Steelcomp-composite sheet

sitework 1.3.2006

Copyright 2006 Rautaruukki Oyj

1. PURCHASING AND DELIVERY .................................................................................................................................3
1.1 Steelcomp composite sheet...................................................................................................................................3
1.2 Purchasing .............................................................................................................................................................3
1.3 Delivery ..................................................................................................................................................................3
2. ERECTION ..................................................................................................................................................................4
2.1 Propping.................................................................................................................................................................4
2.2 Preparing................................................................................................................................................................5
2.3 Constructional details.............................................................................................................................................5
3. CASTING CONCRETE................................................................................................................................................7
3.1 Demands for concrete............................................................................................................................................7
3.2 Casting ...................................................................................................................................................................7
3.3 Drying of concrete ..................................................................................................................................................8
4. FINISHING OF COMPOSITE SLAB............................................................................................................................9
4.1 Openings................................................................................................................................................................9
4.2 Removal of propping..............................................................................................................................................9
4.3 Coatings .................................................................................................................................................................9
4.4 Installing hangers .................................................................................................................................................11
Appendices: ...................................................................................................................................................................12

Copyright 2006 Rautaruukki Oyj

1. PURCHASING AND DELIVERY

1.1 Steelcomp composite sheet

Steelcomp composite sheet has a national type approval in Finland (type approval 288/
6221/2003). Composite sheets are manufactured by roll forming either from galvanized or from
coated constructional sheet S350GD+Z275 (EN 10326). Tolerances for composite sheet are
defined in EN 508-1 and material tolerances are according to EN 10143.

Steel thickness is 0.7 mm, 0.9 mm or 1.1 mm. Normally composite sheets are supplied as hot-
galvanized with total zinc layer of 275 g/m (altogether on both sides) or if the lower surface
remains visible as polyester coating (white). It is possible to get other types of coatings and
colours by order.

1.2 Purchasing

Composite sheets are delivered with pre-defined lengths, therefore designer has to fill in material
list (Table 1.2-1) and manufacturers package list (Table 1.2-2).

The maximum sizes for a package are 22 sheets and 1500 kg. Sheets are supplied to customer-
specified lengths, usually with lengths divisible by 10 mm. Following information is needed:

customer and contact information

time of delivery and delivery address
material list for composite sheets
coating information
delivery order for packages
special demands for packages

1.3 Delivery

Purchaser has to ensure before delivery that there is enough space for unloading.

Delivery check has to be done right after unloading and the following information should be
checked:

lengths
thicknessess
coating

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 amount of composite sheets
weight of composite sheets
overall appearance of the sheets

It is recommended to lift packages directly near erection area. One package at time should be
lifted by fastening ropes attached to the structures of transport pallets. Sheet stacks must not be
lifted without their pallets. The width of the rope must be at least 50 mm,

If a sheet stack is lifted on installed sheet span, it must be positioned so that the supports of the
transport package run across the sheet profile, and the package supports must be placed near
propping.

If composite sheets are to be stored at site following information should be taken into
consideration:

place sheets stacks to an area where is as little traffic as possible.

store sheets in their transport packages on even flooring and sheets must be supported on
their pallets
it is not allowed to store sheets directly on ground
take care of ventilation and removal of water caused by rain, longer storage requires a storage
room
it is not allowed to store more than 1 pallets on the top of another pallet, note that the transport
pallets are exactly on the top of each other
no heavy objects or items causing local loading may be stored on the top of the sheets
handling of sheets must not cause permanent deformations to the sheets
check the overall condition of composite sheet packages

2. ERECTION

2.1 Propping

Erection of propping devices must be done before installing sheets. Propping span lengths must
be presented in constructional details. In addition to that final propping plan is a part of erection
plan made by the contractor. This plan is to be approved by the constructor before erection.

If marks in the lower surface of composite sheet is allowed, then prop spacing is presented in
Detail 2.1-2 and in Figures 2.2-2...5. If visible marks are to be avoided, then recommended
maximum bearing distances: 1.2 m 0.9 mm sheet and 1.5 m 1.1 mm sheet.

Propping must be erected carefully in order to avoid damage to the visible surface. In this case, it
is recommended to use minimum propping width of 125 mm and at least 50 mm if some visible
damages are allowed. If necessary the prop surface can be extended, e.g. using a plywood bank,

Copyright 2006 Rautaruukki Oyj

which reduces prop marks considerably, see Detail 2.1-2. Also the edges of composite sheets
must be propped.

The support provided by the propping must be continuous (e.g. horizontal beam). Pre-raising of
composite slab can be achieved by installing sheets on raised propping. Naturally the whole
propping structure must be stable, no movements are allowed during casting of concrete. It is
very important to ensure that there is no vertical movement in the propping due to shifting of sub-
structures. Propping must be braced in order to avoid lateral displacements.

Propping can be removed then 60 % of the designed strength of concrete is reached, unless
there is other kind of demands presented in constructional design specification for that site.

2.2 Preparing

Propping installation must be finished before it is allowed to use composite sheets as a working
platform.

If there is water, snow or ice on the sheets, the surface is slippery. It is recommended to set your
feet on two ribs then you are walking on the composite sheet platform.

Safety regulations must be taken into account: safety rails must be installed in order to prevent
falling from the platform and all holes must be covered. These facts should be described in sites
safety manual and erection plan.

Sheets should be lifted with care in order to avoid scratches in visible surfaces. Any impacts of
dropping tools or etc may cause permanent visible drawback.

If it is forced to store heavy items on a composite sheet platform, it should be done as follows: put
support beams transverse to the forming direction on the top of the ribs, make sure that these
support beams locate exactly at the same line as the propping beams. However heavy or local
loads should be avoided.

2.3 Constructional details

Composite sheets are installed with narrow profiling up by interlacing the sheets for a width of
one rib. Each sheet can be installed by hand.

Support width
Minimum support width is 50 mm. All sheets are fixed to the support at the bottom of every other
rib. Composite sheets may not be fastened to the propping because the inserts remain visible
after dismounting the propping.

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Protective lining
Free edge of the sheet is sealed up by using protective lining: lining profile, L-profile or taping in
order to stop concrete from running down (Detail 2.3-1).

Edge profile
It is possible to supply edge profiles with the sheet supply (U- or L-profile).Edge profiles can be
attached to the steel beams at works (Detail 2.3-2). Edge profiles are fixed to the composite
sheets c/c 500 mm. It is possible to use other materials for edge profiles.

Openings
Openings should be boxed out prior to the pouring of the concrete
larger openings than 300 x 300 mm require special reinforcement and support on every edges
timber shutter or dense polystyrene block can be used in order to delimit the area, after
concrete has hardened enough sheet is cut off.

Fixings
Composite sheets are fixed to permanent supports either with nails or screws with a span
determined in the structure design. Composite sheets must also be fixed on the interlaced edge,
either using hidden rivets or screws with a maximum spacing of 500 mm.

Fixing information is presented in Table 2.3-1.

The pre-raising of a slab can be achieved by installing composite sheets on raised propping
which will result in the desired pre-raising of the slab. Also the pre-cambering of primary and/or
secondary beams should be taken into account in the planning of the propping.

Fixings.

To masonry or Spike D 03-4.8x25, minimum

to concrete distance from sheet edge 50
mm!
Upat-UDN nail-anchor 6/35

To steel SFS SD14 5,5 x32 / EJOT HS 38

or equilvalent
Nail Hilti ENP2-21-L15

To closures etc SFS SL range/EJOT SF25 or

equilvalent

Side laps SFS SL range/EJOT SF25 or

equilvalent
Rivet 4,8x8

Table 2.3-1 Fixing types

Copyright 2006 Rautaruukki Oyj

Reinforcement

Transversal reinforcement of the lower part of the slab is installed directly on the top of the ribs. In
this way it is easier to install main (longitudal) reinforcement, see Detail 2.3-3. Transversal
reinforcement covers sheets and makes it easier to move on platform. Note that the location
(height) of the transversal reinforcement is determined in constructional drawings.

Upper reinforcement has to be supported by plastic spacers, Z-strip or spacing elements, see
Detail 2.3-4. This supporting has to be done in such manner that it is possible walk on upper
reinforcement.

3. CASTING CONCRETE

3.1 Demands for concrete

The cube strength of the concrete used must be at least 25 MN/m2. If concrete is about to be
covered then the cube strength of the concrete should be at least 30 MN/m2. Normally concrete
should dry as fast as possible therefore concrete should have as small water/cement ratio as
possible and use of agents is recommendable. It is possible to use normal weight concrete or
light weight concrete in composite slabs.

The granular size D of the concrete must meet the requirements D < hc, D < 32 mm. The effect of
concrete type on the drying of the concrete is presented in Figures 3.1-1...5.

There are many agents which have effect on the properties of concrete. The most important
property of concrete (in addition to strength) is its ability to dry after casting. Water-cement ratio
should be set to a value of 0.5 and the amount of air in the concrete should be near 7 to 8 %.
Agents increasing the workability of concrete should be used in order to make the pumping
easier.

3.2 Casting

Prior to casting composite sheets should be cleaned and the slots between the sheets and
between the structures next to them are sealed with structures suitable for this purpose. In
addition to that following matters should be taken into account

compare propping and support widths to the plan

check reinforcement: amount and location
check sealing

Concrete can be pumped or moved in more traditional manner.

Copyright 2006 Rautaruukki Oyj

The casting is done spreading the concrete in even layers. Maximum thickness of the layer is the
slab height. The spreading of the concrete must be started from the sheet ends, moving on to the
middle of the sheet span. The drop height of the concrete onto the composite sheets must be
minimized, and concrete can not be heaped on the slab locally.

Concrete can be consolidated using any ordinary consolidation methods and it is covered by
plastic or after-treatment substance. Any work joints should locate near at one third of the span.
Joint mesh should be used in work joints, see 2.3-14.

After casting it should be checked that

all concrete leaks are removed as soon as possible

3.3 Drying of concrete

Composite slab must be dry enough before any covering can be installed. Circumstances,
concrete type, slab height define the time which is needed for drying. All drying will happen
upwards due to the fact that water can not penetrate tight sheeting.

After concrete has hardened it is not allowed to douse it because drying time is long. Relative
humidity should be measured from slab, and this measured value should be compared to the
allowed relative humidity of the selected covering material. Informative allowed relative humidity
is given in Table 3.3-1.

Covering Relative humidity in

composite slab
Vinyl 85-90%
Linoleum 85%
Parquet 80%
Table 3.3-1

The properties of the concrete, vapour resistance of the top layers (filler and glue) and the
covering itself define how humidity distributes over the structure. It is very important to use fast
drying concretes, e.g. NP K30 (C25/30) contains large amount of cement and they dry about 2-3
times fasters than ordinary concretes. Another major point is after-treatment of concrete. It is
recommended to use plastic cover or after-treatment substance (plastic cover is preferred). After-
treatment should be started right after casting of concrete in order to avoid plastic cracks in the
concrete. Fast drying of concrete increases these plastic cracks.

Copyright 2006 Rautaruukki Oyj

 4. FINISHING OF COMPOSITE SLAB

4.1 Openings

The openings should be boxed out before pouring of the concrete. Metal deck is cut after
concrete has reached 75 % of its design strength, see 4.1-1.

Openings with diameter < 150 mm can be drilled through the slab.

4.2 Removal of propping

After concrete has reached 60 % of its design strength propping can be removed unless there are
more strict demands presented in constructional design. It is possible to have effect on the time
needed: concrete type, temperature of the concrete, covering of the concrete, heating of the
concrete. The removal of propping has to be planned in erection plan.

There are examples of the hardening process of concrete in Figure 4.2-1. However actual values
should be checked from the supplier of concrete case by case.

4.3 Coatings

Steelcomp-composite decking can be painted: touch-up painting or repair painting of an old

colour coating . Cleaning agents and maintenance paints are presented in the following table.

Cleaning agents Paints Manufacturer

PELTIPESU PLASTON Teknos
KIRJO AQUA www.teknos-group.com
GALVEX
PANSSARIPESU REPCO Tikkurila
TEMAKEEP www.tikkurila.com
ROSTEX SUPER

Cleaning

Dirty or soiled places should be washed with a soft brush and water. High-pressure water (< 50
bar) can also be used for cleaning. More stubborn dirt or stains can be removed using a cleaning
agent suitable for paint coatings, which after leaving for a few minutes to take effect should then
be carefully washed off. Difficult dirt spots can be removed with cloth moistened in white spirit.
The use of strong or unsuitable cleaning agents will damage the colour coating.

Copyright 2006 Rautaruukki Oyj

Touch-up painting

Touch up painting of scratches while they are still fresh means that the area to be repaired is
usually small and the repair is quick and simple. Only paints suitable for maintenance painting of
colour coatings should be used. The damaged area should be cleaned with white spirit before
repainting. After drying, the area should be touch-up painted using as small brush as possible. If
the damage reaches down to the primer coat only, one coat of paint is sufficient. If, however, the
damage reaches down to the zinc coating, it is recommended that a second coat of paint is
applied after the first coat is dry. If the zinc coating is clearly damaged then products like Galvex
or Rostex Super should be used as a new primer. Spray-paints must not be used.

PVDF Plaston or Repco

Pural Repco or Plaston
Matt pural Repco or Plaston
Polyester Repco or Plaston
Matt polyester Repco or Plaston

Most common coating for Steelcomp is polyester (indoor thickness, white colour).

Coating Properties
Outdoors PVDF Excellent corrosion
protection and visual
stability

Matt polyester Good corrosion protection

and visual stability

PURAL Excellent corrosion

protection and good visual
stability

Indoors Polyester Good mechanical

properties

Table 4.3-1

Repair painting of an old colour coating

The life time of an undamaged original colour coating without repainting is on average 25 to 40
years, depending on the type of coating, building method and climatic conditions.

- check the adhesion of the coating

- remove any peeling or flaking coating
- remove any rust
- wash the surface using either Peltipesu or Panssaripesu
- rinse thoroughly

Copyright 2006 Rautaruukki Oyj

 - prime coat any areas from which peeling coating or rust has been removed, using either
Rostex Super or Galvex
- Paint 1-2 coats
o PVDF Plaston or Temakeep+Repco
o Pural Repco* or Plaston
o Matt polyester Repco* or Plaston
o Polyester Repco* or Plaston
o Plastisol Repco or Kirjo Aqua
* Temakeep primer is recommended if the surface is strongly faded

4.4 Service hanger systems

The dovetail shaped re-entrant rib allows quick and easy suspensions of ceiling and services
using threaded wedge nut fixings, (see Figure 4.1-1). The dovetail shaped wedge nuts will lock
into the dovetail re-entrants under vertical loading. The maximum allowed load is 1 kN and
minimum spacing is 200 mm. Heavier loads needs to be considered separately by constructor.

Copyright 2006 Rautaruukki Oyj

Appendices:

1. Figure 2.1-1/ Example drawing

2. Detail 2.1-2/ Propping
3. Table 1.2-1/ Sheet list
Table 1.2-2/ Package list
Figure 2.2-2/ Maximum spans
Figure 2.2-3/ Maximum spans
Figure 2.2-4/ Maximum spans
Figure 2.2-5/ Maximum spans
4. Detail 2.3-1/ Protective lining
5. Detail 2.3-2a/ Free edge of sheeting
6. Detail 2.3-2b/ Connection to the steel beam
7. Detail 2.3-3a/ Standard prefabricated reinforcement 1400 mm
8. Detail 2.3-3b/ Prefabricated reinforcement 1000 mm
9. Detail 2.3-3c/ Standard mesh reinforcement 1400 mm
10. Detail 2.3-3d/ Standard mesh reinforcement 1000 mm
11. Detail 2.3-4a/ Reinforcement at upper surface
12. Detail 2.3-4b/ Reinforcement at upper surface
13. Detail 2.3-5/ Connection to steel beam/mid-support
14. Detail 2.3-6/ Connection to steel beam/mid-support
15. Detail 2.3-7/ Connection to steel beam/end support
16. Detail 2.3-8a/ Connection to concrete/end support
17. Detail 2.3-8b/ Connection to concrete/end support
18. Detail 2.3-9/ Connection to concrete/mid-support
19. Detail 2.3-10/ Connection to ComBeam/internal support
20. Detail 2.3-11a/ Connection to punching shear component
21. Detail 2.3-11b/ Connection to punching shear component
22. Detail 2.3-12/ Connection of sheets
23. Detail 2.3-13/ Connection to masonry
24. Detail 2.3-14/ Work joint
25. Detail 4.1-1/ Openings and installations
26. Figure 3.1-1/ Drying of composite slab
Figure 3.1-2/ Drying of composite slab
Figure 3.1-3/ Effect of concrete to drying time
Figure 3.1-4/ Drying of composite slab
Figure 3.1-5/ Drying of composite slab
Figure 4.2-1/Development of strength in composite slab
27. Figure 3.1-6/ Humidity in composite and concrete slab

Copyright 2006 Rautaruukki Oyj

 STEELCOMP 1(3)
SITE MANUAL
Propping APPENDIX 3
Construction 2006-02-27

SHEET LIST
CONSTRUCTOR: STEELCOMP
SITE ID: LISTED BY:
RELATES TO DRAWING: PHONE
SHEET LIST NUMBER DATE:

ID t PCS Length LEV Grade Weight/pcs NOTE!

[mm] [mm] [mm] [kg]

PCS AREA WEIGHT

[m2] [kg]
TOTALLY

Table 1.2-1/Sheet list.

PACKING LIST
DESIGNER: STEELCOMP
SITE ID: LISTED BY:
RELATES TO DRAWING: PHONE:
SHEET LIST NUMBER DATE:

SHEET STACK SHEET STACK SHEET STACK SHEET STACK

ID PCS ID PCS ID PCS ID PCS

TOTALLY TOTALLY TOTALLY TOTALLY

Table 1.2-2/Package list.

Rautaruukki Oyj Suolakivenkatu 1 Phone +358 20 5911

POX 138 Faksi +358 20 592 9088
FIN-00811 Helsinki www.ruukki.com
FINLAND
 STEELCOMP 2(3)
SITE MANUAL
Propping APPENDIX 3
Construction 2006-02-27

Maximum span for 1-span decking,

deflection limit L/180 or 20mm
Propping may cause marks on sheets

3000
2900
2800
2700
2600 t=1.1mm
2500
2400
Span (mm)

t=0.9mm
2300
2200 t=0.7mm
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
100 120 140 160 180 200 220 240 260
Slab depth (mm)

Maximum span for 1-span decking,

no deflection limit
Propping may cause marks on sheets

3000 t=1.1mm
2900
2800 t=0.9mm
2700
2600 t=0.7mm
2500
Span (mm)

2400
2300
2200
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
100 120 140 160 180 200 220 240 260
Slab depth (mm)

Figures 2.2-2 and 2.2-3 Maximum spans.

Rautaruukki Oyj Suolakivenkatu 1 Phone +358 20 5911

POX 138 Faksi +358 20 592 9088
FIN-00811 Helsinki www.ruukki.com
FINLAND
 STEELCOMP 3(3)
SITE MANUAL
Propping APPENDIX 3
Construction 2006-02-27

Maximum span for 2-span continuous decking,

deflection limit L/180 or 20mm
Propping may cause marks on sheeting

3000
2900 t=1.1mm
2800 t=0.9mm
2700
2600 t=0.7mm
2500
2400
Span (mm)

2300
2200
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
100 120 140 160 180 200 220 240 260
Slab depth (mm)

Maximum span for 2-span continuous decking,

no deflection limit
Propping may cause marks on sheets

t=1.1mm
3000 t=0.9mm
2900 t=0.7mm
2800
2700
2600
2500
2400
Span (mm)

2300
2200
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
100 120 140 160 180 200 220 240 260
Slab depth (mm)

Figures 2.2-4 and 2.2-5 Maximum spans.

Rautaruukki Oyj Suolakivenkatu 1 Phone +358 20 5911

POX 138 Faksi +358 20 592 9088
FIN-00811 Helsinki www.ruukki.com
FINLAND
 STEELCOMP 1(4)
SITE MANUAL
Drying and strength Appendix 26
Construction 2006-02-27

Drying time for concrete with w/c=0,7 to 85% relative humidity

180
10C/80%
160 10C/35%
Drying time (week)

140 18C/60%
120 25C/35%
100
80
60
40
20
0
10 15 20
Slab depth (one drying direction) (cm)

Figure 3.1-1 Drying of composite slab

Drying time for concrete with w/c=0,4 to 85 % relative humidity

30
10C/80%
25 10C/35%
Drying time (week)

18C/60%
20 25C/35%

15

10

0
10 15 20
Drying time (one drying direction) (cm)

Figure 3.1-2 Drying of composite slab

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POX 138 Fax +358 20 592 9088
FI-00811 Helsinki www.ruukki.com
Finland
 STEELCOMP 2(4)
SITE MANUAL
Drying and strength Appendix 26
Construction 2006-02-27

The effect of concrete to drying time

Time (month) then RH=90%

20
Composite slab 250mm
15
Concrete slab 250mm

10

0
w/c=0.4 w/c=0.4 w/c=0.8

Figure 3.1-3 Effect of concrete to drying time.

SteelComp-composite slab 140 mm, RH=45%, T=20C

Cube strength 70
100 (w/c=0,38)
laboratory
Plastisicer.C25/30(w
/c=0,53), air 10%),
95 laboratory
C25/30 (w/c=0,80)
laboratory
RH in slab %

90

85

80

75
1 3 5 7 9 11 13 15
Time (week)

Figure 3.1-4 Drying of composite slab.

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POX 138 Fax +358 20 592 9088
FI-00811 Helsinki www.ruukki.com
Finland
 STEELCOMP 3(4)
SITE MANUAL
Drying and strength Appendix 26
Construction 2006-02-27

Drying of 120mm composite slab to 90% RH, if RH40% in air and

temperature above and below slab varies. Concrete C25/30

200

180
Drying time (days)
160

140
Drying time (days)

120

100

80

60

40

20

0
b10C/a10C b10C/a20C b20C/a10C b20C/a20C b30C/a10C

Temperature above and below slab

Figure 3.1-5 Drying of composite slab.

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POX 138 Fax +358 20 592 9088
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Finland
 STEELCOMP 4(4)
SITE MANUAL
Drying and strength Appendix 26
Construction 2006-02-27

Development of strength for 200mm composite slab with

normal concrete and with fast drying concrete.
No covering after casting, mild wind (3m/s)

35

30

25
Compressive strength (MN/m 2)

80% of design strength

(cube strength 24
2
20 MN/m )

60% of design strength

15 (cube strength 18
2
MN/m )

10

C25/30, air temperature +20oC

NP C25/30, air temperature +20oC
5
C25/30, air temperature +5oC
NP C25/30, air temperature +5oC

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
Time(days)

Figure 4.2-1 Development of strength in composite slab.

Rautaruukki Oyj Suolakivenkatu 1 Phone +358 20 5911

POX 138 Fax +358 20 592 9088
FI-00811 Helsinki www.ruukki.com
Finland