Composite Slab Flooring

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Using DRAMIX Steel Fibre Concrete - Projects Book

Composite Slab Flooring System

Building

to the Power of

Structura l Products

CI/SfB(28) Hh2

February 2007



great step forwardin compositefloor construction

‘

No Mesh Construction

Dramix®

Steel Fibre Concrete, has been used

throughout Europe in Industrial Floors and ExternalPavements for many years. Following extensive test

work and analysis by The Steel Construction Institute it

is now available for multi-storey applications. Dramix

steel fibres with Multideck profiles have been proven by

testing to achieve full fire performance for 1 - 1.5 hours.

The use of a Dramix® Steel Fibre reinforced Concrete

slab provides a “pre-reinforced” concrete slab

- no mesh has to be installed.

Are You Still Quoting For Mesh?

Mesh is hassle. You have to buy it, transport it, store it,

crane it, and fix it. It’s tricky to work on AND it costs

good money. If you’re still using mesh you’ve probably

not heard of Dramix steel fibres.

Kingspan and BekaertComposite Slab

1. Steel fibres addedto hopper 2. Fibres mix perfectlywith concrete 3. Concrete pumpedinto position 4. Mixture spreadonto deck

So what is Dramix?

Dramix fibres are steel wire filaments with hooked ends – manufactured by Bekaert Ltd. They are added to the concretemix to provide a pre-reinforced concrete suitable for pumpingstraight on to the metal deck.

And it’s as good as mesh?

Yes, The fibres provide full depth reinforcement and excellent

crack control. What’s more the design is endorsed by theSteel Construction Institute (SCI).

Is it more difficult to pump?

No. The fibres spread evenly during the mix. Pumping to

heights is no problem using normal pumping equipment.

How does it lay?

Dramix lays perfectly. And, of course, there’s no mesh to tripover - eliminating a site safety hazard.

So who is using it?

Dramix has been used on many projects in different sectors suchas the Colmore Plaza on all of its 14 floors, 10 storey TeessideHouse in Middlesbrough. Thanet Retail Park, Spurriergate in Yorkmixed development and the prestigious Quebec BuildingsResidential Development in Salford Manchester.

Why are Kingspan promoting the product?

We believe this is a great step forward in composite floorconstruction for multi-storeys. So we’ve spent considerabletime and resources testing Dramix and Multideck.The combination is the first design with a proven 1-hour and1.5 hour fire rating.

Where can I get more information?

For literature & technical advice on the Dramix productcontact Bekaert on 01142 427 485or email [email protected]

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5. No mesh means notripping hazard 6. Mixture floated off 7. Floating providesa smooth finish 8. Floor completedin double quick time

Construction Advantages

• Pre-Reinforced Concrete

• Simplified process

• No mesh to transport,buy, store, lay etc...

• Time savings on site

• Earlier project completion

• Concrete volume savings

• Reduction in crane hire time

Technical Advantages

• Proven 1 hour & 1.5 hour fire rating

• Structural design informationdeveloped by SCI

• Full depth reinforcement offersexcellent crack control

• Design advice and assistance

Health & SafetyAdvantages

• Minimises site handling

• Reduces site congestion

• Minimises crane lifts

• Eliminates hand carrying

of mesh into position• Reduces tripping hazards



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Hi-Rise

floor laying process – significantly reducingcompletion time and improving health andsafety onsite. Dramix ® fibres are made fromprime quality hard-drawn steelwire toguarantee high tensile strength and closetolerances. Added to the concrete mix, thefibres ensure full depth reinforcement andexcellent crack control.

For the Colmore building, Kingspanapproved installer MSW laid the Multideck,whilst Twintec co-ordinated the addition ofthe steel fibres at a Cemex batching plant.

The reinforced concrete was then pumpedinto each floor of the office buildingaccording to a strictly controlled night-time

The £155million Colmore Plaza project inBirmingham is the tallest building in the UKto specify Dramix ® Steel Fibre Concrete foreach of its 14 floors.

The Plaza’s city centre location necessitatedcarefully planned night pours of theinnovative flooring solution. Space at thesite is so restricted that a traditionalmesh-based flooring solution was fraughtwith problems – but Dramix ® pumped ontoKingspan Multideck was the easier andmore economical answer.

Dramix ® steel fibre reinforced concreteprovides a pre-reinforced concrete slabwhich requires no mesh and simplifies the

Project Name

Colmore Plaza

Location

Birmingham

Structural Consultant

Brookbanks Consulting

Main Contractor

Bowmer & Kirkland Ltd.

Sub Contractors

MSW, Twintec

Usage

Offices

Colmore PlazaBirmingham



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schedule to cause minimum disruption tothe surrounding area.

When used in conjunction with Kingspan

Multideck MD60-V2, Dramix ® Steel FibreConcrete provides a proven 1 hour and 1.5hour fire rating. Not only does mesh becomeredundant, but the shear resistance ofDramix ® concrete exceeds that of its meshreinforced equivalent. In addition, the uniquedesign of Kingspan Multideck reduces thevolume of concrete required, bringing costas well as time savings to a project.

Dramix ® is now being specified in a numberof key projects across the UK – mostnotably where access or architecturalconservation are significant issues.The solution, a joint initiative between

Kingspan and Bekaert, has been testedby the Steel Construction Institute (SCI)and endorsed for multi-storey applications.

‘tallest building in the UK to specify

Dramix ® Steel Fibre Concrete’



4

Hi-Rise

replacing it with steel fibre reinforcedconcrete.

The placing of the concrete took place inthe first quarter of 2006, making it at thetime the tallest building to have steel fibreconcrete pumped onto its floors right up to10 storeys

The £3,160,000 project Teesside House inMiddlesbrough is a 10 Storey scheme toprovide a 388 bed student accommodationblock in Middlesbrough town centre, withretail units and a restaurant on the groundfloor. Due to the very limited access on theside roads on this town centre developmentthe option to use fibres was put forward byMetaldeck, so as to remove the placementof large sheets of mesh reinforcement ontothe 10 floors which would have been veryproblematic.

The Mandale Group accepted theargument, and were persuaded by thesavings in both time and money, not tomention the health and safety issues, byremoving mesh from the scheme and

Project Name

Teesside House

Location

Middlesbrough


Billinghurst George & Partners

Main Contractor

The Mandale Group

Sub Contractors

Metaldeck Ltd., Sidlow Brothers Ltd.

Usage

Student Accommodation/Retail

Carrmills, Leeds

savings inboth timeand money

‘

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Teesside HouseMiddlesbrough



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Leisure

The £9,000,000 scheme is a new leisure centrecomprising of a 4 court sports hall, 6-lane 25mpool, 12m by 10m learner pool, health andfitness/dance facility, shapers plus fitness room,multi purpose hall, wet and dry changing rooms,boxing club facility, aerobics studio, adminoffice, reception area, 6-lane athletics track, 2artificial turf soccer pitches, landscaping andparking.

Time savings and Health and Safety issues ofusing mesh were taken into account by the

main contractor and the client in their decisionto use a steel fibre reinforced concrete solutionfor the first floor, even though in this caseaccess was not a problem!

Kirkby LeisureCentreLiverpool Project Name

Kirkby Leisure Centre

Location

Liverpool

Architect and Engineer

Knowsley Metropolitan

Borough Council

Main Contractor

Shepherd Construction Ltd.

Sub Contractors


Usage

Leisure

time savingswith steelfibre reinforced

concrete

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Mixed Use

The £8,000,000 scheme comprises officeand shop units on the ground floor and firstfloor with 56 apartments over 6 storeysabove. 28 parking spaces are also included.

This was the first time the Engineer hadseriously considered steel fibre concreteon decks, but due to its very restrictedcorner site the use of mesh would havemeant all sort of complications in gainingaccess to lay.

Artisan asked the Engineer to consider theuse of Steel Fibre Concrete, as they couldsee that there were a number of days timesaving to be made and after looking at allthe evidence and information given byBekaert, Kingspan and Metaldeck, theengineer made an informed decision toproceed with Dramix Fibre Reinforcement.

ExpressNetworksManchester

Project Name

Express Networks

Location

Manchester


Marston and Grundy

Main Contractor

Artisan Ltd.

Sub Contractors


Usage

Offices/Residential

due to itsvery restrictedcorner site,steel fibreconcrete wasthe answer

‘

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7

Kingspan and Dramix provided an innovative

solution to the parking difficulties andconstricted conditions in York City centre.The Spurriergate project comprised retailspace on the ground floor and 13two-bedroom apartments over a furtherthree floors. The area was sited in the busiestshopping location in what is, ostensibly,a medieval city layout.

Due to the confined nature of the site theengineers and main contractor needed tominimise site traffic and crane lifts. One wayto do this was by eliminating the steel meshused in the composite floor decking. Dramixsteel fibres were added to the hopper duringmixing to create "pre-reinforced" concretewhich meant several lorry loads and crane liftscould be eliminated from the programme.In addition this meant that valuable storagespace on site could be freed up for otheruses. Using Dramix Steel Fibres inconjunction with Kingspan's Multideck MD60gave a mesh-free, proven fire-rated solution.

The complex fixing and concrete pumpingrequirements was undertaken by Kingspanapproved fixers, Metaldeck of Skelmersdale.

Mixed Use

SpurriergateYork

Project Name

Spurriergate

Location

York


Halcrow Group Ltd

Main Contractor

Quarmby

Sub Contractor

Metaldeck

Usage

Shops/Offices/Single Living

Withington House, Manchester

pre-reinforcedconcrete‘

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Education

This £11,000,000 scheme comprised of theconstruction of phase 2 of the Centre forBio Molecular Sciences research buildingsand general academic buildings.

This was the first time that the engineerThe Ward Cole Partnership had consideredthe use of Steel Fibre Concrete on SteelDecks, tight proximity of the new building toexisting buildings created access problemswhich would have been difficult to solve withmesh reinforcement. So they looked veryseriously at the Fibre Solution and decidedto proceed!

Thomas Fish & Son Ltd bought its steelfibre reinforced concrete form Lafarge, whodosed the fibre into their concrete at a localbatching plant. Thomas Fish were veryimpressed with the ease of laying the floorsand their Site Manager Ranjit Lall stated thathe would certainly consider Steel FibreReinforcement on decks on future projects!

University ofNottinghamNottingham

Project Name

University of Nottingham

Location

Nottingham


Ward & Cole Partnership

Main Contractor

Thomas Fish & Sons Ltd

Sub Contractors

MSW, Northern Flooring

Usage

University

very impressedwith the ease

of layingthe floors

‘

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9

The £9,500,000 scheme comprised of thecomprehensive re-development of thecollege’s main campus, including thedemolition of approximately 8,380 sqm ofbuildings and the construction of 7,000 sqmof classrooms. Metaldeck made thesuggestion of using Steel Fibre Concrete onthe decks of this project, and CundallJohnston made an investigation into the

viability and decided that there were definiteadvantages to the use of fibres over mesh.Tarmac bought and dosed the fibres at theirlocal batching plant for Wyn Construction topump and place the concrete onto all 3storeys of the building.

All went successfully and Surgo are nowconsidering Fibres as a solution for its latest

project, another educational building in theNorth East of England

Education

BishopAucklandCollegeCounty Durham

Project Name

Bishop Auckland College

Location

County Durham

Engineer

Cundall Johnston & Partners

Main Contractor

Surgo Construction Ltd

Sub Contractor

Metaldeck Ltd., Wyn Construction

Usage

College

solution forlatest project‘

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Residential

Technic Flooring who have worked withRichardson Projects on previous jobs,suggested the use of Fibre concrete at ameeting where access problems with layingthe mesh were being discussed.

Richardson Projects took this on board andafter discussions with the client proceededwith the fibre reinforced concrete.

The £15,000,000 scheme comprises of theerection of 2 apartment blocks (six storeysand seven storeys high) along with 45 2bedroom apartments, and a multi storey carpark to provide 460 spaces on 10 splitlevels.

The site is a corner site with very tightaccess between the main road and therailway line, giving a very cramped area forservices on site. So the use of fibres wasconsidered so as to remove the obviousproblems that laying large sheets of meshreinforcement presented. So Steel FibreReinforcement was decided upon foraccess reasons, but also for time savings,and the Health and Safety issue of removingan obvious trip hazard.

Project NameBroad Road Apartments

Location

Sale, Manchester

Architect

MBLA Architects & Urbanists

Main Contractor

Richardson Projects Ltd.

Sub Contractors

Metaldeck Ltd.,

Technic Concrete Floors Ltd

Usage

Residential

tight access- so fibrereinforcedconcrete wasthe perfectsolution

‘

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Broad Road ApartmentsSale, Manchester



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Residential

Quebec Buildings in Salford, Greater Manchesteris a residential scheme built by propertydevelopers, the Vermont Group. The £7 milliondevelopment comprises 152 apartmentstogether with smaller commercial units. Thecomplex is 6 storeys high and includes abasement car park for residents. Designed byStephenson Bell Architects the building featureszinc metal cladding on the facade.

The Structural Consultant, Clancy Consultantsselected a composite slab floor to reduce theoverall amount of concrete that would berequired in the build programme. By specifyingDramix steel fibres the consultant also ensuredthat the floor construction would be fast-trackand not reliant on mesh which is problematic totransport, store, lift and position.

Construction Director for Vermont, Mr MarkColton commented “Using steel fibres with a composite deck was a first for the group and it was essential that everything went right on such a large project as this. We were impressed with how the product simplified and speeded up the pouring process. The end result was a smooth floor with less of the hassle involved with mesh .”

Fire and acoustics are important areas inresidential design. The SCI’s robust details forcomposite slab floors provide residentialsolutions to meet Part E of the Buildingregulations. In addition the SCI have proven the

performance of Kingspan Multideck MD60 andDramix steel fibres together and endorse thedesign for 1 and 1.5 hours fire rating.

QuebecSalford

Project Name

Quebec Buildings

Location

Salford


Clancy Consulting

Main Contractor

Vermont Group

Sub Contractors

Metaldeck/CAY Flooring

Usage

Residential

Havenside, Cambridgeshire E1.4, Milton Keynes



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Retail

The problems were solved by usingKingspan MD60 decking with un-proppedspans up to 3.3m infilled with concretereinforced with Bekaert RC65/60BN steelfibres.

Despite some contractor concern the use offibres became an unqualified success andfixing of screed rails and stop ends wasconsiderably simplified as was the powerfloating of the slabs.

The success of steel fibre reinforcedconcrete metal decking led to the groundfloor slabs also being constructed usingsteel fibre. This obviated placementdifficulties when working over mesh andprovided far more extensive crack controlthrough the full depth of the concrete.

Comments by Roger Stagg

One of the challenges facing the designteam on the £50m contract for theWestwood Cross Shopping Centre, Thanetwhich opened in June 2005 was the largearea of first floor which needed to beconstructed with maximum flexibility to suitthe future incoming tenants. Alongside thiswere the needs for ultra fast constructionand no applied finishes.

The problem of keeping composite floorseconomically thin whilst providing fireresistance and adequate crack control isnormally frustrated by the use of steel meshreinforcement particularly at the lappositions. All too frequently this leads to theneed for increased concrete thickness toprevent the mesh ‘grinning’ through.

Project Name

Westwood Cross

Location

Thanet, Broadstairs, Kent


Reuby & Stagg

Main Contractor

Carillion

Sub Contractors

MSW/O’Keefes

Usage

Retail Park

Debenhams, Thanet

maximumflexibility andultra fastconstruction

‘

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Westwood CrossBroadstairs, Kent



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Commercial

The first project for 2004 using Kingspan’sMD60 and Dramix fibres was a 4 storey officedevelopment on Talbot Road in Manchester. Thesite had very limited access being situatedbetween two existing office blocks and the onlysite access being onto the small car park areaat the front of the building.

The decision was made to use Dramix steelfibres instead of mesh mainly because of siteaccess, but also health and safety issues suchas reducing mesh handling, and trip hazardsduring the flooring operation. The steeldeck &fibre concrete solution carries a minimum 1 hourfire rating. Fire load tables were developed bythe Steel Construction Institute based on largescale fire testing undertaken at the WarringtonFire Research Establishment.

The fibres were batched by conveyor directly intothe truck mixers at the Tarmac Topmix Batchingplant in Salford. After arriving on site the concretewas pumped directly onto all 4 floors which were

laid in 2 days. Despite being on a main road,congestion was kept to a minimum, aspre-reinforced concrete was pumped into place.

Talbot RoadManchester

Project Name

Talbot Road

Location

Manchester


Shaw Whitmore Fyffe Partnership

Main Contractor

Parkinsons

Sub Contractors

Metaldeck/Tarmac Topmix

Usage

Offices

IO Business Centre, Glasgow Sunderland Marine Assurance, Durham

4 floors laidin 2 days‘

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Kingspan Metl-Con LimitedSherburn, Malton, North Yorkshire, YO17 8PQ, EnglandTel: +44 (0) 1944 712000 Fax: +44 (0) 1944 710555

Email: [email protected]

visit our website kingspanstructural com or our group website kingspan com

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