Documente Academic
Documente Profesional
Documente Cultură
Design and
Construction Manual
Warranty
BlueScope Lysaght has a number of comprehensive product warranties
that cover not only the corrosion performance of the material but also the
structural and serviceability performance of a wide range of products.
BlueScope Lysaght can back their products with over 150 years experience
and credibility. The LYSAGHT brand is widely recognised as setting
the benchmark on quality products, and is trusted and respected by our
customers and competitors nationwide.
2009
Contents
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Features and applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Spanning capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Composite action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Design efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Economical design for fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Quicker trouble free installation . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Technical support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Specification and Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 ,93!'(4 7
$%+ composite slabs. . . . . . . . . . . . . . . . . . . . . . . 6
2.2 ,93!'(4 7
$%+ section properties . . . . . . . . . . . . . . . . . . . . . 6
2.3 Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Reinforcement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Shear connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Design methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Formwork design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Deflection limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Formwork design load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1 Design for strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.2 Design for serviceability . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Formwork Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Composite slab design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Crack control options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Design load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5.1 Strength load combination . . . . . . . . . . . . . . . . . . . . . . . 14
4.5.2 Serviceability load combination . . . . . . . . . . . . . . . . . . . 14
4.5.3 Superimposed dead load. . . . . . . . . . . . . . . . . . . . . . . . . 14
4.6 Design for Strength in negative regions . . . . . . . . . . . . . . . . . . . 15
4.6.1 Negative bending Strength . . . . . . . . . . . . . . . . . . . . . . . 15
4.6.2 Shear strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.7 Design for strength in positive regions . . . . . . . . . . . . . . . . . . . . 15
4.7.1 Positive bending Strength . . . . . . . . . . . . . . . . . . . . . . . . 15
4.7.2 Shear strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Design for fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Design for insulation and integrity . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Design for structural adequacy . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3.1 Design loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Reinforcement for fire design . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.5 Location of longitudinal reinforcement
for fire design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. Design Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Use of design tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Single span design tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Interior span design tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4 End spans design tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2.1 Propping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2.2 Laying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2.3 Interlocking the sheets . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2.4 Securing the platform . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2.5 Installing 7
$%+ on steel frames . . . . . . . . . . . . . . . . . . . 32
7.2.6 Fastening side lap joints . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2.7 Fitting accessories for edge form . . . . . . . . . . . . . . . . . . 33
7.2.8 Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2.9 Items embedded in slabs . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2.10 Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2.11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2.12 Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3 Reinforcement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.1 Transverse reinforcement . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.2 Longitudinal reinforcement . . . . . . . . . . . . . . . . . . . . . . . 37
7.3.3 Trimmers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4
Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4.2 Concrete additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4.3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4.4 Construction joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4.5 Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4.6 Curing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.4.7 When to remove props . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5.1 Soffit and edge form finishes . . . . . . . . . . . . . . . . . . . . . 39
7.5.2 Plastering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5.3 Change in floor loadings . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.6 Suspended ceilings & services . . . . . . . . . . . . . . . . . . . . . . . . 40
7.6.1 Plasterboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.6.2 Suspended ceiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.6.3 Suspended services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8. Composite beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1 Shear stud capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2009
Background
LYSAGHT W-DEK is a new innovative profiled steel decking which brings
greater economy and design freedom to building with composite concrete
slabs. Our design engineers scoured the globe to find the best Wprofiles in the world. After careful examination, our engineers incorporated
the best aspects of each profile into new ,93!'(4 7
$%+. The profile
has been specifically developed for Australian high tensile steels - which
makes ,93!'(4 7
$%+ one of the best performing W profiles in the
world.
,93!'(4 7
$%+ is a profiled zinc-coated high tensile steel decking for use
in the construction of composite floor slabs. It has exceptional composite
performance no additional reinforcement is required in most applications.
It can be used as formwork during construction and as a reinforcement
system in composite slabs.
Our increased understanding of composite slabs, together with testing in
our NATA-accredited laboratory and leading Australian universities, has
paid off with an optimised product, which provides significant cost savings
for projects.
,93!'(4 7
$%+ has exceptional spanning characteristics and spans up to
4.1 metres, reducing the need for supporting structures.
The built-in properties of high tensile steel are maximised in the design
and fabrication of the deck profiles which result in products with high
strength-to-weight ratio. ,93!'(4 7
$%+ is currently the most economical
structural steel decking in Australia for typical applications because it
provides widest cover per weight of steel.
The profiled ribs are 78mm in height, resulting in ,93!'(4 7
$%+ having
excellent concrete displacement characteristics and minimal propping
requirements. This speeds up installation and makes the costs of delivery,
erection and structural framing significantly lower than for other systems.
Scope
This manual provides information on the design of formwork, propping,
composite slabs and design for fire and some information for composite
beams.
This manual is developed to the latest versions of the relevant Australian
Standards and Eurocodes.
Conditions of use
This publication contains technical information on the following grades of
,93!'(4 7
$%+:
s ,93!'(4 7
$%+ 0.75 mm thickness
s ,93!'(4 7
$%+ 1.00 mm thickness
Additionally, ,93!'(4 7
$%+ software allows you to get quicker and
more economical solutions with a range of options. Call Steel Direct
on 1800 641 417 to obtain additional copies of the Design Manual and
Software.
Where we recommend use of third party materials, ensure you check
the manufacturer's requirements. Diagrams are used to explain the
requirements of a particular product. Adjacent construction elements of
the building that would normally be required in that particular situation
are not always shown. Accordingly aspects of a diagram not shown should
not be interpreted as meaning these construction or design details are
not required. You should check the relevant Codes associated with the
construction or design.
Warranties
Our products are engineered to perform according to our specifications
only if they are installed according to the recommendations in this manual
and our publications. Naturally, if a published warranty is offered for the
product, the warranty requires specifiers and installers to exercise due
care in how the products are applied and installed and are subject to final
use and proper installation. Owners need to maintain the finished work.
4
2009
2009
Mesh
reinforcement
Embossments
b
yb
dcb
tbm (BMT)
SHEETING
ELASTIC
CENTROID
LYSAGHT W-DEK
Figure 2.1
LYSAGHT W-DEK profile dimension and
reinforcement
78mm
700mm
713.6mm
Figure 2.2
,93!'(4 7
$%+ profile and dimensions
Thickness
B MT mm
1.00 BMT
0.75 BMT
1.00
0.75
Self Weight
(kg/m2)
11.63
8.85
Full C ross-sectional
area of W-DECK
Ash mm2/m
Effective second
moment of area
l x 104 mm4/m
1414
1060
119.9
77.5
Table 2.1
Notes: 1. Self weight is given for Z350 coating.
2. Effective second moment of area varies depending on span values in a table.
Values are given for longest spans only.
2009
2.3 Sheeting
,93!'(4 7
$%+ is rolled-formed from hot dipped, zinc-coated, high
tensile steels in base metal thickness (BMT) of 1.0 and 0.75 mm.
1.2 mm BMT is not available in the design tables and software. However,
the solution using ,93!'(4 7
$%+ 1.2 mm BMT is available subject to
enquiry.
The steel conforms to:
s !3 AND
s AND "-4
STEEL GRADE IS '
s "-4 n STEEL GRADE IS '
The coating is Z350 (350 g/m2 minimum coating mass) or Z450 (450 g/m2
minimum coating mass) is available subject to enquiry.
Embossments on the top of flanges and web embossing provide the
mechanical connection between the steel and concrete.
2.4 Concrete
All tables have been developed for the 32 MPa grade of concrete with
normal density of 2400 kg/m3 (wet density). Other concrete grades are
available in the software.
2.5 Reinforcement
s 3TEEL REINFORCEMENT IS NECESSARY TO CONTROL SHRINKAGE AND TEMPERATURE
effects, as flexural negative reinforcement over supports and in
some instances for fire engineering purposes and as bottom tensile
reinforcement. It shall comply with the requirements of AS/NZS
4671:2001.
s &OR NEGATIVE POSITIVE AND FIRE REINFORCEMENT $. OR 9 IS USED IN
the software. D500N is used only in the tables.
s $, OR $. REINFORCEMENT CAN BE USED AS SHRINKAGE MESH
s /UR DESIGN TABLES ASSUME THE USE OF $. MM MAXIMUM DIAMETER
bars for negative and fire reinforcement in addition to 500L shrinkage
mesh.
2009
3. Formwork Design
The ,93!'(4 7
$%+ formwork shall be designed in accordance to AS
3610 - 1995 and AS2327.1.
,93!'(4 7
$%+ capacities and stiffness have been derived from tests
conducted at our NATA-accredited laboratory at BlueScope Lysaght
Technology, Chester Hill, NSW.
Our design tables can be used to detail ,93!'(4 7
$%+ acting as a
structural formwork, provided the following conditions are satisfied:
s 4HE SUPPORT LINES EXTEND ACROSS THE FULL WIDTH OF THE SHEETING AND HAVE A
minimum bearing of 50 mm at the ends of the sheets, 100 mm minimum
bearing length for interior supports.
s 4HE SHEETS CONTINUE WITHIN EACH SLAB SPAN LENGTH WITHOUT ANY OVERLAPS
or intermediate splicing or jointing longitudinally.
s 4HE SHEETS ARE DESIGNED AS SINGLE OR CONTINUOUS SPAN FORMWORK
s 4HE SLAB HAS A UNIFORM CROSS SECTION
s 3EPARATE CONSIDERATION IS GIVEN TO SIDES OF THE SHEETING WHERE EDGES
shall be restrained.
s ,93!'(4 7
$%+ sheeting ends shall be securely fixed at all permanent
and temporary supports to the supporting structure
s 4HE RATIO OF THE LONGER SLAB SPAN TO THE SHORTER SLAB SPAN ,l/Ls) of any
two adjacent spans does not exceed 1.2 (i.e. Ll/Ls 1.2).
s 4HE SUPPORTS ARE EFFECTIVELY RIGID SUCH THAT THEIR VERTICAL DEFLECTIONS
during the construction phase can be ignored in design.
Outline of
concrete
50mm
minimum
End
support
Interior
support
Temporary
props
Temporary
props
LYSAGHT
W-DEK
Slab span L
Interior
support
Slab span L
Interior
support
Figure 3.1
,93!'(4 7
$%+ formwork
2009
DURING HANDLING AND ERECTION OF THE FORMWORK AND
s
O NCE THE FORMWORK IS ERECTED BUT PRIOR TO THE PLACEMENT OF THE
concrete,
2009
9.73
Minimum value of:
7.2
3.2
(i) 6.61
(ii) 3.46 + 1.26Ll
where Ll is in metres (distance between centres
of permanent or temporary supports)
(F Vu,sh)
Table 3.2
Values of coefficient kd for calculation of $
(The maximum vertical deflection always occurs in the
end span for these conditions.)
10
2009
130
3100
4100
3800
135
3050
4050
3750
140
3000
4000
3700
145
2950
3950
3650
150
2900
3900
3600
160
2850
3800
3500
175
2750
3650
3400
200
2600
3500
3200
130
5200
5200
5200
135
5200
5200
5200
140
5400
5400
5400
145
5600
5600
5600
150
5600
5600
5600
160
6000
6000
6000
175
6000
6000
6000
200
6000
6000
6000
1 prop
Slab thickness, mm
Single span
Two spans
Three or more spans
130
2700
3500
3300
135
2650
3450
3250
140
2600
3400
3200
145
2550
3350
3150
150
2550
3300
3100
160
2450
3200
3050
175
2300
3050
2950
200
2100
2900
2800
1 prop
Slab thickness, mm
Single span
Two spans
Three or more spans
130
5200
5200
5200
135
5200
5200
5200
140
5400
5400
5400
145
5600
5600
5600
150
5600
5600
5600
160
6000
6000
6000
175
5950
5950
5950
200
5650
5650
5650
NOTES:
1. Continuous maximum spans are limited as given in composite slab tables for interior spans and total 6000mm limit.
2. Maximum formwork spans are based on Ll/240 deflection limit and ratio of two adjacent spans equal 1:1.
3. Use ,93!'(4 7
$%+ software to get longer spans with Ll/130 deflection limit and wider supports.
4. 1kPa Live Load due to stacked materials is used.
2009
11
4.2 Application
Our design tables and software can be used to design composite slabs
with ,93!'(4 7
$%+ provided the following conditions are satisfied:
s 4 HE SPECIFIED CONCRETE STRENGTH GRADE c is in the range 25 MPa to 40
MPa (as specified in AS-36002001). The concrete density Rc may be
for normal weight concrete, taken as Rc 2400kg/m3.
s 4 HE CONCRETE MANUFACTURE AND MATERIALS SATISFY THE REQUIREMENTS OF
AS 36002001, Section 19.
s 4 HE LINES OF SUPPORT EXTEND ACROSS THE FULL WIDTH OF THE SHEETING AND
have a minimum bearing of 50 mm at the ends of the sheets, and 100
mm at intermediate supports over which sheeting is continuous.
s 4 HE RATIO OF THE LONGER SLAB SPAN L1) to the shorter slab span ( Ls ) of
any two adjacent spans does not exceed 1.2, that is L1/Ls b 1.2.
s 4HE SLAB HAS A UNIFORM CROSS
SECTION
s 4 HE DESIGN LOADS FOR SERVICEABILITY AND STRENGTH DESIGN SHALL BE
uniformly-distributed and static in nature.
s 4 HE BENDING MOMENTS AT THE SUPPORTS ARE ONLY CAUSED BY THE ACTION OF
vertical loads applied to the slab.
s 4HE EXPOSURE CLASSIFICATION IS ! ! " OR "
s /