IntroductionComFlor® is a composite floor decking system designed for rapid installation and efficient construction. It offers various profiles tailored for specific applications, ensuring optimal performance and cost-effectiveness. The manual provides detailed specifications, design, and construction guidelines for each ComFlor®
profile.
Span Parameters
The manual outlines span parameters for different ComFlor® profiles, including assumptions for quick reference span tables. It provides guidance on construction stage deflection, normal stage deflection, concrete grades, and construction loads.
ComFlor® Profiles- ComFlor® 46: Known for transport efficiency and fast laying capabilities.
- ComFlor® 51+: Features a flat soffit and enhanced composite performance.
- ComFlor® 60: Combines trapezoidal and re-entrant profiles for versatility.
- ComFlor® 80: Offers long span capability with easy service attachment.
- ComFlor® 100: Designed for long spans, reducing the need for temporary propping.
- ComFlor® 210 and 225: Deep profiles for ultra-long spans, suitable for integrated beam systems.
Design, Construction, and Sitework Information
The manual provides comprehensive design and construction guidelines for each profile, including fire engineering and load/span tables. It emphasizes the importance of using the ComFlor® 9 software for detailed design.
Sustainability and Quality Assurance
Tata Steel is committed to sustainable practices, producing steel responsibly and facilitating recycling. The company adheres to quality management standards and offers professional support through a technical help desk.
Health and Safety
ComFlor® profiles are designed with health and safety in mind, offering quick and safer installation. The manual includes guidelines for transport and handling to ensure safety on site.
Conclusion
The ComFlor® manual serves as a comprehensive guide for selecting and implementing composite floor decking systems, providing essential information for efficient and sustainable construction.
Overview of ComFlor® 46
ComFlor® 46 is a composite flooring system known for its nestable design, ease of transport, and efficient installation. It is particularly suitable for export and sites with difficult access due to its compact packaging and quick installation process.
Key Features- Nestable Design: Maximizes square meters per bundle.
- Low Transport Cost: Reduces environmental impact and transportation expenses.
- Fast Installation: Allows for quick concrete pouring.
- Economic Efficiency: Offers lower cost and reduced concrete usage.
- Export Efficiency: Maximizes square meterage in each container.
Design Specifications- Deck Material: Made from Tata Steel Galvatite®, conforming to BS EN 10346 standards.
- Anti-Crack Mesh: Minimum reinforcement requirements specified for different constructions.
- Supporting Beam Width: Assumed to be 152mm for load/span tables.
- Fire Design: Fire resistance calculated using Steel Construction Institute guidelines.
Technical Services
Tata Steel's Technical Department provides advisory services for the design of composite flooring, offering support beyond the provided literature and software.
Volume and Weight Specifications
Detailed tables on the weight of concrete and slab depth for both normal and lightweight concrete, conforming to British Standards.
Section Properties
Details on nominal thickness, design thickness, cross-sectional area, profile weight, and ultimate moment capacity are provided for different configurations.
Fire Method Tables
Tables outline the load capacities for various slab depths and fire periods, with specifications for both unpropped and propped conditions.
Overview of ComFlor® 51+ Profile
ComFlor® 51+ is an advanced re-entrant profile design, widely used in British construction since the 1970s. It offers a flat soffit for aesthetic appeal and superior composite deck fire performance. The profile features new embossments for enhanced composite slab strength and effective shear stud interaction. Dovetail grooves at 150mm centers provide optimal anchorage for services.
Composite Performance- Floor Slab: New embossments improve shear key performance and point load resistance.
- Beam: Re-entrant profile shape ensures effective shear stud performance.
Fire and Acoustic Performance
The profile's low intrusion into concrete allows for good fire ratings and sound reduction, with the flat soffit offering excellent fire protection to the beam's top flange.
Design Information- Material: Tata Steel Galvatite®, zinc-coated steel, suitable for non-aggressive environments.
- Anti-crack Mesh: Minimum reinforcement requirements specified for crack control.
- Fire Design: Fire resistance calculated per SCI guidelines.
Technical Services
Tata Steel provides advisory services for composite flooring design, with additional support available for queries not covered by existing literature or software.
Section Properties
ComFlor® 51+ section properties conform to BS 5950 and Eurocode standards, detailing nominal thickness, design thickness, cross-section area, profile weight, and moment capacities.
Composite Slab Volume and Weight
Includes a table detailing the weight of concrete per slab depth, with values for both normal and lightweight concrete, wet and dry conditions.
Fire Method Tables
Tables provide data on single and double span decks, slab depths, mesh requirements, and total applied loads for various fire periods.
Specifications:
Tata Steel Galvatite® is a hot dip zinc coated steel conforming to BS EN 10346 S350GD+Z275, with a minimum proof strength of 350N/mm² and a zinc coating mass of 275g/m². It is suitable for internal floors in non-aggressive environments.
Anti-Crack Mesh:
For simply-supported continuous slabs, the anti-crack reinforcement should be at least 0.2% of the concrete cross-sectional area above the ribs for unpropped construction, and 0.4% for propped construction.
Concrete Cover:
A nominal cover of 25mm is required for exposure level XC1, applicable to both normal and lightweight concrete.
Supporting Beam Width:
The ComFlor® 60 load/span tables assume a support beam width of 152mm.
Fire Design:
The fire resistance of composite slabs with nominal anti-crack mesh is calculated using SCI NCCI PN005.
Technical Services:
Tata Steel's Technical Department provides advisory services for composite flooring design.
Design Information:
Details on the ComFlor® 60 composite slab, including section properties and weight, are provided.
Fire Resistance Tables:
Tables are provided for single and double span decks, detailing slab depth, mesh requirements, and total applied load for various fire periods.
Overview: The document provides technical specifications and guidelines for the use of ComFlor® 60 and ComFlor® 80 composite flooring systems.
Specifications: The document outlines the specifications for ComFlor® 60 and ComFlor® 80, including the use of normal weight concrete and the Eurocode standards for beam width and slab depth.
Procedures: The document details the procedures for calculating the load capacities and fire resistance of composite slabs using the Mesh and Deck Fire Method and the Bar Fire Method.
Design Notes: Design notes include information on the materials used, such as Tata Steel Galvatite® for the decking, and the importance of anti-crack mesh reinforcement.
Fire Design: The document explains the fire design methods available for composite slabs, referencing the Steel Construction Institute's guidelines.
Key Data from Tables: The tables provide detailed data on slab depths, mesh requirements, and total applied loads for different fire periods and slab configurations.
Recommendations: The document recommends consulting the Technical Department for specific queries not covered in the literature or software.
Overview of ComFlor® 100 and ComFlor® 210:
ComFlor® 100 and ComFlor® 210 are composite flooring systems designed for use with steel, concrete, or masonry supports.
ComFlor® 100:
- Design and Specifications: Features a strong long-span profile suitable for non-composite beams.
ComFlor® 210:
- Design and Specifications: Originally designed for Slimflor® systems, it features a deep profile with cross stiffener technology.
General Notes:
- Both profiles are designed to conform to British Standards for density and section properties.
Key Tables and Data:
- ComFlor® 100: Tables provide data on slab depth, concrete volume, and weight for both normal and lightweight concrete.
Shrinkage and Creep: Concrete experiences shrinkage during curing and drying. Creep effects also need consideration in composite construction.
Composite Deck Durability: Steel decking surfaces must be protected against atmospheric conditions.
Anti-Crack Mesh: Composite floors are typically designed as simply supported slabs.
Forklift Trucks: For areas with concentrated loading, a minimum reinforcement of 0.5% is recommended.
Exposed Floors: Crack width control is generally not required for covered floors.
Control of Cracking: Adequate reinforcement is necessary to distribute tensile strains and prevent large cracks.
Minimum/Maximum Anti-Crack Mesh Cover: Minimum concrete cover is determined by bond and environmental conditions.
Bar Reinforcement: The axis distance for bar reinforcement ranges from 25mm to the profile height.
Transverse Reinforcement: Transverse reinforcement is necessary to ensure shear resistance in composite beams.
Modular Ratio: The modular ratio is 10 for normal concrete and 15 for lightweight concrete.
Bearing Requirements: Bearing lengths must prevent damage and ensure load capacity.
Fire Design: Composite slabs must meet load-bearing, integrity, and insulation criteria under fire conditions.
Specifications and Standards:
The document discusses the reinforcement requirements for composite slabs, referencing BS EN 1994-1-2.
Fire Design Methods:
Two fire design methods are outlined: the 'Mesh and Deck Method' and the 'Bar Method'.
Construction Stage Considerations:
The document emphasizes the importance of limiting deflection during construction.
Vibration and Dynamic Sensitivity:
The dynamic sensitivity of composite slabs is generally not critical due to their stiffness.
Loads and Load Arrangement:
Construction loads during concrete casting are specified.
Lateral Restraint and Diaphragm Action:
ComFlor® steel decking provides temporary lateral restraint and diaphragm action during construction.
Acoustic Performance:
Acoustic performance is addressed, with guidance on achieving regulatory requirements.
Openings in Composite Slabs:
Guidelines for accommodating openings in slabs are provided.
Composite Floor Decks - Design and Construction Overview
1. Reinforcement and Load Transfer:
Reinforcement in composite slabs often involves bars placed in the troughs of the decking.
2. Shear Stud Design:
Composite beams can achieve up to 50% savings in beam weight.
3. Shear Stud Specifications:
The most common shear connection in buildings is the 19mm diameter headed shear stud.
4. Mesh Positioning and K Factor Modification:
Modern practice uses a single layer of mesh.
5. Minimum Shear Connection:
SCI publication P405 provides rules for the minimum degree of shear connection.
6. Anchorage and Deck Suitability:
Appropriate anchorage is crucial for non-continuous decks.
7. Construction Details:
Details include typical floor layouts, edge trims, cantilever specifications, and reinforcement requirements.
8. Design Guides and Recommendations:
For comprehensive design and construction practices, refer to SCI P300 and P359 publications.
Installation and Structural Requirements:
- The installation of decks onto ledger angles requires a minimum bearing of 50mm.
Deck Fixing:
- Decks must be fixed immediately after laying using powder actuated pins or self-drilling screws.
Edge Trim and Bearing Requirements:
- Edge trims are used to retain wet concrete and are fixed similarly to the deck.
Shear Connectors:
- Commonly used shear connectors are 19mm diameter headed studs.
Concrete Casting and Mesh Placement:
- Decking must be clean before concrete pouring.
Ceilings and Services Hanger Systems:
- ComFlor® profiles allow for easy suspension of ceilings and services.
Openings and Temporary Supports:
- Openings greater than 300mm require design by an engineer.
Deep Composite Floor Decks:
- These decks integrate with beams for a shallow structural floor.
Design Procedure:
- The design involves two stages: construction and composite action.
Temporary Propping and End Bearing:
- Temporary props should be spaced to prevent damage.
CE Marking:
- All ComFlor® decks are CE marked in accordance with BS EN 1090.
Reinforcement and Structural Integrity: The document discusses the use of reinforcing bars in the troughs of decking to enhance the ultimate load resistance and bending resistance of composite slabs.
Cracking and Reinforcement: Cracking over beams is normal and not detrimental.
Fire Resistance: Slab depth is crucial for fire resistance.
Vibration Considerations: The dynamic sensitivity of composite slabs is checked against standards.
Partial Continuity and Service Attachments: Partial continuity in deep decking is considered for British Standard designs.
Openings in Slabs: Guidelines for accommodating service openings in slabs are provided.
Construction Details: Detailed instructions for fixing ComFlor® 225 decking onto various supports are provided.
Health and Safety: Installation must be carried out by approved contractors.
Specifications and Procedures:
The document outlines the specifications for ComFlor® 210 and 225 deep composite floor decks.
Fixing Information:
For ComFlor® 225, end fixings require two per trough.
Edge Details and Cantilevers:
The document emphasizes the need for stable steelwork and adequate restraint around columns and openings.
Reinforcement and Temporary Support:
Reinforcement involves bars in each trough and mesh near the slab top.
Permanent Formwork Profiles:
ComFlor® offers permanent non-composite formwork profiles.
ComFlor® 60 with Closed Ends:
This profile offers enhanced acoustic and fire performance.
ComFlor® Active:
ComFlor® Active is designed for sustainable temperature control in buildings.
Colorcoat FD®:
Colorcoat FD® pre-finished steel is used for exposed ComFlor® soffits.
Introduction
The document provides detailed information on Colorcoat FD® pre-finished steel products, their specifications, applications, and handling procedures.
Colorcoat FD® Specifications- Colorcoat FD® 25: A 25-micron polyester coating designed for internal environments.
- Colorcoat FD® 170: Features a 170-micron coating with a warranty of up to 25 years.
Mechanical Properties
Both Colorcoat FD® 25 and FD® 170 are available in various steel grades.
Handling and Installation
Special care is required during offloading and handling to prevent damage.
ComFlor® Software
The ComFlor® 9 software is available for designing composite floor slabs.
Sustainability Initiatives
Tata Steel is committed to sustainable practices, aiming to reduce CO2 emissions by 50% by 2050.
ComFlor® in Construction
CPD seminars are offered to provide insights into composite floor decks.
Transport and Handling
Guidelines for receiving, checking, and storing composite floor decking are provided.
Installation Procedures
Decking should be installed promptly upon delivery.
Health & Safety Guidelines- Handling Hazards: Zinc-coated steel decking should be handled with care.
- Eye Hazards: Wear eye protection when breaking strapping or cutting steel.
- Noise Hazards: Use ear defenders when handling or cutting decking.
- Respiratory Hazards: Use respiratory equipment to prevent metal fume fever.
- Explosives and Fumes: Follow safety instructions for shot fired fixings.
- Occupational Exposure Limits: Follow recommended limits for iron and zinc oxides exposure.
- General Safety Points: Secure decks before use and avoid overloading.
Design Standards- Eurocode Standards: The document follows Eurocode standards for structural design.
- Supplementary Publications: Includes references to SCI and Concrete Advisory publications.
- British Standards: Compliance with British Standards for composite floor decks.
Trademarks and LiabilityColorcoat FD, ComFlor, Slimdek, and Slimflor are trademarks of Tata Steel UK Limited.