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 Introduction
ρc= 2000 kg/m3 (lightweight) and
ρc= 2400 kg/m3 (normal density)
See Table 1.1 for strengths.
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
D 32 32
hr = 54 29
52
51
Required
cover
Concrete
Concrete
Edge
Drip lip Form
SQ UARE
Bondek
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 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
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.
2.4.4
LOAD
CONCENTRATED VERTICAL LIVE
(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 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
=
(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.
3.3 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,
3.4 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
3.5.3 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
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
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
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
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.
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
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.
+
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
(
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 ⎪⎭
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⎭
L
zmin =
2
26 FIRE DESIGN
A—st Ast—
— Muo— — Muo—
Envelope MuoT— Envelope
MuoT—
0 0
wf wf
wf wf
— —
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
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
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.
5.3 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)
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
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
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).
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
External corner
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.
Fastening positions
Hoop iron
Hoop iron
Bondek
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
Top-face reinforcement
Zone for pipes laid across the ribs
Bottom-face reinforcement (between top and bottom reinforcement)
Concrete
Bondek
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
Ln
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
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
5.4.3 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.
5.5.3 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
Transverse construction joint Construction joints transverse to the span of the BONDEK sheeting are
normally located where shear forces are a minimum (such as the mid-
Form boards sandwiching third of a slab span) and ideally over a line of propping. Locate
continuous reinforcement.
Concrete 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
BONDEK
be prepared to receive the new concrete, and the preparation
Longitudinal construction joint method will depend upon the age and condition of the old concrete.
Figure 5.13 Generally, thorough cleaning is required to remove loose material, to
Typical construction joints 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
5.6 FINISHING
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.
5.7.1 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
5.8 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
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.
Design parameters
Exposure classification: A1
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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