BONDEK II

Formwork And Installation

BHP Steel Lysaght (Singapore) Pte Ltd

Established in Singapore in 1965, BHP Steel Lysaght (Singapore) Pte Ltd is a wholly owned subsidiary of BHP Steel Limited, the largest steel group in Australasia. A manufacturer and a supply-and-fix total solution provider, BHP Steel Lysaght Singapore offers steel and non-steel (titanium zinc, copper, stainless steel and painted aluminum) roofing and walling profiles such as KLIPLOK 406, SPANDEK, TRIMDEK, SELECT SEAM, LOCKED SEAM, V-CRIMP, EASYCLAD and PRESTIGE PANEL. BHP Steel Lysaght Singapore also manufactures a full range of C & Z galvanized purlins from web size of 100mm to 300mm. We are also a market leader in the design and supply of structural decking such as LYSAGHT BONDEK II, and the new millennium steel decking POWERDEK.

SMARTRUSS is our new and innovative way of construction in light gauges, high strength steel trusses offered to the market as steel intensive building solution.

In July 1997, the company was conferred the Singapore Quality Class Award (SQC) status for having achieved a commendable level of performance on the quality journey towards business excellence. In April 1998, we received the Singapore National Productivity Award for outstanding achievements in productivity movement and in November 2001, were also awarded by the Building & Construction Authority for achieving an exemplary level of innovativeness in the BAUCON ASIA exhibition. In June 2002, BHP Steel Lysaght Singapore also obtained accreditation from Lloyds Register Quality Assurance for the ISO14001: 1996 Environmental Management System Standard.

BHP Steel Lysaght Singapore also offers customers with comprehensive range of technical and consultancy services. These value-added services distinguish the company from other manufacturers and suppliers of steel building products. The commitment to continuous research, development and innovation together with the practice of quality assurance at all levels and keeping abreast with the dynamics of the building and construction technology, has earned the Company the trust and confidence of its customers. In March 1993, BHP Steel Lysaght Singapore obtained accreditation from Lloyds Register Quality Assurance for the ISO9002 Quality Management System.

2 June 2003 BHP Steel Lysaght Singapore

Introduction Lysaght Bondek II

LYSAGHT BONDEK profiled steel

sheeting was developed in the mid 1960s. Since its inception it has been widely accepted by the building construction industry to be a highly efficient, versatile and robust formwork and reinforcement. It has been used to great effect on many major building projects. Since1986 Lysaght has funded a major research investigation at BHP Research - Melbourne Laboratories (BHPR-ML) into the behaviour of composite slabs. As a result it has been possible to transform BONDEK profiled sheet into new LYSAGHT BONDEK II without significantly changing its familiar profile shape, while dramatically improving its

effectiveness as longitudinal tensile reinforcement. Embossing the tops of the ribs has been important in this regard, and in long uniformlyloaded spans the full tensile strength of the sheeting can now be developed. In such situations it is then more effective than the same area of deformed bars or welded wire fabric due to its higher yield strength and larger effective depth. Subsequently a very extensive series of tests on LYSAGHT BONDEK II profiled sheet has been performed in order to thoroughly investigate its structural behaviour as formwork, and as longitudinal reinforcement in one-way composite slabs. Comprehensive design rules, in

accordance with British Standard BS 5950: Part 4: 1982 Structural Use of Steelwork in Building - Code of Practice for Design of Floors with Profiled Steel Sheeting, have been prepared for both situations (see references (1) and (2)). The results of fire tests performed at BHPR-ML on BONDEK composite slabs have also supported the development of rules for designing unprotected LYSAGHT BONDEK II composite slabs for fire resistance in accordance with BS 5950: Part 8: 1990 -Structural Use of Steelwork in Building - Code of Practice for Fire Resistant Design (see reference (3)). Design Manuals have been prepared from these design rules.

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References (BHPR-ML Research Reports) (1) Patrick M and Poh KW, Design of Floors with LYSAGHT BONDEK II Profiled Steel Sheeting to British Standards, Part A - Permanent Shuttering, BHP Research Report No. BHPR/ENG/R/92/086/PS641Q, October, 1992. (2) Patrick M and Goh CC, Design of Floors with LYSAGHT BONDEK II Profiled Steel Sheeting to British, Part B - Composite Slabs, BHP Research Report No. BHPR/ENG/R/ 92/087/PS641Q, October, 1992. (3) Bennetts ID, Proe DJ, Patrick M and Poon SL, Design of Floors with LYSAGHT BONDEK II Profiled Steel Sheeting to British Standards, Part C - Fire Resistance, BHP Research Report No. BHPR/ENG/R/92/088/ PS641QP, October, 1992. Design Manuals The following BHP Design Manuals have been written for the use of LYSAGHT BONDEK II profiled steel sheeting in masonry wall and steelframe construction:

(a) Formwork Design & Installation Manual The Formwork Design Manual provides engineers and builders with Temporary Propping Tables for a wide range of design solutions, and can be readily used to minimize bare metal thickness and propping requirements. The maximum deflection of the sheeting under wet concrete may be chosen according to whether or not the slab soffit is exposed to view after construction, and is given as part of each design solution. Tables are given for imposed storage loads of 4 kPa. In the Installation Manual, designers are provided with essential practical information concerning construction of LYSAGHT BONDEK II composite slabs. The topics covered in the manual include: sheeting installation and propping; detailing for durability; reinforcement placement; concreting and prop removal; soffit and edge finishing; and installation of profile accessories to support suspended ceilings and services.

(b) Composite Slab Design Manual The complete set of design rules for normal temperature conditions is presented. Reinforcement selection tables are presented for a wide range of design solutions, and can be used to minimize the reinforcement requirements of positive and negative moment regions of either simply-supported or continuous slabs, noting that positive tensile reinforcement (in the form of deformed bars or weldedwire fabric) is only necessary when designing for fire resistance. Different incremental deflection limits may be satisfied on whether the non-structural elements being supported are brittle or non-brittle. Computer Software Computer software has been written to produce the solutions in the temporary propping tables in the Formwork Design Manual and in the reinforcement selection tables in the Composite Slab Design Manual. The program names are as follows: BIISPAN - formwork design in accordance with reference (1) BIISLAB - composite slab design in accordance with reference (2) BIIFIRE - design for fire resistance in accordance with reference (3)

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Program BIISLAB is included as Part 3 of the composite slab design manual. Programs BIISPAN and BIIFIRE are kept as in-house software for use by staff of the Marketing Department of BHP Steel Lysaght (S) Pte Ltd who should be contacted when designs outside the scope of the temporary propping and reinforcement selection tables are required. I. FORMWORK DESIGN MANUAL DESIGN OF STRUCTURAL FORMWORK GENERAL DESIGN PRINCIPLES Comprehensive design rules have been developed for the design of LYSAGHT BONDEK II profiled steel sheeting acting as structural formwork in masonry wall and steel frame construction. The rules were developed at BHP Research - Melbourne Laboratories and based on the results of extensive structural testing of LYSAGHT BONDEK II sheeting in single and multiple span arrangements performed in accordance with British Standard BS 5950: Part 4: 1982 Structural Use of Steelwork in Building - Code of Practice for Design of Floors with Profiled Steel Sheeting. Both uniformly-distributed and concentrated loading situations were simulated in the tests.

CONDITIONS OF APPLICATION The temporary propping tables may be used to detail LYSAGHT BONDEK II profile steel sheeting acting as structural formwork provided the following conditions are satisfied. 1. The support lines extend across the full width of the sheeting and have a minimum bearing of 50mm at the ends of the sheets, and 100mm at intermediate supports over which the sheeting is continuous. 2. The sheets continue over each slab span length without any intermediate splicing or joining. 3. The ratio of the longer slab span L1 to the shorter slab LS of any two adjacent spans does not exceed 1.2, i.e. L1 /LS <= 1.2 4. The slab has a uniform crosssection.

5. The supports are effectively rigid such that their vertical deflection during the construction phase can be ignored in design. FORMWORK DESIGN PARAMETERS The temporary propping tables have been compiled using the range of values of the design parameters defined in this Section. BONDEK II PROFILE The nominal dimensions of LYSAGHT BONDEK II profiled steel sheeting are shown in Fig. 1. In the assembled state, the profile comprises two intermediate dovetail ribs for every interlocking side-lap joint. The assembled ribs are all boldly embossed along their exposed top faces and the nominal height of the embossments is 2 mm.

FIG.1

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MATERIAL SPECIFICATION
LYSAGHT BONDEK II profiled steel

DEFLECTION LIMITS The British Standard recommended(BS 5950:Part 4: 1994) that in general the sheeting deflection should not exceed L/ 130(but < 30mm) under its own weight plus the weight of wet concrete (including reinforcement) provided ponding is taken into account. In this publication, deflection limits of L/130 is adopted. LOADING PARAMETERS 1. Sheeting dead load Gdp is taken as 0.13 tbm Kpa BONDEK II UNIT WEIGHT 0.75mm Bondek II 10.3 Kg/m2 1.00mm Bondek II 13.6 Kg/m2 2. Concrete dead load Gdc for normal weight concrete includes an allowance for the weight of additional concrete due to sheeting

deflection and for the weight of steel reinforcement. 3. Basic Construction loads Qc (BS5950:Part 4: Cl2.2.3.1) The basic construction loads Qc is taken as not less than 1.5 kPa in addition to the normal dead load. For span less than 3 m, the basic construction load should be increased to not less than 4.5/L kPa. 4. Storage Load Qs (BS5950:Part 4: Cl2.2.3.1) The provision of 4 kPa is made in the formwork design. As it is common practice to store building material on erected sheeting prior to concreting, this provision is a must to ensure safety of sheeting. 5. Load Combination The basic load combination for the construction stage are referred to in BS 5950: Part 4: Table 1 and is tabulated below:

sheeting is roll-formed from hotdipped, zinc-coated, chromatepassivated, high-strength grade BHP Steel ZINC HI-TEN steel strip in bare metal thicknesses of either 0.75 or 1.00 mm. The steel strip has a specified tensile strength Remin. of 550 MPa which conforms to both BS EN 10147 and AS 1397. The minimum coating class is Z200 for mild exposure conditions (e.g. internal floors in a non-aggressive environment), while heavier coating classes or painting must be specified in moderate or severe exposure conditions (see Rule 28 of Part I). However, Z275 coating class is being supplied in local environment.

TABLE 1 - Factored Load Combinations for strength and Deflection Calculations

Construction Stage (see Note 1) la lb lla llb Notes: 1 2 3 Construction Stage l is defined a being prior to the placement of concrete, and Construction Stage ll as during the placement of concrete up until the concrete hardens. Gdc includes an allowance for concrete ponding and the weight of steel reinforcement Both distributed and line load cases must be considered separately. Design Case Sheeting Dead Load Concrete Dead Load Imposed Construction Loads Qc 1.6 1.6 Imposed Storage Loads Qs 1.6 -

Gdp
(see Note 2) Strength Strength Strength Deflection (see Note 3) 1.4 1.4 1.4 1.0

Gdc
1.4 1.0

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SLAB GEOMETRY Minimum Nominal overall depth Ds is taken as 105 mm (BS 5950:Part 4:Cl 3.3.5) in this publication, overall slab thickness up to 200 mm is considered. The span-to-depth ratio L/D for composite slab using normal weight concrete tabulated in the following table. (Cl 6.6.3)
Span-To-Depth Ratio L/Ds Simply-Supported Slab Continuous Slab 15 L/D 35 15 L/D 40

II. INSTALLATION MANUAL GENERAL INFORMATION AVAILABLE LENGTHS The sheets are readily available custom-cut in any length from 600 mm up to 12000 mm (Length Tolerance +0, -10 mm). Lengths greater than 12000 mm require suitable transportation and on-site handling facilities, and the hours of transportation may be restricted by law. For speed of installation, LYSAGHT BONDEK II sheeting should generally be used in lengths covering multiple spans (handling weight permitting). FIRE RESISTANCE
LYSAGHT BONDEK II composite slabs

CORROSION PROTECTION Zinc-coated LYSAGHT BONDEK II profiled sheeting will provide long and trouble free life without additional corrosion protection in the following applications: Where building, or underside of the slab, is fully enclosed or partly exposed for brief periods, elevated exposed slabs with adequate under-floor ventilation in commercial, rural and urban areas in arid climatic zones. Where the exposed underside of LYSAGHT BONDEK II profiled steel sheeting is subjected to a more severe corrosive environment (such as industrial, coastal and tropical or temperate climatic zones), a suitable corrosion protection system should be chosen to match. Suggested zinc corrosion protection systems for LYSAGHT BONDEK II sheeting in different exposure classifications may be obtained at BHP office.

In addition, for continuous slab, it is required that the ratio of the longer to the shorter of any two adjacent spans should not exceed 1.2

can obtain a fire resistance level (FRL) to the requirements of the British Standard BS 5950: Part 8. For more details please contact BHP Steel Lysaght (S) Pte Ltd (Marketing Department).

tbm

= 0.75mm

TABLE 1 SPANNING TABLE

MAXIMUM SPAN (mm)
SLAB THICKNESS (MM) MAX. UNPROPPED SPAN 105 2730 110 2730 115 2730 120 2730 125 2680 130 2650 135 2610 140 2570 145 2540 150 2500

Deflection Limit = L/130

155 2470

160 2440

165 2410

170 2380

180 2330

190 2280

200 2230

tbm

= 1.00mm

TABLE 2 SPANNING TABLE

MAXIMUM SPAN (mm) SLAB THICKNESS (MM) MAX. UNPROPPED SPAN 105 110 115 120 125 130 135 140 145 150

Deflection Limit = L/130

155

160

165

170

180

190

200

3220 3170 3120 3080 3040 3000 2960 2920 2890 2860 2830 2800 2770 2740 2690 2640 2600

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SAFETY THE LYSAGHT BONDEK II sheeting has bold embossments along the top of the exposed ribs. These embossments enhance safety by reducing the likelihood of workers slipping on the sheets. The LYSAGHT BONDEK II is also provided with knurling on the upper face of the flutes, which provides even further enhancement of safety against slippage. Safety is also provided to personnel working on the floor below by providing a covering and by minimizing the obstruction caused by props. STORING ON-SITE
LYSAGHT BONDEK II profiled steel

PROPPING Depending upon the span of the LYSAGHT BONDEK II composite slab, temporary lines of support (or propping) located between the slab supports may be required. This support will need to be kept in place during the laying of the LYSAGHT BONDEK II sheeting, the concrete placement and until the concrete has achieved sufficient strength to support the loads. Detailed information on span of LYSAGHT BONDEK II sheets between lines of support may be obtained from Table 1 to 4, Section I Formwork Design.
LYSAGHT BONDEK II sheeting is

Notwithstanding the requirement for minimum bearing, where the underside of the LYSAGHT BONDEK II sheeting is featured as the finished ceiling, the use of wide form ply strips attached to the bearers will minimize bearer marks. The width of the form ply strips will depend upon the slab depth, sheeting thickness and spans. Form ply strips of 300 mm width have been successfully used. For the design of propping, please refer to Section I of this manual. CUTTING Cutting of LYSAGHT BONDEK II sheets is sometimes necessary to trim sheet sides or to cut sheet ends around projections such as columns and stairways.
LYSAGHT BONDEK II sheets may be

sheeting is delivered in strapped bundles. If not required for immediate use, sheets or bundles should be neatly stacked clear of the ground. When stacked, they should be on a slight slope to allow drainage of water should wetting occur prior to use. The sheets or bundles should not be left exposed in the open for extended periods. If unavoidable, then they should be protected from rain and moisture with waterproof covers.

normally placed directly upon prepared propping and the propping shall support the LYSAGHT BONDEK II sheeting across its full width. Propping generally consists of substantial timber or steel bearers (minimum bearer width 100 mm is required) supported by vertical props installed to prevent settlement during the placement and curing of concrete.

readily cut using a power saw fitted with an abrasive disc or metal cutting blade. For cutting, it is suggested that the sheeting be initially laid ribs down and cut through the pans and part through the ribs. The sheeting could then be turned over and the cutting of the ribs completed.

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LAYING
LYSAGHT BONDEK II profiled steel

sheeting must be laid with the sheeting ribs aligned in the direction of the spans. Where LYSAGHT BONDEK II sheets are laid to form a continuous platform, the following details must be observed (refer to Figure 2): The slab supports must be prepared for bearing and slip joints as required. LYSAGHT BONDEK II sheets must continue over each slab span without any intermediate splicing or jointing.

LYSAGHT BONDEK II sheets must be laid end to end and the joint generally centralized at the slab supports. Where jointing material is required, the sheets may be butted against the jointing material. LYSAGHT BONDEK II sheets must be supported across the full width at the slab support lines and the temporary support lines (propping). The end and edges of the

A minimum bearing is required for supports to carry the wet concrete and construction loads. The minimum bearing is 50 mm for ends of LYSAGHT BONDEK II sheets and 100 mm for intermediate supports over which the sheeting is continuous. The LYSAGHT BONDEK II sheeting must be assembled with the side lap ribs interlocking. Interlocking can be achieved by two methods as described below. However, either method may be used in most situations. Variations to these methods may be acceptable.

LYSAGHT BONDEK II sheets must be

provided with a suitable edge treatment in exposed applications to prevent entry of moisture.

FIG.2

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One method of achieving the interlocking is to progressively lay the LYSAGHT BONDEK II sheets parallel with the previous sheet. The female lap rib is placed overlapping the male lap rib of the previous sheet and interlocking is achieved by applying foot pressure, or light kick, to the female lap rib to clip onto, and

interlock with, the male lap rib. Interlocking should be done progressively as each sheet is laid down (see Figure 3). An alternative method requires the female lap rib to be placed down at an angle to overlap the male lap rib of the previous sheet. The angled

sheet is then simply lowered down through an arc to rest adjacent to the previous sheet (see Figure 4). The lap ribs should thus be properly interlocked. Where this does not occur due to some damage or distortion from site handling or construction practices, then it is recommended that sufficient side lap fasteners be used to pull the laps tightly together.

FIG.3

FIG.4

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ACCESSORIES
LYSAGHT BONDEK II accessories include: BONWEDGE, BON-NUT, CEILING SUSPENSION NUT, EDGE FORM, BONFILL AND BONSTRIP, each

of which simplify the construction of

LYSAGHT BONDEK II composite slab

and the installation of ceilings and services. Please note that except for the EDGE FORM, these accessories are available on a project to project basis only.

BONWEDGE A lightweight, pressed metal, wedge-shaped bracket which is inserted from below into the LYSAGHT BONDEK II ribs and locked into place in the profiled rib to support rods, wires or hangers which carry suspended ceilings or services, other than fire sprinkler systems (see Figure 5).

BON-NUT A heavy duty square nut adhered to a paper strip to allow easy insertion from below into the LYSAGHT BONDEK II ribs. Threaded rods may then be screwed into the BON-NUT and locked into position. Available in three convenient thread sizes (M8, M10 and M12), BON-NUT may be used to support threaded rods for various services and suspended ceilings (see Figure 6).

FIG.5

FIG.6

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CEILING SUSPENSION NUT A lightweight pressed metal, wedgeshaped suspension nut which is inserted from below and locks into the profiled rib of the LYSAGHT BONDEK II Used to support M6 threaded rods for suspended ceiling and services other than fire sprinkler systems (see Figure 7). EDGE FORM A galvanized profiled steel edge formwork. It is available in any stock sizes to suit commonly used slab depths not exceeding 200 mm, and standard stock length is 3000 mm (see Figure 8). Pre-painted finish and other zinc coating thicknesses may also be obtained for special applications. BONFILL A rib infill made of polystyrene foam, available in a standard stock length of 1200 mm. It is used to reduce concrete seepage and to reduce air flow through the ribs at walls which support the LYSAGHT BONDEK II slab (see Figure 9).

FIG.7

FIG.8

FIG.9

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BONSTRIP A long plastic insert which snaps into and seals the gap of the dove-tail rib. Available in a standard stock length of 3000 mm, it is used in exposed soffits where gaps need to be covered to provide a uniform exposed ceiling line (see Figure 10). INSTALLING ON STEEL FRAME
LYSAGHT BONDEK II profiled steel

sheeting may be installed directly upon the erected structural steelwork. The sheeting may be secured to the structural steel slab supports where required using spot welds or fasteners such as drive nails and selfdrilling tapping screws. Where a movement joint is detailed at a slab support, the sheeting must

FIG.10

not be continuous over this support. The end of one sheet may be secured to the support, the end of the abutting sheet must not be secured to allow for movement of the composite slab to take place (see Figure 11).

FIG.11

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The locations of the securing points (fasteners and spot welds) are to be in the flat areas of the pans adjacent to the ribs or between the flutes. The frequency of securing points to provide uplift resistance or lateral restraint will be dependent upon wind or seismic load conditions and accepted building practice. For information on the frequency, type and size of securing systems advice should be obtained from a practicing structural engineer. One securing system which has been successfully utilized is described below. However, the frequency of the securing points may need to be altered to suit the conditions on the project. Securing points adjacent to every rib at the end of sheets and adjacent to the female rib of the side lap at each intermediate slab support over which the sheeting is continuous (see Figure 11). Secure LYSAGHT BONDEK II with drive nails, self-drilling tapping screws or spot welds.

Drive nails should be powderactivated steel mails 4 mm nominal diameter, suitable for structural steel of 4 mm or greater flange thickness. Self-drilling, tapping screws should be No. 12 - 24 x 32 mm hex head, suitable for structural steel up to 12 mm flange thickness: for structural steel greater than 12 mm flange thickness, then pre-drilling will be necessary with the use No. 12 - 24 x 32 mm hex-head thread forming screws. Spot welds should be 12 mm diameter, made with 3.25 mm diameter cellulose, iron powder AD/ DC high penetration electrodes. When welding, suitable safety precautions should be taken regarding fumes given off during welding of zinc coated products. Surfaces to be welded must be free of loose material and foreign matter. Where the LYSAGHT BONDEK II soffit or the structural steelwork has a pre-painted surface, securing methods other than welding may be more appropriate.

In projects of composite beam construction, the LYSAGHT BONDEK II sheeting must be fastened in each pan at each compositely designed steel beam. In some projects of composite beam construction where stud welding through the sheet has been specified, the stud welding has been considered to be a suitable securing method for the sheeting, however some preliminary fixing by one of the methods mentioned above is necessary to secure sheeting prior to the commencement of stud welding. Stud welding must be between pan flutes for sheets transverse to beams to ensure there is no gap between mating surfaces.

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FASTENING SIDE LAP JOINT To maintain a stable platform under load, and to minimize concrete seepage during pouring, the side lap joints may require fastening. Fasteners shall be No. 12 - 24 x 20 mm self-drilling tapping screws and be located on the side lap rib midway between embossments (see Figure 12). The frequency of fasteners will depend upon the situation as described below: The minimum fastener requirement is one fastener at midspan for support spacing of 2750 mm or greater.

To obtain a point load rating of 2.3 KN (235 kg), the side lap joints will require fastening for support lines spaced over 2000 mm. For 1.0 BMT LYSAGHT BONDEK II, a single fixing at mid-span is required up to a maximum of 3250 mm spacing between supports. For 0.75 LYSAGHT BONDEK II, two fixings at third points are required up to a maximum of 2400 mm spacing between supports. For exposed LYSAGHT BONDEK II soffits where good visual quality is required, it may be necessary to provide fasteners at closer spacing to ensure a uniform soffit between adjoining sheets, and to further reduce concrete seepage.

CUTTING AND FITTING EDGE FORM Edge Form is a simple, strong, lightweight, easy to use edge form. Edge Form simplifies the installation of most LYSAGHT BONDEK II slabs, neatly retaining the concrete. Edge Form is easily fastened to the LYSAGHT BONDEK II sheeting and provides a smooth top edge for quick and accurate screeding. Edge Form should be made of the same material as LYSAGHT BONDEK II. Edge Form is easily spliced and bent to form internal and external corners of any angle and should be fitted and fully fastened as the sheets are installed.

12 - 24x20mm

FIG.12

15 June 2003 BHP Steel Lysaght Singapore

The Edge Form must be fastened to the underside of unsupported panels every 300 mm. The top flange of Edge Form must be tied to the ribs every 600 mm with builders strapping (see Figure 13). No. 10 - 24 x 16 mm self-drilling, tapping screws or similar fasteners should be used for all fastening.

SEALING Seepage of water or fine concrete slurry can be minimized by following accepted construction practices. The following is provided as a guide only. The gap between abutting LYSAGHT BONDEK II sheets may be sealed using a waterproof tape (see Figure 14). Alternatively, by sandwiching contraction joint material between the butting ends of sheeting, seepage would be minimized.

LYSAGHT BONDEK II sheeting ends

which abut Edge Form may be more effectively sealed with waterproof tapes as above, but in any case with the minimum bearing requirement the concrete seepage would be minimized. Side laps of LYSAGHT BONDEK II sheeting must be fastened as recommended on pg. 15 - Fastening Side Lap Joints in order to minimize the concrete seepage.

FIG.13

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Where there is a sizable gap between the end of the LYSAGHT BONDEK II sheet and adjoining Edge Form or adjoining LYSAGHT BONDEK II sheet, it may be necessary to provide a support for the overlaying waterproof tapes. BONFILL may be used for this support (see Figure 14). Alternatively, the ends of the ribs can be taped off individually. There are various commonly used water proof tapes with qualities suitable for the application. Reference to the manufacturer of such tapes should be made for details.

HOLING
LYSAGHT BONDEK II profiled steel

sheets act as longitudinal tensile reinforcement as per conventional bar or fabric reinforcement in reinforced concrete slabs. Holing of LYSAGHT BONDEK II sheets to accommodate pipes and ducts would reduce the effective area of steel. Acceptable regions for holing are as follows, however the size and quantity of holing must be on the approval of the design engineer since the extent of holing, and the accompanying reduction in area of concrete, may affect the slab performance (refer to Figure 15).

Keep within a length of 0.1 x clear span from an interior support of the slab for slabs designed as a continuous slab. Holes should be placed in the central span of any sheet with a minimum edge distance of 15 mm from the rib gap. Holes should be circular with a maximum of 150 mm in diameter. Holes must be cut using a suitable drill or hole saw. Cutting of LYSAGHT BONDEK II sheeting should be carried out after the concrete has cured. This will require accurate location of ducting outlets (e.g. electrical outlets) during formworking. Small pilot holes drilled through the LYSAGHT BONDEK II prior to concreting could be used. The pilot holes should be taped to prevent concrete seepage. For holes outside the above limitations, advice is available from BHP Steel Lysaght Singapore Pte Ltd or from a practicing structural engineer.

FIG.14

FIG.15
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INSPECTION Inspection of the installed sheeting by the relevant site supervisor is recommended at regular intervals of installation to ensure that the sheeting has been installed in accordance with this publication and with accepted building practice. REINFORCEMENT GENERAL
LYSAGHT BONDEK II profiled steel

may be positioned in other orientations. Refer to Figure 18 for a typical cross-section of a LYSAGHT BONDEK II composite slab and terms associated with the placement of reinforcement. Reinforcement must be properly positioned, lapped where necessary to ensure continuity, and tied to prevent displacement during construction. Fixing of reinforcement is to be in accordance with BS-8110: Part 1. The uppermost layer of reinforcement must be positioned and tied to prevent displacement during construction to obtain the specified minimum concrete cover (refer to BHP Steel Composite Slab Design Manual for guide to the recommended concrete cover). For movement joints, the reinforcement is stopped short on either side of the joint to permit movement of the adjoining slabs. Where fabric (such as BRC Mesh) is to be used in thin slabs or where fabric is used to act as both longitudinal and transverse reinforcement, particular attention should be taken to ensure the specified minimum concrete cover and the required design reinforcement depth are maintained at the splices. To assist in this matter, it is prudent to use splice bars.

sheeting is capable of withstanding temporary construction loads including the mass of workmen, equipment and materials all in accordance with BS 5950: Part 4: 1982 (refer to Section I). However, it is good construction practice to ensure protection from concentrated loads, such as barrows, by use of some means such as planks and/or boards.
LYSAGHT BONDEK II sheeting acts

Fixing of reinforcement using chairs and spacers must be such that the chairs and spacers are placed upon the pan area. Depending upon the chair type used and the load they carry, it may be necessary to use plates underneath the chairs to alleviate depressions in the LYSAGHT BONDEK II sheeting, particularly where the soffit will be exposed. Transverse reinforcement may be utilized as spacers or supports for longitudinal reinforcement. TRANSVERSE REINFORCEMENT Transverse reinforcement is positioned across the ribs of the LYSAGHT BONDEK II profiled steel sheeting. Transverse reinforcement may be detailed as deformed bar or fabric reinforcement. In most applications, the transverse reinforcement is for the crack control due to shrinkage and temperature effects. Transverse reinforcement for large holes is used to distribute loads into adjacent strips of composite slabs. To control flexural cracking in the top face of the slab, transverse reinforcement in the top-face may be detailed over walls or beams, which run in the same direction as the LYSAGHT BONDEK II sheets. For ease of construction, reinforcement for control of cracking due to shrinkage and temperature effects is generally fabric reinforcement.

as longitudinal tensile reinforcement and should be treated as such. The condition of the sheeting should be inspected before the concrete is poured. Reinforcement in slabs is required to carry and distribute the design loads and to control cracking. Reinforcement is generally detailed as transverse and longitudinal in relation to span, but other reinforcement required for trimming

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Unless otherwise specified, the bottom-face transverse reinforcement for control of cracking due to shrinkage and temperature effects should be placed directly on top of the ribs of LYSAGHT BONDEK II profiled steel sheeting for unexposed slabs not exceeding 200 mm in depth, otherwise instruction from the design engineer will be required. LONGITUDINAL REINFORCEMENT Longitudinal reinforcement is positioned in the same direction as the ribs of the LYSAGHT BONDEK II profiled steel sheeting. Longitudinal reinforcement may be detailed as deformed bars or fabric reinforcement. Longitudinal reinforcement is positioned to carry design loads and is located in the top and bottom faces of the slab. Top-face longitudinal reinforcement is located over interior supports of the slabs and extends into approximately a third of the adjoining spans, or as detailed by the structural engineer. For design information refer to BHP COMPOSITE SLAB DESIGN MANUAL. For single spans, top-face longitudinal reinforcement is not normally detailed.

Bottom-face longitudinal reinforcement is located between supports of the slab but depending upon the detailing over the interior supports, it may be continuous, lapped or discontinuous. Bottomface longitudinal reinforcement may be placed on top or below transverse reinforcement. Location of bottom-face longitudinal reinforcement in elevated temperature conditions requires special detailing. Generally, this will require the bottom-face longitudinal reinforcement to be kept a minimum distance away from the ribs and soffit of the LYSAGHT BONDEK II sheeting. Refer to BHP Steel COMPOSITE SLAB DESIGN MANUAL for more information. TRIMMERS Trimmers are used to distribute the design loads to the structural portion of the slab and/or to control cracking of the concrete at penetrations, fittings and re-entrant corners.

Trimmers may be either deformed bars or fabric reinforcement and in straight lengths or shaped. The trimmers may be detailed or specified to be laid at angles. The trimmer reinforcement is generally detailed between the top and bottom layers of transverse and longitudinal reinforcement. Fixing of trimmers is generally with ties from the top and bottom layers of reinforcement. FINISHING SOFFIT AND EDGE FORM FINISHES For many applications, the LYSAGHT BONDEK II profiled steel sheeting provides an attractive appearance to the underside (or soffit) of a composite slab and will provide a satisfactory ceiling. For example, in car parks, under-house storage and garages, industrial floors and the like. Similarly, the Edge Form will form a suitable edging. In such applications, a cleaning of the exposed surfaces may be required (see Table 3 for cleaning preparations).

TABLE 3: BONDEK II Soffit and Edge Form Preparation

SOFFIT AND EDGE FORM TYPE Galvanized soffit or edge PREPARATION Light corrosion marks indicated by white to grey staining due to wet bundles may be removed with a kerosene rag. Grease or oil deposits may be removed with a kerosene rag. For stubborn deposits, use paint thinners. Concrete seepage marks and dirt to be removed by washing as described above.

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Where the LYSAGHT BONDEK II soffit is to be the ceiling, then care should be taken during construction to minimize propping marks (refer to Pg. 8 - Propping) and to provide a uniform surface at the side laps (refer to Pg. 15 - Fastening Side Lap Joints). FIRE SPRAYS Where a building is being refurbished and due to a change of occupancy, the fire resistance of the LYSAGHT BONDEK II composite slabs may need to be increased. This may be achieved by the addition of a suitable fire-protection material to the underside of the slabs. The addition of such materials to the underside of the slab will increase the fire-resistance of the slab with respect to insulation, integrity and structural adequacy. In the case of fire spray materials, the presence of the LYSAGHT BONDEK II open ribs will provide a positive key to keep the fire spray in position throughout a fire.

For details regarding the preparation of soffit, application and thickness of materials to be applied for various situations, refer to the manufacturer of the fire protective material. SUSPENDED CEILINGS AND SERVICES SUSPENDED CEILING Ceilings are easily suspended from LYSAGHT BONDEK II slabs using Ceiling Suspension Nuts, BON-NUT suspension nuts, or BONWEDGE suspension brackets. Threaded rods or wire hangers are then used to support the ceiling. Alternatively, hangers may be attached to eyelet pins powder driven into the underside of the slab, or to pigtail hangers inserted through pilot holes in the LYSAGHT BONDEK II sheeting before concreting (see Figure 16).

FIG.17
SUSPENDED SERVICES Services such as fire sprinkler systems, piping and ducting are easily suspended from LYSAGHT BONDEK II slabs using BON-NUT suspension nuts (see Figure 17). Ceiling Suspension Nuts or BONWEDGE suspension brackets are suitable for services other than fire sprinkler systems. Threaded rods are then used to support the services. Load capacities and threaded rod size for these accessories need to be considered when making a selection for the particular service.

FIG.16

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Typical Steel Framing Plan

FIG.18

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Details Incorporating BONDEK II

DETAIL 1-1

DETAIL 4-4

DETAIL 2-2

DETAIL 5-5

DETAIL 3-3

DETAIL 6-6

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23 June 2003 BHP Steel Lysaght Singapore