Building a monolithic floor out of corrugated board is a useful and doable project for many do-it-yourselfers who want to improve their houses. Concrete is poured over corrugated steel sheets using this technique, creating a sturdy and long-lasting floor. Comprehending the process is essential for a successful project, be it building a new space, adding an extension, or renovating a basement.
Precise computation is the first stage in this undertaking. You must calculate the size of your floor area and the quantity of materials needed. This covers the corrugated steel sheets that will act as the formwork in addition to the concrete. Determine the desired thickness of the concrete slab by measuring it while keeping the floor’s intended use and load-bearing capacity in mind. Accurate computation guarantees that you buy the appropriate amounts and prevent needless expenses or delays.
Careful planning and preparation precede corrugated board installation. The structure that the concrete will be poured onto is provided by these sheets. Start by spreading the sheets out over the whole floor, making sure they are evenly spaced and firmly attached. To evenly support the weight of the concrete, there should be a consistent distance between the sheets. Furthermore, look for any overlaps or gaps that might compromise the integrity of the floor after it has been poured.
It’s time to get the concrete mix ready after the corrugated board is installed. Select an appropriate concrete mix that strikes a balance between strength and workability based on the specifications of your project. As directed by the manufacturer, thoroughly mix the concrete to a uniform consistency that is neither too wet nor too dry. It is important to pay close attention to every detail when mixing this mixture because it will serve as the sturdy base for your monolithic floor.
It is important to pour concrete carefully and quickly. Equally fill the spaces between the corrugated sheets as you move from one corner of the floor to the other. To make sure the concrete covers every part of the formwork, use a shovel or a concrete pump as needed. As you pour, level the surface by sawing back and forth across the tops of the corrugated sheets with a screed board. This stage guarantees a smooth, level finish and aids in the removal of extra concrete.
Give the concrete time to properly cure after pouring. The strength and longevity of the floor depend on curing. To avoid cracks and weak spots caused by rapid drying of the concrete, keep it covered and moist. There are a number of variables that can affect the curing time, including the type of concrete mix and the weather. After the formwork has completely dried, carefully remove it to reveal your newly built corrugated board monolithic floor.
To sum up, building a monolithic floor out of corrugated board is a do-it-yourself project that can be completed with careful thought, accurate math, and methodical execution. You can create a sturdy and long-lasting floor that improves the usability and market value of your space by following these instructions and paying close attention to detail.
Step | Description |
1. Preparation | Clean the area and lay the corrugated board as the base. Make sure it is securely fastened. |
2. Formwork | Set up formwork around the edges to contain the concrete. Ensure it is stable and well-supported. |
3. Reinforcement | Place steel reinforcement bars over the corrugated board. This will strengthen the concrete floor. |
4. Concrete Pouring | Mix the concrete and pour it evenly over the corrugated board, covering the reinforcement bars. |
5. Leveling | Use a screed to level the concrete surface, ensuring it is smooth and even. |
6. Curing | Allow the concrete to cure for several days, keeping it moist to prevent cracks. |
7. Finishing | Once the concrete has fully cured, remove the formwork and your monolithic floor is ready for use. |
- Advantages of a floor with corrugated board
- Calculation of the floor
- Construction of a monolithic overlap
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Advantages of a floor with corrugated board
The following benefits of a corrugated board floor are evident:
- Low cost of material and installation work. Since it is easy to install the floor with your own hands, financial costs remain minimal. The material itself is sold at an affordable price.
- The possibility of implementing any architectural solutions and installing different geometric shapes.
- The pouring process is relatively simple and eliminates the need for formwork. The use of ridges reduces the consumption of concrete mix, which also has a positive effect on the final cost of work.
- Even an inexperienced beginner can complete the installation of the system.
- The finished floor is lighter than a reinforced concrete structure with removable formwork, while its strength properties remain at the highest level. As a result, the system does not place large loads on the foundation and remains an effective solution for old buildings. With the help of a profiled sheet, you can achieve proper distribution of efforts.
- Being an indispensable component of a monolithic structure, corrugated sheets take on the role of a reinforced frame.
- Floor thickness indicators are determined by the place of its operation. In order for them to meet the required standards, a number of calculations need to be performed.
- The finished slab has good strength, and the presence of a metal profile strengthens the structure and gives an increased degree of rigidity.
- There are different brands and types of corrugated sheets available on the market. This expands your choice and allows you to find the best option for any application conditions.
- The material is characterized by increased resistance to ignition. Fire resistance indicators are 30 minutes, and if we are talking about a monolithic system with a reinforced span – 45 minutes.
- The floors between floors are characterized by reinforced formwork, which allows you to arrange the ceiling without a finishing layer or other installation work.
- Profile developments are indispensable for rooms with a metal frame. Reinforcement is used to connect the columns, making the frame rigid and resistant to various negative impacts.
Because profiled sheeting is lightweight, stiff, and resistant to corrosive processes, it is widely used in the construction of buildings for a variety of uses.
Attached to a concrete mixture, it absorbs a portion of the loads that fall upon the floor slabs. The cost of constructing foundations and buying wall materials is decreased because the monolithic element is fixed on a light load-bearing frame. As such, foam blocks or lightweight gas blocks are utilized. The profiled sheeting is poured with concrete mortar without the need for intricate formwork.
The structure will show greater strength and resistance to negative impacts if you adhere to the fundamental operating guidelines and service it on time.
Additionally, corrugated sheet slabs have a minimal weight and a tidy appearance. You can stop worrying about finishing or insulating layers when you install such a solution in your house.
The substance is simple to use and carry.
Calculation of the floor
Planning to construct a floor out of corrugated sheets requires some computations, which should be done in accordance with SNiP, STO, and other standards and requirements. It’s critical to consider the room’s measurements, the cross beams’ length, the imposed load, the step size during installation, and the characteristics of the supporting material. Additionally, note that each sheet along the length rests on three beams. The height of the slab and the thickness of the reinforced elements are determined based on the intended load.
The proportion of 1:30, which is dependent on the spacing between the crossbars, is taken into consideration when choosing the structure’s thickness. The thickness of a monolithic element can range from 70 to 250 mm.
The issue of sheet deflection can be avoided by lowering the span step. The weight of the useful load that the interfloor overlap accepts must also be considered. Three-thirds is added to the standard of 150 kg/m².
It is essential to precisely ascertain the test design loads and the structure weight in order to compute a monolithic overlap. The support beams’ thickness and profile type are influenced by these factors.
Construction of a monolithic overlap
In order to construct a monolithic overlap on corrugated board, a reinforced concrete element must be present.
Corrugated sheet, reinforcing frame, and concrete are the main elements of a corrugated board overlap. A beam frame serves as the foundation for this product, and the columns bear the load rather than the wall structures. Every column has a foundation of its own.
A monolithic overlap on corrugated board is a structure that suggests obtaining a surface for form-forming and increases builders’ capacity to execute intricate projects and geometric shapes.
The choice of a suitable formwork stand is made based on floor height. Products that are telescopic are single and frame. If the height is significant, it is preferable to use a formwork tower and increase the floor’s thickness to 1000 mm.
It is acceptable to use products with a 300 mm thickness at a low height. You must use a wooden glued beam of varying lengths to achieve a complex configuration.
Building a monolithic floor out of corrugated board is a do-it-yourself project that can be completed with accuracy and careful planning. You can get a long-lasting and reasonably priced flooring solution for a variety of applications by knowing the fundamentals of calculation and installation.
Precisely estimating the materials required is essential before beginning any project. Calculate the necessary thickness of the concrete slab by measuring the area where the floor will be installed. Consider the load-bearing capacity required for the particular use—residential, commercial, or industrial—that you have in mind. This computation guarantees that you buy the appropriate quantity of corrugated board and concrete, avoiding waste and costs that aren’t necessary.
When it comes to installation, start by making sure the subfloor is level and clean. As you firmly fasten the corrugated boards to the subfloor, arrange them in a staggered pattern. After the concrete is poured, these boards act as reinforcement and formwork for the slab. Make sure to caulk any spaces between the boards to stop the concrete mixture from leaking.
Next, according to the manufacturer’s instructions, mix the concrete to the proper consistency. Working your way from one end to the other, evenly pour the concrete over the corrugated boards. To ensure that the entire surface of the concrete is smooth, level it with a screed board. Take your time in order to prevent any unevenness or air pockets that might cause the floor to become weaker.
After the concrete has been leveled, let it cure properly for the amount of time that the manufacturer specifies. To stop the floor from cracking during this time, shield it from extreme moisture and temperature changes. Following the first curing period, the formwork can be carefully removed. Care must be taken to prevent any damage to the freshly poured floor.
Lastly, look for any flaws or areas that might need more care on the completed monolithic floor. You can further finish the surface with coatings or treatments to improve its durability and aesthetics, depending on the specifications of your project. Your monolithic floor will last longer with regular maintenance, like cleaning and sealing, so it will continue to be a sturdy and dependable foundation for many years to come.
With confidence, you can complete this do-it-yourself project and create a monolithic floor on corrugated board by following these steps and comprehending the underlying principles. Recall that obtaining a high-quality outcome that satisfies your unique needs and expectations requires careful planning, meticulous execution, and close attention to detail.
We’ll walk you through the steps of building a monolithic floor on corrugated board by yourself in this article from "All about Concrete." Everything will be covered, including how much material you’ll need and how to install it step-by-step. Knowing these methods can help you save time and money when remodeling an area or beginning a new building project. Join us as we break down the calculations and guide you through every step of the installation to guarantee that you get a sturdy floor that satisfies your requirements.