1. Introduction
1.1Concrete Floor Systems
Reinforced concrete slabs are components commonly used in floors, ceilings, garages,
and outdoor wearing surfaces. There are several types of concrete floor systems in use today,
and are shown in Figure 1-1:
Two-way flat plate (biaxial slab) - There are no beams supporting the floor between the
columns. Instead, the slab is heavily reinforced with steel in both directions and
connected to the columns in order to transfer the loads.
Two-way flat slab with drop panels- This system differs from the two-way flat plate
system by the drop panel used to provide extra thickness around the columns. This
strengthens the column to floor connection in consideration of punching shear.
One-way beam and slab- This is the most typical floor system used in construction.
The slab loads are transferred to the beams, which are then transferred to the columns.
One-way joist slab- The joists act like small beams to support the slab. This floor system
is economical since the formwork is readily available and less reinforcement is required.
One-way wide module joist slab- This system is a variation on the one-way joist slab with
wider spaces between the joists.
Two-way joist slab (waffle slab) - This floor system is the stiffest and has the least
deflection of those mentioned since the joists run in two directions (Concrete Reinforcing
Steel Institute)
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Figure 1-1: Types of Reinforced Concrete Floor Systems (Concrete Reinforcing Steel Institute)
Reinforced concrete has many advantages for floor systems- it provides resistance to
high compressive stresses and to bending stresses; it is relatively cheap to produce and
construct; and it can be molded into virtually any shape and size. Disadvantages include a
high weight-to strength ratio and difficulty in structural health monitoring (Reinforced
Cement Concrete Design).
1.2Hollow-Core Slabs
In the mid-20th Century, the voided or hollow core floor system was created to reduce
the high weight-to-strength ratio of typical concrete systems. This concept removes and/or
replaces concrete from the center of the slab, where it is less useful, with a lighter material in
order to decrease the dead weight of the concrete floor. However, these hollow cavities
significantly decrease the slabs resistance to shear and fire, thus reducing its structural
integrity.
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2. BUBBLE DECK
2.1Materials
BubbleDeck is composed of three main materials- steel, plastic spheres and concrete,
as see in Figure 2-1.
Steel- The steel reinforcement is of higher Grade. The steel is fabricated in two formsmeshed layers for lateral support and diagonal girders for vertical support of the bubbles.
Plastic spheres- The hollow spheres are made from recycled high-density polyethylene or
HDPE.
Concrete- The concrete is made of standard Portland cement with a maximum aggregate
size of 3/4 in. No plasticizers are necessary for the concrete mixture. (BubbleDeck
International).
2.2Schematic Design
BubbleDeck is intended to be a flat, two-way spanning slab supported directly by
columns. The design of this system is generally regulated by the allowed maximum
deflection during service loading. The dimensions are controlled by the span (L) to effective
depth (d) ratio (L/d) as stated by BS8 110 or EC2. This criterion can be modified by applying
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In addition, larger spans can be achieved with the use of post tensioning as the L/d
ratio can be increased up to 30%. (BubbleDeck-UK)
L/d < 30 for simply supported, single spans
L/d < 41 for continuously supported, multiple spans
L/d < 10.5 for cantilevers
There are five standard thicknesses for BubbleDeck, which vary from 230 mm to 450
mm, and up to 510 mm and 600 mm for specific designs pending KOMO certification. The
varieties of BubbleDeck can be found in Table 2-1.
Table 3-1: Versions of BubbleDeck* (The Biaxial Hollow deck- The way to new solutions)
2.3Types of BubbleDeck
All of the BubbleDeck versions come in three forms- filigree elements, reinforcement
modules, and finished planks. They are depicted in Figure 2-2. For all types of BubbleDeck,
the maximum element size for transportation reasons is 3 m. Once the sections are connected
on site however, there is no difference in the capacity.
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2.3.1
60 mm thick concrete layer that acts as both the formwork and part of the finished depth is
precast and brought on site with the bubbles and steel reinforcement unattached. The bubbles
are then supported by temporary stands on top of the precast layer and held in place by a
honeycomb of interconnected steel mesh. Additional steel may be inserted according to the
reinforcement requirements of the design. The full depth of the slab is reached by common
concreting techniques and finished as necessary. This type of BubbleDeck is optimal for new
construction projects where the designer can determine the bubble positions and steel mesh
layout.
2.3.2
sandwich of steel mesh and plastic bubbles, or "bubble lattice". These components are
brought to the site, laid on traditional formwork, connected with any additional
reinforcement, and then concreted in place by traditional methods. This category of
BubbleDeck is optimal for construction areas with tight spaces since these modules can be
stacked on top of one another for storage until needed
2.3.3
reinforcement mesh and concrete in its finished form. The module is manufactured to the
final depth in the form of a plank and is delivered on site. Unlike Type A and B, it is a oneway spanning design that requires the use of support beams or load bearing walls. This class
of BubbleDeck is best for shorter spans and limited construction schedules (BubbleDeck*UK).
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2.4Advantages of BubbleDeck
2.4.1
than normal solid slabs. The bubbles replace the non-effective concrete in the center of the
section, thus reducing the dead load of the structure by removing unused, heavy material.
Decreased concrete material and weight also leads to less structural steel since the
need for reinforcement diminishes. The building foundations can be designed for smaller
dead loads as well. Overall, due to the lighter floor slabs, the several downstream components
can be engineered for lower loads and thus save additional material (Wrap).
2.4.2
Structural Properties
Due to the lower dead weight of the slab and its two-way spanning action, load-
bearing walls become unnecessary. BubbleDeck is also designed as a flat slab, which
eliminates the need for support beams and girder members. As a result, these features
decrease some of the structural requirements for the columns and foundations.
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2.4.3
Type A includes a 60 mm precast concrete plate as the base and formwork for the slab. This
type of slab would eliminate the need for on site erection of formwork, thus significantly
cutting down construction time. Similar to modem precast concrete flooring modules,
BubbleDeck can be fully shop fabricated and transported on site for installation as well.
Time savings can also be achieved through the faster erection of walls, columns and
MEPs due to the lack of support beams and load bearing walls for this innovative flat slab.
Addition time may be saved from the quicker curing time since there is less concrete in the
slab.
2.4.4
Cost Savings
In relation to the savings in material and time, cost reductions are also typical with the
BubbleDeck system. The decreased weight and materials mean lower transportation costs,
and would by more economical to lift the components. With less on-site construction from
the full and semi-precast modules, labor costs will decrease as well. In addition, money can
be saved downstream in the design and construction of the building frame elements (columns
and walls) for lower loads.
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Green Design
The number of owners, designers and engineers who desire green alternatives is
growing exponentially. BubbleDeck is a fitting solution for lowering the embodied carbon in
new buildings. According to the BubbleDeck Company, 1 kg of recycled plastic replaces 100
kg of concrete. By using less concrete, designers can save up to 40% on embodied carbon in
the slab, resulting in significant savings downstream in the design of other structural
members. Carbon emissions from transportation and equipment usage will also decrease with
the use of fewer materials. Additionally, the bubbles can be salvaged and reused for other
projects, or can be recycled.
Generally, for every 5,000 m2 of BubbleDeck floor slab, the owner can save:
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3.2Bending Strength:
Bubble Deck where compared to a solid decks both practically and theoretically. The
results showed that for the same deck thickness the bending strength is the same for
BubbleDeck and for a solid deck and that the stiffness of the Bubble Deck is slightly lower.
3.4Sound
A comparison was made between Bubble Deck and one-way prefabricated hollow
deck of similar height. The noise reduction with Bubble Deck was 1 db higher than the one
way prefabricated hollow deck. The main criterion for reducing noise is the weight of the
deck and therefore Bubble Deck will not act otherwise than other deck types with equal
weight.
The Bubble Deck construction is following every usual criteria, and can be calculated
according to usual principles. The construction is not deviating, in any way, from what is
already known and used. The construction is analogous to an equivalent solid deck.
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3.5Deflection:
Due to the bubbles a Bubble Deck slab is not as stiff as a solid slab but this effect is
small. Studies and tests have shown that Bubble Deck has approximately 87% of the flexural
stiffness of a solid slab. If no other measures were taken, this would mean marginally higher
deflections at SLS than in an equivalent solid slab in direct proportion to this ratio. However,
the effect can be compensated for by adding a modest amount of steel even though the
deflection is significantly mitigated by the fact that Bubble Deck is lighter and in long term
SLS, where frequently the load combination comprises 100% permanent load and a
proportion such as 33% imposed load, the permanent weight saving maximizes Bubble
Decks effect. Long term SLS is frequently the governing criteria for flat slab designs.
3.6Durability
The durability of Bubble Deck slabs is not fundamentally different from ordinary
solid slabs. The concrete is standard structural grade concrete and; combined with adequate
bar cover determined in accordance with EC2 or BS8110; is what provides most control of
durability commensurate with normal standards for solid slabs. When the filigree slabs are
manufactured, the reinforcement module and balls are vibrated into the concrete and the
standard and uniformity of compaction is such that a density of surface concrete is produced
which is at least as impermeable and durable, arguably more so, to that normally produced on
site.
Bubble Deck joints have a chamfer on the inside to ensure that concrete surrounds
each bar and does not allow a direct route to air from the rebar surface. This is primarily a
function of the fire resistance but is also relevant to durability.
Cracking in Bubble Deck slabs is not worse, and probably better, than solid slabs
designed to work at the same stress levels. In fact Bubble Deck possesses a continuous mesh,
top and bottom, throughout the slab and this ensures shrinkage restraint is well provided for
and that cracking is kept to a minimum whether it is intrinsic or extrinsic cracking.
3.7Seismic Design:
This is a specialist area outside the scope of this brief technical note. However, the
concerns in Seismic design are largely similar to any flat slab structure. Punching shear under
seismic conditions is the most critical issue and damage at the slab-column junction during
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Lifting and Placing Filigree Elements: The filigree elements must ONLY be lifted by the
lattice beam girder reinforcement. Lifting hooks must ALWAYS be attached under the upper
angles of the girder reinforcement diagonal web bars. Lifting hooks must NEVER be attached
to the upper reinforcement mesh as this would be unsafe.
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5.2Car park
Car park built with BubbleDeck in Frankfurt Germany in 2001. BubbleDeck was
chosen to reduce the weight of the decks and to get wider spans.
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6. CONCLUSION
Bubble Deck will distribute the forces in a better way than any other hollow floor
structures.
Because of the three-dimensional structure and the gentle graduated force flow the
hollow areas will have no negative influence and cause no loss of strength.
Bubble Deck behaves like a spatial structure - as the only known hollow concrete
floor structure. The tests reveal that the shear strength is even higher than presupposed. This
indicates a positive influence of the balls.
Furthermore, the practical experience shows a positive effect in the process of
concreting the balls cause an effect similar to plasticizer additives.
All tests, statements and engineering experience confirm the fact that BubbleDeck in
any way acts as a solid deck and therefore will follow the same rules/regulations as a solid
deck (with reduced mass), and further,leads to considerable savings.
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7. BIBLIOGRAPHY
1. www.BubbleDeck.com
2. Magazine Corner Stone, Page No:30 & 31, autumn 2004 edition.
3. www.bubbleDeck-UK.com
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