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SLAB DESIGN
All too frequently it is the practice to use a rule-of-
thumb design for a slab of, for example, 6 inches at grade
with nominal reinforcement of 40 pounds per 100
square feet. For a small shop or home garage this might
suffice; for an industrial plant it invites trouble.
Proper slab design is a complicated subject involving
To isolate columns from the floor slab, box them out with many factors, including soil-bearing capacity, strength
square wood forms or screeds (left) or with circular of mix, and the area and position of the static and dy-
fiberboard forms (right). namic loads applied. In practice, however, some of these
factors must be estimated because of the difficulty of de-
termining them accurately. The overall controlling factor
Placing a 6-inch layer of sand or gravel beneath the then becomes the heaviest concentrated load which can
slab gives a base which can be more firmly and uniform- be expected. In general this will be the wheel load of ei-
ly compacted, and also provides a safe permeable layer ther an industrial or highway vehicle. With such dynam-
exhibiting little or no volume change in the event of an ic loads it should be assumed that they will be applied
unexpectedly high water table. Such a layer should ob- at the edges of the slab. It may be decided that individual
viously not be placed over sod, muck or organic waste; foundations are desirable with heavy static loads such as
similarly roots or other obstructions should be dug out, presses, lathes and the like, although in general greater
backfilled, and carefully tamped. Hand tamping is also flexibility of operations follows from direct placement on
important around columns, wall edges, or other ob- the slab. With separate foundations the slab should be
structions such as service outlets. Pipe trenches must cast on the compacted subbase around the foundation
also be thoroughly compacted. A tamper weighing not concrete which may itself be at floor level; using the
less than 50 pounds with a face not greater than 100 haunch to support the edge of the slab will inevitably
square inches is recommended. result in uneven bearing and lead to cracking.
Many modern builders believe that every concrete Theoretically a thin slab on a uniform base will carry
slab resting on the ground, or just clear of the ground, a very heavy uniformly distributed live load. In practice,
should have some sort of membrane under it to function however, the minimum satisfactory thickness is 5 inch-
as a vapor barrier. Certain it is that this practice would go es. Extra thickness, with additional safety for the unfore-
far toward correcting such problems as chronically seeable future, will only increase the material cost,
damp basements, warped wood floors, moisture con- which in itself is negligible compared with total con-
densation on walls and exterior paint failures. struction costs.
The use of a saucer of impermeable material as a bot- Much work has been done to reduce slab design to a
tom form in casting a concrete slab performs two im- simple tabular level. The curves of Figures 1, 2 and 3
portant functions: by preventing the loss of water in the were derived by the Portland Cement Association. Prob-
mix by absorption into a dry subgrade, the membrane ably the best way of explaining their use is to take as an
permits the concrete to cure from the bottom; and it example a 5,000 psi mix to be used for an industrial floor
stops or greatly impedes the migration of water vapor carrying lift trucks having 12-inch wide solid rubber tires
from the subgrade through the slab into the structure and a 10,000-pound wheel load. The maximum concen-
above the slab. The importance of the latter is apparent trated load expected is 10,000 pounds. An allowance of
when it is recognized that 20 gallons of water vapor is 25 percent for impact gives a total equivalent static load
of 12,500 pounds. From Figure 1 it can be seen that for
5,000-pound concrete the flexural strength is 700 psi. As-
suming a very frequent repetition of the loading, Figure
2 suggests that we use a factor of safety of 2. The flexural
design stress then becomes 7002 or 350 psi. We can
now use Figure 3 which gives the required slab thickness;
however, since these curves are drawn for concrete with
a flexural design stress of 300 psi and we are working
with 350 psi concrete, the design load must be corrected
accordingly; i.e., 12,500 pounds x 300350 which equals
10,700. This is not a point load, and for the wheels in our
problem an area of contact of about 25 square inches per
wheel can be assumed. From Figure 3, using a loaded
area of 25 square inches and a load of 10,700 pounds,
we get a slab thickness of about 7 inches.
REINFORCEMENT
Theoretically, reinforcing steel is not necessary for on-
grade slabs since the subgrade should provide uniform
support. Steel does, however, perform the function of
preventing cracks from opening, and under some condi-
tions cracks can be expected in slabs with dimensions
greater than 15 feet. Correct jointing will do much to
hold down cracking, but the dangers of uneven loadings
and variable bearing capacity in the subgrade make the
use of reinforcement highly desirable.
A simple formula has been worked out to calculate the
amount of steel necessary:
A= WLf
2t
where A = area of reinforcement needed in square
inches per foot of width;
W = weight of slab per square foot;
L= length between joints in feet;
f= coefficient of friction between slab and
subgrade;
t= allowable tensile stress in steel.
Since f and t, under average conditions, can be taken
as 2 and 25,000 respectively, the formula can be simpli-
fied even further to:
WL
A= 25,000
For slabs over 6 inches in depth steel for crack control
should be not more than 2 _ inches below the surface;
for slabs less than 6 inches in depth the distance to the
steel should be 2 inches or mid-depth, whichever is the
least.
The easiest reinforcing steel to handle is, of course,
welded wire fabric mats (not rolls) placed on suitable
chairs or small concrete spacers. The mix should then be
worked under and over it at the same time. The practice
of placing the steel on the subgrade and then attempting
to lift it into place all too frequently results in air pockets,
bond-breaking dirt inclusions and incorrect location. sistency should be cast to the level of the reinforcement,
Setting the mesh on a first layer of hardened concrete the mats of reinforcement being then placed and im-
gives a weaker slab and increases the danger of the en- mediately topped with the rest of the concrete all in one
try of foreign matter. If permitted, concrete of a stiff con- operation.
JOINTS between 15 and 25 feet is desirable. Joints should be sit-
Tests and experience have shown that in a normal ed along column lines if possible; but 25 feet is a maxi-
heated building the initial shrinkage of concrete is gen- mum limit and if the distance between columns is
erally greater than any subsequent expansion due to greater, intermediate joints should be provided.
temperature changes. It is therefore possible, with but Concrete men probably disagree more on the subject
few exceptions, to cut out expansion joints entirely. of joints than any other single problem involving con-
crete. Dummy joints, which consist essentially of a
weakened plane (created by grooving plastic concrete
or sawing hardened concrete) have a strong following in
the industry, but the full-depth control joints seems to
be gaining acceptance as a more dependable construc-
tion device. With this type of joint it is desirable to use ei-
ther steel dowels or tongue-and-groove construction to
assist in transferring loads across the joint. With all con-
trol joints reinforcement must be cut in order to permit
the joints to serve their purpose.
PUBLICATION #C620161
Copyright 1962, The Aberdeen Group
All rights reserved