ENP2 X-ENP-19 L15 nail/Spit
the supporting structure. Powder SBR14 or equivalent. For temporary fixing (i.e. where weld through shear
actuated pins or self-drilling screws are studs are to be used) – Hilti PINDAK16*
used. Side lap fixings are required at Self-drilling screws. To steel up to 11mm thick – SFS SD14 – 5.5 x 32 /
1000mm centres for CF46, CF60 and EJOT HS 38 or equivalent. To steel up to 17mm thick SFS TDC-T-6.3
CF80. Where shear studs are being x 38 or equivalent
used, the deck requires two fixings per To masonry Pre drill hole – use self tapping fixing suitable for masonry/concrete –
sheet per support at sheet ends and or concrete SFS TB-T range/EJOT 4H32 or equivalent
one fixing per sheet at intermediate To side laps Self drilling stitching screw typically SFS SL range/EJOT SF25 or
supports. or closures etc. equivalent
20
Sitework Shallow composite floor decks
Bearing requirements
End bearing and shared bearing (minimum) Continuous bearing (minimum)
Masonry Masonry
Edge trim
This is used to retain the wet concrete
to the correct level at the decking
perimeters. It is fixed to the supports
in the same manner as the deck and the
top is restrained by straps at 600mm
centres, which are fixed to the top of
the deck profile, by steel pop rivets or
self-drilling screws.
21
Shallow composite floor decks Sitework
Shear connectors Ceilings and services hanger systems (b) GTD-clip hangar fixings
Most commonly used shear connectors The dovetail shaped re-entrant rib on
are 19mm diameter headed studs, ComFlor 51 and the 15mm high raised
which are welded to the support beam minidovetail re-entrant stiffener on
through the deck, a process carried out the ComFlor 60 and ComFlor 80 profiles
by specialist stud welding contractors. allow for the quick and easy suspension
Site conditions must be suitable for of ceiling and services, using either of
welding and bend tests carried out as the two following suspension systems.
appropriate.
The spacing and position of the shear
connectors is important and must be
defined by the design engineer on the
deck set out drawings.
Minimum Spacing: The minimum centre-
to spacing of stud shear connectors
should be 5d along the beam and 4d
between adjacent studs, where d is the
nominal shank diameter. Where rows of
studs are staggered, the minimum
transverse spacing of longitudinal lines
of studs should be 3d. The shear stud
should not be closer than 20mm to the
edge of the beam. Further guidance
on shear studs for designers and
installers may be found in The Steel ComFlor 51
Construction Institution publications:
P300 Composite Slabs and Beams
Using Steel Decking: Best Practice for GTD-clip hangar fixings are cold formed
Design and Construction, P055 Design thin steel hangers with circular openings
of Composite Slabs and Beams with in the soffit to take metric bolts,
Steel Decking. threaded rods or further pipe clamp
hangers. The system is installed after
Mesh placement the composite slab has been poured
FibreFlor can be used in place of anti and the concrete is sufficiently
crack mesh, which eliminates all mesh hardened.
position issues. However if reinforcing
mesh is used, it is positioned towards Installation
the top of the slab. The top cover to the To install the GTD-clips, the two dovetail
reinforcement mesh should be a shaped ends are compressed by hand
minimum of 15mm and a maximum of and inserted into the dovetail re-entrant
30mm. Support stools are required to of the profile, before being rotated 90
maintain the correct mesh height. The ComFlor 80 degrees. One then lets go of the two
mesh must be lapped by 300mm for ends and the clip will snap into position
A142 and A193 mesh, and by 400mm (a) Threaded wedge nut fixings and is tightly connected. Finally, bolts,
for A252 and A393 mesh. Wedges are dovetail shaped steel threaded rods or pipe clamps are
blocks, which are threaded to take connected into the soffit opening of the
Casting concrete metric bolts or threaded rods. The GTD-clip.
Before the concrete is poured, the wedge nut hanger system is installed
decking must be cleared of all dirt and after the concrete of the composite slab Loadbearing capacities
grease, which could adversely influence has been poured and is hardened. Thread Maximum
the performance of the hardened slab. System size static working
The oil left on the decking from the roll Installation load (kg)
forming process does not have to be For installation of the system, wedge Wedge Nut 4 100
removed. Concrete should be poured nuts are inserted into the raised re- 6 100
evenly, working in the direction of span. entrants of the profile before being 8 100
Care should be taken to avoid heaping rotated 90 degrees, after which the GTD – Clip 6 90 8 90
of concrete in any area during the dovetail shaped wedge nuts will lock 10 90
casting sequence. Construction and day into the dovetail re-entrants under GTD – Clip and N/A 45
joints should occur over a support vertical loading. Finally, the bolts or Pipe Clamp
beam, preferably also at a deck joint. threaded rods are finger tightened up
to the roof of the re-entrants and A minimum safety factor of 4 has been applied
mechanically tightened. to the safe working load capacities
22
Sitework construction details Shallow composite floor decks
Openings
Openings greater than 300mm must
be designed by the engineer, with extra
reinforcement placed around the
opening. Openings up to 700mm can
be accommodated readily in composite
slabs, by boxing out prior to pouring
concrete and cutting out the deck after
concrete has cured. Larger openings
require support trimming steel, which
must be installed prior to the decking.
The decking is cut away immediately
and the opening edges are then treated
like any other perimeter with edge trim. Timber shutter Dense polystyrene block
Temporary supports
The safe design and installation of
temporary props is the responsibility of
the main contractor or designated sub-
contractor. Where temporary supports
are required by the design, these must
provide continuous support to the
profiled sheeting. Spreader beams
(timbers) are used, supported by
temporary props at one metre centres.
[a] The timbers and props must be of
adequate strength and construction
[b] The temporary supports are placed
at midspan or at other suitable centres
if more supports per span are required.
Please contact our Technical Department
[c] The spreader beams or timbers are
to provide a minimum bearing width of
100mm. The spreaders must not deflect
more than 10mm and should be placed
narrow edge up, see diagram.
[d] The propping structure is not to be Percussive drilling
removed until the concrete has reached Percussive drilling into composite
at least 70% of its characteristic concrete slabs is not recommended,
strength. The horizontal bearer timbers however small scale rotary hammer drills
must be at least 100mm wide and are considered to be satisfactory.
should be propped at no more than 1m
centres. Sometimes the specification Temporary props
may call for 150mm wide bearers, as Timber bearer guide (shallow decks)
determined by the structural engineer All to be min. 100mm wide
or concreting contractor. Slab depth (mm) Bearer depth (mm)
up to 120 150
Props should be stable without relying 130 – 160 200
on friction with the deck for laterial 170 – 200 250
stability. The end props in a row should
be self supporting, and braced to the
internal props.
23
ComFlor 210
ComFlor 210
Deep composite profile
Typical unpropped span
4.5m – 6.0m
The original SlimFlor long span steel deck, ComFlor 210
has the capability to span up to 6 metres in unpropped
construction. Suitable for use in Corus Slimdek®
construction, which offers minimal structural depth,
fast construction and many other benefits.
• With cross and longitudinal stiffeners, • Simple single bar reinforcement in • The nestable profile shape reduces
CF210 is structurally efficient and each trough, combined with anti- transport and handling costs.
offers excellent composite action with crack mesh near the top of the
the concrete. concrete slab gives the composite • Up to 2 hours fire rating with
slab superb structural strength and unprotected soffit.
fire properties.
24
ComFlor 210
ComFlor 210 design information
350 A393 4.7 4.7 4.7 4.7 4.5 4.7 4.7 4.7 3.7 4.7 4.7 4.7
Single span slab
290 A193 3.7 4.9 5.3 5.3 3.4 4.4 5.3 5.3 2.7 3.5 4.3 5.3
1.5 hrs 300 A193 3.7 4.9 5.2 5.2 3.4 4.5 5.2 5.2 2.7 3.6 4.4 5.2
350 A393 3.8 4.7 4.7 4.7 3.5 4.6 4.7 4.7 2.8 3.8 4.6 4.7
305 A193 2.0 2.7 3.3 4.1 1.8 2.4 3.0 3.7 1.5 1.9 2.4 3.0
2 hrs 350 A393 2.1 2.7 3.4 4.2 1.9 2.5 3.1 3.8 1.5 2.0 2.5 3.1
400 A393 2.1 2.7 3.4 4.2 1.9 2.6 3.2 3.9 1.6 2.1 2.6 3.3
Design notes
Deck material For further information refer to SCI AD150. Bar reinforcement
Corus Galvatite, hot dip zinc coated steel Mesh top cover must be a minimum of End anchorage for bar reinforcement. All
EN 10326-S350GD+Z275 or equivalent. 15mm, and a maximum of 30mm. Mesh laps cases require properly anchored L-bars at the
Guaranteed minimum yield stress 350N/mm2. are to be 300mm for A142 mesh and 400mm supports, except for those indicated in yellow.
Minimum zinc coating mass 275g/m2 total for A193, A252 and A393 mesh. Cases indicated in yellow may have straight
both sides. bars, with an anchorage length of 70mm from
Technical services the edge of the support. One bar is placed in
Anti-crack mesh Corus International offers a comprehensive each profile trough, the cover to deck soffit is
BS 5950: Part 4 currently recommends that advisory service on design of composite assumed at 70mm.
anticrack mesh should comprise 0.1% of slab flooring, which is available to all specifiers
area. The Eurocode 4 recommendation is that and users. Should queries arise which are not Details of full design, load spans and
anticrack mesh should comprise 0.2% of slab covered by this literature or by the ComFlor profile performance can be found by using
area for unpropped spans and 0.4% of slab software, please contact us. the ComFlor software CD. Your free copy
area for propped spans. Where forklift truck can be found on the inside back cover of
(or other similar concentrated loading) is Fire this publication.
expected 0.5% minimum percentage For details of the performance of composite
reinforcement should be used over the slabs comprising ComFlor 210 decking in
supports and 2% elsewhere to control simplified design cases or for full fire
cracking. engineering, refer to the ComFlor software.
25
Deep composite floor decks Design information
Design information
Deep Composite Floor Decks will be considered where longer span (4m plus) floor slabs are required.
When combined with Corus Slimdek® system, deep decks are designed to achieve a very shallow overall structural floor.
Corus Slimdek® system Asymmetric Slimflor® Beam (ASB), which is a hot rolled section with a narrower top flange than
This system comprises Asymmetric bottom flange.
Slimflor® Beams (ASB) and deep CF210
decking.
Slimflor® Fabricated Beam (SFB), which is a Universal Column section with a wide flange plate
welded to its underside.
Rectangular Hollow Slimflor® Beam (RHSFB), which is a rectangular hollow section with a flange
plate welded to its lower face (generally used for edge beams).
26
Design information Deep composite floor decks
27
Deep composite floor decks Design information
Slab design Cracking mesh at the top and one bar in each
The design of composite slabs using It is normal for some cracking to occur concrete rib. For CF210 decking, the bar
deep decking differs from that for in the slab over the beams. These is placed at an axis distance, dependent
shallow decking in the following ways: cracks run parallel with the beams and on the fire resistance period. The axis
are not detrimental to the structural distance must not be less than 70mm.
Placing bar reinforcement in the troughs behaviour of the slab. They may be To maximise fire resistance capacity the
of the decking increases the ultimate controlled by mesh reinforcement axis distance needs to be 70, 90 and
load resistance of the slab. The benefit provided across the tops of the beams. 120mm (from the soffit of the deck) for
of these bars is considered in both the Guidance on the detailing of 60, 90 and 120 minutes fire resistance,
‘normal’ and fire conditions. reinforcement to control cracking may respectively. However where fire
be found in the Corus Slimdek® manual. resistance is not the limiting factor it
The slab depth may need to be chosen may be more effective for the axis
not only to satisfy the structural, Additional reinforcement may be distance to be at the minimum.
durability and fire resistance required to fulfil the following roles:
requirements of the slab itself, but also • Transverse reinforcement adjacent to Concrete thickness above deck
to provide appropriate cover over ASB shear connectors. Fire resistance NWC LWC
or Slimflor beams. • U-bars at composite edge beams. 60min 70mm 60mm
• Additional crack control 90min 80mm 70mm
The reinforcing bars in the troughs of the reinforcements 120min 95mm 80mm
decking provide additional tensile area • Strengthening around openings.
to that provided by the decking, and • Strengthening at positions of Reduced mesh
thus enhance the bending resistance of concentrated loads. Where EC4 mesh rules are used, as
the composite slab. recommended by The Steel
Fire resistance Construction Institute and Corus, the
Bar diameters range from 8mm to One of the principal considerations full stipulated mesh applies to the slab
32 mm, depending on the span and governing the choice of slab depth is 1.2m either side of every support.
fire resistance requirements. the required fire resistance period. Outside of this, i.e. in the midspan area,
Minimum depths are given above as a the mesh area may be halved (to 0.2%
Straight bars may be used to achieve function of the concrete type and fire for propped and 0.1% for unpropped
60 minutes fire resistance (provided resistance required and are based on construction), provided there are no
that shear stresses are low). In other insulation requirements. concentrated loads, openings etc. to be
cases, L bars should be used to The Fire Engineering Method: The considered. Also the reduced midspan
provide sufficient end anchorage in capacity assessment in fire is based mesh must be checked for adequacy
fire conditions. on a single or double layer of standard under fire, for the rating required.
28
Design information Deep composite floor decks
on the assumption of simple supports following summarises the options that Service integration
at the ends. Conversely, for dance floor are available to the designer: The Slimdek system offers considerable
type applications or for floors supporting opportunity for the integration of
sensitive machinery, the limit may need Openings up to 300mm x 300mm can services. This is covered in detail in
to be set higher. be accommodated anywhere in the slab Corus Construction Centre publication
over a crest section of the deck, Slimdek – Structure and services
In the Slimdek system, consideration normally without needing additional integration.
should be given to the system frequency reinforcement.
of the floor as a whole if the natural Parameters assumed for deep deck
frequency of the slab and/or the Openings up to 400mm wide x 1000mm quick reference span tables
supporting beam is less than 5Hz. long may be taken through the crest of Mesh
the deep decking. Additional See notes on page 25.
For design to the Eurocodes, the loads reinforcement, which should be
considered for the vibration check are designed in accordance with BS 8110, Spans
increased using the psi-factor for may be required around the opening. Measured centre to centre of supports.
imposed loads (typically 0.5). The
natural frequency limit may be reduced Openings up to 1000mm wide x Deck
to 4Hz, because of this higher load 2000mm long may be accommodated Standard deck material specification.
used in the calculation. by removing one rib (maximum) of the
decking, fixing suitable edge trims and Bearing width
Partial continuity providing additional reinforcement to The width of the support is assumed
Partial continuity for deep decking: transfer forces from the discontinuous to be 200mm.
Tests have shown that the CF210 rib. The slab should be designed as a
composite slabs supported on a steel ribbed slab in accordance with BS 8110, Prop width
beam and provided with adequately with decking being used as permanent Assumed to be 100mm.
detailed continuity mesh reinforcement formwork. Guidance may be found in
over the steel beam support exhibits a the Corus Slimdek Manual. Deflection
degree of continuity at the support. Construction stage L/130 or 30mm
The beneficial effect of partial continuity (ponding has been taken into account).
at the supports may be taken into Opening up to 1000mm
account by specifying CONTINUOUS in Deflection
the Span Type field. When this option is Composite stage L/350.
specified, the following assumptions are
made by the design software; Concrete grade
• a 20% reduction in the deflections of The concrete is assumed to be grade
the composite slab at the normal Larger openings will generally require 35 with a maximum aggregate size of
design stage. trimming by secondary beams. 20mm. The wet weight of concrete is
• a 30% reduction in the deflections taken to be normal weight 2400kg/m3.
when assessing the natural frequency If an opening greater than 300mm x The modular ratio is 10 for normal
of the slab. This is justified by the 300mm lies within the effective width of weight.
lower stress levels during vibration. slab adjacent to a beam (L/8), the beam
• stresses in the composite slab in fire should be designed as non-composite. Construction load
conditions are derived from a model A close grouping of penetrations No allowance is made for heaping.
which assumes full continuity at one transverse to the span direction of the
end and a simple support at the other decking should be treated as a single Fire
(i.e a propped cantilever condition). large opening. The fire engineering method (FE)
In this case, the amount of mesh has been used to calculate the
reinforcement is increased to a minimum reinforcement needed to achieve the
T12 bar x 1500 long ASB beam
of 0.4% of the cross-sectional area of fire rating. The minimum slab thickness
the concrete topping in order to develop M indicated in each table for each fire
≥500
≤1000
Note that in all cases, partial continuity 300 Span/depth ratio. This is limited to
is ignored in assessing the capacity of Minimum 30 for lightweight concrete and 35 for
the composite slab at the normal design A142 mesh normal weight concrete.
throughout
stage. ≤400
Construction details
Cut deck – Option 1 Cut deck – Option 2
Asymmetric SlimFlor beam Closure flashing Asymmetric SlimFlor beam Closure flashing
Beam centres
CF210 Deck
Asymmetric cut along top
SlimFlor beam section only
Closure flashing
Restraint strap at
600mm centres
Restraint strap
Edge trim Edge trim
Reinforcement Reinforcement
as specified Closure as specified
flashing
100mm
Temporary props Temporary prop
required for spans
greater than 500mm
30
Construction details Deep composite floor decks
Steel trims
20
50
Slab
depth
190
90 50 min (steel)
31
Deep composite floor decks Sitework
Sitework
Health and safety Unpunched single diaphragms are also Where CF210 deck is being used with
ComFlor 210 should only be installed available. Where the deep deck lands Asymmetric SlimFlor Beams, the top
by contractors experienced in fixing onto a support at a rake, the single flange of the profile must be notched
long span steel decking. diaphragms are used doubled up, and back by 50mm, so that the concrete can
adjusted on site to take up the extra be observed passing between the end
It is the responsibility of the contractor length required due to the fact that the diaphragm and the beam to allow
to provide safe working procedures for end of the deck is at a raked angle to concrete to flow into the beam.
the installation of deep decking on any the support rather than at right angles.
particular project and to provide a risk The crown of the deck sheet is fixed to
assessment to the main contractor. The concrete that the diaphragms the top of the diaphragms using one self
entrap around the Asymmetric Slimflor drilling screw for CF210.
Reference should be made to the BCSA Beam, give the beam its fire rating,
Code of Practice for Metal Decking and therefore the diaphragms must be When fixing to other types of supports
Stud Welding, with special reference to placed strictly according to such as reinforced concrete, or load
the addendum for long span decking. specification. bearing walls, 1 suitable fixing must be
used in each CF210 trough as for the
The following general guidelines should steel supports.
also be followed to maximise health and
safety on site Side laps
CF210 side laps are to be stitched at
1. Diaphragms should where reasonably 350mm centres with 5.5mm diameter
practicable be fitted from a safe End diaphragm for ComFlor 210 self drilling screw, the location is marked
working platform or from below from by an indentation in the overlap tail.
a MEWP or a platform access Deck fixing Every side lap fastener must fix and
system. The decking sheets are manually locate a trough shear connector clip into
2. Deck cutting should be carried out as lowered individually onto the beams. position. The clip is partly responsible
the last operation in each bay. Thus it In the Slimdek system, the end bearing for the composite action of the decking
can be carried out on a safe working of the sheets should be 50mm; the and must not be omitted unless the
platform of previously laid deck. flange widths are such that this can be CF210 is being used as formwork only.
achieved, whilst still being able to drop
End diaphragms the sheets vertically into position (i.e.
Steel end diaphragms, as manufactured without having to thread them between
by Corus, are essential for both deep the top and bottom flanges).
deck systems to ensure the structural
integrity of the deck. The end Once the sheets for the whole bay are
diaphragms, are fixed first and are in place, they are secured to the beam
supplied in lengths of 1800mm, to cover flanges using heavy duty shot-fired
three of our deep deck profiles. They are fixings. CF 210 requires one main fixing ComFlor 210 shear clip
fixed using at least two shot-fired pins per trough.
for each length; in the Slimdek system
the end diaphragms align with the edge
of the lower flange of the beam.
32
Sitework Deep composite floor decks
Deck top
Beam top
Fixing spacings
ComFlor 210
End fixing 1 per trough
Side laps 1 fixing with shear clip at
350mm c/c
Side fixing 1 fixing at 600mm c/c
onto support
33
Deep composite floor decks Sitework
Edge details Any shear studs that are required (to Edge trims selector
The steelwork must be stable and make SFBs or RHSFBs composite) may Edge Maximum Cantilever (mm)
adequately restrained with support for be welded to these sections during trim Galv. Steel Edge Trim Thickness (mm)
the deck around columns and openings. fabrication, because they do not depth
Corus deep decking can be easily cut, interfere with the decking. If they are to (mm) 1.6 2.0
and fitted, to accommodate columns be welded on site, the precautions and 270 100 135
and other awkward shapes. Where there procedures outlined on page 32 should 300 0 100
is no supporting steelwork, brackets be considered. 350 x 0
fixed to the column will have to be used 400 x 0
for local support to the deck. x – not recommended
Cantilevers
Our deep decks can be Cantilevered
in its length up to 500mm during
construction. When Cantilevers are
required perpendicular to the span of
the profile, stub beams or some similar
type of support has to be supplied.
In both cases, the Cantilever must
be assessed, for the final stage,
in accordance with BS8110 Part 1,
to determine whether additional
reinforcement is required.
Reinforcement
The decking forms a part of the slab
reinforcement, with the remainder being
supplied by a bar in each trough of the
decking and a mesh placed near to the
top of the slab. Reinforcement should
be fixed in accordance with the
requirements of the Structural Designer.
Normally, circular plastic spacers are
used to position the bars 70mm from
the base of the trough. This distance
can increase to 90 or 120mm
(respectively) when 90 or 120 minutes
fire resistance are required. There may
be additional mesh or bar requirements
to fix adjacent to the supports or edge
beams, or above beams for crack
control purposes.
34
Transport and handling
35
FibreFlor
Benefits of FibreFlor
Cost savings Technical superiority
• Labour cost savings • Independent testing proves that the
• Up to 20% programme savings FibreFlor system provides equivalent
• No mesh to purchase, transport or or superior performance to traditional
store welded wire mesh solutions
• Reduction in crane hire costs • Quality assured concrete
• Potential concrete volume savings. reinforcement system
• FibreFlor is proven to reduce plastic
Easier to install shrinkage and settlement cracking
• No hoisting/lifting or manual handling • Unlike macro-synthetic fibres, the
of mesh micro-synthetic fibres in FibreFlor
• No steel fixing/tying requirements are also proven to mitigate the
• No spacer requirements explosive spalling tendency of
• 3-Dimensional reinforcement delivered concrete during fires
ready mixed in concrete • The inclusion of steel fibres in
• Easier concrete application (No trip FibreFlor provides load bearing
hazards or snagging from mesh) capabilities, increased toughness
• Fibre reinforcement always in the and long term crack control.
correct position.
36
FibreFlor
FibreFlor
In recognition of the many practical impact and abrasion resistance together
difficulties associated with the use of with reduced permeability of the
traditional welded wire fabric in upper concrete. Fibermesh micro-synthetic
floor construction and in response to the fibres are also internationally proven to
ever increasing demands for improved provide resistance to explosive spalling,
speed of construction, improved quality in the event of fire.
and cost effectiveness, Corus and
Propex Concrete Systems have joined Novocon high performance steel fibres
forces to develop FibreFlor. are proven to provide both a high level
of ductility to the concrete and long
Independent testing of ComFlor FibreFlor is a combination of Novocon term crack control. This allows the load
composite floor deck at the Namas certified high performance steel fibres and carrying capability to replace traditional
fire test facility. Fibermesh micro-synthetic fibres mesh reinforcement. Testing approved
providing a unique three dimensional by the Steel Construction Institute
concrete reinforcement solution for confirmed that FibreFlor also provided
composite metal decks and designed to longitudinal shear resistance in excess
replace traditional welded wire mesh. of that provided by A393 steel wire
fabric.
By combining the attributes of both
types of fibre, FibreFlor provides FibreFlor reinforced composite metal
performance benefits over the entire life deck systems have been extensively
span of the concrete – from simplifying tested in accordance with BS EN 1365-
placement, to minimising cracks in the 2:2000 standards at NAMAS certified
plastic state, to controlling cracks in the fire test facilities, under the guidance of
hardened state, to providing years of the Steel Construction Institute (SCI).
exceptional durability.
Results, analysed and approved by
In the development of FibreFlor, it was the SCI, show that FibreFlor reinforced
identified that many properties were composite metal deck systems provide
required to provide both an optimum equivalent or superior performance to
technical solution for the necessary fire traditional wire mesh solutions with fire
rating, but also practically in providing a ratings of up to two hours.
concrete solution that is easily handled,
pumped and finished. The world leading
brand of Fibermesh micro-synthetic
fibres are proven to inhibit both plastic
shrinkage and settlement cracking.
Additional benefits include increased
37
References Health and Safety
References
Health and Safety
38
ComFlor software References
ComFlor
Software
39
www.comflor.com
Copyright 2008
Corus
Corus International Projects Corus Middle East FZE Corus International India (Pvt) Ltd
897 Silbury Boulevard PO Box 18294 503/504 Raheja Chambers
Central Milton Keynes Jebel Ali 213 Backbay Reclamation
MK9 3XJ Dubai Mumbai 400-021
United Kingdom United Arab Emirates India
T: +44 (0)1908 508 250 T: +971 (0)4 887 3232 T: +91 22 2282 3126
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