Super Holorib

Technical Manual
SUPER HOLORIB SUPER HOLORIB is an advanced composite floor slab profile now available and manufactured in Malaysia. Formed from hot dipped zinc plated thin gauge steel sheet, the SUPER HOLORIB profile has been carefully designed to optimise performance when acting as permanent shuttering to support wet concrete slabs. The profile design, with its repetition module of 152.5 mm allows thinner gauges of SUPER HOLORIB to be specified than with wider spaced ribs on similar profiles. SUPER HOLORIB is not only a convenient shuttering system as it also bonds with the concrete, both chemically and mechanically, to act as all or part of the structural reinforcement in the composite floor slab. This composite action is achieved without the need for any end anchorage in the form of shear studs due to the regularly spaced embossments along the top of the profile and its re-entrant shape which prevents vertical separation of the concrete from the steel. Extensive fire testing of the profile has been carried out in the UK to assist in the development of unified design rules. These tests were instrumental in the development of BS 5950:Part 8: 1990 which all fire designs now follow. Available in a range of gauges from 0.8 mm up to 1.2 mm, SUPER HOLORIB is the composite floor decking profile of choice for international design offices around the world. This Technical Manual is offered as an introduction to the design and use of SUPER HOLORIB for Engineers and Specifiers. Additional assistance is available from European Profiles Contracting Sdn Bhd at their Head Office in Rawang.

Super Holorib

Technical Manual
COMPOSITE FLOOR DECKING The full benefits of steel framed building design are realised when composite floor decking is used in unpropped construction. Using this construction method allows the contractor maximum flexibility in programming works and minimises the number of obstructions to following trades. It is therefore the construction stage, when the decking profile is supporting wet concrete and construction personnel, that dictates the choice of decking gauge for most design applications. Composite floor decking is fast to install and uses a minimum of labour. This can contribute towards overall economies on the total building cost, whilst reducing the risk of accidents associated with labour intensive operations. For high rise construction with unpropped decking consider the following sequence : 1) Deliver deck for Level 1 and load bundles on to the frame. This operation is most efficiently performed before beams for Level 2 are installed as they may obstruct the crane access. 2) Deliver deck for Level 2 and load bundles on to the frame. 3) Deliver deck for Level 3 and load bundles on to the frame. 4) Spread out the decking at Level 3 and secure in place. This will provide a protective layer for the workplace below, providing protection from falling objects as well as shelter from sun and rain. 5) Spread out the decking at Levels 1 & 2 whilst erecting steel and delivering deck bundles for Levels 4, 5 & 6. The decking at Level 3 allows these operations to proceed at the same time. 6) Repeat steps 4 & 5 for subsequent levels in 3 storey increments .

Super Holorib

Technical Manual
DESIGN When considering the use of a composite floor slab, reference can be made to the tables contained within this brochure or to the company's technical department for complimentary advice. Outlined below is a brief guide to the design considerations that are taken into account. Initial Sizing The SLAB DEPTH should be deep enough for the desired fire rating. The SPAN / DEPTH RATIO should not exceed 35:1 Construction Stage DEFLECTION is limited to span / 130 after the full effects of ponding are taken into account. For continuous sheets the NEGATIVE BENDING MOMENT is calculated and, if applicable, reduced to a residual level on formation of a plastic hinge. For both single and continuous sheets, the POSITIVE BENDING MOMENT is calculated and checked against the known sheet capacity. WEB BUCKLING is checked where the sheeting passes onto both end and intermediate supports. Combined effects of BENDING and BUCKLING are checked at intermediate supports. The bearing stresses have the effect of reducing the resistance of the sheet to applied loading when compared with a pure bending situation. Immediately adjacent to both end and intermediate supports, the WEB SHEAR capacity is checked. Composite Stage In the composite slab analysis, all slabs are considered as simply supported. DEFLECTION due to IMPOSED LIVE LOADS is limited to span / 350. DEFLECTION due to TOTAL IMPOSED LOADS is limited to span / 250. POSITIVE BENDING is checked against the capacity of the fully composite section. In addition, the effects of SHEAR BOND on the horizontal interface between concrete and decking must be analysed as the full moment capacity can seldom be mobilised. VERTICAL SHEAR through the concrete in the troughs of the composite slab is checked adjacent to the supports. Fire Limit State Where the slab passes over the top of intermediate beams, the load capacity of the slab is evaluated by comparison with fire test results using FIRE METHOD A. In all instances, the moment capacity required in the fire limit state is calculated and reinforcing bars detailed in accordance with FIRE METHOD B. Method B takes account of reduced materials properties as a result of elevated temperatures.

Super Holorib

Technical Manual
UNPROPPED CONSTRUCTION Maximum unpropped spans are achieved when the SUPER HOLORIB sheets are detailed to be continuous over two or more spans. This allows the negative bending resistance of the profile to be fully mobilised. Full scale testing of SUPER HOLORIB sheeting in a two span configuration at the British Steel Test Centre in South Wales has allowed the true resistance of the profile to be taken into consideration when preparing the safe span tables presented here. Where circumstances dictate that the sheeting be used in single span configurations, the maximum permissible spans will be reduced due to the greater flexibility during construction. The construction stage so dominates the design that the final composite slab is often capable of carrying far greater loads than required. In the following table it can be seen 2 that load carrying capacity in excess of 15 kN/m is common. Unpropped Construction Tables
Multiple Span Condition Deck Gauge Slab Depth 100 120 125 140 150 170 200 100 120 125 140 150 170 200 100 120 125 140 150 170 200 100 120 125 140 150 170 200 Shutter Only 3.12 2.96 2.92 2.81 2.74 2.62 2.47 3.35 3.18 3.15 3.04 2.98 2.87 2.73 3.50 3.35 3.31 3.20 3.14 3.02 2.88 3.50 3.66 3.62 3.50 3.43 3.31 3.15 Imposed Load (kN/m2) 7.5 3.12 2.96 2.92 2.81 2.74 2.62 2.47 3.35 3.18 3.15 3.04 2.98 2.87 2.73 3.50 3.35 3.31 3.20 3.14 3.02 2.88 3.50 3.66 3.62 3.50 3.43 3.31 3.15 10.0 3.03 2.96 2.92 2.81 2.74 2.62 2.47 3.24 3.18 3.15 3.04 2.98 2.87 2.73 3.33 3.35 3.31 3.20 3.14 3.02 2.88 3.41 3.66 3.62 3.50 3.43 3.31 3.15 15.0 2.40 2.69 2.77 2.81 2.74 2.62 2.47 2.56 2.89 2.98 3.04 2.98 2.87 2.73 2.74 3.12 3.21 3.20 3.14 3.02 2.88 2.98 3.50 3.62 3.50 3.43 3.31 3.15 Shutter Only 2.75 2.59 2.56 2.46 2.40 2.29 2.16 3.00 2.87 2.83 2.73 2.66 2.54 2.39 3.00 3.08 3.04 2.94 2.89 2.77 2.61 3.00 3.26 3.23 3.12 3.06 2.95 2.81 Single Span Condition Imposed Load (kN/m) 7.5 10.0 15.0 2.75 2.59 2.56 2.46 2.40 2.29 2.16 3.00 2.87 2.83 2.73 2.66 2.54 2.39 3.00 3.08 3.04 2.94 2.89 2.77 2.61 3.00 3.26 3.23 3.12 3.06 2.95 2.81 2.75 2.59 2.56 2.46 2.40 2.29 2.16 3.00 2.87 2.83 2.73 2.66 2.54 2.39 3.00 3.08 3.04 2.94 2.89 2.77 2.61 3.00 3.26 3.23 3.12 3.06 2.95 2.81 2.40 2.59 2.56 2.46 2.40 2.29 2.16 2.56 2.87 2.83 2.73 2.66 2.54 2.39 2.74 3.08 3.04 2.94 2.89 2.77 2.61 2.98 3.26 3.23 3.12 3.06 2.95 2.81

0.8

0.9

1.0

1.2

General notes on Construction tables 1. 2. 3. The spans indicated are from centre to centre of supports which are assumed to be of minimum width 100 mm. Concrete density is taken to be 2400 kg/m during construction, 2350 kg/m after curing. During construction, a live load allowance of 1.5 kN/m has been included to account for construction personnel and lightweight equipment.
2 3 3

Super Holorib

Technical Manual
PROPPED CONSTRUCTION W he re un pr op pe d co ns tr uc ti on is no t po ss ib le or so ff it de fl ec ti on s ar e to be min imis ed during construction, then temporary props may need to be considere d. It is recommended that temporary props be left in position until the concrete has reached at least 75% of its intended design strength. Early removal of props can be detrimental to the overall performance of the compositeslab as the vital shear bond between concreteand decking may be weakened due to deflection of the immature slab. This deflection can also cause cracking of the concrete where it passes over support beams. Prop removal will always allow deflection to take place and will lead to a slight dishing effect on the top surface of the slab. For this reason, it is recommended that some forms of finishes are applied to the slab after props are removed.
Propped Construction Tables

Single Line of Props Deck Gauge Slab Depth 100 120 125 140 150 170 200 100 120 125 140 150 170 200 100 120 125 140 150 170 200 100 120 125 140 150 170 200 Shutter Only Imposed Load (kN/m ) 7.5 10.0 15.0
2

0.8

3.00 3.60 3.75 4.20 4.50 5.10 5.02 3.00 3.60 3.75 4.20 4.50 5.10 5.42 3.00 3.60 3.75 4.20 4.50 5.10 5.71 3.00 3.60 3.75 4.20 4.50 5.10 6.00

3.00 3.60 3.75 4.20 4.50 5.10 5.02 3.00 3.60 3.75 4.20 4.50 5.10 5.42 3.00 3.60 3.75 4.20 4.50 5.10 5.71 3.00 3.60 3.75 4.20 4.50 5.10 6.00

3.00 3.49 3.59 3.88 4.07 4.42 4.90 3.00 3.60 3.75 4.20 4.41 4.81 5.35 3.00 3.60 3.75 4.20 4.50 5.10 5.71 3.00 3.60 3.75 4.20 4.50 5.10 6.00

2.41 2.71 2.79 3.01 3.16 3.44 3.84 2.57 2.92 3.01 3.26 3.43 3.75 4.19 2.75 3.15 3.25 3.54 3.73 4.10 4.61 2.98 3.50 3.63 4.02 4.29 4.81 5.35

0.9

1.0

1.2

4. In calculating deflections during construction, the effects of ponding are taken into 2 account in an iterative procedure. A temporary live load of 0.5 kN/m is included in deflection calculations to account for non recoverable deflections caused by the construction personnel. 5. Deflections are limited to span/130 in accordance with BS 5950:Part 4:1994. 6. A span to depth ratio limit of 35:1 is imposed. 7. Concrete is grade C30. 8. Composite slabs are designed as simply supported with nominal crack control fabric over the supports.

Super Holorib

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

Design principles Insulation To ensure temperatures on the top surface of the slab do not rise excessively due to fire below the soffit Integrity Com partme ntalisation. To ens ure that the sla b doe s not allow the pen etrati on of smoke and flames from one compartment to another. Stability To ensure that the structure remains standing without endangering the lives of people during the period of evacuation and firefighting.

Full scale fire test on SUPER HOLORIB floor slab at Warrington Fire Research Centre (UK)

Super Holorib

Technical Manual
Minimum Slab Depth To satisfy the insulati on requ irem ent without the need for any soff it prot ection, the total com posite slab dept h when using SUPER HOLORIB should not be less than the nom inal fig ure s given in the table bel ow. Two set s of fig ure s are given in the ta bl e, on e fo r ea ch of th e tw o de si gn me th od s de sc ri be d be lo w. W he n us in g Method A, note that the slab thickness is increased compared to Method B for a two hour fire rating. Method A has not been proven to be applicable beyond 2 Hours.

Minimum permissible Slab Depths (mm) for Fire Engineering Design is Fire Rating Period (Hrs) Overall Depth (mm) Method A Method B 1/2 Hr 100 100 1 Hr 100 100 1 /2 Hr 110 110
1

2 Hr 140 125

3 Hr

4 Hr

150

170

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

WRCSI 21809 WRCSI 23887 WRCSI 23927 Warres 35965 Warres 43405

4 hrs 1 1 /2 hrs 2 hrs 1 1 /2 hrs 2 hrs

125 mm slab with mineral fibre protection 130 mm slab , 12 mm bars @ 152 centres 155 mm slab , 16 mm bars @ 152 centres 120 mm LWC slab with A6 fabric only 150 mm LWC slab with A7 fabric only

Super Holorib

Technical Manual
Method A Th is is a simp lified me tho d appl icable on ly wh er e the fl oor sl ab has co ntinuity over intermediate beams . The slab contains no reinf orcem ent other than the stated fabric which doubl es as a crack contr ol mesh . Under fire conditions, the slab gains its strength from the fabric acting in tension over the supports. This method is cons iste nt with BS 5950 :Par t 8:19 90 and is supp orte d by full scale tests carried out at Warrin gton Fire Researc h Centre in the UK. It is applica ble to fire ratings up to 2 hours maximum. Method A
Fire rating for SUPER HOLORI B Slab achieved with top mesh only. No other reinforcement.

KLCC Convention Center

Sup er Hol ori b

Technical Manual

Table A Maximum permissible span for Fire Engin eering Method A designs
1 Hr Im posed Load kN/mm2 Slab Dept h mm A6 m A7 m A6 m 1-1/2Hr A7 m A7 m 2 Hr A8 m

100 120 125 5.0 140 150 170 200

2.78 3. 31 3.34 3.43 3.49

2.78 3.31 3.97 4.07 4.10 4.10 4.10

2.83 2.85 3.37 3.42

2.83 2.85 3.99 4.06 4.10 4.10 3.30 3.35 3.45 3.50 3.98 4.09 4.10

100 120 125 6.7 140 150 170 200

2.50 3.00 3.03 3.12 3.19

2.50 3.00 3.60 3.71 3.78 3.90 4.08

2.56 2.59 3.06 3.12

2.56 2.59 3.63 3.71 3.82 4.00 3.00 3.06 3.16 3.30 3.63 3.75 3.93

100 120 125 10.0 140 150 170 200

2.14 2.58 2.61 2.71 2.76

2.14 2.58 3.10 3.21 3.28 3.41 3.58

2.20 2.23 2.65 2.71

2.20 2.23 3.14 3.22 3.33 3.52 2.60 2.65 2.76 2.90 3.15 3.27 3.45

Notes to Table A The fabric sizes refer to the wir e diameter in millim eters. All 'A' type fabrics consis t of wires welded on a 200 x 200 square grid. The fabric should be positioned in the top of the slab with typically 25 mm of concrete cover above the wires over sup port beams. Draping of the mesh is permitted but is not compulsory. Lapping and end anchorage of the fabric should follow con ventional practice.

Su pe r Ho lo ri b

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

Method B
Fire rating for SUPER HOLORIB Slab achieved with top mesh plus reinforcing bars in every or alternate troughs.

Notes to table B Bar size/spacing combinations are arranged in ascending order of cross-sectional of steel provided. All reinforcement is assumed to consist of high yield deformed bars with a minimum yield 2 strength of 460 N/mm . Imposed loads include all live and dead loads other than slab self weight which can be ignored when reading the tables. Load factors are taken as 1.0 throughout.

Sup er Hol ori b

Technical Manual
Maximum permissible span for Fire Engin eering Method B designs
1 HOUR Imposed Load Slab Depth 100 120 125 140 150 170 200 100 120 125 140 150 170 200 100 120 125 140 150 170 200 Reinforcing Bars (Diameter / Spacing) 8 mm @ 305 2.05 2.33 2.39 2.55 2.65 2.82 3.03 1.84 2.11 2.17 2.33 2.42 2.59 2.79 1.58 1.82 1.87 2.01 2.10 2.26 2.46 10 mm @ 305 2.55 2.93 3.01 3.21 3.33 3.54 3.80 2.30 2.65 2.73 2.92 3.04 3.24 3.50 1.97 2.28 2.35 2.53 2.64 2.83 3.08 8 mm @ 152 2.83 3.27 3.36 3.61 3.76 4.00 4.29 2.55 2.96 3.05 3.29 3.43 3.66 3.96 2.18 2.55 2.63 2.85 2.98 3.20 3.48 12 mm @ 305 3.04 3.50 3.59 3.86 4.01 4.27 4.58 2.74 3.17 3.26 3.51 3.66 3.91 4.22 2.34 2.73 2.81 3.04 3.18 3.41 3.71 10 mm @ 152 3.48 4.03 4.15 4.47 4.66 4.98 5.38 3.13 3.65 3.76 4.07 4.25 4.57 4.96 2.68 3.14 3.25 3.52 3.69 3.99 4.37 16 mm @ 305 3.55 4.25 4.42 4.95 5.26 5.62 6.07 3.55 4.14 4.26 4.60 4.80 5.15 5.60 3.04 3.56 3.67 3.98 4.17 4.50 4.92 12 mm @ 152 3.55 4.25 4.42 4.95 5.30 5.92 6.28 3.55 4.25 4.42 4.82 5.04 5.42 5.86 3.13 3.71 3.83 4.17 4.37 4.73 5.08

5.0

6.7

10.0

1 HOUR Imposed Load Slab Depth 120 125 140 150 170 200 120 125 140 150 170 200 120 125 140 150 170 200 Reinforcing Bars (Diameter / Spacing) 8mm @ 305 2.25 2.31 2.46 2.56 2.72 2.92 2.03 2.09 2.24 2.33 2.49 2.69 1.75 1.80 1.94 2.03 2.18 2.37 10 mm @ 305 2.81 2.88 3.08 3.19 3.40 3.65 2.55 2.62 2.80 2.91 3.11 3.36 2.19 2.26 2.43 2.53 2.72 2.96 8mm @ 152 3.16 3.25 3.49 3.62 3.85 4.14 2.86 2.95 3.18 3.30 3.53 3.82 2.46 2.54 2.75 2.87 3.08 3.36 12 mm @ 305 3.35 3.44 3.69 3.83 4.07 4.37 3.03 3.12 3.36 3.49 3.73 4.02 2.61 2.69 2.91 3.04 3.26 3.54 10 mm @ 152 3.89 4.00 4.30 4.48 4.79 5.16 3.52 3.63 3.92 4.09 4.39 4.76 3.03 3.13 3.39 3.55 3.84 4.19 16 mm @ 305 4.25 4.42 4.82 5.01 5.36 5.78 3.95 4.07 4.38 4.57 4.91 5.32 3.40 3.51 3.80 3.97 4.29 4.68 12 mm @ 152 4.25 4.42 4.95 5.29 5.67 6.13 4.14 4.27 4.62 4.83 5.20 5.65 3.56 3.68 4.00 4.19 4.54 4.97

5 .0

6.7

10.0

2 HOUR Imposed Load Slab Depth 125 140 150 170 200 125 140 150 170 200 125 140 150 170 200 Reinforcing Bars (Diameter / Spacing) 8mm @ 305 2.00 2.14 2.22 2.36 2.54 1.81 1.95 2.02 2.16 2.34 1.56 1.68 1.76 1.89 2.06 10 mm @ 305 2.48 2.65 2.75 2.92 3.13 2.25 2.41 2.51 2.68 2.89 1.94 2.09 2.18 2.34 2.54 8mm @ 152 2.83 3.03 3.14 3.34 3.59 2.57 2.76 2.87 3.06 3.31 2.22 2.39 2.49 2.68 2.91 12 mm @ 305 2.97 3.17 3.29 3.49 3.75 2.70 3.40 3.00 3.20 3.45 2.32 2.50 2.60 2.79 3.04 10 mm @ 152 3.48 3.74 3.89 4.14 4.44 3.16 2.89 3.55 3.79 4.09 2.72 2.95 3.08 3.31 3.60 16 mm @ 305 3.87 4.14 4.30 4.59 4.91 3.51 3.77 3.93 4.20 4.53 3.02 3.27 3.41 3.67 3.98 12 mm @ 152 4.11 4.42 4.60 4.92 5.31 3.73 4.03 4.20 4.51 4.89 3.22 3.49 3.65 3.94 4.30

5.0

6.7

10.0

Sup er Hol ori b

Technical Manual
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