Super Holorib

Technical ManualSUPER HOLORIB

SUPER HOLORIB is an advanced composite floor slab profile now available andmanufactured in Malaysia. Formed from hot dipped zinc plated thin gauge steel sheet,the SUPER HOLORIB profile has been carefully designed to optimise performance whenacting as permanent shuttering to support wet concrete slabs. The profile design, with itsrepetition module of 152.5 mm allows thinner gauges of SUPER HOLORIB to bespecified than with wider spaced ribs on similar profiles.

SUPER HOLORIB is not only a convenient shuttering system as it also bonds with theconcrete, both chemically and mechanically, to act as all or part of the structuralreinforcement in the composite floor slab. This composite action is achieved without theneed for any end anchorage in the form of shear studs due to the regularly spacedembossments along the top of the profile and its re-entrant shape which prevents verticalseparation of the concrete from the steel.

Extensive fire testing of the profile has been carried out in the UK to assist in thedevelopment of unified design rules. These tests were instrumental in the developmentof BS 5950:Part 8: 1990 which all fire designs now follow.

Available in a range of gauges from 0.8 mm up to 1.2 mm, SUPER HOLORIB is thecomposite floor decking profile of choice for international design offices around the world.This Technical Manual is offered as an introduction to the design and use of SUPERHOLORIB for Engineers and Specifiers. Additional assistance is available from EuropeanProfiles Contracting Sdn Bhd at their Head Office in Rawang.

Super Holorib

Technical ManualCOMPOSITE FLOOR DECKING

The full benefits of steel framed building design are realised when composite floordecking is used in unpropped construction. Using this construction method allowsthe contractor maximum flexibility in programming works and minimises the numberof obstructions to following trades. It is therefore the construction stage, when thedecking profile is supporting wet concrete and construction personnel, that dictatesthe choice of decking gauge for most design applications.

Composite floor decking is fast to install and uses a minimum of labour. This cancontribute towards overall economies on the total building cost, whilst reducing therisk of accidents associated with labour intensive operations. For high riseconstruction with unpropped decking consider the following sequence :

1) Deliver deck for Level 1 and load bundles on to the frame. This operation is mostefficiently performed before beams for Level 2 are installed as they may obstructthe crane access.

2) Deliver deck for Level 2 and load bundles on to the frame.

3) Deliver deck for Level 3 and load bundles on to the frame.

4) Spread out the decking at Level 3 and secure in place. This will provide aprotective layer for the workplace below, providing protection from falling objectsas well as shelter from sun and rain.

5) Spread out the decking at Levels 1 & 2 whilst erecting steel and delivering deckbundles for Levels 4, 5 & 6. The decking at Level 3 allows these operations toproceed at the same time.

6) Repeat steps 4 & 5 for subsequent levels in 3 storey increments.

Super Holorib

Technical ManualDESIGN

When considering the use of a composite floor slab, reference can be made to thetables contained within this brochure or to the company's technical department forcomplimentary advice. Outlined below is a brief guide to the design considerationsthat are taken into account.

Initial Sizing

The SLAB DEPTH should be deep enough for the desired fire rating. The SPAN / DEPTH RATIO should not exceed 35:1

Construction Stage

DEFLECTION is limited to span / 130 after the full effects of ponding are takeninto account.

For continuous sheets the NEGATIVE BENDING MOMENT is calculated and, ifapplicable, reduced to a residual level on formation of a plastic hinge.

For both single and continuous sheets, the POSITIVE BENDING MOMENT iscalculated and checked against the known sheet capacity.

WEB BUCKLING is checked where the sheeting passes onto both end andintermediate supports.

Combined effects of BENDING and BUCKLING are checked at intermediatesupports. The bearing stresses have the effect of reducing the resistance of thesheet to applied loading when compared with a pure bending situation.

Immediately adjacent to both end and intermediate supports, the WEB SHEARcapacity is checked.

Composite Stage

In the composite slab analysis, all slabs are considered as simply supported.

DEFLECTION due to IMPOSED LIVE LOADS is limited to span / 350. DEFLECTION due to TOTAL IMPOSED LOADS is limited to span / 250.

POSITIVE BENDING is checked against the capacity of the fully compositesection. In addition, the effects of SHEAR BOND on the horizontal interfacebetween concrete and decking must be analysed as the full moment capacity canseldom be mobilised.

VERTICAL SHEAR through the concrete in the troughs of the composite slab ischecked adjacent to the supports.

Fire Limit State

Where the slab passes over the top of intermediate beams, the load capacity ofthe slab is evaluated by comparison with fire test results using FIRE METHOD A.

In all instances, the moment capacity required in the fire limit state is calculatedand reinforcing bars detailed in accordance with FIRE METHOD B. Method Btakes account of reduced materials properties as a result of elevatedtemperatures.

Super HoloribTechnical Manual

UNPROPPED CONSTRUCTION

Maximum unpropped spans are achieved when the SUPER HOLORIB sheets aredetailed to be continuous over two or more spans. This allows the negative bendingresistance of the profile to be fully mobilised. Full scale testing of SUPER HOLORIBsheeting in a two span configuration at the British Steel Test Centre in South Wales hasallowed the true resistance of the profile to be taken into consideration when preparingthe safe span tables presented here.

Where circumstances dictate that the sheeting be used in single span configurations, themaximum permissible spans will be reduced due to the greater flexibility duringconstruction.

The construction stage so dominates the design that the final composite slab is oftencapable of carrying far greater loads than required. In the following table it can be seenthat load carrying capacity in excess of 15 kN/m2 is common.

Unpropped Construction Tables

Multiple Span Condition Single Span ConditionDeck

GaugeSlab

Depth Shutter Imposed Load (kN/m2) Shutter Imposed Load (kN/m²)Only 7.5 10.0 15.0 Only 7.5 10.0 15.0

100 3.12 3.12 3.03 2.40 2.75 2.75 2.75 2.40120 2.96 2.96 2.96 2.69 2.59 2.59 2.59 2.59125 2.92 2.92 2.92 2.77 2.56 2.56 2.56 2.56

0.8 140 2.81 2.81 2.81 2.81 2.46 2.46 2.46 2.46150 2.74 2.74 2.74 2.74 2.40 2.40 2.40 2.40170 2.62 2.62 2.62 2.62 2.29 2.29 2.29 2.29200 2.47 2.47 2.47 2.47 2.16 2.16 2.16 2.16

100 3.35 3.35 3.24 2.56 3.00 3.00 3.00 2.56120 3.18 3.18 3.18 2.89 2.87 2.87 2.87 2.87125 3.15 3.15 3.15 2.98 2.83 2.83 2.83 2.83

0.9 140 3.04 3.04 3.04 3.04 2.73 2.73 2.73 2.73150 2.98 2.98 2.98 2.98 2.66 2.66 2.66 2.66170 2.87 2.87 2.87 2.87 2.54 2.54 2.54 2.54200 2.73 2.73 2.73 2.73 2.39 2.39 2.39 2.39

100 3.50 3.50 3.33 2.74 3.00 3.00 3.00 2.74120 3.35 3.35 3.35 3.12 3.08 3.08 3.08 3.08125 3.31 3.31 3.31 3.21 3.04 3.04 3.04 3.04

1.0 140 3.20 3.20 3.20 3.20 2.94 2.94 2.94 2.94150 3.14 3.14 3.14 3.14 2.89 2.89 2.89 2.89170 3.02 3.02 3.02 3.02 2.77 2.77 2.77 2.77200 2.88 2.88 2.88 2.88 2.61 2.61 2.61 2.61

100 3.50 3.50 3.41 2.98 3.00 3.00 3.00 2.98120 3.66 3.66 3.66 3.50 3.26 3.26 3.26 3.26125 3.62 3.62 3.62 3.62 3.23 3.23 3.23 3.23

1.2 140 3.50 3.50 3.50 3.50 3.12 3.12 3.12 3.12150 3.43 3.43 3.43 3.43 3.06 3.06 3.06 3.06170 3.31 3.31 3.31 3.31 2.95 2.95 2.95 2.95200 3.15 3.15 3.15 3.15 2.81 2.81 2.81 2.81

General notes on Construction tables

1. The spans indicated are from centre to centre of supports which are assumed to beof minimum width 100 mm.

2. Concrete density is taken to be 2400 kg/m3 during construction, 2350 kg/m3 aftercuring.

3. During construction, a live load allowance of 1.5 kN/m2 has been included to accountfor construction personnel and lightweight equipment.

Super Holorib

Technical ManualPROPPED CONSTRUCTION

Where unpropped cons truc tion is no t poss ib le or so ff it defl ec ti ons are to beminimised during construct ion, then temporary props may need to be considered. Itis recommended that temporary props be left in position until the concrete has reached atleast 75% of its intended design strength. Early removal of props can be detrimental totheoverall performance of the compositeslab as the vital shear bond between concreteanddecking may be weakened due to deflection of the immature slab. This deflection canalso cause cracking of the concrete where it passes over support beams. Prop removalwill always allow deflection to takeplace and will lead to a slight dishing effect on the topsurface of the slab. For this reason, it is recommended that some forms of finishes areapplied to the slab after props are removed.

Propped Construction Tables

Single Line of Props

Imposed Load (kN/m2)DeckGauge

SlabDepth Shutter

Only 7.5 10.0 15.0

100 3.00 3.00 3.00 2.41120 3.60 3.60 3.49 2.71125 3.75 3.75 3.59 2.79

0.8 140 4.20 4.20 3.88 3.01150 4.50 4.50 4.07 3.16170 5.10 5.10 4.42 3.44200 5.02 5.02 4.90 3.84

100 3.00 3.00 3.00 2.57120 3.60 3.60 3.60 2.92125 3.75 3.75 3.75 3.01

0.9 140 4.20 4.20 4.20 3.26150 4.50 4.50 4.41 3.43170 5.10 5.10 4.81 3.75200 5.42 5.42 5.35 4.19

100 3.00 3.00 3.00 2.75120 3.60 3.60 3.60 3.15125 3.75 3.75 3.75 3.25

1.0 140 4.20 4.20 4.20 3.54150 4.50 4.50 4.50 3.73170 5.10 5.10 5.10 4.10200 5.71 5.71 5.71 4.61

100 3.00 3.00 3.00 2.98120 3.60 3.60 3.60 3.50125 3.75 3.75 3.75 3.63

1.2 140 4.20 4.20 4.20 4.02150 4.50 4.50 4.50 4.29170 5.10 5.10 5.10 4.81200 6.00 6.00 6.00 5.35

4. In calculating deflections during construction, the effects of ponding are taken intoaccount in an iterative procedure. A temporary live load of 0.5 kN/m2 is included indeflection calculations to account for non recoverable deflections caused by theconstruction personnel.

5. Deflections are limited to span/130 in accordance with BS 5950:Part 4:1994.6. A span to depth ratio limit of 35:1 is imposed.

7. Concrete is grade C30.

8. Composite slabs are designed as simply supported with nominal crack control fabricover the supports.

Super Holorib

Technical ManualFIRE ENGINEERING DESIGN

Design of composite floor slabs in the fire limit state is covered by BS 5950: Part 8:1990. This code of practice uses fire engineering techniques to design fire resistanceinto the slab and dispense with the need for soffit protection. By following the guidelinesin the tables that follow a significant saving on project costs may be achieved.

Design principles

Insulation

To ensure temperatures on the top surface of the slab do not rise excessively dueto fire below the soffit

Integrity

Compartmentalisation. To ensure that the slab does not allow the penetration ofsmoke and flames from one compartment to another.

Stability

To ensure that the structure remains standing without endangering the lives of peopleduring the period of evacuation and firefighting.

Full scale fire test on SUPER HOLORIB floor slab at

Warrington Fire Research Centre (UK)

Super Holorib

Technical ManualMinimum Slab Depth

To satisfy the insulation requirement without the need for any soff it protection, thetotal composite slab depth when using SUPER HOLORIB should not be less thanthe nominal figures given in the table below. Two sets of figures are given in thetable, one fo r each of the two design methods descri bed be low. When us ingMethod A, note that the slab thickness is increased compared to Method B for a two hourfire rating. Method A has not been proven to be applicable beyond 2 Hours.

Minimum permissible Slab Depths (mm) for Fire Engineering Design is

Fire Rating Period (Hrs) 1/2 Hr 1 Hr 11/2 Hr 2 Hr 3 Hr 4 Hr

Method A 100 100 110 140OverallDepth (mm)

Method B 100 100 110 125 150 170

Fire Tests

During the development of both the SUPER HOLORIB profile and the British Standardcode of practice for design, a number of full scale fire tests have been carried out at UKand European Fire Test Centres. Listed below are the most significant of these teststogether with a brief description of their performance.

WRCSI 21809WRCSI 23887WRCSI 23927Warres 35965Warres 43405

4 hrs11/2 hrs2 hrs11/2 hrs2 hrs

125 mm slab with mineral fibre protection130 mm slab , 12 mm bars @ 152 centres155 mm slab , 16 mm bars @ 152 centres120 mm LWC slab with A6 fabric only150 mm LWC slab with A7 fabric only

Method AFire rating for SUPER HOLORIB Slab achieved with top meshonly. No other reinforcement.

Super Holorib

Technical ManualMethod A

This is a simpli fied method appl icable only where the floor slab has cont inuityover intermediate beams. The slab contains no reinforcement other than the statedfabric which doubles as a crack control mesh. Under fire conditions, the slab gainsits strength from the fabric acting in tension over the supports.

This method is consistent with BS 5950:Part 8:1990 and is supported by full scaletests carried out at Warrington Fire Research Centre in the UK. It is applicable tofire ratings up to 2 hours maximum.

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Sup er Hol ori b

Technical Manual

Table AMaximum permissible span for Fire Engineering Method A designs

1 Hr 1-1/2Hr 2 HrImposed

LoadSlab

Depth A 6 A7 A6 A7 A7 A8

kN/mm2 mm m m m m m m

100 2.78 2.78120 3. 31 3.31 2.83 2.83

125 3.34 3.97 2.85 2.85

5.0 140 3.43 4.07 3.37 3.99 3.30

1503.49 4.10 3.42 4.06 3.35 3.98

170 4.10 4.10 3.45 4.09200 4.10 4.10 3.50 4.10

100 2.50 2.50120 3.00 3.00 2.56 2.56

125 3.03 3.60 2.59 2.59

6.7 140 3.12 3.71 3.06 3.63 3.00

150 3.19 3.78 3.12 3.71 3.06 3.63

170 3.90 3.82 3.16 3.75200 4.08 4.00 3.30 3.93

100 2.14 2.14120 2.58 2.58 2.20 2.20

125 2.61 3.10 2.23 2.23

10.0 140 2.71 3.21 2.65 3.14 2.60

150 2.76 3.28 2.71 3.22 2.65 3.15

170 3.41 3.33 2.76 3.27200 3.58 3.52 2.90 3.45

Notes to Table A

The fabric sizes refer to the wire diameter in mil limeters.

All 'A' type fabrics consist of wires welded on a 200 x 200 square grid.

The fabric should be positioned in the top of the slab with typically 25 mm of concretecover above the wires over support beams. Draping of the mesh is permitted but is notcompulsory.

Lapping and end anchorage of the fabric should fol low conventional practice.

Su pe r Ho lo ri b

Technical ManualMethod B

This method can be applied universally, either on its own or in combination with Method A forisolated or exceptional spans. In addition to the crack control fabric, reinforcing bars are designedand detailed in to the soffit of the slab to act in tension under positive bending conditions. Method B

Notes to table B

Bar size/spacing combinations are arranged in ascending order of cross-sectional ofsteel provided.

All reinforcement is assumed to consist of high yield deformed bars with a minimum yieldstrength of 460 N/mm2.

Imposed loads include all live and dead loads other than slab self weight which can beignored when reading the tables. Load factors are taken as 1.0 throughout.

Method BFire rating for SUPER HOLORIB Slab achievedwith top mesh plus reinforcing bars in every oralternate troughs.

Method BFire rating for SUPER HOLORIB Slab achievedwith top mesh plus reinforcing bars in every oralternate troughs.

Sup er Hol ori b

Technical Manual

Maximum permissible span for Fire Engineering Method B designs1 H O U R

Imposed Slab Reinforcing Bars (Diameter / Spacing)

Load Depth 8 mm 10 mm 8 mm 12 mm 10 mm 16 mm 12 mm@ 305 @ 305 @ 152 @ 305 @ 152 @ 305 @ 152

100 2.05 2.55 2.83 3.04 3.48 3.55 3.55120 2.33 2.93 3.27 3.50 4.03 4.25 4.25125 2.39 3.01 3.36 3.59 4.15 4.42 4.42

5.0 140 2.55 3.21 3.61 3.86 4.47 4.95 4.95150 2.65 3.33 3.76 4.01 4.66 5.26 5.30170 2.82 3.54 4.00 4.27 4.98 5.62 5.92200 3.03 3.80 4.29 4.58 5.38 6.07 6.28100 1.84 2.30 2.55 2.74 3.13 3.55 3.55120 2.11 2.65 2.96 3.17 3.65 4.14 4.25125 2.17 2.73 3.05 3.26 3.76 4.26 4.42

6.7 140 2.33 2.92 3.29 3.51 4.07 4.60 4.82150 2.42 3.04 3.43 3.66 4.25 4.80 5.04170 2.59 3.24 3.66 3.91 4.57 5.15 5.42200 2.79 3.50 3.96 4.22 4.96 5.60 5.86100 1.58 1.97 2.18 2.34 2.68 3.04 3.13120 1.82 2.28 2.55 2.73 3.14 3.56 3.71125 1.87 2.35 2.63 2.81 3.25 3.67 3.83

10.0 140 2.01 2.53 2.85 3.04 3.52 3.98 4.17150 2.10 2.64 2.98 3.18 3.69 4.17 4.37170 2.26 2.83 3.20 3.41 3.99 4.50 4.73200 2.46 3.08 3.48 3.71 4.37 4.92 5.08

1 ½ H O U R

Reinforcing Bars (Diameter / Spacing)Imposed

LoadSlab

Depth 8mm 10 mm 8mm 12 mm 10 mm 16 mm 12 mm@ 305 @ 305 @ 152 @ 305 @ 152 @ 305 @ 152

120 2.25 2.81 3.16 3.35 3.89 4.25 4.25125 2.31 2.88 3.25 3.44 4.00 4.42 4.42

5 .0 140 2.46 3.08 3.49 3.69 4.30 4.82 4.95150 2.56 3.19 3.62 3.83 4.48 5.01 5.29170 2.72 3.40 3.85 4.07 4.79 5.36 5.67200 2.92 3.65 4.14 4.37 5.16 5.78 6.13120 2.03 2.55 2.86 3.03 3.52 3.95 4.14125 2.09 2.62 2.95 3.12 3.63 4.07 4.27140 2.24 2.80 3.18 3.36 3.92 4.38 4.62

6.7 150 2.33 2.91 3.30 3.49 4.09 4.57 4.83170 2.49 3.11 3.53 3.73 4.39 4.91 5.20200 2.69 3.36 3.82 4.02 4.76 5.32 5.65120 1.75 2.19 2.46 2.61 3.03 3.40 3.56125 1.80 2.26 2.54 2.69 3.13 3.51 3.68140 1.94 2.43 2.75 2.91 3.39 3.80 4.00

10.0 150 2.03 2.53 2.87 3.04 3.55 3.97 4.19170 2.18 2.72 3.08 3.26 3.84 4.29 4.54200 2.37 2.96 3.36 3.54 4.19 4.68 4.97

2 H O U RReinforcing Bars (Diameter / Spacing)

ImposedLoad

SlabDepth 8mm 10 mm 8mm 12 mm 10 mm 16 mm 12 mm

@ 305 @ 305 @ 152 @ 305 @ 152 @ 305 @ 152125 2.00 2.48 2.83 2.97 3.48 3.87 4.11140 2.14 2.65 3.03 3.17 3.74 4.14 4.42

5.0 150 2.22 2.75 3.14 3.29 3.89 4.30 4.60170 2.36 2.92 3.34 3.49 4.14 4.59 4.92200 2.54 3.13 3.59 3.75 4.44 4.91 5.31125 1.81 2.25 2.57 2.70 3.16 3.51 3.73140 1.95 2.41 2.76 3.40 2.89 3.77 4.03

6.7 150 2.02 2.51 2.87 3.00 3.55 3.93 4.20170 2.16 2.68 3.06 3.20 3.79 4.20 4.51200 2.34 2.89 3.31 3.45 4.09 4.53 4.89125 1.56 1.94 2.22 2.32 2.72 3.02 3.22140 1.68 2.09 2.39 2.50 2.95 3.27 3.49

10.0 150 1.76 2.18 2.49 2.60 3.08 3.41 3.65170 1.89 2.34 2.68 2.79 3.31 3.67 3.94200 2.06 2.54 2.91 3.04 3.60 3.98 4.30

Sup er Hol ori b

Technical ManualMETAL DECK DETAIL