HIGH STRENGTH PERMANENT CONCRETE FORMWORK FOR SUSPENDED …

1300 751 701 | FTIGROUP.COM.AU

PRODUCT INFORMATION & INSTALLATION MANUAL

HIGH STRENGTH PERMANENT CONCRETE FORMWORK FOR SUSPENDED SLABS

INSTALL ISSUE?

RING THE HOTLINE

1300 751 701 | FTIGROUP.COM.AU2

CONTENTS

Introduction 3

Features and Specifications

1. Product features 4

2. Usage and installation features 4

3. Specifications 5

a. Product data 5

B. Dimensions 5

C. Section properties 5

Fire Design

1. Fire resistance period 6

Installation Information

1. Propping and support 7

2. Deck installation 7

3. Deck fixing 8

4. Edge formwork 8

5. Slab reinforcement 9

6. Concrete placement 9

Span Tables

1. Use of span tables 10

2. Span tables 11

3. Notes on span tables 11

1300 751 701 | FTIGROUP.COM.AU 3

BlueDeck is a rigid permanent metal decking formwork for simplifying the construction of suspended concrete slabs.

It’s made from high-tensile steel offering high spanning capabilities. The durable galvanised finish creates a neat & clean, low maintenance ceiling finish.

BlueDeck comes with a signature blue anti-glare coating that’ll reduce heat & glare off the deck during the warmer months.

BlueDeck is ideal for carparks, office buildings, hospitals and deep beam style slabs.

INTRODUCTION


Prevents seepage &

Prevents seepage &

better interlocking better interlocking

connectionconnection

Anti-glare coatingAnti-glare coating

FEATURES AND SPECIFICATIONS

0.75MM OR 1.0MMTHICKNESS

MADE TO SUIT YOUR PROJECT REQUIREMENTS

CUSTOM LENGTHS

550 MPA (MIN)YIELD STRENGTH

Z350 IN CONFORMANCE WITH AS1397GALVANISED ZINC COATING

ANTI-GLARE COATING

Embossed Embossed profileprofile

2. Usage and Installation Features

High Tensile steel: Excellent spanning capacity and cantilever strength.

Light weight: 0.75mm 3.1kg/Lm and 1.0mm 4kg/lm, easy to handle.

Soffit Finish: No voids to fill, clean neat ceiling finish.

Installation: Clips together, fast efficient, snug fit joint.

Fire Rating: BlueDeck achieves a 2hour fire rating with a fully cured concrete slab as per the fire resistance table on page 6. The BlueDeck contains no open ribs and retains the majority of its strength over that period.

Anti-Glare Coating: Blue waterbased film, non-toxic or hazardous coating reduces glare by up to 82% and does not compromise the composite slab performance.

1. Product Features


b. Dimensions

3. Specifications

a. Product Data

Material (base metal thickness)

Grade (yield strength)

Galvanised coating

Weight per lineal metre

Weight per m2

Coverage m2 per metric tonne

Lineal metre per tonne

0.75mm 550mpa 350g/m2 3.18 9.51 105 315

1.0mm 550mpa 350g/m2 4.02 12.06 83 249

c. Section Properties

Thickness Cross-sectional area of FTI Ash (mm)

Sheeting Elastic Centroid dcb (mm)

0.75 0.75 1106.34 13.64

1.0 1.0 1475.12 13.64


1. Fire Resistance Period

Any composite slab must be designed to achieve a fire resistance period (FRP) for structural adequacy, integrity and insulation of not less than the required fire resistance level (FRL) as specified in The National Construction Code – Building Code of Australia (NCC-BCA)

Chart shows FRP for insulation of various slab thicknesses constructed using BlueDeck. The FRP has been calculated in accordance with Australian Standards: Composite Structures, AS 2327-2017 EN Combined, Clause 7.7.2.2 – Insulation for composite slabs, and modified taking into account.

FIRE DESIGNJ200038 69 Copford Rd, Goulburn NSW 2580

Design & Assessment │ 22 July 2020 │ Neilly Davies & Partners Pty Ltd Page 24 of 26

5. FIRE DESIGN

Fire Resistance Period

FTI Deck Profile Any composite slab must be designed to achieve a fire resistance period (FRP) for structural adequacy, integrity andinsulation of not less than the required fire resistance level (FRL) as specified in The National Construction Code –Building Code of Australia (NCC-BCA).

Chart shows FRP for insulation of various slab thicknesses constructed using FTI Deck. The FRP has been calculated in accordance with Australian Standards: Composite Structures,AS 2327-2017 EN Combined, Clause 7.7.2.2 – Insulation for composite slabs, and modified taking into account.

6. REFERENCES• AS/NZS 1170.0:2002 General principles• AS/NZS 1170.1:2002 Permanent, imposed and other actions• AS 1397:2011 Continuous hot-dip metallic coated steel sheet and strip - Coatings of zinc

and zinc alloyed with aluminium and magnesium• AS 1530.4:2005 Methods for fire tests on building materials, components and structures -

Fire-resistance tests of elements of building construction• AS 2327.1:2003 Composite structures - Simply supported beams• AS 3600:2009 Concrete structures• AS/NZS 4600:2018 Cold-formed steel structures• AS 3610:1995 Formwork for concrete• AS 3610 Supp 2 :1996 Formwork for concrete - Commentary• AS 2327-2017 EN Combined

020406080

100120140160180

30 60 90 120 180 240

Critical Thickness

Critical Thickness

MMininutes


1. Propping and Supports

If temporary propping is required, it must be fitted before BlueDeck installation and be perpendicular to the length of the sheets being installed, where the span becomes greater than the dimensions on the un-propped span charts

Prop width to be 100mm or greater and must be in accordance with AS3610 and the site engineers’ requirements.

Refer to the span tables for all propping information.

Structural/Permanent deck supports to be minimum 100mm bearing.

2. Deck Installation

BlueDeck installation is very simple and fast. Starting from one side with the correct sheet orientation (RIBS facing away from install path) hook the next deck over the previous placed end rib and drop to the support structure. The tight locking action of the profile provides a near waterproof joint.

Continuous over single slab span

Equal formwork spans

Slab span

Temporaryprop

Concrete slab

L L

INSTALLATION INFORMATION


3. Deck Fixings

Securing of the BlueDeck must follow immediately after placement of each section to prevent any uplift caused by wind.

Minimum requirements:

• 1 fixing in each end of every deck into a permanent structure

• 1 fixing into every second pan, at every permanent support location

• Fix approx. 30mm from the rib

Fixings: use powder actuated fixings or self-drilling screws into permanent supports as the substrate requires.

4. Edge Formwork

Install Edgeform to edges that require formwork and use strap ties at approx. 900 centers to secure back to the pan using self-drilling screws provided.

Edgeform is fitted by sliding under the BlueDeck and screw fixing

Edgeform

Strap ties

self-drilling screws


5. Slab Reinforcement

Once deck is secure and all edge forms installed, place reinforcement to engineers’ requirements specific to that slab.

6. Concrete Placement

Ensure that the deck is clean of any debris, preferably blown down with powered blower and free of any grease or oils that would prevent concrete adhesion.

Concrete to be poured evenly across the deck and mounding of wet concrete in a concentrated zone must be avoided at all times.

Wa

ll

Wa

ll

Wa

ll

Continuous over two slab spans

Slab span


One row oftemporary props

Two rows oftemporary props


Slab span

Concrete slab

LLL L L

Formwork joints overpermanent supports only

Slab span


One row oftemporary props

Two rows oftemporary props

Slab span

Concrete slab

L

LL

L L

Continuous over single slab span


Slab span

Temporaryprop

Concrete slab

L L

Concrete pour location

Incorrect concrete pour location

Incorrect concrete pour location


The spanning tables presented in this Section are based on the following assumptions and constraints. The reader needs to ensure that the particular situation being designed falls within these assumptions and constraints.

1. These tables can be used for different types of construction (steel-frame, concrete-frame, masonry wall supports) provided BlueDeck sheets are securely fixed to all permanent and temporary supports at every pan.

• Suitable secure fixing methods should be used such as spot welds, self-drilling screws or drive nails.

• Temporary props are equally spaced within each slab span.

• There are 2 formwork tables for 0.75mm and 1.0mm material.

• Ratio of two adjacent slab spans equal 1:1, that is I/L=1

• The ratio of the longer slab span (L,) to the shorter slab span (L5) does not exceed 1.2, that is I1 /L5 ≤ 1.2

2. The tables shall be used for normal density concrete (2400 kg/m3).

3. The lines of support shall extend across the full width of the sheeting and have a minimum bearing 100 mm at the ends of the sheets and 100 mm at intermediate supports over which sheeting is continuous, including at props. 50 mm minimum bearing length at the ends of sheets is acceptable in concrete frame construction.

4. The tables are based on the following maximum construction loads:

• Workmen and equipment = 100 kg/m2

• Mounting of concrete = 300 kg/m2 over an area of 1.6 x 1.6 m and zero over the remainder.

• Stacking of material on BlueDeck sheets before placement of concrete only = 100 kg/m2. This load shall be clearly indicated on the formwork documentation and controlled on-site.

5. Tables developed based on maximum BlueDeck length is 19,500 mm (check availability of local lengths.) - To be confirmed by the manufacturer.

6. No loads from stacked materials are allowed until the concrete has set.

7. The sheets shall not be spliced or jointed.

8. Allowance for the weight of reinforcement as well as the effect of ponding has been taken into account.

9. Supports shall be effectively rigid and strong to support construction loads.

10. The sheeting shall not have cantilever portions.

11. Wet concrete deflection of BlueDeck = 1/240 or 1/130, where the distance between centres of props or permanent supports.

12. The information contained in the publication is intended for guidance only. This information to be used only in conjunction with a consulting structural engineer.

13. Further details can be sought from the FTI Group.

1. Use of span tables

SPAN TABLES

1300 751 701 | FTIGROUP.COM.AU 11

2. Span Tables

3. Notes on Span Tables

Maximum slab spans, mm

BlueDeck sheets continuous over single slab span

Formwork deflections limit L/240 (Visual appearance important)

1. These are formwork selection tables only. Maximum slab spans in these tables shall be designed by a qualified structural engineer.

2. Prop must be equally spaced between the span and prop bearers & support widths should be minimum 100mm.

3. 1 kPa Live Load due to stacked materials is used – this shall be indicated on formwork documentation and controlled on-site.

4. Refer to General Engineering Notes Section 3.1 when using these tables.

5. Care must be exercised when placing concrete to avoid excessive mounding.

6. Spreaders shall be provided to prevent any concentrated loads being applied to the sheeting, in particular, avoiding direct point loading of the sheet overlap ribs and unsupported edges of the sheeting.

7. When using the table for two or more spans the adjacent spans should not differ in length by more than 5%.

8. *300/*350 slab should be designed under the typical reinforced slab AS 3600-2009 by a qualified structural engineer.

BLUEDECK™ BMT THICKNESS – 0.75MM

Slab thick ness (mm)

L/240-Visual Quality Important

Single Span Two Span Continuous Span

Un propp

ed

1 Row

Props

2 Rows Props

Un propp

ed

1 Row

Props

2 Rows Props

Un propp

ed

1 Row

Props

2 Rows Props

100 2150 5850 8150 2900 5550 8350 2700 5550 8350

110 2050 5700 7900 2850 5400 8100 2650 5400 8100

120 2000 5550 7700 2750 5250 7850 2550 5250 7850

130 1950 5400 7500 2700 5100 7650 2500 5100 7650

140 1900 5300 7300 2650 5000 7500 2450 5000 7500

150 1850 5200 7100 2600 4850 7300 2350 4850 7300

160 1750 5050 6900 2500 4750 7100 2300 4750 7100

170 1750 5000 6750 2500 4600 6950 2250 4600 6950

180 1700 4900 6550 2450 4500 6750 2150 4500 6750

190 1650 4750 6400 2350 4400 6600 2100 4400 6600

200 1600 4650 6250 2300 4300 6450 2050 4300 6450

210 1550 4550 6150 2250 4200 6300 2050 4200 6300

220 1550 4450 6000 2200 4100 6200 2000 4100 6200

230 1500 4350 5900 2150 4050 6050 1950 4050 6050

240 1500 4300 5800 2150 3950 5950 1900 3950 5950

250 1450 4200 5650 2100 3900 5850 1850 3900 5850

*300 1200 3100 3300 1500 3250 4200 1450 3250 4300

*350 950 2500 3650 1100 2650 3700 1200 2700 3750

BLUEDECK™ BMT THICKNESS – 1.0MM

Slab thick ness (mm)

L/240-Visual Quality Important

Single Span Two Span Continuous Span

Un propp

ed

1 Row

Props

2 Rows Props

Un propp

ed

1 Row

Props

2 Rows Props

Un propp

ed

1 Row

Props

2 Rows Props

100 2350 6500 9050 3250 6150 9250 3000 6150 9250

110 2250 6350 8800 3150 5950 8950 2900 5950 8950

120 2200 6150 8550 3050 5800 8750 2850 5800 8750

130 2150 6000 8350 3000 5650 8500 2750 5650 8500

140 2100 5900 8100 2950 5550 8300 2700 5550 8300

150 2050 5750 7900 2850 5400 8100 2600 5400 8100

160 2000 5650 7700 2800 5250 7900 2550 5250 7900

170 1950 5550 7500 2750 5150 7700 2500 5150 7700

180 1900 5400 7350 2700 5000 7550 2450 5000 7550

190 1850 5300 7200 2650 4900 7350 2400 4900 7350

200 1850 5200 7050 2600 4800 7200 2350 4800 7200

210 1800 5050 6900 2500 4700 7100 2300 4700 7100

220 1750 5000 6800 2500 4600 6950 2250 4600 6950

230 1700 4900 6650 2450 4550 6850 2200 4550 6850

240 1700 4800 6550 2400 4450 6700 2150 4450 6700

250 1650 4750 6450 2350 4400 6600 2150 4400 6600

*300 1400 4000 4050 1850 3450 4300 1550 3500 4450

*350 1050 2650 3700 1150 3350 3800 1250 2800 3800

PO Box 1103, Goulburn, NSW, 2580E: [email protected]

P: 1300 751 701

ftigroup.com.au

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HIGH STRENGTH PERMANENT CONCRETE FORMWORK FOR SUSPENDED …