USING BONDEK

USING BONDEK
Design & Construction
Guide
2005 Edition

1
 INTRODUCTION 1

1 INTRODUCTION

1 Introduction
1.1 PREFACE
BLUESCOPE LYSAGHT proudly presents this new publication on LYSAGHT
BONDEK®. We have simplified the work of engineers with this single
book which replaces eight previous publications. Further, it tabluates
the propping, composite slab data and fire design for varioius
situations, all at one view. Additionally, the book includes
BONDEK 2003, our easy-to-use interactive computer software, which
enables you to bypass the tables altogether and get quick and more
economical solutions with more options.
BONDEK is the centre of a formwork and reinforcement system for
concrete slab construction. It is a profiled steel sheeting widely
accepted by the building construction industry to be highly
economical, versatile and robust. It has been used to great effect on
many major building projects, as well as countless small ones.
This new work now embodies limit state design philosophy, and is
based on our extensive research conducted on BONDEK, so the
information is not applicable to other sheeting profiles.
We now consider concrete-frame buildings, and several major new
technical developments:
• linear elastic analysis of continuous composite slabs;
• saving of up to 30% in negative reinforcement due to
moment redistribution;
• partial shear connection strength theory for designing
positive-moment regions;
• increased unsupported spans of BONDEK sheeting at the
formwork stage (due to the inclusion of negative moment region
capacities);
• design for reliable control of flexural cracking in support regions;
• New reinforcement grades D500N and D500L; and
• Enhanced fire design
These developments allow you to make significant improvements
compared with the design methods we previously published for
slabs using BONDEK.

1.2 SCOPE
This manual and computer software provide engineers with a
convenient aid to design BONDEK composite slabs used in masonry
wall, concrete and steel-frame construction. The book also contains
practical construction methods.

1.3 DESIGN METHODS FOR BONDEK

There are three ways you can design concrete slabs using BONDEK.

1. The easiest way of designing for BONDEK is to run our BONDEK

2003 software included with this manual on the inside back
cover (see Chapter 9).
2. Use the design tables in this book.
3. Calculate from first principles using the data in Chapters 2,
3 and 4.
Section 1.13 gives a flowchart outlining the process assumed
for design.
2 INTRODUCTION

1.4 GENERAL DESIGN PARAMETERS

The design solutions are provided for the following broad range
of design parameters:
• design loads are essentially uniformly-distributed;
• spans are either simply-supported, or are end and interior spans
of continuous slabs;
• BONDEK sheeting has three base metal thicknesses (BMT or tbm)
of 1.00, 0.75 or 0.6 mm;
• concrete is either normal density or lightweight;
• vertical deflection limits for a composite slab are L/250 total,
or L/250 total and L/500 incremental;
• vertical deflection limits for formwork are L/150 or L/240;
• exposure classifications are A1, A2, B1 and B2
(as defined in AS 3600—2001);
• reinforcement may be normal or low ductility grades 400Y,
D500N, D500L or 450F;
• ƒ’c = 25, 32 and 40 MPa
• maximum live load is 15 kPa;
• ratio of the longer slab span (Ll) to the shorter slab span (Ls),
of any two adjacent spans, does not exceed 1.2;
• fire resistance periods of 60, 90, 120 and 180 minutes; and
• Masonry-wall, steel or concrete-frame construction.

1.5 MATERIALS: SHEETING

BONDEK is roll-formed from hot dipped, zinc-coated, high tensile zinc
HI-TEN™ steel, in base metal thicknesses (BMT or tbm) of 1.00, 0.75
and 0.6 mm.
The steel conforms to AS1397 grade G550 (550 MPa minimum yield
strength); and
• Z350 and Z450 coatings
In special circumstances BONDEK may be obtained:
• in other base metal thickness;
• with a non-standard zinc coating mass;
• with a pre-painted finish to the underside.
The mass of BONDEK sheeting (Z350) is:
• 13.79 kg/m for 1.00 BMT
2

• 10.50 kg/m2 for 0.75 BMT

• 8.52 kg/m2 for 0.6 BMT.
 INTRODUCTION 3

1.6 MATERIALS: CONCRETE

1 Introduction
ρc= 2000 kg/m3 (lightweight) and
ρc= 2400 kg/m3 (normal density)
See Table 1.1 for strengths.

1.7 MATERIALS: REINFORCEMENT

• For negative, shrinkage and fire reinforcement use D500N, or
400Y, or 450F grades.
• For negative and shrinkage reinforcement use D500N, or D500L,
or 400Y, or 450F grades.
Our design tables assume the use of D500N 10 mm maximum
diameter bars for negative reinforcement. If you want to use other
grades, refer to Section 3.10. If you want to use diameters other
than 10 mm, run BONDEK 2003. The diameter of reinforcing bars must
not exceed 20 mm.

1.8 DIMENSIONS AND PROPERTIES

The dimensions and properties of BONDEK are presented in Figure 1.1
and Table 1.2.

Table 1.2
Section properties of Bondek
Section Cross-sectional Second moment
Thickness modulus area of BONDEK of area
BMT mm Zx 103 mm3/m Ash mm2/m Ix 104 mm4/m
1.00 BMT BONDEK 1.00 16.69 1678 64.08
0.75 BMT BONDEK 0.75 12.50 1259 47.98
0.60 BMT BONDEK 0.60 9.99 1007 38.37

1.9 AVAILABLE LENGTH

BONDEK sheets are readily available, custom-cut, in any length from
600 mm up to 19,500 mm (length tolerance +0, –10 mm). Ask us
about longer lengths up to a maximum of 25,000 mm.
To maximise speed of installation, use lengths of BONDEK that cover
multiple spans.

Negative reinforcement Shrinkage and

CENTROID OF ALL for flexure and temperature
NEGATIVE REINFORCEMENT Embossments on ribs crack control reinforcement
b • Top location
Concrete (continuous spans)
c dct
• Bottom location
(single spans)

D 32 32
hr = 54 29
52

51

dcb SHEETING tbm (BMT) 13

ELASTIC
Bondek
CENTROID 200 200 190
Flute
Cover width 590
Pan
Sheet width 620
Figure 1.1
Bondek dimensions (2 sheets shown)
(Fire reinforcement is not shown, see Chapter 4)
4 INTRODUCTION

1.10 CORROSION PROTECTION

Zinc-coated BONDEK will provide long and trouble free life without
additional corrosion protection for Exposure classifications A1, A2
and B1 as defined in AS 3600—2001, Clause 4.3.
Where the exposed underside of BONDEK is subjected to a more
severe corrosive environment use a suitable corrosion protection
system.
In any exposed application, you need to treat the edges of BONDEK
to prevent moisture entering between the concrete and the sheeting
(Figure 1.2).

1.11 FURTHER INFORMATION

• BLUESCOPE LYSAGHT Service Centres
• BLUESCOPE LYSAGHT Information Service on 1800 641 417
• www. lysaght.com

1.12 YOUR SUGGESTIONS

Please send your suggestions for improvements to this manual to:
the Technical Writer,
BLUESCOPE LYSAGHT Technology Centre,
PO Box 504, Chester Hill, 2162.

Required
cover
Concrete

Concrete
Edge
Drip lip Form
SQ UARE
Bondek

Drip lip Bondek

AN G LED

Required
cover Concrete
Required
cover
Concrete

Bondek
Drip strip cast into
concrete (plastic or Alcor)
Bondek
Drip groove

Figure 1.2
Examples of edge treatment to prevent moisture entry at edge of slabs
 INTRODUCTION 5

1.13 DESIGN FLOWCHART

1 Introduction
This chart outlines the process assumed in this book for the design of
BONDEK slabs.
6 FORMWORK DESIGN

2 FORMWORK DESIGN

2.1 GENERAL
New design rules have been developed for the design of LYSAGHT
BONDEK acting as structural formwork for the construction of
composite and non-composite slabs (where BONDEK is used as lost
formwork). The rules for calculating moment capacities are based on
testing performed at BLUESCOPE LYSAGHT Technology Centre facility at
Chester Hill, AS/NZS 4600:1996, and a finite element strip buckling
analysis.
The data obtained allowed us to include moment capacities in
negative regions of the design model. As a consequence, the span
limits that previously applied to BONDEK have been increased by up
to 8%.
Formwork design calculations are covered in this section—geometric
layout considerations are generally covered in Chapter 5
(Construction).

2.2 APPLICATION
Our design tables may be used to detail BONDEK 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 50 mm at the ends of the
sheets, and 100 mm at intermediate supports over which the
sheeting is continuous.
2. The sheets continue over each slab span length without any
intermediate splicing or jointing.
3. The 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 ≤1.2.
4. Prop lines are positioned at equal spacings (L´) within a span (L)
in the case of propped construction.
5. The slab has a uniform cross section.
6. The supports are effectively rigid such that their vertical
deflection during the construction phase can be ignored
in design.
7. BONDEK formwork is not normally cantilevered, though you can
seek advice from our information service for special situations.
8. Separate consideration is given to sides of the sheeting where
edges are restrained or where the side of the sheeting is cut
longitudinally.
Equal sheeting spans L’

Outline of
concrete

Bondek

Temporary Temporary
props props

Slab span L Slab span L

End Interior Interior
support support support
Figure 2.1
Temporary props must be equispaced
 FORMWORK DESIGN 7

2.3 DEFLECTION LIMITS

AS 3610—1995 Formwork for concrete, defines five classes of
surface finish (numbered 1 to 5) covering a broad range of
applications.
We recommend a deflection limit of span/240 for the design of
composite slabs in which good general alignment is required, so that
the soffit has a good visual quality when viewed as a whole. We
consider span/240 to be suitable for a Class 3 and 4 surface finish
and, in many situations, Class 2. Where alignment affects the
thickness of applied finishes (for example vermiculite), you may

2 Formwork design
consider a smaller limit of span/270 to be more suitable.
We consider span/150 to be a reasonable maximum deflection limit
appropriate for profile steel sheeting in situations where visual quality
is not significant (Class 5).
The design rules presented may be used for deflection limits other
than those stated above however, for deflection greater than
span/150, you may contact our information service.

2.4 FORMWORK DESIGN LOADS

BONDEK must be designed as formwork for two stages of
construction. Stage I—prior to the placement of the concrete, which
includes the time:
• during handling and erection of the formwork; and
• once the formwork is erected but prior to the placement of the
concrete, (Stage I as defined in AS 3610—1995.)
When a live load due to stacked materials can be adequately
controlled on the site at less than 4 kPa, the reduced design live load
must be clearly indicated on the formwork documentation.
Stage II—during placement of the concrete up until the concrete has
set (until fcm reaches 15 MPa and concrete is able to act flexurally to
support additional loads such as stacked materials). No loads from
stacked materials are allowed until the concrete has set.
Stage III—as defined in AS 3610—1995 must not be considered in
the rules presented here.

2.4.1 DEAD LOAD OF BONDEK SHEETING

The dead load of the BONDEK sheeting (Gsh) is:
G sh = 0.13tbm (AS 3610—1995, Clause 4.4.2.1)
(Gshis in kPa, when tbmis in mm)

2.4.2 DEAD LOAD OF CONCRETE

The dead load of the concrete (Gc) must include an allowance for the
weight of reinforcement as well as the effect of ponding, and is
calculated as:
Gc = ρ ( D + 0.7∆ ) (AS 3610—1995, Clause 4.4.2.2)

The effect of ponding must be taken as 0.7 times the maximum

deflection (∆) of the sheeting when supporting the wet concrete.
8 FORMWORK DESIGN

2.4.3 UNIFORM VERTICAL LIVE LOAD

The uniform vertical live load (Quv), for the appropriate stage of
construction, is:
For Stage I construction
Q uvI = 1.0 kPa
For Stage II construction
Q uvII= 1.0 kPa (AS 3610—1995, Clause 4.4.2.3)

2.4.4
LOAD
CONCENTRATED VERTICAL LIVE

A concentrated vertical live load (Qc) is:

Q c = 3.0 kPa (over an area 1.6 m2 placed at any location)
(AS 3610—1995, Clause 4.4.2.3)
Provided the formwork design conforms to this manual, you need not
consider concentrated loads as specified in AS 2327.1—1996,
Appendix F2.

2.4.5 VERTICAL LIVE LOAD DUE

TO STACKED MATERIALS
A vertical live load (QM) due to stacked materials is:
For Stage I construction
Q MI = 4 kPa maximum

(AS 2327.1—1996 does not allow less than 4 kPa for composite
beam construction.)
For Stage II construction
Q MII = 0 kPa (AS 3610—1995, Clause 4.4.2.4)

2.4.6 LOAD COMBINATIONS

FOR STRENGTH
The design loads for strength are taken from the following load
combinations:
For Stage I construction
FdI = 1.25G sh + 1.5Q uvI + 1.5Q mI
For Stage II construction
FdIIa= 1.25G sh+ 1.5G c + 1.5Q uvII
FdIIb= 1.25G sh+ 1.5G c + Q c (AS 3610—1995, Clause 4.5.4.1)

2.4.7 LOAD COMBINATIONS

FOR SERVICEABILITY
The design service load for vertical deflection is:
Fdef = Gsh + Gc (AS 3610—1995, Clause 4.5.4.4)
 FORMWORK DESIGN 9

2.4.8 DESIGN FOR STRENGTH

Design moments
The design positive bending moment (M*+) must be calculated from
statics —treating each span as continuous with design negative
moments over supports —and not exceed the values shown in
Table 2.1.
Design negative capacities are significantly less than maximum
negative and positive capacities, because negative regions begin to
‘soften’ well before the design positive capacity is reached.

2 Formwork design
Design shear
The design vertical shear force (V*) must be calculated from statics,
treating each span as continuous with design negative moments over
Table 2.1 supports as shown in Table 2.1. Each load combination for strength
BONDEK moment capacities must be considered and the concentrated vertical live load (Qc) must
Design positive Design negative be placed in a position which maximises the vertical reaction.
capacity capacity
tbm Mu.sh+ (kNm) Mu.sh- (kNm) Design support reaction
1.0 7.99 2.34 The design support reaction (R*u) must be calculated from statics,
0.75 4.89 1.75 treating each span as continuous with design negative moments
0.6 3.32 1. 4 0 over supports as shown in Table 2.1. Each load combination for
strength must be considered and the concentrated vertical live load
(Qc) must be placed in a position which maximises the vertical
reaction.
Strength of positive moment regions
The design positive moment capacity ( Mu.sh+) is given in Table 2.1.
The capacity is applicable when the loading is applied to the pans,
or the tops of the ribs provided the distribution width on the ribs is a
minimum of 50 mm.
Strength of support regions
The design shear capacity (ØVu.sh) for bearing length of 50 mm or
more, is:
Vu.sh = 33.99tbm 2 + 8.17tbm

2.4.9 DESIGN FOR SERVICEABILITY

The maximum vertical deflection (∆), at completion of the concrete
placement in all spans, is:

kd Fdef ( L or L' ) ( L or L' )

4

=
(E I )
s ef
150 (or 240)
Where:
• the values of the coefficient kd are given in Table 2.2; and
• the value of the effective second moment of area Ief is calculated
Table 2.2 as follows:
Values of coefficient kd for calculation of ∆ Single span sheets
(The maximum vertical deflection always occurs
in the end span for these conditions.) Ief /tbm = 205L = 96025
Longer Longer
Equi-span span is an span is an (for the range of 301025≤ Ief /tbm ≤ 50800)
end span interior span
Number Multiple span sheets
L1/Ls ≤ 1.2 L1/Ls ≤ 1.2
of spans
1 5/384
2 1/185 0.00643
(for the range of 169750 ≤ Ief / tbm ≤ 508000 )
3 0.00687 0.00761 0.00687
4 or more 0.00646 0.00725 0.00725 To keep the amount of ponded concrete to a manageable level,
the maximum vertical deflection (∆) within any span must not exceed
(L or L´ )/150.
3 COMPOSITE SLAB DESIGN
10 COMPOSITE SLAB DESIGN

3.1 GENERAL
This chapter discusses the parameters upon which our design tables
are based. Solutions to your design problems may be obtained by
direct reference to either our BONDEK 2003 software, or our design
tables.
The design solutions are based on partial shear connection theory.
Data about the shear connection performance of LYSAGHT BONDEK
have been obtained from slip-block tests and full-scale slab tests.
Mechanical and frictional resistance have now been identified as the
major contributors to the bond, and a composite slab no longer
depends on adhesion bond for anchorage. A method of design for
vertical shear is also presented.
Major savings are achieved by allowing moment redistribution from
negative to positive moment regions in continuous composite slabs,
and this leads to a significant reduction in the amount of top-face
reinforcing. Our design tables assume the use of 500 N-class fire and
negative reinforcement. In our composite slab design tables, slab
thickness has been developed for FRL60. The tables for continuous
slabs have been developed for end spans and can be used for
interior spans also. Our BONDEK 2003 software often gives more
economical designs.

3.2 CRACK CONTROL OPTIONS

An advanced method of crack control for flexure limits the crack
width to 0.3 mm. Our design tables assume continuous slabs with
flexural cracking control. However, if aesthetics (wide cracks over
supports) is not important, it may be economical to design a
continuous slab as a series of one-way slabs—no negative
reinforcement is necessary in such case (refer to Worked example 1,
Chapter 6).
Slab design calculations are covered in this section—geometric layout
considerations are generally covered in Section 5 (Construction).

3.3 APPLICATION
The rules presented can be used to design BONDEK composite slabs
provided the following conditions are satisfied.
1. The specified concrete strength grade ƒ´c is in the range 25 MPa
to 40 MPa (as specified in AS 3600—2001). The concrete density
ρc may be either lightweight (1800 ≤ ρc ≤ 2100 kg/m3) or normal
density (2100 ≤ ρc ≤ 2800 kg/m3) (as specified in AS 3600—
1994).
2. The concrete manufacture and materials satisfy the requirements
of AS 3600—2001, Section 19.
3. The 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 min at intermediate supports over which
sheeting is continuous.
4. The 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
≤ 1.2.
5. The slab has a uniform cross-section.
6. The design loads for serviceability and strength design must be
uniformly-distributed and static in nature.
7. The bending moments at the supports are only caused by the
action of vertical loads applied to the slab.
 COMPOSITE SLAB DESIGN 11
8. The exposure classification is A1, A2, B1, or B2.
9. The geometry of the steel sheeting profile must conform to the
dimensions and tolerances shown on our production drawings.
Sheeting with embossments less than the specified lower
characteristic value must not be used compositely unless the
value of Hr is revised.
10. Material and construction requirements for conventional
reinforcing steel must be in accordance with AS 3600—2001,
Clause 19.2, and the design yield stress, ( ƒsy ), must be taken
from AS 3600—2001, Table 6.2.1, for the appropriate type and
grade of reinforcement, and manufacturers’ data.
11. Material and construction requirements for concrete must be in
accordance with AS 3600—2001, Clause 19.1.
12. BONDEK must not be spliced, lapped or joined longitudinally in
any way.
13. The permanent support lines must extend across the full width
of the slab.
14. Similar to the requirement in AS 2327.1, Clause 4.2.3,

3 Composite slab design

composite action must be assumed to exist between the steel
sheeting and the concrete once the concrete in the slab has
attained a compressive strength of 15 MPa, that is ƒ´cj ≥ 15 MPa.
Prior to the development of composite action during
construction (Stage 4 defined in AS 2327.1), potential damage to
the shear connection must be avoided; and no loads from
stacked materials are allowed.
15. The first interior span must have the same thickness as the
end span.

3.4 DURABILITY
The exposure classification relevant to the design of BONDEK slabs are
A1, A2, B1 and B2 as defined in AS 3600—2001, Clause 4.3.
Table 3.1
The minimum concrete cover (c) to reinforcing steel, measured from
Minimum concrete cover (c) in BONDEK slabs
the slab top face, must comply with AS 3600—2001, Table 4.10.3.2.
Exposure Concrete strength grades f'c These requirements relevant to the design of BONDEK slabs are in
classification 25 MPa 32 MPa 40 MP a
Table 3.1.
A1 20 mm 20 m m 20 mm
A2 30 mm 25 m m 20 mm The minimum overall depth (D) of BONDEK slabs must at least comply
B1 40 mm 30 mm with the requirements given in Table 3.2. The values take into
B2 45 mm account the appropriate exposure classification and concrete
strength grade ƒ´c. They have been derived assuming that the
minimum distance from the top face of the top bar to the soffit of
Table 3.2
the slab is 70 mm, and that the cover is equal to the appropriate
Minimum overall depth (D) in BONDEK slabs
minimum value specified in Table 3.1.
Exposure Concrete strength grades f'c
classification 25 MPa 32 MPa 40 MP a Crack control is important for durability where cracks could provide
A1 90 m m 90 m m 90 m m pathways for ingress of corrosive substances such as water, and also
A2 100 m m 95 m m 90 m m for aesthetic reasons. The maximum crack width under long-term
B1 110 m m 100 m m serviceability loads must not exceed 0.3 mm.
B2 115 m m
12 COMPOSITE SLAB DESIGN

3.5 DESIGN LOADS

3.5.1 STRENGTH LOAD COMBINATIONS

For strength calculations, design loads for both propped and
unpropped construction must be based on the following load
combination.
( )
1.25 G c + G sh + G sup + 1.5Q
Or simplified:
1.25G + 1.5Q
Composite slabs are designed assuming one-way action, and therefore
reduction of uniformly-distributed live load is not appropriate.

3.5.2 SERVICEABILITY LOAD COMBINATIONS

For serviceability calculations other than deflection, design loads are
based on the relevant load combination from Table 3.3. Appropriate
values of ψs and ψl given in AS 1170.1 are used, depending on the
type of building occupancy.
Table 3.3
Load combinations for serviceability,
excluding deflection
Proped spans Unproped spans
Short-term G + ψs Q Gsup + ψs Q
Long-term G + ψ1 Q Gsup + ψ1 Q

3.5.3 DEFLECTION
For deflection calculations, design loads must be based on the
relevant load combination from Table 3.4, provided that the live
load (Q) is applied after the removal of any temporary props and
after the addition of any deflection-sensitive finishes. For other
cases, appropriate design loads must be derived from the principles
of mechanics.

Table 3.4
Load combinations for deflection
Proped spans Unproped spans

Total (1 + kcs)G + (ψs + kcs ψ1) Q (1 + kcs)Gsup + (ψs + kcs ψ1) Q

Incremental kcs G + (ψs + kcs ψ1) Q kcs Gsup + (ψs + kcs ψ1) Q
Immediate G + ψs Q Gsup + ψs Q

The multiplier for creep and shrinkage ( kcs ) is determined in

accordance with AS 3600—2001, Clause 8.5.3.3. The ratio Asc /Ast , is
obtained by dividing the area of conventional reinforcement in
compression by the area of all reinforcement in tension, including
sheeting and conventional reinforcement, making no allowance for
the different design yield stresses of the steels involved.
Where:
Asc
kcs = 2 − 1.2 ≥ 0.8 (AS 3600—2001, Clause 8.5.3.3)
Ast
For this equation:
• Asc /Ast is to be taken at the midspan cross-section for a simply-
supported
or continuous span and at the support for a cantilever span; and
• BONDEK sheeting must be included in Ast
For deflections in concrete-frame buildings, refer to Section 3.12.
 COMPOSITE SLAB DESIGN 13

3.5.4 LIGHTWEIGHT CONCRETE LOAD

Our design tables assume the use of normal density concrete
(2100 < ρc ≤ 2800 kg/m3) as specified in AS 3600—2001. They may
also be conservatively used for lightweight concrete (1800 < ρc ≤
2100 kg/m3). Use BONDEK 2003 for more economical solutions.

3.5.5 SUPERIMPOSED DEAD LOAD

The maximum superimposed dead load assumed in our design
tables is 1 kPa. However bigger loads might be considered in some
design situations. It is possible to treat additional superimposed
dead loads as factored live load:
Qadditional = 2 Gin excess of 1 kPa (see Worked example 3)
Use BONDEK 2003 for more economical solutions.

3.6 LINEAR ELASTIC ANALYSIS

For strength and serviceability calculations, the linear elastic analysis
method of AS 3600—2001, Clause 7.6, must be used to determine

3 Composite slab design

design bending moments and vertical shear forces. In calculating
action effects in slabs which are continuous over beams, the vertical
flexibility of the supporting beams must be small enough to be
ignored. For strength calculations, redistrib-ution of moments are
permissible up to the limit defined in AS 3600—2001, Clause 7.6.8,
with the following exceptions:
• The redistribution limit in each negative moment region
is based on the value of ku in that particular negative-moment
region only.
• Redistribution of moments is permitted from negative-moment
regions to positive-moment regions but not from positive-
moment regions to negative-moment regions.
• No redistribution of moments are permissible where the
contribution of class 450F and D500L reinforcement (low
ductility) has been included in the calculation of the design
negative moment capacity.
The ductility requirements of AS 3600—2001, Clause 7.6.8, need
not be applied to the positive-moment regions of BONDEK slabs.
For strength calculations, the inclusion of pattern variations of live
load results in a bending moment envelope in which some regions
are both negative-moment regions and positive-moment regions.
These regions must comply with the requirements for both types
of region. For serviceability calculations, pattern live loads must
be included for short-term live loads but excluded for long-term
live loads.
14 COMPOSITE SLAB DESIGN

3.7 DESIGN FOR STRENGTH

IN NEGATIVE-MOMENT REGIONS
For strength calculations in negative-moment regions use the
detailed procedure in Design of composite slabs for strength
(Design booklet DB3.1, BHP, 1998).

3.7.1 MINIMUM BENDING STRENGTH

The minimum bending strength requirement of AS 3600—2001 must
be satisfied at all potential hinge locations in negative-moment
regions—thus, conventional tensile reinforcement must be provided
to ensure that:
Muo − ≥ 1.2 Mcr −
Where:
• The negative moment region is part of a cantilever; and
• Class 450F or D500L reinforcement is used to provide negative
moment capacity.

3.7.2 SHEAR STRENGTH

Negative-moment regions must be designed for shear strength, to
satisfy AS 3600—2001, Section 9. The negative-moment regions of a
composite slab can be treated as solid reinforced-concrete sections.

3.7.3 DETAILING OF CONVENTIONAL

TENSILE REINFORCEMENT
Conventional tensile reinforcement in negative-moment regions
must be detailed in accordance with the relevant requirements for
one-way slabs in AS 3600—2001, Clause 9.1.3.
Pattern 1
Negative-moment regions must be designed to satisfy the
requirements of AS 3600—2001, Section 9. The composite slab
negative-moment regions can be treated as solid reinforced-
concrete sections.

Negative
reinforcement
0.3Ln 0.3Ln
Wall
Wall

Cover

Concrete slab

0.3Ln
Bondek
Wall
Wall

Ln Ln

L(span) L(span)
Restraint at Continuous over Little or no
end support interior support restraint at
end support
by mass of wall

Figure 3.1
Pattern 1 for conventional (standard) reinforcement
 COMPOSITE SLAB DESIGN 15

0.3Ln 0.3Ln
Wall
Wall
Cover

Concrete slab

0.3Ln
Bondek

1/3 of negative

Wall
Wall
reinforcement

Ln Ln

L(span) L(span)
Restraint at Continuous over Little or no
end support interior support restraint at
by mass of wall end support

Figure 3.2
Pattern 2 for conventional reinforcement

Pattern 2

3 Composite slab design

When live loads exceed twice the dead load (red, bold figures in our
design tables), at least one third of negative reinforcement must
continue over a whole span.
Shrinkage and fire reinforcement, laid on the top, can be assumed to
contribute to that additional one third of negative reinforcement.

3.7.4 BENDING STRENGTH

For the strength design of negative-moment regions, the presence
of the sheeting in the slab is ignored and the slab designed as an
equivalent solid reinforced-concrete member. For this purpose, use
the provisions of AS 3600—2001 as they relate to the design of one-
way slabs. For a slab which is continuous over any support, but
treated as simply-supported for strength at that support, the design
negative bending moment at the support ( M*– ) must be taken equal
to zero.
In calculating the design negative bending moment ( M*– ) an
allowance may be made for negative-to-positive moment
redistribution up to the limit specified in AS 3600—2001, Clause
7.6.8. Thus, the elastic design bending moment before redistribution
( M*–e ) may be reduced in magnitude to obtain the design negative
bending moment after redistribution ( M*– ).
The nominal negative moment capacity ( Muo– ) is calculated based on
the principles of rectangular stress block theory as defined in AS
3600—2001, Clause 8.1.2.
For potential hinge locations at which the neutral axis parameter
( ku– ), as defined in AS 3600—2001, exceeds 0.4, the requirements
of AS 3600—2001, Clause 8.1.3 must be satisfied. In the
application of this clause, it may be assumed that the minimum
compressive reinforcement requirement is satisfied by the presence
of the steel sheeting in the negative moment region.
When applying AS 3600—2001, Clause 7.6.8, be sure that:
• redistribution is normally only allowed if Class N or Class Y
(as opposed to Classes L or F) reinforcement is used over the
supports;
• the elastic bending moment distribution before redistribution is
determined assuming uncracked cross-sections; and
• the amount of redistribution is measured by the percentage of
the moment before redistribution.
16 COMPOSITE SLAB DESIGN

3.8 DESIGN FOR STRENGTH

IN POSITIVE-MOMENT REGIONS
For strength calculations in positive-moment regions use the
detailed procedure in Design of composite slabs for strength
(Design booklet DB3.1, BHP, 1998).

3.8.1 MINIMUM BENDING STRENGTH

The minimum bending strength requirement of AS 3600—2001,
Clause 8.1.4.1 must be satisfied at all potential hinge locations in
positive-moment regions, that is, Muo + ≥ 1.2 Mcr + . The steel proportion
for rectangular cross-sections deemed to satisfy this requirement
under Clause 8.1.4.1 must not be used. The contribution of both
the sheeting and the conventional reinforcement must be included in
the calculation of Muo+.

3.8.2 SHEAR STRENGTH

Positive-moment regions must be designed for vertical shear
strength, such that at every cross-section located at distance of at
least D from the face of a support, the design positive vertical shear
capacity ( Vuc+ ), is not less than the design positive vertical shear
force ( V*+ ). The design positive vertical shear capacity ( Vuc+ ) may
be calculated in accordance with Design of composite slabs for
strength (Design booklet DB3.1, BHP, 1998).

3.8.3 DETAILING OF CONVENTIONAL

TENSILE REINFORCEMENT
The termination locations of any conventional tensile reinforcement
in positive-moment regions must be determined by extending the
reinforcement a distance D + Lsy.t past the point at which it is no
longer required for strength. The requirements of AS 3600—2001,
Clause 9.1.3 do not apply.
To allow the concrete to flow into place, the minimum clear distance
between parallel bars should be restricted to the larger of either 1.5
times the maximum nominal size of aggregate (normally the
maximum aggregate size is 20 mm), or the diameter of the largest
reinforcing bar.

3.8.4 BENDING STRENGTH

Positive-moment regions are designed for bending strength such
that at every cross-section the design positive moment capacity
( Muo+ ) is not less than the design positive bending moment ( M*+ ).
For slabs analysed using linear elastic analysis, the design positive
bending moment ( M*+ ) is calculated such that equilibrium is
maintained after accounting for any redistribution of moments.
The design positive moment capacity ( Muo+ ) within the slab at each
cross-section may then be calculated on the basis of either a
complete or partial shear connection, as appropriate.
In calculating the design positive moment capacity ( Muo+ ) at any
slab cross-section, the entire cross-sectional area of the sheeting is
assumed to be available to act as longitudinal reinforcement, with its
effectiveness at any particular cross-section being dependent on the
degree of shear connection. Conventional longitudinal tensile and
compressive reinforcement may be considered to contribute to the
positive moment capacity at a cross-section, provided due allowance
is made for the required development length for anchorage of the
reinforcement in accordance with AS 3600—2001, Section 13.
 COMPOSITE SLAB DESIGN 17
The design positive moment capacity ( Muo+ ) may be calculated in
accordance with Design of composite slabs for strength (Design
booklet DB3.1, BHP, 1998).

3.9 DESIGN FOR STRENGTH

IN MULTIPLE SPANS
Our design tables have been worked out for end spans of
continuous slabs. The data in the tables can be used for interior
spans also, assuming uniform thickness for end an interior spans.
BONDEK 2003 will give more economical solutions for interior spans,
and also offers the opportunity to design interior spans with reduced
thickness as compared with end spans.

3.10 DESIGN OF REINFORCEMENT

OTHER THAN CLASS D500N
Our design tables have been worked out for 10 mm diameter
D500N reinforcement bars for negative reinforcement.
It is possible to replace D500N negative reinforcement with D500L,

3 Composite slab design

400Y or 450F grades, increasing the area of reinforcement by the
factors shown in Table 3.5. The area of reinforcement required is a
function of:
• yield stress;
• moment redistribution (not allowed for 450F and D500L); and
• crack control (small diameter bars are more effective).
BONDEK 2003 will give more economical solutions and allow more
design flexibility using other diameters and grades.

Table 3.5
Factors to increase area of negative
reinforcement when not using D500N
Reinforcement Note
Grade Factor
Diameter must be less than
D500L 1.43 10mm. Must not be used if
design for fire is required.
400Y 1.44 12 mm diameter only
Diameter must be
450F 1.59
less than 10mm

3.11 DESIGN FOR SERVICEABILITY

3.11.1 VERTICAL DEFLECTIONS

Deflection limits must be selected appropriate to the intended use
of the slab. These limits must not exceed those listed in AS 3600—
2001, Table 2.4.2. In that table the reference to members supporting
masonry partitions is taken to refer to slabs supporting any
deflection-sensitive finishes. (Incremental deflection is the deflection
which occurs after the addition or attachment of supporting
masonry partitions.)
Immediate deflections are calculated in accordance with the
simplified method. Incremental and total deflections must be
calculated as for immediate deflections, using the appropriate
corresponding load combinations from Clause 3.6.3 of this manual.
Contributions of sheeting and conventional reinforcement must be
included in the calculation of Ief.
18 COMPOSITE SLAB DESIGN

As a guide for calculation of Ief you may use:

• Crack control of beams (Design booklet RCB-1.1(1), BHP, 2000);
• Rules for limit-state design to Australian Standards of simply-
supported and continuous BONDEK composite slabs in steel-frame
or masonry wall buildings (BHPR/SM/R/005, 1996); and
• Rules for design to Australian Standards of BONDEK composite
slabs in concrete-frame buildings (Report No.
BHPR/R/1998/066).

3.11.2 CRACK CONTROL FOR SHRINKAGE

AND TEMPERATURE EFFECTS
For BONDEK slabs with an overall depth (D) not exceeding 250 mm,
the one layer of transverse reinforcement is required at any height
within the cover slab provided the appropriate concrete cover is
maintained.
However, our design tables, and BONDEK 2003, have been developed
assuming shrinkage reinforcement is placed at the top for
continuous slabs, and at the bottom for single spans. For single
spans, longitudinal reinforcement must be located as specified for
Fire Detail 2 (Chapter 4). This may result in reduced slab thickness,
and less negative and fire reinforcement.
Major bars of shrinkage reinforcement mesh must run across
BONDEK ribs.

Using D500N as shrinkage reinforcement (say N10 at 200 mm x N10

at 200 mm) will always reduce both negative and fire
reinforcement—for short spans, it may even eliminate it. This is due
to the normal ductility of D500N which can be treated as fire
reinforcement and negative reinforcement with moment
redistribution. You will have to run BONDEK 2003 for this option.

Table 3.6
Minimum area of D500L reinforcement for crack control in BONDEK slabs
Exposure classifications
A1 & A2 B1 & B2
Degree of crack control
Minor Moderate Strong
D (mm) mm2/m mm2/m mm2/m mm2/m
90 SL62 SL62 SL72 SL72
100 SL62 SL62 SL82 SL82
110 SL62 SL72 SL92 SL92

120 SL62 SL82 SL102 SL102

130 SL62 SL82 RL818 RL818
140 SL62 SL92 RL818 RL818
Table 3.7
150 SL62 SL92 RL1018 RL1018 Cross-reference of OneSteel’s mesh
160 SL72 SL102 RL1018 RL1018 specifications with Grade 450 fabrics
170 SL72 SL102 RL1018 RL1018
Meshes to Equivalent
D500L Grade F450
180 SL72 SL102 RL1018 RL1018 specification fabrics
190 SL82 RL818 RL1018 RL1018 SL62 F62
200 SL82 RL818 RL1218 RL1218 SL72 F72
SL82 F82
210 SL82 RL818 RL1218 RL1218
220 SL92 RL1018 RL1218 RL1218 SL92 F92
230 SL92 RL1018 RL1218 RL1218 SL102 F102
RL818 F818
240 SL92 RL1018 RL1218 RL1218
250 SL92 RL1018 2RL1218 RL1218 RL1018 F1018
RL1218 F1218
 COMPOSITE SLAB DESIGN 19
Determine the cross-sectional area of transverse reinforcement
required to control cracking of the cover slab, due to shrinkage and
temperature effects, by:
• using AS 3600—2001, Clause 9.4.3.4 (Reinforcement in the
secondary direction in restrained slabs); and
• substituting the overall slab depth (D) with the cover slab depth
(D – hr ) in the equations for the minimum cross-sectional area of
transverse reinforcement.
Cross-references of OneSteel’s mesh specifications with Grade 450
fabrics are shown in Table 3.7.

3.11.3 CRACK CONTROL FOR FLEXURE

For crack control of slabs in flexure, we recommend that you follow
OneSteel’s specifications: Crack control of slabs, Part 1: AS 3600
Design (Design Booklet RCB-2.1(1).
Since maximum steel stress in cracked sections is a function of a bar
diameter, the bar diameter in our tables is 10 mm (the minimum
possible for D500N reinforcement).

3 Composite slab design

The crack control for flexure may not always be required, which is
often the case for A1 exposure classification, and when aesthetics
are not important. A continuous slab in such conditions may be
designed as a series of simply-supported slabs without any negative
reinforcement, or as a continuous slab with negative reinforcement
designed without crack control, depending on which option is
more economical.

3.11.4 END SLIP CONTROL

Check each span to ensure that no sheeting end-slip occurs under
the loading for short-term serviceability, as follows:
• Under the loading for strength, determine the critical cross
section in the positive-moment region, which is the cross-section
at which M* / ( Muo ) is the greatest. (The critical cross-section is
where a major crack is assumed to open, thus causing the test
block to slip towards the end.)
• At the critical cross section in the positive-moment region,
determine the distance to the nearer end of the sheeting, xend.
• Calculate the limiting force in the sheeting to produce end slip
from the equation:
Tslip = 200 xend
Where:
Tslip is expressed in kN and xend in metres.
(Value of 200 is obtained from tests as an ‘average’ value.)
• Under the loading for short-term serviceability, determine the
moment at the critical cross section in the positive-moment
region ( Mss ) and calculate the force in the sheeting ( Tss ) from
cracked elastic analysis of the cross-section. For this purpose,
the properties of the sheeting may be considered to be acting in
a plane 15 mm above the soffit of the slab.
• Ensure that there is no end slip between the sheeting and
concrete under service loads. To do this check that Tss ≤ Tslip and,
if necessary, alter the design for strength of the span (for
example: increase Dc and maybe tbm).
20 COMPOSITE SLAB DESIGN

3.12 DESIGN FOR CONCRETE-FRAME

BUILDINGS
This section covers design of slabs spanning between wide reinforced-concrete beams (band-beams) or
prestressed band-beams of concrete-frame buildings.
Other forms of concrete-frame constructions, such as slabs spanning between ‘narrow’ reinforced
concrete beams, or reinforced concrete walls, may be designed using the rules for steel-frame and
masonry wall buildings.
Use Rules for design to Australian Standards of Bondek composite slabs in concrete-frame buildings (BHP
R/R/1998/006).
Our design tables assume the use of steel-frame or masonry wall buildings. However, they may be used
for concrete-frame buildings, with the following restrictions:
• The sheeting end must penetrate at least 25 mm into the Table 3.8
concrete cover on the side of a concrete beam formed up with Area of anchorage reinforcement as a
temporary formwork (Figure 3.3). percentage of negative reinforcement
• Where BONDEK terminates, bending moments must be zero or Percentage of negative reinforcement
negative for all loading combinations. If the moments are w/L Interior End supports with
supports band beams
positive (BONDEK is in tension), additional bottom anchorage % %
reinforcement must be designed (Figure 3.3 and Table 3.8). ≤0.1 Not required 12
Bottom fire reinforcement Detail 2 can be treated as 0.2 16 23
anchorage reinforcement. Development lengths must be 0.3 29 32
designed according to AS 3600—2001, Section 13. 0.4 40 41
0.5 49 49
• Vertical flexibility of the support beams must be small enough
to be ignored.
Our tables don’t allow for any beneficial effect on deflections and propping requirements by band-beams.
Run BONDEK 2003 for more economical solutions yielding thinner slabs and fewer props.
For the design of concrete-frame buildings, use the following rules
in addition to those of steel-frame or masonry wall buildings:
• Calculate the immediate deflections in accordance with the simplified method as defined in AS
3600—2001, Clause 8.5.3.1, but don’t use the method of averaging Ief over several cross-sections.
Determine the values of Ief at an appropriate number of selected cross-sections referring to the shape
of the moment-curvature diagram for the member to enable deflections to be calculated by
integration of curvatures along the length. The curvature at each cross-section is obtained by dividing
the bending moment by EcIef.
• Calculate the nominal positive moment capacity ( Muo+ ) at cross-sections within the band-beam using
conventional reinforced-concrete design methods in accordance with AS 3600—2001.
• Ignore the contribution of frictional resistance force µR*u in developing the shear connection force.
• Shear capacity must be calculated according to Rules for design to Australian Standards of BONDEK
composite slabs in concrete-frame buildings (Report No. BHPR/R/1998/066).

Anchorage reinforcement
(or continuous fire reinforcement Negative
Concrete
to Fire detail 2) reinforcement

Bondek

25 mm minimum

Span L
W
Figure 3.3
Additional bottom anchorage reinforcement
 FIRE DESIGN 21

4 FIRE DESIGN

4.1 GENERAL
This chapter discusses the parameters relating to the exposure of
the soffit to fire, upon which our design tables are based. Solutions
to your design problems may be obtained by direct reference to
either our design tables, or our BONDEK 2003 software.
The software has enhanced fire design module which allows BONDEK
sheeting to be partially effective during fire for up to 2 hours.
Software will give more economical results. Guide tables in this
manual have not been modified for enhanced fire design.
Reduction factors are applied to allow for the effect of temperature
on the slab materials and slab cross-section. Values of these
reduction factors have been derived from extensive analysis of
BONDEK slab cross-sections. These reduction factors account for the
adverse effect of elevated temperatures on the mechanical
properties of concrete and steel, and also include the effect of
thermally induced stresses caused from the temperature gradient
across the section, resulting in differential thermal expansion.
Extensive testing has been conducted to validate the analysis and
determine the fire-resistance periods for insulation and integrity.
The distribution of temperature through a cross-section of a
composite slab subject to fire, is affected by the geometry of the
sheeting profile (Figure 4.1). The features important in the sheeting
profile are: the rib geometry (shape, height and spacing of
intermediate ribs and lapping ribs), and the pan geometry (such as
stiffening flutes).
Fire design calculations are covered in this section—geometric
layout considerations are generally covered in Section 5
(Construction).

4 Fire design
y A y Thermal Total y
strain strain
Steel
Temperature stress
contours Stress-inducing
strain (tensile)

Stress-inducing Concrete
strain stress
B B (compressive)
x + strain + stress

A
Strain distribution Stress distribution
Section along A-A along A-A

Figure 4.1
Diagrammatic distribution of thermally induced stress and strain
22 FIRE DESIGN

4.2 APPLICATION
Our fire design tables may be used to detail BONDEK composite slabs
when the soffit is exposed to fire provided the following conditions
are satisfied.
1. The composite slab acts as a one-way element spanning in the
direction of the sheeting ribs for both room temperature and fire
conditions.
2. The composite slab has been initially designed and detailed for
room temperature conditions in accordance with this manual.
3. The fire design load is essentially uniformly distributed and static
in nature.
4. Transverse reinforcement for the control of cracking due to
shrinkage and temperature effects is provided.
5. Adequate detailing of slab jointing, edges, slab holes and
cavities (for penetrating, embedded or encased services) to
provide the appropriate fire resistance period. Alternatively the
local provision of suitable protection (such as fire spray material)
will be necessary.
6. The fire cases are for periods of 60, 90, 120 or 180 minutes.
7. Reinforcement conforms to Section 4.6 of this manual.

4.3 FIRE RESISTANCE PERIODS

Four fire cases are considered. In each fire case the fire resistance
periods for structural adequacy, integrity and insulation are taken to
be of equal duration. The fire cases considered are:
• Fire case F60 = FRL 60/60/60
• Fire case F90 = FRL 90/90/90
• Fire case F120 = FRL 120/120/120
• Fire case F180 = FRL 180/180/180

4.4 DESIGN FOR INSULATION

AND INTEGRITY
Table 4.1 Details are in Table 4.1.
Minimum overall depth D of BONDEK
slabs for insulation and integrity
Fire Normal
resistance density Lightweight
concrete
period concrete
Minutes D (mm) D (mm)
60 90 90
90 100 100
120 120 115
180 140 125
240 170 150

4.5 DESIGN FOR STRUCTURAL

ADEQUACY

4.5.1 DESIGN LOADS

Use AS 1170.1, Clause 2.5, together with:
Design load for fire ω f = 1.1 G + ΨcQ
 FIRE DESIGN 23

4.5.2 POTENTIALLY CRITICAL

CROSS-SECTIONS
All potentially critical cross-sections at which hinges may form must
be identified (Figure 4.2) and checked for strength. All negative
moment hinges may be assumed to be plastic under fire conditions.
These cross-sections correspond to where:
• negative moments are a maximum over supports;
• negative tensile reinforcement is curtailed;
• positive bending moment is a maximum; or
• at any changes in cross-section (for example changes in depth or
where there is a significant hole through the slab).

Assumed critial
cross-sections PCC = Other potentially
critical cross-sections
Max. positive
moment
PCC PCC PCC
Concrete

Bondek

zj
zk
L
z
Interior span
Assumed critial PCC = O ther potent
cross-section critical cross-section
M ax. positive
moment
PCC PCC
Concrete

4 Fire design
Bondek

zj
L
z
End span

Critial cross-section
M ax. positive moment
Concrete

Bondek

L
z
Single span
Concrete

xb d+
D
yb

Bondek Bottom
reinforcement
Nomenclature for location of reinforcing bars
Figure 4.2
Critical cross sections
24 FIRE DESIGN

4.5.3 STRENGTH OF POSITIVE

MOMENT REGIONS
At the potentially critical cross section where the positive
moment is a maximum, the design strength in bending (
MuoT+ ) is determined for the given period of fire exposure
as follows:
⎧ Rst Ast+ f sy ⎫
M uoT,i+ = Rst Ast+ f sy d + ⎨1 − 0.6 ⎬
⎩ bd + f c′ ⎭
Where:
The reduction factor Rst is given in Table 4.2.
The form of this equation is identical with that used to calculate the
Table 4.2
Yield stress reduction factor for BONDEK ( Rst )
Distance Fire resistance period (minutes)
Concrete from rib 60 90 120 18 0 240
type xb yb Rst yb Rst yb Rst yb Rst yb Rst
Normal 30 mm 10 0 15 0 25 0 40 0 50 0
density 30 0.65 40 0.53 60 0.74 85 0.88 90 0.75
55 1.0 75 1.0 90 1.0 120 1.0 140 1.0

85 mm 10 0 15 0 20 0 30 0 40 0
25 0.69 40 0.67 45 0.55 75 0.7 80 0.55
50 1.0 65 1.0 85 1.0 11 5 1.0 135 1.0

Light- 30 mm 10 0 20 0 25 0 40 0 55 0
weight 30 0.6 35 0.35 70 0.75 90 0.75 90 0.55
55 1.0 75 1.0 90 1.0 115 1.0 130 1.0

85 mm 10 0 15 0 20 0 35 0 40 0
25 0.55 40 0.55 45 0.55 60 0.5 8 5 0. 6
50 1.0 65 1.0 80 1.0 100 1.0 130 1.0
Notes: 1. Linear interpolation may be used to determine values of Rst for intermediate values of yb.
2. Position of longitudinal bottom face reinforcement with respect to the rib centre and
the soffit of the slab is shown in Figure 4.2.
3. For a fire-resistance period of 30 minutes, the bending strength of the composite slab
cross-section, due to the effects of heating, is unlikely to be affected significantly.
However, for design, you may use a fire resistance period of 60 minutes.

design strength in bending of under-reinforced concrete cross-

sections at room temperature conditions, but makes allowance for
the influence of temperature on the strength of the reinforcing
steel.
Similar procedure shall be used to calculate additional capacity
due to BONDEK being particularly effective against fire.
Reinforcement used to control shrinkage and temperature effects
often provides adequate fire resistance.
It is normal to ignore the small design strength in positive bending
associated with any continuous top face reinforcement, however on
some projects this may be sufficient to provide an equilibrium state
without the need to provide any additional reinforcement.
At the end of the fire period the value of kuT+ where the positive
moment is a maximum:

+
Rst Ast,f+ f sy
k = ≤ 0.4
ut
0.85γbd + f c′
Where:
The reduction factor ( Rst ) is given in Table 4.2; and γ = [0.85 -
0.007 (f´c – 28)] within the limits of 0.65 to 0.85, and f´c must be in
MPa (AS 3600—2001, Clause 8.1.2.2).
 FIRE DESIGN 25

Table 4.3 4.5.4 STRENGTH OF NEGATIVE

Values for dx for negative bending MOMENT REGIONS
ku – d– Fire resistance periods (minutes) At the potentially critical cross sections associated with negative moments
(mm) 60 90 120 180 240
0 5 10 20 30 35
over supports, or where the negative steel is curtailed, the design
70 80 85 90 95 105 strength in bending ( MuoT+ ) for the given period of fire exposure is:
120 155 175 190 215 235
M uoT,i− = R stA st
−
f sy(d− − d )
x
Notes:
1. Intermediate values of k u− d −may be linearly interpolated.
No extrapolation is permitted. Where:
−
Ast− f sy The reduction factor Rst is given in Table 4.2; and dx is given in Table 4.3.
2. ku = ≤ 0.4
0.85γbd − f c′
3. See figure 4.3 for the location of the resultant compressive
This equation takes into account the adverse effect of elevated
force in the concrete with respect to the soffit of the slab. temperatures on the compressive strength of the concrete in the slab
soffit, and also includes the effect of thermally induced stresses.

4.5.5 CHECK FOR STRUCTURAL

Concrete
ADEQUACY
dct Ast– The structural adequacy of the end, interior or simple spans must be
Rst Ast– fsy
h
checked for the assumed period of fire exposure. Do this by finding an
d
–
C
equilibrium state whereby—under the applied loads ( ωf ) — the bending
dx
moments ( Mz ) at the potentially critical cross sections, do not exceed the
BONDEK
relevant values of positive and negative design bending strength MuoT+
and MuoT– respectively.
Figure 4.3
Location of resultant compressive force Interior spans (Figure 4.2)
The bending moment distribution along an interior span for an assumed
pair of plastic hinges at potentially critical cross sections in negative
bending can be expressed as:

(
M z = zj − z )
2 ωf
(
⎧⎪ M uoT,j− − M
+ zj − z ⎨ )
−

+
( )
ω f zk − zj ⎫⎪ −
⎬ + M uoT,j
uoT,k

2 ⎪⎩ zk − zj ( ) 2 ⎪⎭

The minimum bending moment (Mmin) corresponds to the maximum

4 Fire design
positive value and is located between the ends of the member. The
location of Mmin can be found from:
⎧⎪ M uoT,j− − M uoT,k−
zmin = zj+ ⎨ +
zk − zj ( ) ⎫⎪
⎬
⎩⎪ ω f kz − zj ( 2 ) ⎭⎪
End spans (Figure 4.2)
The bending moment distribution along an end span for an assumed
plastic hinge at the potentially critical cross section in negative bending
can be expressed as:

(
2ω
)
M z = zj− z f + zj− z ⎨
⎧⎪ M
(
−
uoT,j
+
ω f L − zj ⎫⎪
)( −
⎬ + M uoT,j
( )
2
⎩⎪ L − zj
2
⎭⎪ )
The minimum bending moment (Mmin) corresponds to the maximum
positive moment and it is located between the ends of the member. The
location of Mmin can be found from:
⎧⎪ M uoT,j−
zmin = zj+ ⎨ +
L − zj ( ) ⎫⎪
⎬
⎩⎪ω f L − zj ( 2 ) ⎭⎪
Simple spans (Figure 4.2)
The bending moment distribution along a simple span can be expressed as:

Lω fz⎧ z⎫
Mz= ⎨1 − ⎬
2 ⎩ L⎭

The maximum positive moment is located at midspan of the member:

L
zmin =
2
26 FIRE DESIGN

End spans Interior spans

wf wf

A—st Ast—

— Muo— — Muo—
Envelope MuoT— Envelope
MuoT—

0 0

Bending moment Bending moment

due to wf due to wf
+ +
Initial trial
From both these configurations we see that additional
moment capacity is required. Two options are below.

wf wf

Additional Ast— Ast— Ast—

Additional Ast—

— Envelope — Envelope Muo— new

Muo— new
MuoT— original
MuoT— original
0 0
MuoT+
MuoT+
New Original
New Original bending moment bending moment
bending moment bending moment +
+
Option 1: Increase top-face reinforcement
The additional top-face reincorcement will give an increased negative moment capacity and some positive moment capacity (MuoT+),
which is often ignored. For end spans this option is usually not an economical alternative. This option effectively produces a series of
cantilevers.

wf wf

Ast+ Ast— Ast+ Ast—

— —
Envelope Envelope
Muo— Muo—

0 0

—
MuoT MuoT—

+ +
Option 2: Add bottom-face reinforcement
Additional bottom-face reinforcement (Ast+) provides the required positive moment capacity (MuoT+). This is the simplest method,
however it may not be the optimal solution. Fabric placed in the bottom face for temperature and shrinkage reinforcement may be
used in this option.

Figure 4.4
Typical equilibrium diagrams
 FIRE DESIGN 27

4.6 REINFORCEMENT FOR FIRE DESIGN

The arrangement of reinforcement for fire design is shown in
Figure 4.5.
Fire reinforcement is essential, in addition to any negative
reinforcement required by our tables for composite slab design.
The temperature and shrinkage reinforcement of grades D500N,
400Y or 450F can be treated as fire reinforcement if located and
detailed in accordance with Figure 4.5—it may significantly reduce
fire reinforcement, or even eliminate it.
The location of reinforcement Ast.f– for Fire detail 1 is in a single
top layer at a depth of dct below the slab top face (Figure 4.5).
This detail is applicable to end and interior spans only.
The location of reinforcement Ast.f+ for Fire detail 2 is in a single
bottom layer at a distance of yb above the slab soffit (Figure 4.5).
This detail is applicable to end spans, interior spans and simple
spans. The fire reinforcement Ast.f+ must be continuous over
interior supports.
The cross-sectional area of the additional reinforcement for fire
design is designated Ast.f in our tables (D500N with ≥ 10 mm).
The negative reinforcement ( Ast– ) and the additional fire
reinforcement ( Ast.f+ or Ast.f- as applicable), must be located a
distance xb minimum from the centre of any rib.
— —
Ast, transverse Ast Ast.f
Concrete

dct

xb xb d— D

Bondek

Ast— Ast.f—

4 Fire design
Concrete

Bondek

0.3 Ln
Ln
L

Fire detail 1
— +
Ast, Ast Ast.f
transverse
Concrete

+
d
xb xb D
yb

Bondek
+
Ast— Ast.f
Concrete

Bondek

0.3Ln
Ln
L

Fire detail 2
Figure 4.5
Details of reinforcement for fire design
28 FIRE DESIGN
D500N, 450F or 400Y reinforcement can be used for fire design.
D500L reinforcement is not allowed as negative reinforcement in fire
designs. The limitation is due to hinge formation requirements,
which may not be satisfied with only 1.5% uniform elongation for
D500L. Further research may be needed to determine the suitability
of D500L reinforcement for fire design.
D500N fire reinforcement may be replaced with 400Y or 450F
grades, increasing the area of reinforcement by the factors shown in
Table 4.4.

Table 4.4
Factors to increase area of negative
reinforcement when not using D500N
Reinforcement Note
Grade Factor
Diameter to be
400Y 1.25
12, 16 or 20 mm
Diameter must be equal to
450F 1.11
or greater than 10 mm

4.7 LOCATION OF LONGITUDINAL

REINFORCEMENT FOR FIRE DESIGN

4.7.1 FIRE DETAIL 1

(CONTINUOUS SLABS ONLY)
• Cover = 20, 40 and 45 mm
(for exposure classifications A1, B1 & B2 respectively);
• xb = not less than 30 mm on the average (Figure 4.5).

4.7.2 FIRE DETAIL 2 (SIMPLY-SUPPORTED

SLABS AND CONTINUOUS SLABS)
The longitudinal bars which make up Ast.f+ are located within the
zone shown in Figure 4.6. The proximity of the bars to the sheeting
ribs, or the slab soffit, affects their temperature and therefore their
strength under fire conditions.
yb = 60 mm average
xb = 85 mm minimum
Permissible zone for
longitudinal fire reinforcement Ast.f+
Concrete

xb xb

20
yb
50

Bondek

Note: The depth of the permissable zone from soffit (50 to 70mm) is chosen for
practical reasons - this would be normally the depth of fire bars wired to mesh laid on
top of the BONDEK ribs. Fire design tables have been generated using this
recommended permissable zone depth.
Smaller cover to fire bar (down to 20mm) is possible. (See Table 4.2).
Smaller cover may result in more economical solutions in some instances. Minimum
BONDEK slab thickness required for insulation is not affected by depth of concrete cover
to fire bars.

Figure 4.6
Permissible zone for location of longitudinal fire reinforcement for Fire detail 2.
 CONSTRUCTION 29

5 CONSTRUCTION
The construction of LYSAGHT BONDEK composite slabs follows simple,
familiar and widely-accepted building practice. Workers can readily
acquire the skills necessary to install BONDEK formwork and finish the
composite slab. Construction workers will normally be supplied with
fully detailed drawings showing the direction of the ribs, other
reinforcement and all supporting details.

5.1 SAFETY
BONDEK is available in long lengths, so large areas can be quickly
and easily covered to form a safe working platform during
construction. One level of formwork gives immediate protection
from the weather, and safety to people working on the floor below.
The minimal propping requirements provide a relatively open area
to the floor below.
The bold embossments along the top of the ribs of BONDEK enhance
safety by reducing the likelihood of workers slipping. Some LYSAGHT
centres, may supply BONDEK with knurling on the upper face of the
flutes, which provides even more safety against slippage.
It is commonsense to work safely, protecting yourself and workmates
from accidents on the site. Safety includes the practices you use;
as well as personal protection of eyes and skin from sunburn,
and hearing from noise. For personal safety, and to protect the
surface finish of BONDEK, wear clean dry gloves. Don’t slide sheets
over rough surfaces or over each other. Always carry tools, don’t
drag them.
Occupational health and safety laws enforce safe working conditions
in most locations. Laws in every state require you to have fall
protection which includes safety mesh, personal harnesses and
perimeter guardrails where they are appropriate. We recommend
that you adhere strictly to all laws that apply to your site.
BONDEK is capable of withstanding temporary construction loads
including the mass of workmen, equipment and materials all in
accordance with AS 3610—1995. 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.

5.2 CARE AND STORAGE

BEFORE INSTALLATION
BONDEK is delivered in strapped bundles. If not required for
immediate use stack sheets or bundles neatly and clear of the 5 Construction
ground, on a slight slope to allow drainage of water. If left in the
open, protect with waterproof covers.
30 CONSTRUCTION

5.3 INSTALLATION
Cover
Cover
Concrete slab
Slab depth

Bondek
Props where Props where
required required
Bearing of Bondek
(Not less than 50 mm Bearing of Bondek
at end of sheets) (Not less than 100 mm
where sheeting is
continuous)

Slab span Slab span

(Interior span) End span)

5.3.1 PROPPING
Depending on the span of a BONDEK slab, temporary propping may
be needed between the slab supports to prevent excessive
deflections or collapse of the formwork.
BONDEK formwork is normally placed directly on prepared propping.
Props must stay in place during the laying of BONDEK formwork, the
placement of the concrete, and until the concrete has reached the
strength of 15 MPa.
Propping generally consists of substantial timber or steel bearers
supported by vertical props. The bearers must be continuous across
the full width of BONDEK formwork.
Where the underside of BONDEK formwork is featured as a finished
ceiling, wide form-ply strips attached to the bearers will minimise
marking. The width of the form-ply strips depends upon the slab
depth, BONDEK metal thickness and spans. Form-ply strips of 300 mm
width have been used successfully.
Propping must be adequate to support construction loads and the
mass of wet concrete. The number of props you need for given
spans is shown in our tables.

5.3.2 LAYING
BONDEK must be laid with the sheeting ribs aligned in the direction
of the designed spans. Other details include the following.
• The slab supports must be prepared for bearing and slip joints
as required.
• Lay BONDEK sheets continuously over each slab span without any
intermediate splicing or jointing.
• Lay BONDEK sheets end to end. Centralise the joint at the slab
supports. Where jointing material is required the sheets may be
butted against the jointing material.
• Support BONDEK sheets across their full width at the slab support
lines and at the propping support lines.
• For the supports to carry the wet concrete and construction
loads, the minimum bearing is 50 mm for ends of BONDEK sheets,
and 100 mm for intermediate supports over which the sheeting
is continuous.
• In exposed applications, treat the end and edges of the
BONDEK sheets with a suitable edge treatment to prevent entry
of moisture.
 CONSTRUCTION 31

5.3.3 INTERLOCKING OF SHEETS

Method 1 Overlapping ribs of BONDEK sheeting are interlocked. Either of two
Position BONDEK sheet
parallel with methods can be used in most situations, though variations may
previously-laid sheet. also work.
Interlock sheets by
applying pressure to In the first method, lay adjacent sheets loosely in place. Place the
either position.
female lap rib overlapping the male lap rib of the previous sheet and
apply foot pressure, or a light kick, to the female lap rib (Figure 5.2).
In the second method, offer a new sheet at an angle to one
previously laid, and then simply lower it down, through an arc
(see Figure 5.2).
If sheets don’t interlock neatly (perhaps due to some damage or
distortion from site handling or construction practices) use screws
to pull the laps together tightly (see Section 5.3.8, Fastening
Method 2 side-lap joints).
Position BONDEK sheet
at an angle.
Interlock sheets by
lowering sheet through
5.3.4 SECURING THE PLATFORM
an arc.
Once laid, BONDEK provides a stable working platform. Where
additional security is needed (to prevent movement from
construction activities and from wind) you can use:
• weights;
Figure 5.2 • screws or nails into the propping bearers; or
Two methods of interlocking
adjacent BONDEK sheets • BONWEDGE and BON-NUT suspension systems pulling down from
underneath.
Take care if you use penetrating fasteners (such as screws and nails)
because they can make removal of the props difficult, and perhaps
result in damage to the BONDEK.

5.3.5 INSTALLING BONDEK

ON STEEL FRAMES
BONDEK may be installed directly on erected structural steelwork.
General fastening of BONDEK
To provide uplift resistance or lateral restraint, the sheeting may be
fixed to the structural steel using spot welds, or fasteners such as
drive nails or self-drilling screws.
At a movement joint, the sheeting is not continuous over the
support. If one sheet is fastened at the joint, the other is not.
Place the fixings (fasteners and spot welds) in the flat areas of the
pans adjacent to the ribs or between the flutes. The frequency of 5 Construction
fixings depends on wind or seismic conditions and good building
practice.
Fixing at end of sheets
One fixing system is as follows.
• At the end of sheets: use a fixing at every rib (Figure 5.3).

Fixing at intermediate slab supports • At each intermediate slab support over which the sheeting is
over which the sheeting is continuous continuous: use a fixing at the ribs on both edges (Figure 5.3).

Figure 5.3 • Fix BONDEK with drive nails, self-drilling screws or spot welds.
Positions for fixing BONDEK to steel framing
• Drive nails should be powder-activated, steel nails 4 mm nominal
diameter, suitable for structural steel of 4 mm thickness or
greater.
• For structural steel up to 12 mm thick, use 12-24 x 38 mm self-
drilling hexagon head screws.
• For structural steel over 12 mm thick, pre-drill and use 12-24 x
16 mm hexagon head screws.
32 CONSTRUCTION

• Spot welds should be 12 minimum diameter. Use 3.25 mm

diameter cellulose, iron powder AC/DC high penetration
electrodes. Surfaces to be welded must be free of loose material
and foreign matter. Where the BONDEK soffit or the structural
steelwork has a pre-painted surface, securing methods other
than welding may be more appropriate. Take suitable safety
precautions against fumes during welding zinc
coated products.
Fastening composite beams
In projects of composite beam construction the BONDEK sheeting
must be fastened in accordance with AS 2327, Clause 9.2
(Composite beams with slabs incorporating profiled steel sheets).
This provision requires a fixing in each pan at each composite beam.
Stud welding through the sheet has been considered a suitable
securing method for the sheeting in a composite beam; however
some preliminary fixing by one of the methods mentioned above is
necessary to secure the sheeting prior to the stud welding. Stud
welding should comply with the requirements of AS 1554, Part 2
and AS 2327, Part 1. Some relevant welding requirements are:
• Zinc coating on sheeting not to exceed Z450;
• Mating surfaces of steel beam and sheeting to be cleaned of
scale, rust, moisture, paint, overspray, primer, sand, mud or
other contamination that would prevent direct contact between
the parent material and the BONDEK;
• Welding must be done in dry conditions by a certified welder;
• For pre-painted BONDEK sheets, special welding procedures may
be necessary; and
• For sheets transverse to beams, Stud welding must be between
pan flutes to ensure there is no gap between mating surfaces.

5.3.6 INSTALLING BONDEK

ON BRICK SUPPORTS
Brick walls are usually considered to be brittle and liable to crack
from imposed horizontal loads. Thermal expansion and contraction,
long-term shrinkage, creep effects and flexural deflection of
concrete slabs may be sufficient to cause such cracking.
Bondek and reinforcement Jointing
are not continuous through material
the movement joint

Concrete

BONDEK

Slip joint
Minimum cover
20 mm

Concrete

BONDEK

Slip joint

Slip joint

Figure 5.4
Typical movement and slip joints
 CONSTRUCTION 33
To prevent the cracking, BONDEK slabs are not usually installed
directly on brick supports, although this is not always the case in
earthquake construction.
Slip joints
Generally, a slip joint is provided between BONDEK and masonry
supports (Figure 5.4).
• No fasteners are used between BONDEK and its support at a slip
joint.
• Slip joint material may be placed directly in contact with the
cleaned surface of steelwork.
• The top course of masonry should be level, or finished with a
levelled bed of mortar to provide an even bearing surface. Lay
the top courses of bricks with the frogs facing down.
• The width of a slip joint should not extend beyond the face of
the slab support.
• The slip joint material must have adequate compressive strength
to avoid it being compressed into irregularities of the mating
surfaces and thus becoming a rigid joint.
Slip joint material must allow movement to occur, usually by allowing
flow under pressure or temperature, however it must not run or
solidify. Generically, the materials are a non-rotting, synthetic carrier
impregnated with a neutral synthetic or petroleum-based material.
Typical slip joint material is Alcor (a bitumen coated aluminium
membrane).

5.3.7 INSTALLING BONDEK

ON CONCRETE FRAMES
When used in concrete-frame construction, the BONDEK sheeting is
discontinuous through the supports (Figure 5.5).
Concrete

BONDEK

Minimum bearing
of Bondek
25 mm
Figure 5.5
BONDEK is discontinuous in concrete-frame construction.

5 Construction
5.3.8 CONSTRUCTION
AND MOVEMENT JOINTS
Joints used between BONDEK slabs generally follow accepted
construction practices. Construction joints are included between slabs
for the convenience of construction. Movement joints allow relative
movement between adjoining slabs. The joints may be transverse to,
or parallel with, the span of the BONDEK slab. Movement joints need a
slip joint under the BONDEK sheeting. (Figure 5.4).
Joints typically use a non-rotting, synthetic carrier impregnated with
a neutral synthetic or petroleum based material like Malthoid (a
bitumen impregnated fibre-reinforced membrane). Sometimes a
sealant is used in the top of the joint for watertightness.
The BONDEK sheeting and any slab reinforcement are not continuous
through a joint.
Design engineers generally detail the location and spacing of joints
because joints effect the design of a slab.
34 CONSTRUCTION

5.3.9 FASTENING SIDE-LAP JOINTS

If BONDEK sheeting has been distorted in transport, storage or
erection, side-lap joints may need fastening to maintain a stable 10–24 x 16mm hex. head
self-drilling screw, midway
platform during construction, to minimise concrete seepage during between embossments.
pouring, and to gain a good visual quality for exposed soffits
(Figure 5.6).
Figure 5.6
5.3.10 CUTTING AND FITTING Fixing at a side-lap
EDGE FORM
EDGE FORM is a simple C-shaped section that simplifies the installation
of most BONDEK slabs. It is easily fastened to the BONDEK sheeting,
neatly retaining the concrete and providing a smooth top edge for
quick and accurate screeding. We make it to suit any slab thickness.
EDGE FORM is easily spliced and bent to form internal and external
corners of any angle and must be fitted and fully fastened as the
sheets are installed. There are various methods of forming corners
and splices. Some of these methods are shown in Figures 5.7 and
5.8.
Fasten EDGE FORM to the underside of unsupported BONDEK panels
every 300 mm. The top flange of edge form must be tied to the ribs
every 600 mm with hoop iron 25 mm x 1.0 mm (Figures 5.7 and
5.16). Use 10–16 x 16 mm self-drilling screws.
Make sure that the zinc coating on EDGE FORM matches the
corrosion protection requirements of your job (see Section 1.10
Corrosion protection).

External corner

1. Notch top flange

for the required angle

3. Bend corner of Edge Form

2. Cut 'V' to the required angle,
in bottom flange overlapping bottom flanges.

Internal corner
2. Bend Edge Form 3. Fasten top flange,
to required angle. each side of corner,
to Bondek rib,
1. Cut top and bottom 100 mm maximum
flanges square. from corner.

Splicing two pieces

1. Cut-back top and bottom flanges of one

Edge Form section approximately 200 mm.
2. Cut slight taper on web.
3. Slide inside adjoining Edge Form, and fasten
webs with at least 2 screws
Figure 5.7
Fabrication of formwork is easy with EDGE FORM
 CONSTRUCTION 35
Fastening bottom flange of Edge Form
Bondek Edge Form

Fastening positions

Fasten Edge Form to the underside

of unsupported Bondek at 300 mm
maximum centres.

Fastening top flange of Edge Form

Edge Form Edge Form

Hoop iron
Hoop iron
Bondek

Tie top flange of Edge Form,

to Bondek ribs, with hoop iron,
every 600 mm maximum.

Figure 5.8
Typical fastening of EDGE FORM to BONDEK

5.3.11 SEALING
Seepage of water or fine concrete slurry can be minimised by
following common construction practices. Generally gaps are sealed
with waterproof tape or by sandwiching contraction joint material
between the abutting ends of BONDEK sheet. If there is a sizeable
gap you may have to support the waterproof tape, and BONFILL may
be found useful (Figure 5.9).

W aterproof tape
over gap

Sizeable gap betw een

5 Construction
Bondek sheets Where necessary, insert
Bonfill into ribs to support tape
W aterproof tape
Figure 5.9 over end of rib
Use waterproof tape to seal joints in BONDEK sheets
36 CONSTRUCTION

5.3.12 ITEMS EMBEDDED IN SLABS

Generally use items in a manner which complies with AS 3600—
2001, Clause 14.2 (Embedded items and holes in concrete), and
Clause 14.3 (Requirements for fixings). Included are pipes and
conduits, sleeves, inserts, holding-down bolts, chairs and other
supports, plastic strips for plasterboard attachment, contraction joint
material and many more.
Table 5.1
Location of items within the slab (Figure 5.10)
Items Location
• Between the ribs; and
Pipes parallel with the
• below the top-face reinforcement; and
ribs and other items
• above the pans and flutes of the BONDEK
In the space between the top-face and bottome-face reinforcements
Pipes across the ribs
(if there is no bottom-face reinforcement, above the top of the ribs)

Minimise the quantity and size of holes through BONDEK sheeting, by

hanging services from the underside of BONDEK using accessories
such as BON-NUT, BONWEDGE and CEILING SUSPENSION NUT.

Top-face reinforcement
Zone for pipes laid across the ribs
Bottom-face reinforcement (between top and bottom reinforcement)
Concrete

Bondek

Zones for pipes and other items

Figure 5.10 laid parallel w ith the ribs
Zones for the location of items embedded in slabs

5.3.13 HOLES
BONDEK acts as longitudinal tensile reinforcement similarly to
conventional bar or fabric reinforcement does in concrete slabs. Zone for holes through
Consequently, holes in BONDEK sheets, to accommodate pipes and Bondek sheet in central pan
Max. diameter 150 mm
ducts, reduce the effective area of the steel sheeting and can
adversely effect the performance of a slab.
15 mm
Some guidelines for holes are (Figure 5.11): minimum

• Place holes in the central pan of any sheet, with a minimum Location of holes in sheet

edge distance of 15 mm from the rib gap. Minimum Minimum

0.1 Ln Zone for holes 0.1 Ln
• Holes should be round, with a maximum diameter of 150 mm. in continuous slabs

• For slabs designed as a continuous slab: space holes from

an interior support of the slab no less than one tenth of a BONDEK
clear span. Interior supports

Ln

Location of holes relative to

supports in continuous slabs

Figure 5.11
Zones for the location of holes through BONDEK
 CONSTRUCTION 37

5.3.14 INSPECTION
We recommend regular qualified inspection during the installation,
to be sure that the sheeting is installed in accordance with this
publication and with good building practice.

5.3.15 CUTTING
It is easy to cut BONDEK sheets to fit. Use a power saw fitted with an
abrasive disc or metal cutting blade. Initially lay the sheet with its
ribs down, cut through the pans and part-through the ribs, then turn
the over and finish by cutting the tops of the ribs.

5.4 REINFORCEMENT
BONDEK sheeting acts as longitudinal tensile reinforcement.
The condition of sheeting should be inspected before concrete is
poured.
Reinforcement in slabs carries and distributes the design loads and
to control cracking. Reinforcement is generally described as
transverse and longitudinal in relation to span, but other
reinforcement required for trimming may be positioned in other
orientations. Figure 5.12 shows a typical cross-section of a BONDEK
composite slab and associated terms.
Reinforcement must be properly positioned, lapped where necessary
to ensure continuity, and tied to prevent displacement during
construction. Fix reinforcement in accordance with AS 3600—2001,
Clause 19.2.5 (Fixing).
To ensure the specified minimum concrete cover, the uppermost
layer of reinforcement must be positioned and tied to prevent
displacement during construction (Section 3.4 Durability).
Splicing of conventional reinforcement must be in accordance with
AS 3600—2001, Clause 13.2 (Splicing of reinforcement).
Where fabric is used in thin slabs, or where fabric is used to act as
both longitudinal and transverse reinforcement, pay particular
attention the required minimum concrete cover and the required
design reinforcement depth at the splices—splice bars are a prudent
addition.
Always place chairs and spacers on pan areas. Depending upon the
type of chair and its loading, it may be necessary to use plates under
chairs to protect the BONDEK, particularly where the soffit will be
exposed. Transverse reinforcement may be used for spacing or
supporting longitudinal reinforcement. 5 Construction

Fabric Deformed bar

reinforcement reinforcement
Concrete Concrete Reinforcement
cover depth
Top-face
composite slab

reinforcement
Depth of

Bottom-face
reinforcement

Bondek
Longitudinal reinforcement Transverse reinforcement
(parallel with ribs) (90° to ribs)

Figure 5.12
Typical cross-section of a slab showing common terms
38 CONSTRUCTION

5.4.1 TRANSVERSE REINFORCEMENT

Transverse reinforcement is placed at right-angles to the ribs of
BONDEK. Deformed bar or fabric reinforcement may be used. In most
applications the transverse reinforcement is for the control of cracks
caused by shrinkage and temperature effects, and for locating
longitudinal reinforcement.
To control flexural cracking in the top face of the slab, transverse
reinforcement in the top-face may be required over walls or beams
which run in the same direction as the BONDEK sheets.
For ease of construction, reinforcement for control of cracking due
to shrinkage and temperature is usually fabric reinforcement (Section
3.11.3, Crack control for flexure).

5.4.2 LONGITUDINAL REINFORCEMENT

Longitudinal reinforcement is positioned to carry design loads in
the same direction as the ribs of BONDEK. Deformed bar or fabric
reinforcement may be used. Design information is in Chapters 2, 3
and 4.
Top-face longitudinal reinforcement is usually located over interior
supports of the slab and extends into approximately a third of the
adjoining spans.
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. Bottom-
face longitudinal reinforcement may be placed on top of or below
transverse reinforcement.
Location of bottom-face longitudinal reinforcement in elevated
temperatures requires special design (Figures 4.5 and 4.6).

5.4.3 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. Deformed bar or fabric
reinforcement may be used.
Trimmers are sometimes laid at angles other than along or across the
span, and generally located between the top and bottom layers of
transverse and longitudinal reinforcement. Trimmers are generally
fixed with ties from the top and bottom layers of reinforcement.

5.5 CONCRETE

5.5.1 SPECIFICATION
The concrete is to have the compressive strength as specified
in the project documentation and the materials for the concrete
and the concrete manufacture should conform to AS 3600—2001.

5.5.2 CONCRETE ADDITIVES

Admixtures or concrete materials containing calcium chloride
or other chloride salts must not be used. Chemical admixtures
including plasticisers may be used if they comply with AS 3600—
2001, Clause 19.

5.5.3 PREPARATION
Before concrete is placed, remove any accumulated debris, grease
or any other substance to ensure a clean bond with the BONDEK
sheeting. Remove ponded rainwater.
 CONSTRUCTION 39

5.5.4 CONSTRUCTION JOINTS

Form boards sandw iching It is accepted building practice to provide construction joints where
continuous reinforcement.
Lower board shaped a concrete pour is to be stopped. Such discontinuity may occur as a
to match Bondek profiConcrete
le
result of a planned or unplanned termination of a pour. A pour may
be terminated at the end of a day’s work, because of bad weather or
equipment failure. Where unplanned construction joints are made,
the design engineer must approve the position.
In certain applications, the addition of water stops may be required,
BONDEK such as in roof and balcony slabs where protection from corrosion of
Prop
reinforcement and sheeting is necessary.

Transverse construction joint
Form boards sandwiching
continuous reinforcement.
Concrete
BONDEK
Longitudinal construction joint
Figure 5.13
Typical construction joints
Construction joints transverse to the span of the BONDEK sheeting are
normally located where shear forces are a minimum (such as the mid-
third of a slab span) and ideally over a line of propping. Locate
longitudinal construction joints in the pan (Figure 5.13).
Form construction joints with a vertical face—the easiest technique is
to sandwich a continuous reinforcement between two boards.
Prior to recommencement of concreting, the construction joint must
be prepared to receive the new concrete, and the preparation
method will depend upon the age and condition of the old concrete.
Generally, thorough cleaning is required to remove loose material, to
roughen the surface and to expose the course aggregate.

5.5.5 PLACING
The requirements for the handling and placing of the concrete are
covered in AS 3600—2001, Clause 19.1.3 (Handling and placing of
concrete).
The concrete is placed between construction joints in a continuous
operation so that new concrete is placed against plastic concrete to
produce a monolithic mass. If the pouring has to be discontinued for
any more than approximately one hour, depending on the
temperature, a construction joint may be required.
Start pouring close to one end and spread concrete uniformly,
preferably over two or more spans. It is good practice to avoid
excessive heaping of concrete and heavy load concentrations. When
concrete is transported by wheel barrows, the use of planks or
boards is recommended.
During pouring, the concrete should be thoroughly compacted,
worked around ribs and reinforcement, and into corners of the EDGE
FORMS by using a vibrating compactor. Ensure that the reinforcement
remains correctly positioned so that the specified minimum concrete
5 Construction
cover is achieved.
Unformed concrete surfaces are screeded and finished to achieve
the specified surface texture, cover to reinforcement, depths, falls or
other surface detailing.
Surfaces which will be exposed, such as EDGE FORMS and exposed
soffits, should be cleaned of concrete spills while still wet, to reduce
subsequent work.

5.5.6 CURING
After placement, the concrete is cured by conventional methods, for
example, by keeping the slab moist for at least seven days, by
covering the surface with sand, building paper or polythene sheeting
immediately after it has been moistened with a fine spray of water.
Follow AS 3600—2001, Clause 19.1.5 (Curing and protection of
concrete) and good building practice. Be particularly careful when
curing in very hot or very cold weather.
40 CONSTRUCTION

Until the concrete has cured, it is good practice to avoid

concentrated loads such as barrows and passageways with
heavy traffic.

5.5.7 WHEN TO REMOVE PROPS

Various factors affect the earliest time when the props may be
removed and a slab initially loaded. Methods of calculating times and
other guides are given in AS 3610—1995, Clause 5.4.3 (Stage III of
construction—Formwork stripping and after placement of concrete).

5.6 FINISHING

5.6.1 SOFFIT AND EDGE FORM FINISHES

For many applications, BONDEK gives 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, EDGE FORM will
give a suitable edging. Additional finishes take minimal extra effort.
Where the BONDEK soffit is to be the ceiling, take care during
construction to minimise propping marks (refer to Installation—
Propping), and to provide a uniform surface at the side-laps (refer to
INSTALLATION—FASTENING SIDE-LAP JOINTS).
Exposed surfaces of BONDEK soffit and EDGE FORM may need cleaning
and/or preparation for any following finishes. The cleaning
preparations are shown in Table 5.2.
Table 5.2
Preparation of soffits and Edge Form
• Remove all protective plastic strips from rolled corners.
• Concrete seepage marks and dirt may be removed by washing
with water. For stubborn stains, use a mild solution of pure soap or
Prepainted non-abrasive detergent in warm water.
soffit or edge • Grease or oil deposits may be removed by washing as described
above. For stubborn deposits contact us for advice. Never use
abrasive or solvent type cleaners (like turps, petrol or kerosene) on
pre-painted steel.
• Light corrosion marks indicated by white to grey staining due to wet
bundles may be removed with a kerosene rag. If this is unsatisfactory,
then wire brushing may be necessary. Take care not to unnecessarily
remove any of the zinc coating. If zinc coating is removed, a suitable
Galvanised paint system must be used.
soffit or edge • 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.

5.6.2 PAINTING
Various painting systems are available for use with zinc coatings to
provide a decorative finish and/or to provide an appropriate
corrosion protection system.
There are recommendations suitable for painting soffits and edges in
Painting zinc-coated or zincalume steel sheet (BLUESCOPE LYSAGHT
technical information booklet). Field (on site) painting systems from
that booklet are summarised in Table 5.3.
The performance of a paint system is influenced by the quality of
preparation and application—closely follow the paint manufacturer’s
instructions.
For painted soffits, it may be preferable to cover the gaps of the ribs
prior to painting. BONSTRIP snaps into the gaps of the ribs of the
BONDEK sheeting and produces an attractive appearance (Figure 5.14).
Figure 5.14
BONDSTRIP makes an attractive cover for
The gap at the side-lap joint can be filled with a continuous bead of the gaps formed by BONDEK ribs
silicon sealant prior to painting.
 CONSTRUCTION 41
Table 5.3
Painting BONDEK soffits and edge form
Exposure Primer Finish
classification
(AS 3600) Type Application Type Application
Water-borne acrylic Water-borne acrylic
A1 & A2 Brush Brush
(1 coat) (2 coats)
Alkyd Brush or
2-pack etch primer Brush or (2 coats) spray
(1 coat) spray Oleoresinous/micaceous Brush or
iron oxide (2 coats) spray
Zinc dust/zinc oxide Brush or
B1
(1 coat) spray
Zinc dust/zinc oxide Brush or Alkyd Brush or
(1 coat) spray (2 coats) spray
Oleoresinous/micaceous Brush or
iron oxide (2 coats) spray
High build vinyl
Brush or Spray
2-pack etch primer (2 coats)
B2 spray
(1 coat) 2-pack polyurethane Brush or
(2 coats) spray

5.6.3 PLASTERING
Finishes such as vermiculite plaster can be applied directly to the
underside of BONDEK with the open rib providing a positive key. With
some products it may be necessary to treat the galvanised steel
surface with an appropriate bonding agent prior to application.
Plaster-based finishes can be trowelled smooth, or sprayed on to
give a textured surface. They can also be coloured to suit interior
design requirements.

5.6.4 CHANGE OF FLOOR LOADINGS

Where a building is being refurbished, or there is a change of
occupancy and floor use, you may need to increase the fire
resistance of the BONDEK composite slabs. This may be achieved
by the addition of a suitable fire-protection material to the underside
of the slabs. The open ribs of BONDEK provide a positive key to
keep the fire spray in position. Such work is beyond the scope of
this manual.

5.7 SUSPENDED CEILINGS

AND SERVICES

5.7.1 PLASTERBOARD
A BONDEK soffit may be covered with plasterboard by fixing to
5 Construction
battens.
Fixing to battens
Steel ceiling battens can be fixed directly to the underside of the
slab using powder-actuated fasteners. The plasterboard is then fixed
to ceiling battens in the usual way (Figure 5.15).

Concrete

Batten
BONDEK
Plaster board
Figure 5.15
Fixing plasterboard to BONDEK
42 CONSTRUCTION

5.7.2 SUSPENDED CEILING

Ceilings are easily suspended from BONDEK slabs using Ceiling
Suspension Nuts, BON-NUT suspension nuts, or BONWEDGE suspension
brackets which comply with the load capacity requirements of AS
2785. 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 BONDEK sheeting before
concreting (Figure 5.16).

5.7.3 SUSPENDED SERVICES

Services such as fire sprinkler systems, piping and ducting are easily
suspended from BONDEK slabs using BON-NUT suspension nuts which
comply with the load capacity requirements of AS2118 (Figure5.16).
Ceiling Suspension Nuts or BONWEDGE suspension brackets are
suitable for services other than fire sprinkler systems—threaded rods
being used to support the services.

5.8 ACCESSORIES

Safe load
Bonwedge Configuration Loading (kN)
Lightweight bracket for rods Single Bonwedge Eccentric 1.0
to suspend ceilings or services Double BonwedgeEccentric 1.3
(other than fire sprinkler systems). Hole 8 mm dia. Double Bonwedge Central 1.7

21.5

8.5

Bon-nut
Ceiling suspension nut Heavy duty square nut to Bondek Safe load
Pressed metal threaded bracket suspend ceilings or services. BMT (kN)
to suspend ceilings or services. Glued to a paper strip 0.75 4.4
Thread: M6 makes insertion easy. 1.00 6.7
Max. load: 270 kg Threads: M8, M10 and M12

Brackets from hoop iron

Edgeform
A galvanised section that creates a permanent
formwork at the slab edges—cut, mitred and
screwed on site. Stock slab depths: 100, 125,
150 mm (others to special order).
Stock length: 6100 mm

Bonfill Bonstrip
Polystyrene foam stops concrete Plastic trim to cover gaps formed by ribs.
and air entering ends of ribs. Used when underside of Bondek forms
Stock length: 1200 mm an exposed ceiling.
Required: 300 mm per sheet of Bondek Stock length: 3000 mm

Figure 5.16
BONDEK accessories
 WORKED EXAMPLE 43

6 WORKED EXAMPLES

EXAMPLE 1
Design a three-span composite slab for steel-frame construction.

4.8 m 4.0 m 4.6 m

Design parameters

Maximum slab span (L) = 4.8 m

Superimposed dead load (Gsup) ≤ 1 kPa

Live load ( Q ) = 3 kPa

Negative and fire reinforcement: 10 mm bar of D500N

Exposure classification: A1

Maximum deflection of formwork (D mm) = L’/240

Maximum total deflection of composite slab = L /250

Maximum incremental deflection of composite slab: not required

Concrete density ( ρc ) = 2000 kg/m (ρg = 21 kN/m )

3 3

Concrete strength ( f’c) = 25 MPa

Crack control for flexure: not required

Crack control for shrinkage and temperature effects: minor

BONDEK base metal thickness = 0.75 mm

Fire resistance period = F60

Vertical flexibility of support beams is small enough to be ignored.

The crack control for flexure is not required, consequently two

options may be considered (see Section 3.2). The reduced weight of
lightweight concrete may be ignored (see Section 3.5.4). The ratio of
longer to shorter span length does not exceed 1.2, reinforcing bar is
10 mm diameter, thus all necessary data can be read directly from
the design tables.
Solution 1: Slab is designed as continuous for strength and
serviceability
The data in the tables are applicable to both end and interior spans.
From the table on Page 104: D = 140 mm; 2 rows of propping; 480
mm2 of negative reinforcement laid to standard Pattern 1 (Figure 3.1).
From the table on Page 105: additional fire (longitudinal)
reinforcement of 360 mm2 must be placed as required for Fire Detail
2 (Figure 4.5).
From Table 3.6, mesh SL62, laid on the top (Figure 1.1), may be used
to control cracking due to temperature and shrinkage effects.
Concrete cover is 20 mm.
Solution 2: Slab is designed as a series of simply-supported
6 Worked examples

slabs.
From table on Page 68, Dcs = 170 mm; 2 rows of propping, no
negative reinforcement is necessary. From the table on Page 69:
additional fire (longitudinal) reinforcement of 510 mm2 must be
placed as required for Fire Detail 2 (Figure 4.5)—the only option for
simply-supported slabs. The mesh SL72, laid on the bottom, may be
used to control cracking due to temperature and shrinkage effects.
The choice between these two options may depend on which option
is more economical.
44 WORKED EXAMPLE

EXAMPLE 2
Design multiple-span composite slab for concrete-frame construction.

A B C D E
5.1 m 5.2 m 4.4 m 4.5 m

Design parameters
Band-beam width = 1 m
Superimposed dead load (Gsup) ≤ 1 kPa
Live load ( Q ) = 10 kPa
Negative reinforcement: 9.5 mm bar of D500L
Exposure classification : A1
Maximum deflection of formwork (∆ mm) = L´/240
Maximum total deflection of composite slab = L /250
Maximum incremental deflection of composite slab: not required
Concrete density ( ρc ) = 2400 kg/m3 (ρg = 25 kN/m3)
Concrete strength ( f’c ) = 25 MPa
Crack control for flexure: required
Crack control for shrinkage and temperature effects: moderate
BONDEK base metal thickness = 0.6 mm
Fire design: not required
Vertical flexibility of support beams is small enough to be ignored.

The ratio of longer to shorter span length does not exceed 1.2, thus
all necessary data may be read directly from the design tables.
Support B
From the table on Page 116: Dcs = 190 mm for the end span (A–B);
2 rows of propping; 890 mm2 of negative reinforcement with bar
10 mm diameter, grade D500N only.
Span length must be 5.1 metres, so don’t consider length of interior
span of 5.2 metres.
If the soffit is to be exposed, it is desirable to use form ply strips,
300 mm wide, for props to avoid localised damage to the BONDEK.
However, L-grade reinforcement was specified, thus the area of
negative reinforcement must be increased for all support regions
because moment redistribution is not allowed for L-grade
reinforcement (Section 3.10):
Ast– = 890 x 1.43 = 1273 mm2.
Proper compacting and placing of concrete is possible (Section 3.8.3).
The negative reinforcement pattern is a standard one (Figure 3.1).
The RL818 mesh, placed on top, may be used to control temperature
and shrinkage effects.
 WORKED EXAMPLE 45
Support A
The design of the top negative reinforcement (Figure 1.1) must be
based on rotational restraint provided by the end band-beam
(similar to the left side of Figure 3.1); and can be taken
conservatively as for Support B.
Supports D
The span length is taken as 4.5 m (maximum of 4.4 m, and 4.5 m).
Our design tables would give a thickness less than 190 mm. You may
design the slab with that reduced thickness or keep 190 mm
throughout. In both cases 820 mm2 of negative reinforcement is
acceptable, though a bit conservative for 190 mm. A 160 mm option
would require Pattern 2 of negative reinforcement (Figure 3.2).
Ast– = 820 x 1.43 = 1173 mm2
Note that the first interior span (B-C) must always have the same
thickness as the end span.
Anchorage reinforcement: End support
w/L = (2 x 0.5) / 5.1 = 0.2 (Table 3.8)
Aanchorage = 0.23 x 890 = 205 mm2 (D500L or D500N)
Anchorage reinforcement: Support B
Aanchorage = 0.16 x 890 = 142 mm2
Anchorage reinforcement: Support D
Aanchorage = 0.16 x 820 = 131 mm2
For fire-rated buildings, the bottom fire reinforcement can also be
treated as anchorage reinforcement.
To get a more economical design you could run BONDEK 2003,
because our design tables were developed for steel-frame and
masonry-wall construction and don’t allow for the positive effect
of band-beams on deflections and propping. BONDEK 2003 is likely
to give:
• a thinner slab;
• less reinforcement for interior spans;
• slabs for interior spans may be designed thinner than end spans;
• less negative reinforcement required if D500N is specified for
shrinkage reinforcement; and
• less temporary props.

6 Worked examples
46 WORKED EXAMPLE

EXAMPLE 3
Design simply-supported slab for steel-frame construction.

4.5 m

Design parameters
Slab span = 4.5 m
Superimposed dead load (Gsup) ≤ 3 kPa
Live load ( Q ) = 3 kPa
Exposure classification: A1
Maximum deflection of formwork (∆ mm) = L’/240
Maximum total deflection of composite slab = L /250
Maximum incremental deflection of composite slab = L /500
Concrete density (ρc) = 2000 kg/m3 (ρg = 21 kN/m3)
Concrete strength ( f’c) = 25 MPa
Crack control for flexure: not applicable
Crack control for shrinkage and temperature effects:moderate
BONDEK base metal thickness = 1.00 mm
Fire resistance period = F60

Our Design Tables are worked out for normal weight concrete with
superimposed dead load not exceeding 1 kPa. The superimposed
load in this example is 3 kPa and must be transformed into
additional live load as described in Section 3.5.5. This can be done
using the advantage of light-weight concrete:
Additional Live load = (3 - 1 - (25 - 21) x 0.2) x 2 = 2.4 kPa
(where Dcs = 200 mm - preliminary slab thickness from the table on
Page 58).
Total transformed live load = 5.4 kPa.
From the table on Page 58: Dcs = 190 mm; 1 row of propping.
From the table on Page 59: additional fire (longitudinal)
reinforcement of 460 mm2 (≥10 mm diameter, D500N) must be
placed as required for Fire Detail 2 (Figure 4.5)—the only option for
simply-supported slabs. The mesh RL818, placed on the bottom,
may be used to control shrinkage and temperature effects.
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© Copyright BlueScope Steel Limited 20 January 2005

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are trademarks of BlueScope Steel Limited
A.B.N. 16 000 011 058

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BlueScope Steel Limited trading as BlueScope Lysaght.