Dramix - Jointless

Dramix ®
Jointless Industrial Floor

Working document
for the flooring contractor
This specification was developed by collaboration between

AIB-VINÇOTTE Inter (A.V.I.), international control consultants,
and the BEKAERT company, producer of the Dramix® steel
fibres.
N.V. BEKAERT S.A.

Bekaertstraat 2
B-8550 Zwevegem
(Belgium)
WORKING DOCUMENT FOR THE FLOORING CONTRACTOR
CONTENTS
1. INTRODUCTION ....................................................................................... 4
2. SUB-BASE ................................................................................................ 4
2.1. Preparation ................................................................................................... 4
2.2. The plate bearing test ................................................................................. 5
3. CONCRETE COMPONENTS.................................................................... 7
3.1. Cement .......................................................................................................... 7
3.2. Aggregates.................................................................................................... 7
3.3. Water ............................................................................................................. 7
3.4. Workability .................................................................................................... 7
3.5. Admixtures .................................................................................................... 7
4. CONCRETE .............................................................................................. 8
4.1. Concrete composition ................................................................................. 8
4.2. Notes.............................................................................................................. 8
5. REINFORCEMENT ................................................................................... 9
5.1. Dramix® steel fibres ..................................................................................... 9
5.2. Auxiliary reinforcement ............................................................................... 9
6. JOINTS .................................................................................................... 10
6.1. Expansion and working joints .................................................................. 10
6.2. Isolation joints............................................................................................. 10
7. DESIGN ................................................................................................... 11
8. CONSTRUCTION.................................................................................... 12
8.1. Preparations ............................................................................................... 12
8.2. Pouring and finishing................................................................................. 12
8.3. Post-treatment............................................................................................ 13
8.4. Initial usage................................................................................................. 13
9. CHECKS.................................................................................................. 14
9.1. Self assessment by the flooring contractor............................................ 14
9.2. Checks made by control organisation .................................................... 15
3
1. INTRODUCTION
The aim of this specification is to arrive at an industrial floor using a defined
description of the materials used (concrete, Dramix®, topping …), method of
calculation, placement and finishing method, whereby the final product has a
constant high quality.
2. SUB-BASE
2.1. Preparation
It is assumed that …
The flooring contractor receives a sub-base according the requirements

assumed in the calculation.
There are no compressible layers, swellings or frost-sensitive materials

under the concrete floor.
The water level is adequate under the concrete floor.
The sub-grade is finished flat to a tolerance + zero, -10 mm.

Unevenness, which may arise during pouring, is corrected to tolerance
BEFORE the concrete is cast.
If there are fixed points under the floor, adequate solutions have to be found
to avoid the slab cracking under load over the hard point.
4
2.1.1. Without plastic sheet (cp. par. 8.1.)
The sub-grade fill is composed of the following components:
Cement bound material. Thickness of the stabilised layer depends on the

prescribed k-value and the sub-grade.
Granular sub-base.
The stabilised sand-gravel sub-base should have a continuous grade

distribution so that:
A closed but rough surface is obtained;
A good compression is possible;
Settlement of the sub-base is limited to a minimum.
2.1.2. With plastic membrane
The fill should obtain the necessary load capacity.
2.2. The plate bearing test
General
When a k-value is mentioned in the text this is always the k-value of

Westergaard.
The quality of the sub-base is measured using a plate-bearing test (plate

diameter = 760 mm) and expressed as a k-value (N/mm³).
The plate-bearing test is carried out by a recognised company under
contract to the flooring contractor or the general contractor.
The plate-bearing test is carried out on the finished sub-base and not on
the sub-grade.
TR 34 gives an indication on the sub-base thickness and quality starting out

from a given sub-grade quality in order to reach the required k-value.
The results of these plate-bearing tests are interpreted by N.V. BEKAERT S.A.
or a consultant appointed by BEKAERT.
5
Number
The number of plate-bearing tests is determined as follows:
For floor areas less than 3,000 m² 1 plate-bearing test per 500 m² with a
minimum of 3 plate tests.
For floor areas greater than 3,000 m² 6 plate-bearing tests + one plate-
bearing test for each area unit of 1,000 m² over 3,000 m² (e.g. 7,500 m²
Î 6 + (7000 - 3000)/1000 = 10 plate tests).
If significant differences are found in the quality of the sub-base the total floor
area is notionally subdivided into smaller partial areas for which a uniform
sub-base quality is found. For the determination of the number of plate-
bearing tests the above rules are then applied to the partial areas.
Assessment of the results of the plate-bearing tests
The sub-base constant k must be a minimum of 0.05 N/mm³ over the

whole area.
The mean value of the test results must be greater than or equal to the
k-value, which is used in the calculation of the (partial) area concerned.
Every single value must be within ± 30 % of the calculated mean value of

the (partial) area concerned.
If one of these three conditions is not satisfied, changes in the sub-base

should be made.
6
3. CONCRETE COMPONENTS
3.1. Cement
The permissible cement types are: CEM III A/42.5 (HK 40). The cement
must conform to BS 12.
3.2. Aggregates
The grading of the aggregates (sand + coarse aggregate) is specially

designed by BEKAERT to obtain an optimal steel fibre concrete (cp. par.
4.1).
Sand: in conformity with BS 882.

Coarse aggregate: in conformity with BS 882.
3.3. Water
The mixing water must comply with BS 3148.
3.4. Workability
The concrete must conform to consistency class S4.

The steelfibre concrete must have a slump, measured with an Abrams cone
as for a traditional unreinforced concrete, of 135 mm (± 1/3) according to
BS 532 B).
3.5. Admixtures
In order to get good workability (S4) in the concrete it is necessary to add a

plasticiser or superplasticiser.
Good workability is essential to obtain the required floor flatness.
The quantity of plasticiser or superplasticiser must be adjusted as a function

of the desired flow quality. The quantity can vary as a function of the type of
plasticiser or superplasticiser.
The maximum dose stated by the manufacturer must not be exceeded.
The choice of the type of admixture is a function of weather conditions.
7
4. CONCRETE
4.1. Concrete composition
¹ The basis is British standard BS 5328.
According to this standard the concrete to be used is described as follows:
Strength class C35 or C40

Consistency class (slump) S4/F4 (135 mm (±1/3))
Maximum aggregate size 20 (coarse aggregate)
20 (crushed stone)
¹ Auxiliary requirements for the concrete composition are stated

below
The amount of cement varies between 300 and 340 kg/m³. The choice of
the amount of cement, between these margins, is a function of the
temperature, air humidity etc. during construction.
In principle the cement amount has to be reduced at higher temperatures.
In principle the cement amount has to be reduced by lower air humidity.
The choice of the effective amount of cement, within the margins stated
above, is to be made by the flooring contractor.
The gravel is composed of 2 grades. The grades are in conformity with
the BS 882.
Coarse aggregates or Crushed stone
50% 4/14 40% 2/7
50% 4/28 60% 7/20.
If these grades are not present locally, use can be made of the grades
which are closest to the values above.
The amount of sand varies between 700 and 800 kg/m³.
The W/C factor is maximum 0.52. In the determination of the water

content, the moisture present in the aggregates should be taken into
account and any adjustments made.
4.2. Notes
The only concrete to be used shall come from a plant approved by

QSRMC and decided by the flooring contractor.
The concrete plant is to provide the concrete according to the specifications

given above and is to guarantee the consistent quality of it.
8
The concrete plant shall guarantee a CONSTANT concrete supply in

quantities stated by the flooring contractor.
The concrete for a given pour shall be supplied, where possible, from a
single concrete supplier.
Where not possible, special attention should ensure that if two plants are
used: the cement is of the same type and from the same supplier;
the same admixtures are used at the same dosages;
the distances of the two plants from the jobsite are approximately
the same;
where possible, the concrete of the two plants should not be mixed.
5. REINFORCEMENT
5.1. Dramix® steel fibres
Use is made only of Dramix® RC-65/60-BN or Dramix® RC-80/60-BN steel

fibre.
The Dramix® steel fibres can be added either at the concrete plant or at the
site.
The addition of Dramix® steel fibres shall be effected as follows:
At the plant: The fibres should be mixed together with the aggregates in
the pan mixer. In this case an excellent distribution is ensured as soon as
all collated fibres have dispersed. If the concrete is made directly in the
truckmixer the fibres should be added as described below.
At the site: BEFORE or during the addition of the fibres the concrete is
brought to the correct consistency. The fibres are added to the concrete
mixer evenly at a rate of 60 kg/min. while the concrete mixer drum is
turning at full mixing speed. After the addition of all the fibres mixing is
continued at full speed for five minutes (or 100 revolutions at full speed).
The correct dosing and addition of the Dramix® steel fibres is the
responsibility of the flooring contractor.
5.2. Auxiliary reinforcement
In places in the slab, where cracking may be expected: e.g. around

columns, indentations, solid objects in general … there should be auxiliary
reinforcement.
This auxiliary reinforcement has the purpose of limiting and controlling
crack formation.
9
The flooring contractor is to indicate the location of the auxiliary
reinforcement on the Engineer's drawing.
Some basic principles which should be applied to the location of auxiliary

reinforcement are given in the attached annex.
6. JOINTS
Only isolation and expansion joints are made in the floor. There are NO
shrinkage joints cut.
6.1. Expansion and working joints
The distance between 2 expansion joints is around 45 m.
The length/width ratio of the floor sections must be less than 3:2 and should
be as nearly square as possible.
For the construction of the expansion joints use is made of prefabricated

profiles (cp. execution details).
6.2. Isolation joints
The aim of an isolation joint is to make the slab independent of and free from
restraint by the rest of the construction.
Free movement of the slab must be possible.
A compressible material should be incorporated around columns and other

solid objects, having a minimum thickness of at least 2 cm over the full depth
of the concrete floor.
A compressible material of 1 cm thickness is placed around the edges of the

concrete slab.
The compressible material is applied over at least the full depth of the floor.
10
7. DESIGN
The concrete floor is poured onto a stabilised sand and gravel sub-base: a
complete adhesion between the concrete floor and its sub-grade is aimed at.
Shrinkage movement is obstructed and hindered and may give rise to
formation of micro scopie shrinkage cracks distributed uniformly over the
floor surface.
The loading plan is given by the contract principal. The floor is designed
on the basis of these loading and ground investigation data.
The flatness requirements which the floor must satisfy are to be

determined in consultation with the contract principal. TR 34 can form a
guideline here.
(The flatness is not subject to the insurance)
The calculation is made by the BEKAERT company or the consultant

authorised by BEKAERT.
The minimum concrete thickness is 140 mm.
Special attention must be paid among other things to:

- concrete construction to avoiding curling of the slab;
- zones close to loading / unloading bays;
- zones close to "dock-levellers".
The minimum steel fibre dosage is 30 kg/m³ Dramix® RC-65/60 BN.

From the point of view of the workability, a dosage of 40 kg/m³ is the
maximum. Higher dosages need to be studied specifically.
11
8. CONSTRUCTION
8.1. Preparations
The flooring contractor will make a preliminary check as to whether in all

locations the required level and thickness can be reached. Also the
flatness of the sub-base is checked.
The auxiliary reinforcement is positioned according to the general

principles (cp. annex).
The connection of the slab to the loading dock must be carried out as
given in the annex.
Edge beams and foundation blocks at small depths must be detailed as

stated in the annex.
NO plastic sheeting is spread over the sub-base. Before pouring the floor
the sub-base is wetted at the rate of 10 l/m². This wetting is repeated
continuously depending on the site requirements.
If suitable watering cannot be guaranteed, a double plastic sheet of at

least 0.2 mm thickness should be used.
The building must be completely closed for all weather conditions.
8.2. Pouring and finishing
Concrete complying with the specifications given above must be poured to

the correct level.
Necessary attention must be paid to the requirements of flatness and

horizontally.
Directly after the levelling of the concrete a specially designed curing

compound is applied.
This curing compound protects the concrete against drying out between
pouring and finishing of the floor. Cracks due to plastic shrinkage are
hereby limited.
Under the following conditions this curing compound should be used.

This primary curing compound needs to be used under the following
conditions:
day temperature > 30° C or
air humidity < 40° C or
unusual wind blowing on the floor.
12
The time between the mixing of the concrete and working on site is a
maximum of 100 min. in conformity with BS 5328.
A topping must be laid on the stiffening concrete at the rate of 3.6 kg/m².
This topping consists of 1/3 cement and 2/3 quartz aggregate.
The quartz has a minimum hardness of 5.5 Mohs.
The cement class of the cement for the topping must be the same as that
used in the concrete.
In consultation with the contract principal a choice of a different finish may be

made.
8.3. Post-treatment
After the finishing of the concrete floor a curing compound (100 to

150 g/m²) is sprayed over the floor. This curing compound must conform
to BS 5750.
Directly after the drying of the curing compound, the floor is placed
under water and covered with a plastic sheet. This plastic film must
remain on the floor for a minimum of 14 days, so that the floor
hardens at 100 % humidity during this time.
On NO account should the floor be loaded in any form whatsoever in this

first 14 days.
8.4. Initial usage
In loading the floor the evolution of compressive strength of the concrete has
to be taken into account (conform to BS 1881).
Due to the high joint spacing, the values of the BS 1881 need to be reduced
by 20 %.
By means of an example is given below the loading scheme for a concrete

slab at a temperature of 15° C.
% of the admissible load

0% First 2 weeks after construction
40 % > 2 weeks
60 % > 3.5 weeks
100 % > 6 weeks
13
9. CHECKS
9.1. Self assessment by the flooring contractor
9.1.1. Plate-bearing test
For each site the necessary plate loading tests are carried out as described
in par. 2. The results are entered on pre-printed proformas.
9.1.2. The steel fibre concrete
The steel fibre concrete is checked on the site by spot checks.
The following must be tested:

The proportion of steel fibres.
The homogeneity of these steel fibres in the concrete matrix.
The workability of the steel fibre concrete.
Number of steel concrete samples:

1 per 10 concrete truckmixers except for the first concrete mixer for
which 3 steel concrete samples are taken (first, middle and last part of
the mixer contents). If the test results are negative, three steel concrete
samples are taken from the next mixer which is used.
Volume of the steel concrete sample:

Min. 10 litres of steel fibre concrete.
Assessment of the test results:

The mixing is satisfactory if the proportion differs by less than ± 10 %
from that specified.
What if the results are negative?

Steel proportion too low:
Add the required quantity of Dramix® and remix according to the
method described above.
Poor homogeneity:
Allow the mixer to run an extra 5 min. The mixing time of subsequent
mixers is adjusted. 3 steel concrete samples are taken from the next
mixer.
Poor workability:
If the slump is not between the required 135 mm (± 1/3), extra super-
plasticiser should be added. However, the maximum proportion
permitted by the manufacturer should not be exceeded.
The checks carried out are to be entered in site reports.

14
9.2. Checks made by control organisation
The conformity of the execution with the project description needs to be

checked. The following checks will be carried out as spot checks during the
site visit:
– visual check of the quality of the sub-base;
– inspection of the positioning of the auxiliary reinforcement;
– inspection of the positioning of compressible foil at edges, pillars and
other solid objects;
– inspection of the proportion and homogeneity of distribution of the steel
fibre on the basis of test reports from the flooring contractor, possibly
supplemented by a concrete sample on site;
– the results of the self assessment carried out by the flooring contractor.
15
®
Dramix
Drawings
These floor plans were developed by a collaboration
between AIB-VINÇOTTE Inter (A.V.I.), international control
consultants, and the BEKAERT company, producer of the
Dramix® steel fibres.
N.V. BEKAERT S.A.

Bekaertstraat 2
B-8550 Zwevegem
(Belgium)
Auxiliary reinforcement around column without joints
PLAN
LEGEND
Mesh 150 x 150 x 8 x 8

Dim.: 1.6 x 2 m
Compressible material
thickness 10 mm
Auxiliary reinforcement
5 x ¤ 12 mm – Length: 1.5 m.
Dramix reinforced concrete
Mesh supports: Height dependent on floor

thickness. Allow for 50 mm concrete cover
above mesh
CROSS SECTION
Auxiliary reinforcement around column with 2 construction joints
PLAN
LEGEND
Mesh 150 x 150 x 8 x 8

Dim.: 1 x 1 m
Construction joint
Type omega
thickness 2 cm
5 x ¤ 12 mm – Length: 1.5 m.
Anchorage every 500 mm
Mesh supports: Height dependent on

floor thickness. Allow for 50 mm
concrete cover above mesh.
CROSS SECTION
Auxiliary reinforcement around column with one construction joint
PLAN
LEGEND
Mesh 150 x 150 x 8 x 8

Dim.: 1.6 x 2 m
Construction joint
Type omega
thickness 200 mm
5 x ¤ 12 mm – Length: 1.5 m.
Mesh supports: Height dependent

on floor thickness. Allow for 50 mm
CROSS SECTION
Auxiliary reinforcement around column at the edge
PLAN
LEGEND
Mesh 150 x 150 x 8 x 8

Dim.: 1.6 x 2 m
thickn. 20 mm (column) - 10 mm (wall)
5 x ¤ 12 mm – Length: 1.5 m.

CROSS SECTION
PLAN
LEGEND
Mesh 150 x 150 x 8 x 8

Dim.: 1.6 x 2 m.
5 x ¤ mm – Length: 1.5 m.

CROSS SECTION
with 1 construction joint
PLAN
LEGEND
Mesh 150 x 150 x 8 x 8

Dim.: 1 x 1 m
Construction joint with dowels
5 x ¤ 12 mm – Length: 1.5 m.

CROSS SECTION
Auxiliary reinforcement around an inspection shaft
PLAN
LEGEND
Mesh 150 x 150 x 8 x 8

Dim.: 1.6 x 2 m.
thickness 20 mm
3 x ¤ 12 mm – Length: 1.5 m.

Brick
CROSS SECTION
Auxiliary reinforcement at corners
CROSS SECTION LEGEND
1.5 m Mesh 150 x 150 x 8 x 8

Dim.: 2.0 x 2.5 m.
L/2 L/2
thickness 10 mm
10 x ¤ 12 mm – Length: 1.5 m.
concrete coverage = 5 cm
Wall
Expansion joint
Type omega
Auxiliary reinforcement at docking boards
PLAN
LEGEND
Mesh 150 x 150 x 8 x 8
Brick
Distancers: Height in function of the

floorthickness by a 50 mm concrete
coverage of the re-bars.
CROSS SECTION

Dramix - Jointless

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Dramix ®

Jointless Industrial Floor

This specification was developed by collaboration between

N.V. BEKAERT S.A.

 The flooring contractor receives a sub-base according the requirements

 There are no compressible layers, swellings or frost-sensitive materials

 The water level is adequate under the concrete floor.

The sub-grade is finished flat to a tolerance + zero, -10 mm.

2.1.1. Without plastic sheet (cp. par. 8.1.)

The sub-grade fill is composed of the following components:

 Cement bound material. Thickness of the stabilised layer depends on the

The stabilised sand-gravel sub-base should have a continuous grade

 A closed but rough surface is obtained;

 A good compression is possible;

 Settlement of the sub-base is limited to a minimum.

2.1.2. With plastic membrane

The fill should obtain the necessary load capacity.

2.2. The plate bearing test

When a k-value is mentioned in the text this is always the k-value of

 The quality of the sub-base is measured using a plate-bearing test (plate

TR 34 gives an indication on the sub-base thickness and quality starting out

The number of plate-bearing tests is determined as follows:

Assessment of the results of the plate-bearing tests

 The sub-base constant k must be a minimum of 0.05 N/mm³ over the

 Every single value must be within ± 30 % of the calculated mean value of

If one of these three conditions is not satisfied, changes in the sub-base

 The grading of the aggregates (sand + coarse aggregate) is specially

 Sand: in conformity with BS 882.

 The mixing water must comply with BS 3148.

The concrete must conform to consistency class S4.

In order to get good workability (S4) in the concrete it is necessary to add a

Good workability is essential to obtain the required floor flatness.

The quantity of plasticiser or superplasticiser must be adjusted as a function

The maximum dose stated by the manufacturer must not be exceeded.

The choice of the type of admixture is a function of weather conditions.

4.1. Concrete composition

¹ The basis is British standard BS 5328.

According to this standard the concrete to be used is described as follows:

Strength class C35 or C40

¹ Auxiliary requirements for the concrete composition are stated

 The amount of sand varies between 700 and 800 kg/m³.

 The W/C factor is maximum 0.52. In the determination of the water

 The only concrete to be used shall come from a plant approved by

 The concrete plant is to provide the concrete according to the specifications

 The concrete plant shall guarantee a CONSTANT concrete supply in

 Use is made only of Dramix® RC-65/60-BN or Dramix® RC-80/60-BN steel

 The addition of Dramix® steel fibres shall be effected as follows:

5.2. Auxiliary reinforcement

 In places in the slab, where cracking may be expected: e.g. around

Some basic principles which should be applied to the location of auxiliary

6.1. Expansion and working joints

The distance between 2 expansion joints is around 45 m.

For the construction of the expansion joints use is made of prefabricated

6.2. Isolation joints

A compressible material should be incorporated around columns and other

A compressible material of 1 cm thickness is placed around the edges of the

 The flatness requirements which the floor must satisfy are to be

 The calculation is made by the BEKAERT company or the consultant

 The minimum concrete thickness is 140 mm.

 Special attention must be paid among other things to:

 The minimum steel fibre dosage is 30 kg/m³ Dramix® RC-65/60 BN.

 The flooring contractor will make a preliminary check as to whether in all

 The auxiliary reinforcement is positioned according to the general

The flooring contractor receives a sub-base according the requirements

There are no compressible layers, swellings or frost-sensitive materials

The water level is adequate under the concrete floor.

Cement bound material. Thickness of the stabilised layer depends on the

A closed but rough surface is obtained;

A good compression is possible;

Settlement of the sub-base is limited to a minimum.

The quality of the sub-base is measured using a plate-bearing test (plate

The sub-base constant k must be a minimum of 0.05 N/mm³ over the

Every single value must be within ± 30 % of the calculated mean value of

The grading of the aggregates (sand + coarse aggregate) is specially

Sand: in conformity with BS 882.

The mixing water must comply with BS 3148.

The amount of sand varies between 700 and 800 kg/m³.

The W/C factor is maximum 0.52. In the determination of the water

The only concrete to be used shall come from a plant approved by

The concrete plant is to provide the concrete according to the specifications

The concrete plant shall guarantee a CONSTANT concrete supply in

Use is made only of Dramix® RC-65/60-BN or Dramix® RC-80/60-BN steel

The addition of Dramix® steel fibres shall be effected as follows:

In places in the slab, where cracking may be expected: e.g. around

The flatness requirements which the floor must satisfy are to be

The calculation is made by the BEKAERT company or the consultant

The minimum concrete thickness is 140 mm.

Special attention must be paid among other things to:

The minimum steel fibre dosage is 30 kg/m³ Dramix® RC-65/60 BN.

The flooring contractor will make a preliminary check as to whether in all

The auxiliary reinforcement is positioned according to the general

Edge beams and foundation blocks at small depths must be detailed as

The building must be completely closed for all weather conditions.

Concrete complying with the specifications given above must be poured to

Necessary attention must be paid to the requirements of flatness and

Directly after the levelling of the concrete a specially designed curing

After the finishing of the concrete floor a curing compound (100 to

On NO account should the floor be loaded in any form whatsoever in this