Professional Documents
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TECHNICAL MANUAL
Speed of construction
Elimination of formwork or
propping
Are durable
Accommodation of services
Sound insulation
FLOORING
TECHNICAL MANUAL
CONTENTS
1
Introduction
Design Approach
Pre-planning
Preliminary Design
Final Design
Construction
16
Guide Specification
22
Bibliography
24
Sample Calculation
25
INTRODUCTION
DESIGN APPROACH
Connections
PRE-PLANNING
Tolerances
Construction tolerances must be allowed for in
developing a plan layout. Tolerance in plank length
is absorbed by allowing a gap at the end of the
plank and specifying the minimum length of
bearing. A clearance gap is also required along the
side of a plank that abuts a wall or beam to allow
for an accumulation of width tolerances. Small
increases in floor width can be accommodated by
increasing joint width with the use of a strip of
former to bridge the base of the joint during
grouting, Figure 15.
Floor Depth
For preliminary design the general load-span
graphs in Figures 2 to 7 can be used to determine
a suitable plank depth. To limit the deflection of a
floor slab and its sensitivity to vibration, the ratio of
span to overall depth is usually kept in the range of
3035 but can be up to 40. Roof slabs which are
not subject to foot traffic can range from 3545.
For handling, the ratio should not exceed 45.
The slab thickness may need to be increased if
deflection and vibration are critical such as when
there are sustained live loads, rhythmic action,
masonry partitions or a large number of openings.
Slender planks subject to light repetitive loading
such as foot traffic in quiet environments should be
checked for perceptible vibration. High fire ratings
increase cover and may require an increase in
overall depth. It is not practical to use continuity in
the structure to minimise plank depth.
Plank Width
It is preferable that the floor plan dimensions suit a
1200-mm module width. Never the less, nonmodular dimensions can be accommodated with
longitudinally-cut planks or wet-cast panels.
Alternatively an insitu makeup strip can be used.
Plank Length
The planks are cut to the length required for their
location in the floor-plan. The ends can be cut to
an angle to suit skew layouts.
PRELIMINARY DESIGN
Figure 1
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
L/D = 40
0
L/D = 40
7
10
11
12 0
SPAN (m)
Figure 2
L/D = 40
0
Figure 3
10
11
12 0
12
10
11
12
L/D = 40
9 10 11 12 13 14 15 16 0 1
SPAN (m)
Figure 4
11
SPAN (m)
L/D = 40
0 1
10
L/D = 40
SPAN (m)
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
SPAN (m)
SPAN (m)
9 10 11 12 13 14 15 16
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
L/D = 40
0 1
L/D = 40
9 10 11 12 13 14 15 16 0 1
SPAN (m)
Figure 5
9 10 11 12 13 14 15 16
L/D = 40
0
Figure 6
10
12
14
L/D = 40
16
18
20 0
10
12
14
16
10
12
14
16
L/D = 40
18
20 0
SPAN (m)
Figure 7
20
L/D = 40
0
18
SPAN (m)
SPAN (m)
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
SPAN (m)
SPAN (m)
10
12
14
16
18
20
5
5.1
5.3
FINAL DESIGN
General
Flexural Strength
Section Availability
5.4
Shear Strength
5.5
Transfer Stress
Crack Control
5.8
Load Distribution
Face of
support
L /4
L /4
Effective
width (L /4)
Effective width
(Interpolate)
Effective
width
(Interpolate)
L /4
L /4
Face of
support
1200
L /4 - 600
NOTE:
L = Span in mm
Figure 8
L /2
L /4 - 600
L /4 - 300
Concentrated load
L /2
300
L /4
100
100
1200-wide
units
90
1200 units
Linear loading
90
x
P
16 = L/x
Linear loading
80
80
70
70
60
60
50
50
10
3
40
2
3
1
2
1
30
20
10
0
3
10
11
12
13
14
Span (m)
Figure 9
40
30
L/x
2
16
20
10
L/x
2
0
3
10
10
6
16
8
10
11
12
Span (m)
Figure 10
13
14
100
90
1200-mm-wide units
2
x = 0.5 L
P
80
L
70
60
50
40
30
1
2
3
4
5
20
10
0
3
10
11
12
13
14
Span (m)
Figure 11
5.9
Continuity
5.10
Cantilevers
11
Allow for
camber
Bearing strip
LONGITUDINAL CANTILEVER
Figure 12
5.11
TRANSVERSE CANTILEVER
Structural Integrity
5.12
Diaphragm Action
L1
x 20 kN/m 70 kN
2
Tie bar
Insitu concrete
B
A
L1
L1 + L2
x 20 kN/m 70 kN
2
70 kN
Hollowcore plank
with cores opened
70 kN
Precast support
beam with
projecting ties
A
C
L2
20 kN/m typical
SECTION AA
L2
x 20 kN/m 70 kN
2
Insitu concrete
Tie bar
70 kN
Hollowcore plank
with cores opened
L1
x 20 kN/m 70 kN
2
L1 + L2
x 20 kN/m 70 kN
2
Precast support
beam with
anchored ferrule
70 kN
L1
SECTION BB
Insitu concrete
Tie bar
70 kN
70 kN
A
20 kN/m typical
70 kN
70 kN
L2
Hollowcore plank
with cores opened
L2
x 20 kN/m 70 kN
2
Precast support
beam with
anchored ferrule
SECTION CC
Figure 13
Figure 14
5.13
Fire Rating
Table 1
Section
30
60
90
120
180
240
60
80
100
120
150
170
25
25
25
25
30
34
20
15
25
20
35
25
40
25
55
35
65
45
14
5.14
Sound Insulation
5.15
Durability
Table 2
Classification
Typical
exposure conditions
Al
20
20
30
45
A2
B1
B2
15
6
6.1
CONSTRUCTION DETAILS
Connections
Bearing Support
Table 3
Plank
depth (mm)
Figure 15
Plank-to-Plank Connections
16
steel
150, 200
60
70
250, 300
100
100
350, 400
150
125
Tie as required
Topping with
reinforcement as required
3-mm neoprene
bearing pads, typical*
Sound-proofing across
wall may be required
20 minimum
(or bear on topping)
Precast or insitu
concrete wall
Topping as required
Topping as required
3-mm neoprene
bearing pads, typical*
Precast or insitu
concrete beam
INTERNAL CONCRETE BEAM DETAIL(1)
3-mm neoprene
bearing pads, typical*
Sound-proofing across
wall may be required
Beam reinforcement
Hollowcore
floor plank with
dam in cores
20 minimum
3-mm neoprene
bearing pads, typical*
Topping as required
Hollowcore
floor plank with
dam in cores
3-mm neoprene
bearing pads, typical*
Figure 16
3-mm neoprene
bearing pads, typical*
20 clearance
20 clearance
Topping with
reinforcement as required
Figure 17
3-mm neoprene
bearing pads, typical*
18
3-mm neoprene
bearing pads, typical*
NOTE: Lintel may require
propping if loaded on one
side during erection
6.3
Insitu Connection
6.4
6.5
20 recess
Topping with
reinforcement as required
A
A
Hollowcore floor plank
with dam in cores
Threaded bars, in core breakout, screwed
into anchored ferrules cast into wall
6.6
Topping Layer
6.7
Ties
SECTION AA
Figure 18
19
6.8
Penetrations
Suitable
locations
600 maximum
without use of
header beam
Figure 19
SECTION AA
Penetration Positions
Bearing
length
B
SECTION AA
Hangers
Figure 20
SECTION BB
6.9
Hangers
6.10
Waterproofing
Membranes.
Keys grouted,
topping optional
Figure 21
THRU-BOLT IN CORE
Shot fixing
suitable
30
21
Scope
GUIDE SPECIFICATION
Design
Planks shall be designed in accordance with
AS 3600, except where industry practice provides
a proven alternative method.
The manufacturer shall prepare and submit shop
drawings for approval of the general arrangement
of the planks, adequacy and dimensions prior to
manufacture. Shop drawings shall show the
location of all planks with all major openings
detailed. Shop drawings detailing each unit, cast-in
inserts and its strand configuration shall be
submitted to the building contractor for approval.
The design of the structure, including checking the
adequacy of the hollowcore planks for their
intended use in the structure, shall be the
responsibility of the Structural Engineer for the
project.
Materials
Cement shall comply with AS 3972 and
supplementary cementitious materials with
AS 3582 parts 1 and 2. Aggregates shall comply
with AS 2758.1. Chemical admixtures shall comply
with AS 1478.1.
Prestressing steel shall be stress-relieved lowrelaxation strand complying with AS 1311. Strand
shall be clean and free of deleterious substances
at the time of concreting.
Concrete shall have a minimum characteristic
28-day strength of 40 MPa and shall conform to
the requirements of AS 3600. Concrete strength at
release of prestress shall be a minimum of 25 MPa
or as required by the structural drawings.
Topping concrete shall have a minimum
characteristic 28-day strength of 32 MPa or as
shown on the drawings. If topping concrete is used
to grout the keyways, the maximum aggregate size
shall be 14 mm.
22
Manufacture
Tolerances
Floor planks shall be supplied in accordance with
the following tolerances.
Length
Width
+ 3 mm
- 6 mm
Thickness
+ 3 mm
- 3 mm
Squareness of end
+ 6 mm
- 6 mm
Wind
10 mm per 3000 mm
Location of ferrules
+ 20 mm - 20 mm
Location of strand
Differential camber
adjacent units
+ 10 mm - 10 mm
+ 3 mm
Insitu Topping
The Building Contractor shall provide a wellcompacted insitu structural concrete topping to the
floor planks as detailed on the drawings.
Reinforcement is to be placed in accordance with
structural details. The plank surface shall be clean
and free of loose material and surface-moist
(saturated surface-dry) immediately prior to placing
the topping. Finish and cure the topping so that
plastic shrinkage cracks are controlled to
acceptable levels. Construction joints in the
topping shall be located as shown on the drawings.
- 3 mm
Erection
The Building Contractor shall be responsible for
providing true and level bearing surfaces for the
support of the hollowcore planks. Temporary
shoring and bracing shall also be provided as
necessary to ensure the stability of the structure
during erection. The hollowcore planks shall be
installed by a competent erection contractor.
Where the manufacturer also erects the planks,
the Building Contractor shall be responsible for
providing suitable access at the site to enable
trucks and cranes to operate under their own
power.
23
BIBLIOGRAPHY
24
SAMPLE CALCULATION
Load factors
Ultimate load combination
Ed.dst = [1.2G, 1.5Q]
Moment strength reduction factor
m = 0.8
Shear strength reduction factor
v = 0.7
Short term combination factor
s = 0.7
Long term combination factor
l = 0.4
Working loads
Plank mass
Topping mass
Live load
Superimposed dead load
Ultimate loads
Plank mass
Topping mass
Live load
Superimposed
dead load
1 TRIAL SECTION
Choose a 200 deep hollowcore section with 60 mm
of structural topping, from the load-span charts
(Figure 3). Span/depth ratio is 31 and thus
vibration response will be satisfactory.
Bhc = 1200 mm
Area
Distance to Neutral axis
Moment of Inertia
fchci = 25 MPa
Ehci = 25,250 MPa
fchc = 40 MPa
Ehc = 31,900 MPa
fc.screed = 32 MPa
Escreed = 28,500 MPa
Concrete density
Other Variables
Span
Bearing length
Overhang past bearing
Composite section
Distance to Neutral axis Ybcomp = 138.8 mm
Moment of Inertia
Ls = 8.0 m
Lbrg = 80 mm
Lohang = 0 mm
25
2 SECTION ANALYSIS
M*
1200 dp
= 432
Np =
54.7
mm2
mm2
(Y - Yb)
= 7.9
P
Ahc
P e(Y - Ybhc)
Ihc
Pf = 78% Pi = 445 kN
bpi =
bphc =
26
Pi
Ahc
Pf
Ahc
Pi e
Zbhc
Pf e
Zbhc
= 8.7 MPa
= 6.8 MPa
Mhc
Zbhc
bcomp = bhc -
Msdl
Zbcomp
Bhc dp fc.screed
st = fp 1 -
ku =
k1 k2
= 0.108
= 1761.9 MPa
Ap st
0.85 fc.screed dp Bhc
= 0.147
ku
2
= 179.3 kNm
Mu = m Mu = 143.4 kNm
> M*
OK
= 2.02
> 1.2
Mhc + Mscreed
Zbhc
= 0.37 MPa
compression
- s
Mll
Zbcomp
< allowable ft
k1 = 0.4
Ap fp
Zbhc
k2 =
Mscreed
OK
27
= -2.9 MP
tension
OK
2.4 Shear
The requirements of AS 3600, Clause 8.2, for
flexure-shear must be met at all sections of the
plank. This capacity can be calculated directly. The
provisions for web-shear (principal tension
cracking) only apply to cross-sections uncracked in
flexure. The calculation for web-shear capacity is
more involved except at the neutral axis. Refer to a
standard text for derivation of the formulae, such
as Chapter 12 of Bibliography Item 13.
2.5 Flexure-shear
The flexure-shear capacity at a cross-section must
be calculated at several locations along the span
to locate the critical section. For a UDL the shear
capacity equation in AS 3600, Clause 8.2, is a
descending curve from the support to mid-span.
The minimum difference between the capacity and
the shear force at a section occurs at about
quarter span where shear is significant and
bending moment is reasonably high.
Ls
4
Mx =
= 2.0 m
(Whc + Wscreed)Ls x
2
(Whc + Wscreed) x2
2
= 33.4 kNm
The decompression moment, M0, taking Mx into
account, is:
M0 = bphc -
Mx
Zbhc
V*x
M*x
= 18.1 kN
dp
1000
= 1.518
2 = 1.0
3 = 1.0
Vuc = v 1 2 3 bwhc dp
Ap fchc
1/3
bwhc dp
+ V0
= 72.3 kN
which is compared to the factored shear
at location x
If this section is uncracked then the web-shear
provisions also apply.
28
2.6 Web-shear
The principal tension under the design loading at a
cross-section is limited to 0.33fchc by AS 3600,
Clause 8.2. It is not obvious where the maximum
value will occur and a number of locations in the
section will require examination. These include the
minimum web width, the neutral axis and the
bottom web-flange junction. The latter only applies
to planks with non-circular voids. At positions other
than the neutral axis there will be flexural stress on
the cross-section due to superimposed loads in
addition to the self weight and prestress.
Y = 85 mm
Direct stress at this location is:
x =
s =
px =
M*x =
(W*ll + W*sdl) x
2
V*x Qbfcomp
Icomp bv
Y - Ybcomp
x
2
= 0.6 MPa
+ s2 -
x
2
= 0.24 MPa
tension
< p
Pf = 216.4 kN
(W*hc + W*sdl) x
+ M*x
OK
M*xhc =
Ihc
5 = 0.2
Y - Ybhc
Lbrg
+ M*xhc
x = dp +
Ihc
bv = bwhc
0.9(60db)
Y - Ybhc
- Px e
compression
Ld - 0.1(60 db)
Ahc
= 1.29 MPa
Px =
Px
29
OK
Icomp
2.8 Deflection
Calculate the deflection of the plank at installation
and under long-term service load using the
deflection multipliers from Table 3 in Bibliography
Item 12 (reproduced below). The insitu topping
provides a level surface initially and is the datum
from which subsequent deflections are measured.
Downward deflection is negative in these
calculations.
The hog due to prestress at release is:
Pi e Ls2
ps =
8Ehci Ihc
= 15.6 mm
hc =
Ls
- top.surface
= 524
-5 Wscreed Ls4
= - 4.3 mm
= - 2.3 mm
= - 4.5 mm
Suggested Multipliers for Estimating Long-term Cambers and Deflections for Typical Elements
[Based on Table 3 in Bibliography Item 12]
Stage
Component
Application
Composite topping
Without With
Erection
Deflection (downward)
1.85
1.85
Erection
Camber (upward)
1.80
1.80
Final
Deflection (downward)
2.70
2.40
Final
Camber (upward)
2.45
2.20
Final
Deflection (downward)
3.00
3.00
2.30
Final
Deflection (downward)
30
Rescrete Industries
PO Box 121
Riverstone NSW 2765
Phone: 02 9627 2666 Fax: 02 9627 5161
Email: info@rescrete.com.au
www.npcaa.com.au
ISBN 0 9577467 2 5