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Steelcomp-composite sheetsitework 1.3.2006

Copyright 2006 Rautaruukki Oyj


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1. PURCHASING AND DELIVERY .................................................................................................................................31.1 Steelcomp composite sheet...................................................................................................................................31.2 Purchasing .............................................................................................................................................................31.3 Delivery ..................................................................................................................................................................3

2. ERECTION ..................................................................................................................................................................42.1 Propping.................................................................................................................................................................42.2 Preparing................................................................................................................................................................52.3 Constructional details.............................................................................................................................................5

3. CASTING CONCRETE................................................................................................................................................73.1 Demands for concrete............................................................................................................................................73.2 Casting...................................................................................................................................................................73.3 Drying of concrete..................................................................................................................................................8

4. FINISHING OF COMPOSITE SLAB............................................................................................................................94.1 Openings................................................................................................................................................................94.2 Removal of propping..............................................................................................................................................94.3 Coatings.................................................................................................................................................................94.4 Installing hangers.................................................................................................................................................11

Appendices: ...................................................................................................................................................................12



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1. PURCHASING AND DELIVERY

1.1 Steelcomp composite sheet

Steelcomp composite sheet has a national type approval in Finland (type approval 288/6221/2003). Composite sheets are manufactured by roll forming either from galvanized or fromcoated constructional sheet S350GD+Z275 (EN 10326). Tolerances for composite sheet aredefined in EN 508-1 and material tolerances are according to EN 10143.

Steel thickness is 0.7 mm, 0.9 mm or 1.1 mm. Normally composite sheets are supplied as hot-

galvanized with total zinc layer of 275 g/m (altogether on both sides) or if the lower surfaceremains visible as polyester coating (white). It is possible to get other types of coatings andcolours by order.

1.2 Purchasing

Composite sheets are delivered with pre-defined lengths, therefore designer has to fill in materiallist (Table 1.2-1) and manufacturers package list (Table 1.2-2).

The maximum sizes for a package are 22 sheets and 1500 kg. Sheets are supplied to customer-specified lengths, usually with lengths divisible by 10 mm. Following information is needed:

customer and contact information

time of delivery and delivery address

material list for composite sheets

coating information

delivery order for packages

special demands for packages

1.3 Delivery

Purchaser has to ensure before delivery that there is enough space for unloading.

Delivery check has to be done right after unloading and the following information should bechecked:

lengths

thicknessess

coating



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amount of composite sheets

weight of composite sheets overall appearance of the sheets

It is recommended to lift packages directly near erection area. One package at time should belifted by fastening ropes attached to the structures of transport pallets. Sheet stacks must not belifted without their pallets. The width of the rope must be at least 50 mm,

If a sheet stack is lifted on installed sheet span, it must be positioned so that the supports of thetransport package run across the sheet profile, and the package supports must be placed nearpropping.

If composite sheets are to be stored at site following information should be taken intoconsideration:

place sheets stacks to an area where is as little traffic as possible.

store sheets in their transport packages on even flooring and sheets must be supported ontheir pallets

it is not allowed to store sheets directly on ground

take care of ventilation and removal of water caused by rain, longer storage requires a storageroom

it is not allowed to store more than 1 pallets on the top of another pallet, note that the transportpallets are exactly on the top of each other

no heavy objects or items causing local loading may be stored on the top of the sheets

handling of sheets must not cause permanent deformations to the sheets

check the overall condition of composite sheet packages

2. ERECTION

2.1 Propping

Erection of propping devices must be done before installing sheets. Propping span lengths mustbe presented in constructional details. In addition to that final propping plan is a part of erectionplan made by the contractor. This plan is to be approved by the constructor before erection.

If marks in the lower surface of composite sheet is allowed, then prop spacing is presented inDetail 2.1-2 and in Figures 2.2-2...5. If visible marks are to be avoided, then recommendedmaximum bearing distances: 1.2 m 0.9 mm sheet and 1.5 m 1.1 mm sheet.

Propping must be erected carefully in order to avoid damage to the visible surface. In this case, itis recommended to use minimum propping width of 125 mm and at least 50 mm if some visible

damages are allowed. If necessary the prop surface can be extended, e.g. using a plywood bank,



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which reduces prop marks considerably, see Detail 2.1-2. Also the edges of composite sheetsmust be propped.

The support provided by the propping must be continuous (e.g. horizontal beam). Pre-raising ofcomposite slab can be achieved by installing sheets on raised propping. Naturally the wholepropping structure must be stable, no movements are allowed during casting of concrete. It isvery important to ensure that there is no vertical movement in the propping due to shifting of sub-structures. Propping must be braced in order to avoid lateral displacements.

Propping can be removed then 60 % of the designed strength of concrete is reached, unlessthere is other kind of demands presented in constructional design specification for that site.

2.2 Preparing

Propping installation must be finished before it is allowed to use composite sheets as a workingplatform.

If there is water, snow or ice on the sheets, the surface is slippery. It is recommended to set yourfeet on two ribs then you are walking on the composite sheet platform.

Safety regulations must be taken into account: safety rails must be installed in order to preventfalling from the platform and all holes must be covered. These facts should be described in sites

safety manual and erection plan.

Sheets should be lifted with care in order to avoid scratches in visible surfaces. Any impacts ofdropping tools or etc may cause permanent visible drawback.

If it is forced to store heavy items on a composite sheet platform, it should be done as follows: putsupport beams transverse to the forming direction on the top of the ribs, make sure that thesesupport beams locate exactly at the same line as the propping beams. However heavy or localloads should be avoided.

2.3 Constructional details

Composite sheets are installed with narrow profiling up by interlacing the sheets for a width ofone rib. Each sheet can be installed by hand.

Support widthMinimum support width is 50 mm. All sheets are fixed to the support at the bottom of every otherrib. Composite sheets may not be fastened to the propping because the inserts remain visibleafter dismounting the propping.



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Protective liningFree edge of the sheet is sealed up by using protective lining: lining profile, L-profile or taping inorder to stop concrete from running down (Detail 2.3-1).

Edge profileIt is possible to supply edge profiles with the sheet supply (U- or L-profile).Edge profiles can beattached to the steel beams at works (Detail 2.3-2). Edge profiles are fixed to the compositesheets c/c 500 mm. It is possible to use other materials for edge profiles.

OpeningsOpenings should be boxed out prior to the pouring of the concrete

larger openings than 300 x 300 mm require special reinforcement and support on every edges

timber shutter or dense polystyrene block can be used in order to delimit the area, afterconcrete has hardened enough sheet is cut off.

FixingsComposite sheets are fixed to permanent supports either with nails or screws with a spandetermined in the structure design. Composite sheets must also be fixed on the interlaced edge,either using hidden rivets or screws with a maximum spacing of 500 mm.

Fixing information is presented in Table 2.3-1.

The pre-raising of a slab can be achieved by installing composite sheets on raised propping

which will result in the desired pre-raising of the slab. Also the pre-cambering of primary and/orsecondary beams should be taken into account in the planning of the propping.

Fixings.

To masonry orto concrete

Spike D 03-4.8x25, minimumdistance from sheet edge 50mm!

Upat-UDN nail-anchor 6/35

To steel SFS SD14 5,5 x32 / EJOT HS 38

or equilvalent Nail Hilti ENP2-21-L15

To closures etc SFS SL range/EJOT SF25 orequilvalent

Side laps SFS SL range/EJOT SF25 orequilvalent

Rivet 4,8x8

Table 2.3-1 Fixing types



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ReinforcementTransversal reinforcement of the lower part of the slab is installed directly on the top of the ribs. Inthis way it is easier to install main (longitudal) reinforcement, see Detail 2.3-3. Transversalreinforcement covers sheets and makes it easier to move on platform. Note that the location(height) of the transversal reinforcement is determined in constructional drawings.

Upper reinforcement has to be supported by plastic spacers, Z-strip or spacing elements, seeDetail 2.3-4. This supporting has to be done in such manner that it is possible walk on upperreinforcement.

3. CASTING CONCRETE

3.1 Demands for concrete

The cube strength of the concrete used must be at least 25 MN/m2. If concrete is about to becovered then the cube strength of the concrete should be at least 30 MN/m2. Normally concreteshould dry as fast as possible therefore concrete should have as small water/cement ratio aspossible and use of agents is recommendable. It is possible to use normal weight concrete orlight weight concrete in composite slabs.

The granular size D of the concrete must meet the requirements D < hc, D < 32 mm. The effect ofconcrete type on the drying of the concrete is presented in Figures 3.1-1...5.

There are many agents which have effect on the properties of concrete. The most importantproperty of concrete (in addition to strength) is its ability to dry after casting. Water-cement ratioshould be set to a value of 0.5 and the amount of air in the concrete should be near 7 to 8 %.Agents increasing the workability of concrete should be used in order to make the pumpingeasier.

3.2 Casting

Prior to casting composite sheets should be cleaned and the slots between the sheets andbetween the structures next to them are sealed with structures suitable for this purpose. Inaddition to that following matters should be taken into account

compare propping and support widths to the plan

check reinforcement: amount and location

check sealing

Concrete can be pumped or moved in more traditional manner.



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The casting is done spreading the concrete in even layers. Maximum thickness of the layer is theslab height. The spreading of the concrete must be started from the sheet ends, moving on to themiddle of the sheet span. The drop height of the concrete onto the composite sheets must beminimized, and concrete can not be heaped on the slab locally.

Concrete can be consolidated using any ordinary consolidation methods and it is covered byplastic or after-treatment substance. Any work joints should locate near at one third of the span.Joint mesh should be used in work joints, see 2.3-14.

After casting it should be checked that

all concrete leaks are removed as soon as possible

3.3 Drying of concrete

Composite slab must be dry enough before any covering can be installed. Circumstances,concrete type, slab height define the time which is needed for drying. All drying will happenupwards due to the fact that water can not penetrate tight sheeting.

After concrete has hardened it is not allowed to douse it because drying time is long. Relativehumidity should be measured from slab, and this measured value should be compared to theallowed relative humidity of the selected covering material. Informative allowed relative humidity

is given in Table 3.3-1.

Covering Relative humidity incomposite slab

Vinyl 85-90%Linoleum 85%Parquet 80%

Table 3.3-1

The properties of the concrete, vapour resistance of the top layers (filler and glue) and the

covering itself define how humidity distributes over the structure. It is very important to use fastdrying concretes, e.g. NP K30 (C25/30) contains large amount of cement and they dry about 2-3times fasters than ordinary concretes. Another major point is after-treatment of concrete. It isrecommended to use plastic cover or after-treatment substance (plastic cover is preferred). After-treatment should be started right after casting of concrete in order to avoid plastic cracks in theconcrete. Fast drying of concrete increases these plastic cracks.



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4. FINISHING OF COMPOSITE SLAB

4.1 Openings

The openings should be boxed out before pouring of the concrete. Metal deck is cut afterconcrete has reached 75 % of its design strength, see 4.1-1.

Openings with diameter < 150 mm can be drilled through the slab.

4.2 Removal of propping

After concrete has reached 60 % of its design strength propping can be removed unless there aremore strict demands presented in constructional design. It is possible to have effect on the timeneeded: concrete type, temperature of the concrete, covering of the concrete, heating of theconcrete. The removal of propping has to be planned in erection plan.

There are examples of the hardening process of concrete in Figure 4.2-1. However actual valuesshould be checked from the supplier of concrete case by case.

4.3 Coatings

Steelcomp-composite decking can be painted: touch-up painting or repair painting of an oldcolour coating . Cleaning agents and maintenance paints are presented in the following table.

Cleaning agents Paints ManufacturerPELTIPESU PLASTON

KIRJO AQUAGALVEX

Teknoswww.teknos-group.com

PANSSARIPESU REPCO

TEMAKEEPROSTEX SUPER

Tikkurila

www.tikkurila.com

Cleaning

Dirty or soiled places should be washed with a soft brush and water. High-pressure water (< 50bar) can also be used for cleaning. More stubborn dirt or stains can be removed using a cleaningagent suitable for paint coatings, which after leaving for a few minutes to take effect should thenbe carefully washed off. Difficult dirt spots can be removed with cloth moistened in white spirit.The use of strong or unsuitable cleaning agents will damage the colour coating.

http://www.teknos-group.com/http://www.tikkurila.com/http://www.tikkurila.com/http://www.teknos-group.com/


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Touch-up painting

Touch up painting of scratches while they are still fresh means that the area to be repaired isusually small and the repair is quick and simple. Only paints suitable for maintenance painting ofcolour coatings should be used. The damaged area should be cleaned with white spirit beforerepainting. After drying, the area should be touch-up painted using as small brush as possible. Ifthe damage reaches down to the primer coat only, one coat of paint is sufficient. If, however, thedamage reaches down to the zinc coating, it is recommended that a second coat of paint isapplied after the first coat is dry. If the zinc coating is clearly damaged then products like Galvexor Rostex Super should be used as a new primer. Spray-paints must not be used.

PVDF Plaston or Repco

Pural Repco or PlastonMatt pural Repco or PlastonPolyester Repco or PlastonMatt polyester Repco or Plaston

Most common coating for Steelcomp is polyester (indoor thickness, white colour).

Coating Properties

Outdoors PVDF Excellent corrosionprotection and visualstability

Matt polyester Good corrosion protectionand visual stability

PURAL Excellent corrosionprotection and good visualstability

Indoors Polyester Good mechanicalproperties

Table 4.3-1

Repair painting of an old colour coating

The life time of an undamaged original colour coating without repainting is on average 25 to 40years, depending on the type of coating, building method and climatic conditions.

- check the adhesion of the coating- remove any peeling or flaking coating- remove any rust- wash the surface using either Peltipesu or Panssaripesu- rinse thoroughly



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- prime coat any areas from which peeling coating or rust has been removed, using eitherRostex Super or Galvex

- Paint 1-2 coatso PVDF Plaston or Temakeep+Repcoo Pural Repco* or Plastono Matt polyester Repco* or Plastono Polyester Repco* or Plastono Plastisol Repco or Kirjo Aqua

* Temakeep primer is recommended if the surface is strongly faded

4.4 Service hanger systems

The dovetail shaped re-entrant rib allows quick and easy suspensions of ceiling and servicesusing threaded wedge nut fixings, (see Figure 4.1-1). The dovetail shaped wedge nuts will lockinto the dovetail re-entrants under vertical loading. The maximum allowed load is 1 kN andminimum spacing is 200 mm. Heavier loads needs to be considered separately by constructor.



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Appendices:

1. Figure 2.1-1/ Example drawing2. Detail 2.1-2/ Propping3. Table 1.2-1/ Sheet list

Table 1.2-2/ Package listFigure 2.2-2/ Maximum spansFigure 2.2-3/ Maximum spansFigure 2.2-4/ Maximum spansFigure 2.2-5/ Maximum spans

4. Detail 2.3-1/ Protective lining

5. Detail 2.3-2a/ Free edge of sheeting6. Detail 2.3-2b/ Connection to the steel beam7. Detail 2.3-3a/ Standard prefabricated reinforcement 1400 mm8. Detail 2.3-3b/ Prefabricated reinforcement 1000 mm9. Detail 2.3-3c/ Standard mesh reinforcement 1400 mm10. Detail 2.3-3d/ Standard mesh reinforcement 1000 mm11. Detail 2.3-4a/ Reinforcement at upper surface12. Detail 2.3-4b/ Reinforcement at upper surface13. Detail 2.3-5/ Connection to steel beam/mid-support14. Detail 2.3-6/ Connection to steel beam/mid-support15. Detail 2.3-7/ Connection to steel beam/end support

16. Detail 2.3-8a/ Connection to concrete/end support17. Detail 2.3-8b/ Connection to concrete/end support18. Detail 2.3-9/ Connection to concrete/mid-support19. Detail 2.3-10/ Connection to ComBeam/internal support20. Detail 2.3-11a/ Connection to punching shear component21. Detail 2.3-11b/ Connection to punching shear component22. Detail 2.3-12/ Connection of sheets23. Detail 2.3-13/ Connection to masonry24. Detail 2.3-14/ Work joint25. Detail 4.1-1/ Openings and installations26. Figure 3.1-1/ Drying of composite slab

Figure 3.1-2/ Drying of composite slabFigure 3.1-3/ Effect of concrete to drying timeFigure 3.1-4/ Drying of composite slabFigure 3.1-5/ Drying of composite slabFigure 4.2-1/Development of strength in composite slab

27. Figure 3.1-6/ Humidity in composite and concrete slab



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STEELCOMP 1(3)SITE MANUALPropping APPENDIX 3

Construction 2006-02-27

SHEET LISTCONSTRUCTOR: STEELCOMP

SITE ID: LISTED BY:RELATES TO DRAWING: PHONE

SHEET LIST NUMBER DATE:

ID t PCS Length LEV Grade Weight/pcs NOTE!

[mm] [mm] [mm] [kg]

PCS AREA WEIGHT

[m2] [kg]

TOTALLY

Table 1.2-1/Sheet list.

PACKING LISTDESIGNER: STEELCOMP

SITE ID: LISTED BY:

RELATES TO DRAWING: PHONE:

SHEET LIST NUMBER DATE:

SHEET STACK SHEET STACK SHEET STACK SHEET STACK

ID PCS ID PCS ID PCS ID PCS

TOTALLY TOTALLY TOTALLY TOTALLY Table 1.2-2/Package list.

Rautaruukki Oyj Suolakivenkatu 1 Phone +358 20 5911

POX 138 Faksi +358 20 592 9088

FIN-00811 Helsinki www.ruukki.com

FINLAND


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Maximum span for 1-span decking,

deflection limit L/180 or 20mmPropping may cause marks on sheets

100011001200130014001500160017001800

190020002100220023002400250026002700280029003000

100 120 140 160 180 200 220 240 260

Slab depth (mm)

Span(mm)

t=1.1mm

t=0.9mm

t=0.7mm

Maximum span for 1-span decking,

no deflection limit

Propping may cause marks on sheets

100011001200130014001500160017001800

190020002100220023002400250026002700280029003000

100 120 140 160 180 200 220 240 260

Slab depth (mm)

Sp

an(mm)

t=1.1mm

t=0.9mm

t=0.7mm

Figures 2.2-2 and 2.2-3 Maximum spans.


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FINLAND


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Maximum span for 2-span continuous decking,

deflection limit L/180 or 20mmPropping may cause marks on sheeting

100011001200130014001500160017001800

190020002100220023002400250026002700280029003000

100 120 140 160 180 200 220 240 260

Slab depth (mm)

Spa

n(mm)

t=1.1mm

t=0.9mm

t=0.7mm

Maximum span for 2-span continuous decking,no deflection limit

Propping may cause marks on sheets

1000110012001300140015001600170018001900

20002100220023002400250026002700280029003000

100 120 140 160 180 200 220 240 260

Slab depth (mm)

Span(mm)

t=1.1mm

t=0.9mm

t=0.7mm

Figures 2.2-4 and 2.2-5 Maximum spans.


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STEELCOMP 1(4)SITE MANUALDrying and strength Appendix 26


Drying time for concrete with w/c=0,7 to 85% relative humidity

0

2040

60

80

100

120

140

160

180

10 15 20

Slab depth (one drying direction) (cm)

D

ryingtime(week)

10C/80%

10C/35%

18C/60%

25C/35%

Figure 3.1-1 Drying of composite slab

Drying time for concrete with w/c=0,4 to 85 % relative humidity

0

5

10

15

20

25

30

10 15 20

Drying time (one drying direction) (cm)

Drying

time(week)

10C/80%

10C/35%

18C/60%

25C/35%

Figure 3.1-2 Drying of composite slab


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FI-00811 Helsinki www.ruukki.com

Finland


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The effect of concrete to drying time

0

5

10

15

20

w/c=0.4 w/c=0.4 w/c=0.8Time

(month)thenRH=90%

Composite slab 250mm

Concrete slab 250mm

Figure 3.1-3 Effect of concrete to drying time.

SteelComp-composite slab 140 mm, RH=45%, T=20C

75

80

85

90

95

100

1 3 5 7 9 11 13 15

Time (week)

RHinslab%

Cube strength 70(w/c=0,38)

laboratoryPlastisicer.C25/30(w/c=0,53), air 10%),laboratoryC25/30 (w/c=0,80)laboratory

Figure 3.1-4 Drying of composite slab.


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Drying of 120mm composite slab to 90% RH, if RH40% in air and

temperature above and below slab varies. Concrete C25/30

0

20

40

60

80

100

120

140

160

180

200

b10C/a10C b10C/a20C b20C/a10C b20C/a20C b30C/a10C

Temperature above and below slab

Dryingtime(d

ays)

Drying time (days)

Figure 3.1-5 Drying of composite slab.


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Development of strength for 200mm composite slab withnormal concrete and with fast drying concrete.

No covering after casting, mild wind (3m/s)

0

5

10

15

20

25

30

35

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28

Time(days)

Compressivestrength(MN/m2)

C25/30, air temperature +20oC

NP C25/30, air temperature +20oC

C25/30, air temperature +5oC

NP C25/30, air temperature +5oC

60% of design strength

(cube strength 18

MN/m

2

)

80% of design strength

(cube strength 24

MN/m2

Figure 4.2-1 Development of strength in composite slab.


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