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BRE CERTIFICATION LIMITED

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CERTIFICATE NUMBER 152/09

ISSUED: NOVEMBER 2009
(Change of address January 2011)

CERTIFICATE OF ASSESSMENT
PRODUCT
Cobiax Concrete Flooring System

SUPPLIED BY
Hanson Building Products Ltd
Birchwood Way
Cotes Park Industrial Estate
Somercotes
Derbyshire
DE55 4NH
Tel:
Fax:
Email:
Web:

01773 602 432

01773 603 134
uksales@hanson.biz
www.hanson.co.uk

SUMMARY
Cobiax Concrete Flooring System (Cobiax System) is used for the construction of voided
suspended concrete floor slabs in buildings. The system (see Figure 1) comprises a steel
reinforced pre-cast concrete biscuit with a steel wire cage containing plastic balls cast into its
upper surface. Additional steel reinforcement is site fixed to the top of the cages and
concrete poured in-situ. The plastic balls are maintained in position by the cage and form
voids in the poured concrete. The voids formed by the Cobiax System reduce the volume of
concrete from that required for a solid slab of the same thickness, thus saving both weight
and materials.
The product is used to produce a range of sizes and thicknesses of slab designed in
accordance with BS 8110-1:1997 Structural use of concrete. Code of practice for design and
construction.
The characteristics of the product and its method of application have been reviewed with
respect to the current Building Regulations, British and European Standards and other
publications in the United Kingdom and Republic of Ireland in October 2009.
The assessment is described in the following pages which form integral parts of this certificate
and which should be read in its entirety.
CONDITIONS OF USE
0.1

A structural engineer competent in the design of reinforced concrete structures shall

undertake the design, and oversight of, the installation of the floor and its temporary
and permanent supporting structures.

0.2

Design dead and imposed loads shall be determined using BS 6399: Part 1 Loading
for buildings. Code of practice for dead and imposed loads

0.3

Floor slabs shall be individually designed for each application as two-way spanning
reinforced concrete slabs in accordance with the requirements of BS 8110-1.

0.4

The performance of the system depends on correct installation. Cobiax System shall
be installed strictly in accordance with the certificate holders installation instructions
and the requirements of this certificate. The quality of installation achieved on site is
not covered by this certificate. It is therefore recommended that the quality of
installation and workmanship is subject to appropriate checks by a competent person
for each installation.

STATEMENT
Cobiax Concrete Flooring System is
satisfactory for use within the stated
conditions provided that it is used in
accordance with the certificate
holder's
instructions
and
the
requirements of this certificate.

CONFIRMATION
For and on behalf of BRE Certification

Director
Date: 29 March 2011

1.

TECHNICAL SPECIFICATION

1.1

Description of product and method of application

1.1.1

Cobiax System is used for the construction of voided suspended concrete floor slabs
in buildings. The system comprises a steel reinforced pre-cast concrete biscuit with a
steel wire cage containing plastic balls cast into its upper surface.
Steel
reinforcement cast into the biscuits is a combination of high yield steel reinforcing
bars and welded triangular lattice sections which provide a shear key between the
pre-cast and the in-situ concrete. Additional steel reinforcement is site fixed to the top
of the steel wire cages prior to placing concrete.
Table 1 Product dimensions

Maximum ball diameter

Minimum ball diameter
Thickness of pre-cast concrete
biscuit

450mm
180mm
50 to 70mm

1.1.2

The product is used to produce a range of sizes and thicknesses of slab designed in
accordance with BS 8110-1:1997 Structural use of concrete. Code of practice for
design and construction. At the manufacturing plant a steel cage incorporating the
plastic balls is cast into a concrete biscuit dimensioned and reinforced in accordance
with structural design for each application.

1.1.3

The pre-cast units are transported to site, lifted into position and provided with
temporary support while top reinforcement and site placed concrete are added to
complete the floor structure.

1.1.4

A structural engineer competent in the design of reinforced concrete structures shall

undertake the design, and oversight of the installation, of the floor and its temporary
and permanent supporting structures.

1.2

Product components

1.2.1

Steel wire cage incorporating plastic balls

Steel wire cages are manufactured from steel wire complying with the requirements
of BS 4449:2005+A2:2009 Steel for the reinforcement of concrete. Weldable

reinforcing steel. Bar, coil and decoiled product. Specification. Void formers used are
High Density Polyethylene (HDPE) balls of a diameter to suit the structural design
requirements.
1.2.2

Pre-cast concrete biscuits

Pre-cast concrete biscuits are manufactured by the certificate holder in accordance
with the requirements of BS 8110-1 and BS 8500-1:2006 Concrete. Complementary
British Standard to BS EN 206-1. Method of specifying and guidance for the specifier,
and BS 8500-2:2006 Concrete. Complementary British Standard to BS EN 206-1.
Specification for constituent materials and concrete, at a plant holding QSRMC ISO
9001 Certification (Plant Registered number 01509 Hanson Premix).

1.2.3

Reinforcement in pre-cast concrete biscuits

Reinforcement is high tensile steel bars to BS 4449: 2005 or BS 4482: 2005 Steel
wire for the reinforcement of concrete products. Steel reinforcement is supplied by a
UK Certification Authority for Reinforcing Steels (CARES) accredited supplier. Lattice
reinforcement is third party certificated. Intersig Type 1 as Komo certificate K7342/03.

1.3

Reinforcement and concrete placed in situ (outside the scope of this certificate)
Steel reinforcement shall be supplied in the UK by a CARES accredited supplier and
in Ireland by a National Standards Authority of Ireland registered supplier. Concrete
shall be supplied by a plant holding QSMRC ISO 9001 or BSI Kitemark certification.

PRODUCT PERFORMANCE

2.1

Cobiax System provides a satisfactory means of construction of voided suspended

concrete floor slabs in buildings. Where suitably weather protected the system can
be used to provide flat roofs. Weather protection to roofs is outside the scope of this
certificate.

2.2

Cobiax System floors can be installed in new buildings and may be suitable for
alterations to existing buildings. In all cases the structural design for the building shall
be co-ordinated with the design of the Cobiax System slab.

2.3

Fire resistance of floors shall be determined by reference to the relevant clauses of

BS 8110-1. Clause 3.3.6 and Table 3.4 provide design guidance.

2.4

Cobiax used in accordance with the requirements of this certificate, is considered to

be as durable as traditional reinforced concrete construction in buildings. Project
specific requirements can be met by reference to the relevant clauses of BS 8110-1.
Clauses 3.3.3, 3.3.4, and 3.3.5 provide design guidance.

3.

BUILDING REGULATIONS

3.1

Cobiax System, when used in accordance with this certificate and the certificate
holders installation instructions, can assist in demonstrating that the works within
which the floor or roof slab is installed will meet the stated Requirements of the
following building regulations and standards.

3.2

Building Regulations
The Building Regulations (England & Wales) 2000 (as amended)
AD A Structure
AD B Fire Safety Volume 1 Dwelling Houses
AD B Fire Safety Volume 2 Buildings other than Dwelling Houses

Regulation 7 Materials & Workmanship

The Building (Scotland) Regulations 2004
Regulation 8 Fitness and durability of materials and workmanship.
Regulation 9:
Section 1 Structure
Section 2 Fire
The Building Regulations (Northern Ireland) 2000
Part B Materials & Workmanship
Part D Structure
Part E Fire safety
The Building Regulations Ireland 2007
Part A Structure
Part B Fire safety
Part D Materials and workmanship
3.3

CDM Regulations
The Building Construction (Design and Management) Regulations 2007
Construction (Design and Management) Regulations (Northern Ireland) 1995 (as
amended)
The certificate should form part of the information used by the client, planning
supervisor, designer and contractors to discharge their responsibilities under these
regulations.

4.

INSTALLATION

4.1

General
The performance of the Cobiax System depends on correct delivery, storage and
handling in accordance with the certificate holders installation instructions. The
quality of installation actually achieved on specific sites is not covered by this
certificate. Therefore it is recommended that the quality of installation and
workmanship is subject to appropriate checks by a competent person for each
installation.

4.2

The pre-cast units are transported to site, lifted into position and provided with
temporary support while reinforcement and in-situ concrete are added to complete
the floor structure. A structural engineer competent in the design of reinforced
concrete structures shall undertake the design, and oversight of the installation, of the
floor and its temporary and permanent supporting structures.

4.3

Installation shall be carried out only by installers trained, approved and monitored by
the certificate holder taking into account all relevant health and safety implications.

5.

TECHNICAL INVESTIGATIONS

5.1

Examination of a design submitted by the certificate holder for a project confirmed

that it satisfactorily dealt with the design requirements related to the use of the Cobiax
Concrete Flooring System for the construction of voided suspended concrete floor
slabs in buildings. Assessment has been made of the product design, with reference
to its application and practicality of installation which was found to be suitably
addressed by the manufacturers installation instructions.

5.2

Quality Control
Traceable quality records are maintained by the manufacturer. The manufacturer
carries out checks at regular intervals to ensure the quality of the product is
maintained within the defined product specification. BRE Certification undertakes
regular monitoring of the factory production audits on the manufacture of the product
against an agreed Quality Plan for the product.

5.3

Standards
The following standards have been referred to for this assessment:

BS 4449:2005+A2:2009
BS 4482: 2005
BS 6399-1:1996
BS 8110-1-1997
BS 8500-1:2006

BS 8500-2:2006
BS EN 13369:2004+A1 :
2006
BS EN 10080:2005

Steel for the reinforcement of concrete. Weldable

reinforcing steel. Bar, coil and decoiled product.
Specification
Steel wire for the reinforcement of concrete products
Loading for buildings. Code of practice for dead and
imposed loads
Structural use of concrete. Code of practice for
design and construction.
Concrete. Complementary British Standard to BS EN
206-1. Method of specifying and guidance for the
specifier
Concrete. Complementary British Standard to BS EN
206-1. Specification for constituent materials and
concrete
Common rules for precast concrete products.
Steel for the reinforcement of concrete Weldable
reinforcing steel General

6.

CONDITIONS OF CERTIFICATE ISSUE

6.1

Validity
This certificate will be valid for a period of three years from the date of issue. It will
remain valid in so far as:
a.
b.
c.

6.2

The materials and method of manufacture are unchanged or BRE

Certification has assessed any changes and found them to be satisfactory.
The designs and specifications are unaltered from those examined by BRE
Certification.
The certificate holder continues to have the product checked by BRE
Certification through factory production control procedures.

Health and Safety

This certificate and the recommendations herein do not purport in any way to restate
the requirements of the Health and Safety at Work Act 1974 or any statutory or
common law duty of care which exists now or in the future: nor is compliance with
these recommendations to be assumed as satisfying the requirements of the said Act
or any existing or future statutory or common law duty of care.

6.3

Reference to Other Documentation

Where reference is made in this certificate to any Act of Parliament, Regulation, Code
of Practice, British or other Standard or other publications, it shall be construed as
reference to such publication in the form in which it is in force at the date of issue of
the certificate.

6.4

Patents
BRE Certification makes no representational warranty that any patent or similar
industrial property right is valid or that the manufacture, use, sale, lease or any other
dealing or disposition of the product in whole or in part is not an infringement of any
patent or industrial property right not owned by the certificate holder.

Figure 1 Cobiax composite voided floor

Top
mesh

Insitu concrete

Lattice

Ball
cage

Precast
concrete

Bottom
reinforcement

Confirmation that a certificate is current may be obtained from the BRE Certification website
(www.redbooklive.com)
Copyright BRE Global 2009