Concrete flooring with corrugated sheets

Corrugated sheets combined with concrete flooring is a contemporary option for both residential and commercial structures. This technique combines the structural advantages of corrugated metal sheets with the strength and longevity of concrete. The end product is a floor that is affordable, simple to install, and strong enough to support large loads.

The capacity of corrugated sheets to serve as a formwork during construction is one of the key benefits of using them for concrete flooring. Traditional wooden forms are not necessary because the sheets offer a solid surface for the concrete to be poured over. This lowers the overall cost and expedites the construction process.

Furthermore, the concrete floor’s structural integrity is improved by corrugated sheets. Because of the sheets’ distinctive shape, the floor can support more weight, which makes it perfect for areas where there is a lot of foot traffic or equipment weight. For this reason, corrugated sheet concrete flooring is a common option for large retail spaces, garages, and industrial warehouses.

The adaptability of this flooring system is an additional advantage. Because corrugated sheets are available in a variety of thicknesses and sizes, they can be tailored to meet the unique needs of any project. This method can be modified to suit your needs, regardless of whether you’re building a new structure or renovating an existing one.

Concrete flooring that has corrugated sheets added to it looks more contemporary and industrial while simultaneously performing better. For an unpolished, urban aesthetic, the exposed metal and concrete can be left uncovered, or they can be covered with extra finishes to fit any style preference. Because of its adaptability, it is a preferred choice for modern architectural projects.

All things considered, corrugated sheet concrete flooring is a useful and effective way to construct sturdy, long-lasting floors. It is a great option for a variety of construction projects due to its strength, affordability, and visual appeal.

Advantages of overlapping with corrugated sheets

Because of its light weight, stiffness, strength, and resistance to corrosion, grade "N" corrugated sheets are an excellent solution for construction-related issues. Material in profile: a wave that creates stiffeners, which, when a concrete slab is cast, raise the structure’s overall bearing capacity. Because the sheet is a permanent formwork, concrete and reinforcement costs are lowered.

A portion of the weight is released from the floor slab if it is attached to concrete. Such monolithic components can be supported by a light load-bearing frame, which lowers the cost of forming building foundations (columnar options are adequate). By using foam blocks and light and warm gas blocks, the cost of wall materials is decreased. Corrugated sheets are poured with concrete mortar; intricate formwork is not needed.

When properly maintained, the concrete slab has strong strength indicators and can withstand the effects of the environment. These slabs of reinforced concrete weigh less. The structures’ ceiling surfaces are finished exteriors that are resilient to fire, temperature fluctuations, and humidity levels. The supporting base’s material is lightweight, effortlessly transportable, and built to last for a long time. The profiled sheet is mounted quickly and easily on a supporting frame without the need for lifting tools.

Calculation of ceilings

For the project, drawings must be created, and calculations must be performed (ideally with the assistance of professionals) in compliance with SNiP, 100 0047 – 2005 recommendations. The construction’s dimensions, the transverse beams’ installation process, their length, the load on them and the columns, and the supporting profiled sheet’s attributes (product width, length, thickness, and profile height) are all taken into consideration. It should be predicated on the idea that every sheet should have three beams supporting it along its length. The height of the plate and the cross section of the reinforcement are computed based on the anticipated load on the overlap.

Depending on the separation between the transverse beams, a large-scale relationship (1:30) is used to calculate its thickness. The thickness of a monolithic concrete plate ranges from 70 to 250 mm. The kind and quantity of metal columns, the specifications of their foundation, the kind of beams, and the amount of weight supported by a single column will all be determined by the weight of the monolithic floor. The greater the depth of the sheet profile waves, the more frequently the beams are installed because the mass of concrete in the profile recesses increases when increasing the slab’s thickness is not practical.

You can get rid of the sheets’ deflection by lowering the span step. The weight of the additional useful load that the interfloor overlap will support must be considered; 150 kg/m^is considered the standard and should be increased by 33%. There is a 0.5 kg margin of error in the calculation of the operational load total.

It is from which the cross-sectional dimensions and beam lengths are calculated. By combining profiled sheets and reinforced concrete, you can transfer some of the load to the anchors using vertical rod anchors. Material with a minimum thickness of 0.9 mm is needed for a 3 meter wide span. Essentially, the computations are condensed within software that enables the creation of functional documentation.

Monolithic floor device

A monolithic concrete floor slab is made of concrete, reinforced concrete, and profiled sheets. If such a structure is supported by a beam frame, the load is distributed among the columns rather than the walls. Every column has a foundation of its own. If the cross beams are installed, they can also rest on the walls or not be laid at all.

In this instance, the foundation and the structure’s walls must be supported by the monolithic floor. I-beams are metal beams (channel). Their edges are welded to the embedded components and reinforced in the wall "pockets" (columns). The inner shelf beams can be used to attach sheets, and for short sheets, a maximum distance of 1.5 meters should be chosen between supports. Profiled material can also be installed from above on the outer shelf of channels or I-beams, allowing sheets up to 6 m in length to be placed.

Overlapping installation occurs along the entire length. Beneath the center of the sheet elements is a fixed beam. The corrugation extensions are oriented downward, and the profile waves should be perpendicular to the beams.

The corrugated sheets won’t have any support points in the middle of the space if the device is beamless. Volumetric reinforcement is a necessary component that greatly boosts the monolith’s strength. Welding is used to join the reinforcement to the columns and beams. It is possible to distribute the solution by installing external, detachable formwork. The slab’s smooth surface is created by the concrete.

Installation of floors from corrugated sheets

Perforated sheets are fastened to the internal and external shelves of the cross beams to form the beam floor. When the upper fastening of the sheets is chosen, the formwork is then created. The length of the roll’s span is determined by the parameters of the corrugated sheet’s allowable deflection, which are 1:250. In order to guarantee the structure’s immobility, temporary supports are positioned beneath the corrugated sheet before concrete is poured.

The flooring is reinforced with metal, and the lower deck is concreted in a single pass along the gutter. Both the floor and the ceiling have level surfaces. Once the ceiling has strengthened, the makeshift supports are taken down. A beam-free monolith’s installation requires some subtlety.

Thus, long reinforcing rods are positioned along each of the profiled sheets’ recesses, featuring regular ribbed notches on their surface. They are fastened to a welded metal mesh that is placed on top of the profile using wire. One pass is made while pouring. The concrete base is covered with a cement screed from above once it has hardened. Installed are load-bearing corrugated sheets with a profile height of 0.8 to 1.5 mm thick, grades H60 to H114, which provide the necessary rigidity of the material.

Drills with a 5.5 mm head that are 3.2 cm long and self-tapping are used to secure profile sheets. This kind of hardware is screwed in without first drilling a channel shelf. To guarantee precision and spatial rigidity, they are screwed in every 20 to 40 cm (into each depression of the profile next to the beam). Only above the surface of the beams (size 40–60 mm) does the longitudinal overlap of sheets occur at joints. Self-tapping screws are used to fasten joints every two centimeters.

Reinforcement

Compression work is provided by the internal metal frame in monolithic concrete, ensuring the slab’s grade strength. The longitudinal sections of reinforcement are placed on the bottom of each stiffener and connected by vertical ties using bonding wire or welding to form the volumetric reinforcement structure. The flat welded mesh has 15 x 15 cm cells. Volumetric bonding involves 20 cm steps. The beams and columns are welded to the ends of the metal rods and mesh.

A steel rod (grade A 400C) measuring between 10 and 12 mm in diameter is used as reinforcement. Longitudinal rods measuring 12 mm in diameter and transverse rods measuring 0.6 cm can be used to create the mesh. Notches, or "reefs," are made on the profile to attach the corrugated sheet to the concrete so that it can function as external reinforcement.

Up to four centimeters of concrete surround the steel within the slab to keep it safe. The metal rods are raised by 20 to 40 mm above the surface of the stiffeners’ bottoms through the use of specialized plastic clamps. Concrete covers the reinforcement by 20 to 40 mm from above as well.

Corrugated sheets combined with concrete flooring is a contemporary solution that combines strength, durability, and adaptability. This flooring technique offers improved structural support, uses less concrete, and speeds up construction by utilizing corrugated metal sheets as a base. Perfect for both residential and commercial applications, it offers a strong surface that can support large weights without sacrificing its sleek, industrial appearance. This method reduces expenses while guaranteeing a durable, low-maintenance flooring solution that satisfies a range of functional and design requirements.

Pouring floors on corrugated sheets

Concrete is applied to the floor in sections or all at once, if at all possible. If this isn’t feasible, a schedule that accounts for the material’s setting time is carefully established. Using pre-made concrete of grade M300 and above that contains a small amount of crushed stone (up to 5 mm) that can seep into the formwork beneath the reinforcement is advised. It is required to press the vibration.

Anti-freeze plasticizers are required in the concrete, which is worked on in both positive and negative air temperatures. The solution is first poured along the site and then into the sheet’s perforations. The mixture is poured to the level of the upper shelf before sheets are fastened to the inner shelf of the I-beam.

To guard against outside influences, the solution is leveled with trowels and "ironized" with dry cement. The minimum thickness for a beam-less floor is 250 mm (measured from the profile’s lower edge); for a beam version, it is between 70 and 80 mm (not including the profile’s height). Regular moisturizing and covering the material with moisture-resistant materials up to 70% of its strength (10–14 days at 20 degrees) are part of the material’s maintenance.

The stone’s ripening process is prolonged in cold weather, so its surface needs to be protected. After 28 days, under ideal circumstances for stone maturity, temporary supports are removed. The substance is prepared for further processing.

For many different building applications, corrugated sheet concrete flooring provides a strong and adaptable option. This technique combines the extra support and flexibility offered by the corrugated sheets with the durability and strength of concrete. This combination is especially useful in places like commercial buildings and industrial warehouses where heavy loads are typical.

The simplicity of installation is one of the main advantages of using corrugated sheets for concrete flooring. By serving as a formwork and reinforcement, the sheets shorten the time needed for construction and save concrete. This reduces project expenses overall while also saving time. Furthermore, the floor is stronger and more resilient because of the corrugated design, which strengthens the bond between the concrete and the sheets.

Durability and upkeep are two more important benefits. Corrugated sheet concrete floors are extremely resilient to deterioration, which makes them perfect for high-traffic areas. They save money in the long run because they require less upkeep. Additionally, the corrugated sheets’ improved structural integrity guarantees that these floors can bear a lot of pressure without breaking or degrading.

Finally, for anyone searching for a durable, reasonably priced, and low-maintenance flooring option, concrete flooring with corrugated sheets is a great option. This technique can improve the longevity and functionality of your floors and is suitable for both commercial and residential applications. You are making a long-term investment in a flooring system when you go with this course of action.

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