Professional Documents
Culture Documents
Design information and technical data has been provided for the 500 systems only. For details on
the 400 system, please contact the Ultrafloor Technical Department.
Design Criteria
Slab design is based on the following criteria:
! Simply Supported Greater spans can be achieved with extra topping and/or continuity.
! Fwrk Str strength of beams as formwork
! Slab Str strength of slab as composite prestressed slab
! Fwrk Defl serviceability of beams as formwork
! Slab Defl serviceability of slab under Dead and Live Load (deflection limit = L/250)
! LL Defl serviceability of slab under Live Load only (natural frequency limited to
a minimum of 5.0 Hz)
Beams as formwork are designed for 1.0kPa construction loading and 0.9kPa for stacked
materials. Once the topping reaches 15MPa, a stacking load of 4kPa has been allowed for. Slabs
supporting masonry walls are considered to be supporting a 2400mm high single brick wall. The
wall is deemed to be parallel to the beam span. A deflection limit of L/1000 is an additional design
criterion for slabs supporting masonry.
In addition to the self-weight of the concrete topping, the FC formboard has been designed to carry
a live load of 4kPa to cater for stacked materials, mounding of concrete and the workmen.
The following tables are all based upon 50mm topping concrete over top of beams, 25MPa
concrete topping and SL62 shrinkage control mesh.
SLAB SUPPORTING
130R-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
LIVE LIVE LOAD + 1.0 kPa SDL
(SDL 3.5kPa)
LOAD
BEAMS FREE SPANNING BEAMS PROPPED MIDSPAN BEAMS FREE SPANNING
kPa
ALLOWABLE DESIGN ALLOWABLE DESIGN ALLOWABLE DESIGN
SPAN (m) CRITERIA SPAN (m) CRITERIA SPAN (m) CRITERIA
1.5 4.00 Fwrk Str 5.90 Slab Str 4.00 Fwrk Str
2.0 4.00 Fwrk Str 5.65 Slab Str 4.00 Fwrk Str
2.5 4.00 Fwrk Str 5.40 Slab Str 4.00 Fwrk Str
3.0 4.00 Fwrk Str 5.20 Slab Str 4.00 Fwrk Str
Design Composite Slab
4.0 4.00 Fwrk Str 4.80 Slab Str 4.00 Fwrk Str
Properties Properties/m
5.0 4.00 Fwrk Str 4.50 Slab Str 4.00 Fwrk Str
Weight of slab: Area: 115344 mm2
2.89 kPa 7.5 3.95 Slab Str 3.95 Slab Str 3.60 LL Defl
Igross: 212.0 x E6mm4
Beam weight: 10.0 3.55 Slab Str 3.55 Slab Str 3.10 LL Defl
34 kg/m Mu: 31.7 kNm
15.0 2.50 Slab Str 2.50 Slab Str 2.30 LL Defl
SLAB SUPPORTING
130C-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
LIVE LIVE LOAD + 1.0 kPa SDL
(SDL 3.5kPa)
LOAD
kPa BEAMS FREE SPANNING BEAMS PROPPED MIDSPAN BEAMS FREE SPANNING
LL Defl
15.0 3.50 Slab Str 3.50 Slab Str 3.20 Slab Str
SLAB SUPPORTING
150R-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
LIVE LOAD + 1.0 kPa SDL
(SDL 3.5kPa)
LIVE
LOAD
BEAMS FREE SPANNING BEAMS PROPPED MIDSPAN BEAMS FREE SPANNING
kPa
2.81 kPa 2 4.0 4.50 Fwrk Str 5.80 Slab Str 4.50 Fwrk Str
Area: 111724 mm
Beam weight: 4 5.0 4.50 Fwrk Str 5.35 Slab Str 4.50 Fwrk Str
Igross: 277.5 x E6mm
41 kg/m
7.5 4.10 Slab Str 4.10 Slab Str 3.80 Slab Str
Mu: 45.6 kNm
10.0 3.55 Slab Str 3.55 Slab Str 3.15 Slab Str
15.0 2.55 Slab Str 2.55 Slab Str 2.35 Slab Str
SLAB SUPPORTING
150C-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
LIVE LIVE LOAD + 1.0 kPa SDL
(SDL 3.5kPa)
LOAD
BEAMS FREE SPANNING BEAMS PROPPED MIDSPAN BEAMS FREE SPANNING
kPa
ALLOWABLE DESIGN ALLOWABLE DESIGN ALLOWABLE DESIGN
SPAN (m) CRITERIA SPAN (m) CRITERIA SPAN (m) CRITERIA
Mu: 57.4 kNm 15.0 3.60 Slab Str 3.60 Slab Str 3.40 Slab Str
SLAB SUPPORTING
200C-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
LIVE LIVE LOAD + 1.0 kPa SDL
(SDL 3.5 kPa)
LOAD
BEAMS FREE SPANNING BEAMS PROPPED MIDSPAN BEAMS FREE SPANNING
kPa
ALLOWABLE DESIGN ALLOWABLE DESIGN ALLOWABLE DESIGN
SPAN (m) CRITERIA SPAN (m) CRITERIA SPAN (m) CRITERIA
Weight of slab:
Properties/m 5.0 7.00 Fwrk Str 7.35 Slab Str 6.60 Slab Str
3.52 kPa Area: 145000 mm2 7.5 6.50 Slab Str 6.50 Slab Str 5.95 Slab Str
Beam weight:
112 kg/m Igross: 728.5 x E6mm4 10.0 5.85 Slab Str 5.85 Slab Str 5.45 Slab Str
Mu: 89.5 kNm 15.0 4.60 Slab Str 4.60 Slab Str 4.30 Slab Str
SLAB SUPPORTING
250C-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
LIVE LIVE LOAD + 1.0 kPa SDL
(SDL 3.5 kPa)
LOAD
BEAMS FREE SPANNING BEAMS PROPPED MIDSPAN BEAMS FREE SPANNING
kPa
ALLOWABLE DESIGN ALLOWABLE DESIGN ALLOWABLE DESIGN
SPAN (m) CRITERIA SPAN (m) CRITERIA SPAN (m) CRITERIA
50 4.4 4.1 4.9 4.7 4.8 4.5 5.8 5.5 7.9 7.6 10.3 9.9
60 4.3 4.1 4.8 4.6 4.7 4.4 5.6 5.4 7.7 7.4 10.1 9.7
70 4.2 4.0 4.7 4.5 4.6 4.3 5.5 5.3 7.6 7.3 9.9 9.6
100 4.0 3.7 4.5 4.2 4.3 4.0 5.2 5.0 7.2 6.9 9.5 9.1
60 + setdown
3.9 3.6 4.5 4.2 4.1 3.7 5.1 4.8 6.8 6.5 8.6 8.1
clips
Note : These spans are based on the weight of the wet concrete plus a 1.0 kPa construction
loading only.
The following steps are involved in the design of the Ultrafloor system when used in ground floor
construction and may be used as a checklist by the design engineer:
1. Determine the design live load for the floor. Refer to AS1170.1 SAA Loading Code, Part 1:
Dead and live loads and load combinations.
2. Determine the available lines of support, for example masonry dwarf walls, retaining walls,
bearers and piers, etc.
3. Determine the maximum span between the available lines of support nominated in Step 2.
4. Select an Ultrafloor system using the load / span tables in Section 7.1.1. Input the design
live load and the maximum span.
a) Use the left-hand part of the design table if all internal partitions and walls that are
supported by the floor are of lightweight construction (timber or metal stud).
b) Use right-hand part of the design table if the floor supports non-loadbearing brick walls
of height up to 2.4m.
5. Are the spans such that the load / span tables indicate the need for propping?
6. Does the floor support any concentrated loads due to columns or loadbearing walls bearing
on the floor?
YES: Refer to Section 7.7.2 for details regarding design for concentrated loads.
NO: Continue to Step 7.
YES: Refer to Section 7.3 for details regarding design of Ultrafloor bearers.
NO: Continue to Step 8.
8. Does the slab need to be designed as continuous to achieve larger spans for the selected
system than allowed by the span tables?
YES: Refer to Section 7.7.4 for details regarding designing for continuity.
NO: Continue to Step 9.
YES: Refer to Section 8.3 for details regarding trimming voids with saddle supports.
NO: Continue to Step 11.
YES: Refer to Section 7.8 for details regarding design for durability.
NO: Continue to Step 12.
12. Does the floor require wet area set-downs in the finished floor level?
YES: Refer to Section 8.4.3 for details regarding wet area set-down.
NO: Continue to Step 13.
14. Refer to Section 8.1.1 and the construction details in Section 10 for common details for
supporting Ultrafloor systems in ground floor construction.
The following steps are involved in the design of the Ultrafloor system when used in multi-storey
construction and may be used as a checklist by the design engineer:
1. Determine the design live load for the floor. Refer to AS1170.1 SAA Loading Code, Part 1:
Dead and live loads and load combinations.
2. Determine the available lines of support, for example load bearing walls, steel or concrete
beams etc.
3. Determine maximum span between the available lines of support nominated in Step 2.
4. Select an Ultrafloor system using the load / span tables in Section 7.1.1. Input the design live
load and the maximum span.
a) Use the left-hand part of the design table if all internal partitions and walls that are
supported by the floor are of lightweight construction (timber or metal stud).
b) Use the right-hand part of the design table if the floor supports non-loadbearing brick
walls of height up to 2.4m.
5. Are the spans such that the load / span tables indicate the need for propping?
6. Does the floor support any concentrated loads due to columns or loadbearing walls bearing
on the floor?
YES: Refer to Section 7.7.2 for details regarding design for concentrated loads.
NO: Continue to Step 7.
7. Does the building need to be designed for progressive collapse or earthquake design?
8. Does the slab need to be designed as continuous to achieve larger spans for the selected
system than allowed by the span tables?
YES: Refer to Section 7.7.4 for details regarding designing for continuity.
NO: Continue to Step 9.
YES: Refer to Section 8.3 for details regarding trimming voids with saddle supports.
NO: Continue to Step 11.
YES: Refer to Section 7.8 for details regarding design for durability.
NO: Continue to Step 12
12. Does the floor require wet area set-downs in the finished floor level?
YES: Refer to Section 8.4.3 for details regarding wet area set-down.
NO: Continue to Step 13.
YES: Refer to Section 8.9.3 for details regarding fire and sound separation.
NO: Continue to Step 16.
17. Refer to Section 10 for common details for supporting Ultrafloor systems on load bearing
masonry, steel beams, reinforced concrete beams and post tensioned band beams.
The Ultrafloor system consists of prestressed concrete beams, which act as formwork to support
the weight of a concrete topping and construction loads. When the topping has cured, it acts
compositely with the beams to form a slab capable of supporting the superimposed loads.
The design method is based on Limit State design principles as well as the following Australian
Standards:
AS 1170 2002, SAA Loading Code, Part 1: Dead and live loads and load combinations.
The design process is in two stages: [1] the Ultrafloor beams as formwork, and [2] the composite
slab under design loads. At each stage, checks must be made for strength and serviceability.
The Ultrafloor beams may be simply-supported or continuous. In either case, the composite slab
may be designed as simply-supported, or, by the addition of negative moment reinforcement over
internal supports, as continuous. The load tables in this manual are for the simply-supported slab
condition. It is for the design engineer to design each continuous slab individually.
Verification of the behaviour of the Ultrafloor system (particularly of properties such as ductility,
longitudinal shear transfer, transverse shear capacity, the distribution of line loads across beams,
fire resistance etc) has been carried out by extensive testing, as referred to in Section 3.4.
7.2.2.1 As Formwork
A. LOADING
B. DESIGN
The beams are checked for strength and serviceability criteria. If the beams are propped as
formwork, then they are designed as a series of simply-supported beams, spanning between
props.
1. Bending strength is checked under the above loads against the non-composite capacities
for ultimate moment given in the tables of Section 7.1.1.
2. Shear strength is also checked under the above loads. The shear capacity is the minimum
of the flexure-shear and web-shear capacities.
3. Flexure-shear strength at various locations along the beam using the decompression
moment and shear force at each point.
The flexure-shear strength at x from the support can be determined, after calculating V*/M*
as that point, as:
where Vuc1 is in tabulated in Section 7.5.2.1 and M0 is found from Figure 7.5.2.1a.
Web-shear strength for the non-composite case is also tabulated in Section 7.5.2.1.
5Gl 4 Pel 2
formwork =
384 EI nc 8 EI nc
where L = clear unpropped span
Inc = beam moment of inertia, non-composite
e = eccentricity of centroid of prestress below the neutral axis
P = prestressing force
E = Youngs elastic modulus (noting that Ultrafloor beams reach
a compressive strength of typically 50MPa after 48 hours.
5. The working moment due to Quv and G (factored accordingly) must be less than the cracking
moment of the Ultrafloor beam.
7.2.2.2 As Bearers
Design principles are similar to those for formwork except that the design loads are as per
AS 1170.1 2002, SAA Loading Code, Part I: Dead and live loads and combinations.
Flexure-shear cracking could occur in regions of the beams which are cracked in flexure.
BS 8110 would only require this to be checked where M* > M0, the decompression moment.
Ultrafloor load tables are based on a check for flexure shear capacity, in accordance with
Clause 8.2.7.2 of AS 3600, at numerous sections from the critical section, d from supports, to
the midspan of the beams as formwork.
2 =1
3 = 1 (note that the shear enhancement of 2d0/av permitted under AS 3600 for
strut action has not been adopted. To do so would require increased
anchorage length)
ie V0 = M0 V*/M*
Pe Pe e
Mo = Zb +
A Zb
A prestress force, Pe, equal to 85% of the jacking force has been used to allow for immediate
losses, plus shrinkage and creep losses, at 30 days.
To determine the decompression stress, the prestress force Pe is taken to develop linearly from
zero at Lp/10 from the end of the beam, to full prestress at Lp from the end of the beam. Lp is taken
as 60 times the strand diameter, in accordance with AS 3600 Clause 13.3.2.
Since V0 can vary with the location along the span, the load distribution, and the length of bearing,
it is not possible to determine a specific Vuc for each beam.
To assist designers in checking shear, Section 7.5.2.1 of this manual can be used. This enables
the shear strength at any location to be easily calculated once the designer has determined V*/M*
at that location.
The shear strength at x from the support can be determined, after calculating V*/M* at that point,
as:
Web-shear cracking could occur in regions of the beams near the supports which are uncracked.
It has been checked in accordance with AS 3600 Clause 8.2.7.2.(b), (or by testing) but at a
distance from the support equal to the height of the centroid from the bottom of the beam. This is
the location required by BS 8110 and is more conservative that at d. The results are tabulated in
Section 7.5.2.1.
A minimum length of bearing of 60mm has been set so that the theoretically unstressed length of
tendon, Lp/10 = 56mm from the end, is outside the shear design region. The bearing length used
in testing was only 40mm.
In the composite state, the Ultrafloor system is considered as a slab. In accordance with
Clause 8.2.5(c)(ii) of AS 3600, shear reinforcement is not required if V* < Vuc.
Loading
Composite loadings are based on AS 1170.1. For strength this is as below:
Q = LL as in AS 1170 Part 1
Design
The composite slab is checked for strength and serviceability.
1. Bending strength is checked under the above loads against the composite design moment
capacity described below.
2. Shear strength is also checked under the above loads. The shear capacity is the minimum of
flexure-shear and web-shear capacities. The method of calculations is the same as for the
non-composite situation, however the tables and figures in Section 7.5.4.4 are used.
3. Longitudinal shear should also be checked at the interface of the Ultrafloor beams and the
topping from Clause 8.4.3 of AS 3600.
fct = 0.4 fc and is based on the weaker concrete, generally the topping.
In an unpropped slab, the unfactored slab self-weight is not included in the longitudinal shear
calculation.
Relevant section properties, composite or non-composite, are used depending on the condition
of the slab in relation to the type of deflection being calculated. For the composite condition, an
average value of E can be used throughout based on fc = 45MPa for the full section. Note that
the Ultrafloor beams reach a compressive strength of typically 50MPa after 48 hours.
a) Springiness
Deflection of the composite section is checked under LL only against a limit of L/1200. This
is to guard against springiness with tendons rebounding.
b) Long Term
Short-term deflection = ST
using 0.8 x prestress to account for losses; Icomposite with full service loads
d) Total Deflection is calculated from short-term deflection and creep, and checked as
follows:
Deflection
The principles are as for the unpropped case except that composite section properties are used for
all cases, and there is no deflection under construction loads at the midspan location.
Design
Bending strength is checked under the above loads against the composite design moment
capacity, similarly to a simply supported slab.
Positive Moments:
The design ultimate positive moment is calculated as a simply supported moment for 1.0 x self-
weight (of beams + wet concrete), plus a continuous slab moment for 0.25 x self-weight + 1.25 x
SDL + 1.5 x LL.
Negative Moments:
Negative reinforcement can be designed similarly to a conventionally reinforced continuous slab
by incorporating solid concrete blockouts over the peak negative moment regions as required.
Consideration can be given to using the Ultrafloor beams to carry the compression loads.
The design negative moment is only due to an effective load of 0.25 x self-weight + 1.25 x SDL
+ 1.5 x LL.
2. Ultrafloor slabs are designed for flexure shear to AS 3600 Clause 8.2.
The ultimate shear capacity, Vuc, at the external support of a continuous slab is checked in a
similar manner to a simply supported slab, from AS 3600 Clause 8.2.7.2.(a). To determine the
decompression stress, the prestress force is taken to develop linearly from zero at Lp/10 from
the support to full prestress at Lp from the support, where Lp = 60 times the strand diameter.
At internal supports, where the slab is in tension at the top, Vuc is calculated from AS 3600
Clause 8.2.7.1, where Ast is the area of top reinforcement.
3. Longitudinal shear should also be checked at the interface of the Ultrafloor beams and the
topping from AS 3600 Clause 8.4.3.
fct = 0.4fc and is based on the weaker concrete, generally the topping
In an unpropped slab, the slab unfactored self-weight is not included in the longitudinal shear
calculation.
Positive Moments
During the non-composite stage, ie under self-weight, FRC and wet concrete loads, the beams are
designed in the same way as for a propped simply supported slab design at the same stage (ie for
formwork design). The maximum span with one row of props is double that span obtained for the
unpropped case as no continuity is considered.
For the composite stage the Design Moment Capacity, Mu is as tabulated in Section 7.5.3.
The design positive moment is calculated as a continuous slab moment for the total factored DL +
LL. The central prop load is approximated by including slab DL as a uniform load on the composite
section.
Negative Moments
Negative reinforcement can be designed similarly to a conventionally reinforced continuous slab by
incorporating solid concrete blockouts over the peak negative moment regions. Consideration can
be given to using the Ultrafloor beams to carry the compression loads.
Short-Term Deflection
1. Calculate the deflection at beam placement.
If propping is to occur then it would normally be at this level. A pre-camber could be applied using
the propping. Its effects could be accounted for by increasing the load of the in-situ concrete
applied to the composite slab by an amount equivalent to the reaction from the pre-camber.
2. For unpropped beams calculate the deflection of the beams under wet in-situ concrete.
For a continuous composite slab a model needs to be developed which accounts for the
effects of cracking, and uses an effective moment of inertia.
At Midspan fc = 70MPa
where dn = k.d
5. It is necessary to estimate the location of the regions of cracked and uncracked section of slab.
When the slab is continuous a model needs to be developed which accounts for the effects of
cracking, under serviceability loads, and uses an effective moment of inertia.
Serviceability load is defined at DL* + sLL, where s is given in AS 1170 Part 1 and is
generally 0.7.
! If the beams are unpropped, then the DL to be used is only that which is superimposed,
i.e. it does not include the weight of the beams, FRC or in-situ concrete. This is because
the cracked sections under serviceability load are generally over the supports, and, in an
unpropped situation, the moments at supports are only due to superimposed loads. The
beam self-weight, FRC and in-situ concrete weight has been taken by the beams alone
(non-composite) when the in-situ concrete is placed.
! If the beams are propped, then the DL to be used includes the in-situ concrete but not the
weight of the beams or FRC. This assumes that the props hold the beams at their
installation level. Although strictly speaking the prop reaction is a point load, it is
acceptable to consider the deflection under the in-situ concrete load as being due to a
uniform load on the full composite slab after prop removal. Unless the propping induces a
pre-camber, the in-situ concrete is the only load transferred onto the composite slab from
the non-composite stage. If a precamber is introduced by the propping, then the DL must
be increased by an amount to give an equivalent moment to the that produced by the prop
reaction from precambering.
An elastic analysis can be used, with a uniform stiffness, as an estimate of Ms (moments under
serviceability loads) at the salient points. Areas of cracked section can be located where
Ms > Mcr.
6. Calculate the effective moment of inertia at the salient points, using the relationship in
AS 3600 1994 Clause 8.5.3.1:
7. Model the slab with I = Ief ie varying throughout the span, to calculate short-term serviceability
deflections, serv and moments. This is not strictly accurate as the location of the cracked
sections derived in step 5 was based on uniform stiffness. An iterative process could be
undertaken to recalculate Ieff using moments derived from the step 7 model as Ms, and then re-
run the model with the revised Ieff.
If it is desired to ascertain the immediate deflection after prop removal less conservatively, then
Ms could be based on DL only to calculate Ieff. However, Ieff would need to be reassessed with
full serviceability load, for use in calculating short-term deflection including LL.
However, it should be remembered that many factors make calculation of deflections of precast,
prestressed composite systems an estimate only. Examples are:
The effect of construction loads on the plain plank, and whether it cracks during construction.
The age of the composite system when permanent dead loads are applied.
The inherent stiffness of some superimposed dead loads, compared to the flexibility of the structure,
causing redistribution of those dead loads.
The possibility of some service loads causing undue vibration, especially when the prestressing has
been designed to balance the effect of long-term loads, which theoretically leads to zero deflection.
The location, magnitude, timing and duration of service loads applied during the life of the structure,
and whether any of them cause the composite system to crack.
The restraint to shrinkage by the topping reinforcement and plank, and the distribution of the resultant
shrinkage cracks.
LONG-TERM DEFLECTION
Creep
Creep calculations require the determination of the sustained loads, which act on the composite
section. Sustained loads are taken as DL = l.LL from AS 1170 pt 1, where l is generally 0.4.
This loading will be less than the short serviceability loading of DL + sLL where s is generally
0.7. It is therefore necessary to use the cracked regions and properties determined for the short
term loading case.
Creep occurs under sustained loads and under prestressing loads (basically another type of
sustained load), and is calculated by factoring up the short-term deflection caused by these loads.
Short-term deflection under sustained loads, short term sust is determined from the elastic analysis of
step 5 above, using sustained loads DL + l.LL. Prestress deflection to be factored for creep is
calculated on the composite section as:
The creep factor can be calculated from AS 3600 Clause 8.5.3.3 as:
Therefore,
creep = C [ short term sustained 0.8 pre short term for creep]
1. Short-Term L/360
2. Long-Term
Total L/250
3. Springiness
We recommend the natural frequency of the slab be kept to a minimum of 5.0 Hz. This is to guard
against springiness with tendons rebounding.
Ultrafloor prestressed beams can be used as bearers to support Ultrafloor systems in ground floor
construction. The bearers can be supported on isolated and/or engaged piers. The 170R bearer
section has been developed specifically for this purpose. It courses with two courses of standard
brickwork. When high loads or large spans need to be designed for, double 170R bearers are the
preferred option for ease of construction. The commercial range of beams are very efficient for this
purpose, however, particular care is required to achieve correct levels on the supporting piers, as
these beams do not course easily with brickwork.
Ultrafloor bearers shall be designed to suit the applied loads and the required span between
supports by a professional engineer. The necessary properties and engineering information for the
non-composite beam sections is contained in Section 7.5.1 and are repeated in the bearer data
sheets in this section. Deflection information and load/span tables for the common bearer sections
follow. Construction details for Ultrafloor bearers are included in Section 8.1 as well as Section 10
of this manual.
80 Weight 41 kg/m
130
Youngs modulus of elasticity (Ec) 33840 MPa
Notes:
1. L = Beam span (mm).
2. DLslab = Dead load deflection of bearer due to slab loads (mm).
3. wall = Dead load deflection of bearer due to wall loads (mm).
4. LL = Live load deflection of bearer (mm).
5. The self-weight of the bearer has been allowed for in these deflection formulae.
Notes:
1. Allowable spans are based on the total working load being in the proportion of 60% Dead
Load and 40% Live Load.
2. Self-weight is allowed for in the tables.
Notes:
1. L = Beam span (mm).
2. Dlslab = Dead load deflection of bearer due to slab loads (mm).
3. wall = Dead load deflection of bearer due to wall loads (mm).
4. LL = Live load deflection of bearer (mm).
5. The self-weight of the bearer has been allowed for in these deflection formulae.
Notes:
1. Allowable spans are based on the total working load being in the proportion of 60% Dead
Load and 40% Live Load.
2. Self-weight is allowed for in the tables.
Long term deflection after construction of = 5.011E-15 * L - 1.1272E - 07 * L + 2.025 * DLslab + 3.025 * wall + 1.91*LL
walls(including shrinkage and creep)
Notes:
1. L = Beam span (mm).
2. DLslab = Dead load deflection of bearer due to slab loads (mm).
3. wall = Dead load deflection of bearer due to wall loads (mm).
4. LL = Live load deflection of bearer (mm).
5. The self-weight of the bearer has been allowed for in these deflection formulae.
Notes:
1. Allowable spans are based on the total working load being in the proportion of 60% Dead Load and
40% Live Load.
2. Self-weight is allowed for in the tables.
Notes:
1. L = Beam span (mm).
2. DLslab = Dead load deflection of bearer due to slab loads (mm).
3. wall = Dead load deflection of bearer due to wall loads (mm).
4. LL = Live load deflection of bearer (mm).
5. The self-weight of the bearer has been allowed for in these deflection formulae.
Note:
1. Allowable spans are based on the total working load being in the proportion of 60% Dead Load and
40% Live Load.
2. Self-weight is allowed for in the tables.
A further innovation to the Ultrafloor slab system is to replace the formwork also in conventional
band beams by using specially precast flat soffit shell-beams in a system known as Ultrashell as
shown in Section 4.3.2. Its design is described in Section 7.4.7 below along with further diagrams.
No fibre-cement formboard is used in this instance. It can be post-tensioned or reinforced for
further strength capacity.
The standard Ultrafloor beams and slab therefore are supported by primary beams that have been
created using the same concept designed to reduce formwork and reinforcement placing.
In order to achieve full cost savings in the structure, it is imperative to make use of the structural
capacity of the band system, rather than merely seeing it as a substitute for formwork.
Structural testing (refer to Section 3.4) has shown conclusively that in the concreted state, full
composite action occurs, resulting in a monolithic band beam that carries the required design
actions. Propping is required during concreting until a minimum concrete compressive strength of
22MPa is achieved. For the calculation of propping to the band beams during construction, the
cracking moment (Mcr) is never exceeded (for most cases 1.5m to 1.8m centres is normally
sufficient).
To determine the capacity of the Ultrashell system, one calculates it in the usual manner in
accordance with the relevant codes of practice using the quantities of 9.3mm diameter strand at a
particular effective depth.
Refer to Section 7.5.1 for properties (non-composite) of the range of Ultrashell sections and
Section 7.5.2.2 for the properties of the prestressing strands.
For most normal spans (6-8m) and normal loadings (2-4kPa) very little, if any, additional bottom
reinforcement is required over and above the Ultrafloor band beam systems. Top steel and ties
would generally be the only additional requirement.
In the Ultrashell sections, the cover to the bottom strand is effectively 35mm. The minimum floor
thickness is in the range 190mm to 290mm. This results in a fire rating of at least three hours if the
system is used for structural benefit, namely an FRL of 180/180/180. For greater fire resistance (eg
4 hours), extra cover (eg 40mm) is required.
In selecting the dimensions of the Ultrashell system, it is important to remember that the system is
modularised and is built up as such.
Ultrashell rib-slab comes in modules of 600mm and 1200mm widths and depths of 100mm,
150mm, 200mm and 250mm. Therefore band depths are determined by adding the above options
to the slab depth.
The use of conventionally formed band beams with Ultrafloor slabs has been extensive prior to the
introduction of the Ultrafloor band systems. The minimum embedment of Ultrafloor beams into a
conventional band beam is 150mm for internal spans and 250mm for edge beam embedment.
2Y12 ties are typically placed between each Ultrafloor beam.
It is usual that the 600mm wide Ultrashells are used in order to make the lifting on site easier, and
it is furthermore usual that two 600mm widths are used to form a 1200mm band beam as shown in
Figure 7.4.6a. It is only where greater load capacity is required that an Ultrashell band of wider
than 1200mm would be designed.
Floor depths vary depending on the topping slab depth, namely by adding 100, 150, 200 or 250
millimetres of depth for the precast band beam profile. The minimum recommended topping depth
is 60mm and hence the least band beam thickness is 160mm.
The bending moment capacity can be calculated by considering that each 600mm module has
8 x 9.3mm diameter prestressing strands (six bottom and two top). An approximation method
described at Section 7.4.2.
Figure 7.4.7a shows how the Ultrafloor band beam systems are constructed relative to a structural
column.
b
UNITS 130R 150R 170R
Depth of section (a) mm 130 150 170
Width of section (b) mm 130 130 130
Depth of flange (c) mm 70 100 70
Mass of section kg/m 34 41 41
2
Gross area mm 13470 16440 16790
4 6 6 6
Second moment of area (I Gross) mm 18.5x10 29.5x10 41.8x10
Youngs Elastic Modulus (Ec) MPa 33840 33840 33840
pos
Positive moment capacity (Mu ) kNm 6.1 8.4 10.6
pos
Positive cracking moment (Mcr ) kNm 4.7 6.1 8.2
neg
Negative moment capacity (Mu ) kNm 3.8 7.7 8.4
neg
Negative cracking moment (Mcr ) kNm 2.2 4.4 4.8
See Section
Shear capacity (Vuc) kN
7.5.2.1
b
UNITS 130C 150C 200C 250C
Depth of section (a) mm 130 150 200 250
Width of section (b) mm 190 250 250 250
Depth of flange (c) mm 70 100 150 200
Mass of section kg/m 51 80 112 142
2
Gross area mm 21530 34270 47180 56850
4 6 6 6 6
Second moment of area (I Gross) mm 31.2x10 64.8x10 157.1.0x10 306.3x10
Youngs Modulus (Ec) MPa 33840 33840 33840 33840
pos
Positive moment capacity (Mu ) kNm 12.1 18.2 39.6 61.9
pos
Positive cracking moment (Mcr ) kNm 8.7 12.1 23.2 42.1
neg
Negative moment capacity (Mu ) kNm 10.3 15.8 24.7 27.8
neg
Negative cracking moment (Mcr ) kNm 5.6 9.00 12.8 15.1
See
Shear capacity (Vuc) kN Section
7.5.2.1
The shear strength at x from the support can be determined, after calculating V*/M* at that point,
as:
Web-shear Cracking
Web-shear cracking could occur in regions of the beams near the supports that are uncracked. It
has been checked in accordance with AS 3600 Clause 8.2.7.2(b), (or by testing) but at a distance
from the support equal to the height of the centroid from the bottom of the beam. This is the
location required by BS 8110 and is more conservative that at d. The results are tabulated below.
A minimum length of bearing of 60mm has been set so that the theoretically unstressed length of
tendon, Lp/10 = 56mm from the end, is outside the shear design region. The bearing length used in
testing was only 40mm.
The tendons used for prestressing the Ultrafloor components comply with Clause 6.3 of AS 3600
and the structural design properties are as follows:
The following notes apply to all of the design data presented below:
3. DL is the deflection due to Superimposed Dead Loads. The self-weight of the floor is already
included in the formula.
4. The calculation of LL and DL also include the summation of all point and distributed loads.
Beams may be grouped together to resist the applied loads. The applied loads shall be
apportioned to a beam configuration on the basis of the relative stiffness. Refer to Section
7.7.2 for details.
Unpropped Deflections:
Long term deflection = 3.8152E-14 * L - 9.5414E-07 * L + 1.5 * LL + 3.0 * DL
Deflection after construction of walls = 1.0422E-14 * L - 6.7555E-07 * L + 1.5 * LL + 2.0 * DL
Propped Deflections:
Long term deflection
= 2.1197E-14 * L - 9.5414E-07 * L + 1.5 * LL + 3.0 * DL
Deflection after construction of walls
(props removed after wall is constructed); = 1.3211E-14 * L - 6.7555E-07 * L + 1.5 * LL + 3.0 * DL
Unpropped Deflections:
Long term deflection = 2.1538E-14 * L - 9.4173E-07 * L + 1.42 * LL + 2.8 * DL
Deflection after construction of walls = 7.4780E-15 * L - 6.5670E-07 * L + 1.42 * LL + 1.8 * DL
Propped Deflections:
Long term deflection
= 1.5262E-14 * L - 9.4173E-07 * L + 1.42 * LL + 2.8 * DL
Deflection after construction of walls
= 8.1777E-15 * L - 6.5670E-07 * L + 1.42 * LL + 2.8 * DL
(props removed after wall is constructed);
Unpropped Deflections
Long term deflection = 2.8782E-14 * L - 1.1206E-06 * L + 1.4 * LL + 2.74 * DL
Deflection after construction of walls = 8.4078E-15 * L - 8.9769E-07 * L + 1.4 * LL + 1.74 * DL
Propped Deflections
Long term deflection = 1.7679E-14 * L - 1.1206E-06 * L + 1.4 * LL + 2.74 * DL
Deflection after construction of walls
(props removed after wall is constructed) = 1.0617E-14 * L - 8.9769E-07 * L + 1.4 * LL + 2.74 * DL
Deflection after construction of walls = 7.8093E-15 * L - 8.9769E-07 * L + 1.4 * LL + 1.74 * DL
(props removed before wall is constructed)
Propped Deflections
Long term deflection
= 1.1845E-14 * L - 7.3977E-07 * L + 1.5 * LL + 3.0 * DL
Deflection after construction of walls
(props removed after wall is constructed) = 1.1833E-14 * L - 6.7211E-07 * L + 1.5 * LL + 3.0 * DL
Propped Deflections
Long term deflection
= 1.4531E-14 * L - 6.8967E-07 * L + 1.5 * LL + 3.0 * DL
Deflection after construction of walls
= 9.2406E-15 * L - 5.9647E-07 * L + 1.5 * LL + 3.0 * DL
(props removed after wall is constructed)
Propped Deflections
Long term deflection
= 1.1997E-14 * L - 6.0402E-07 * L + 1.38 * LL + 2.71 * DL
Deflection after construction of walls
= 6.9661E-15 * L - 5.0938E-07 * L + 1.38 * LL + 2.71 * DL
(props removed after wall is constructed)
Unpropped Deflections
Long term deflection = 1.4237E-14 * L - 6.0281E-07 * L + 1.44 * LL + 2.85 * DL
Deflection after construction of walls = 5.9511E-15 * L - 5.0617E-07 * L + 1.44 * LL + 1.85 * DL
Propped Deflections
Long term deflection
Deflection after construction of walls = 1.0920E-14 * L - 6.0281E-07 * L + 1.44 * LL + 2.85 * DL
6.1478E-15 * L - 5.0617E-07 * L + 1.44 * LL + 2.85 * DL
(props removed after wall is constructed) =
Propped Deflections
Long term deflection
= 8.1024E-15 * L - 6.2902E-07 * L + 1.5 * LL + 3.0 * DL
Deflection after construction of walls
= 5.1732E-15 * L - 4.6786E-07 * L + 1.5 * LL + 3.0 * DL
(props removed after wall is constructed)
Unpropped Deflections
Long term deflection = 8.1033E-15 * L - 5.7223E-07 * L + 1.45 * LL + 2.87 * DL
Deflection after construction of walls = 3.8486E-15 * L - 4.0715E-07 * L + 1.45 * LL + 1.87 * DL
Propped Deflections
Long term deflection
= 6.5541E-15 * L - 5.7223E-07 * L + 1.45 * LL + 2.87 * DL
Deflection after construction of walls
= 3.8390E-15 * L - 4.0715E-07 * L + 1.45 * LL + 2.87 * DL
(props removed after wall is constructed)
1. Determine the imposed bending moment M* due to all loads imposed on the section of slab
under consideration (concentrated and distributed loads plus self-weight).
2. The total imposed ultimate moment can be proportioned to each of the beam elements within
the effective load width as outlined in Section 7.7.2. The moment capacity of each beam
element within the effective load width is checked against the composite moment capacity
tabulated in Section 7.5.3.
Composite beam elements of this shape are referred to as Beam Configuration 1 or BC1
Composite beam elements of this shape are referred to as Beam Configuration 2 or BC2
Composite beam elements of this shape are referred to as Beam Configuration 3 or BC3
4. If a grouping of two beams is insufficient to resist the flexure actions, a structural steel or
concrete beam should be used to support the load concentration.
1. Determine imposed ultimate shear force V* due to all loads imposed on the section of slab
under consideration (concentrated and distributed loads plus self-weight).
2. The total imposed shear force can be proportioned to each of the beam elements within the
effective load width as outlined in Section 7.7.2. The shear capacity of each beam element
within the effective load width is checked against the composite shear capacities contained in
Section 7.5.4.4.
3. If a grouping of two beams is insufficient to resist the shear actions, a structural steel or
concrete beam should be used to support the load concentration.
Refer to Section 7.2 for the principles adopted for deflection calculation.
1. Determine the dead load deflection and the live load deflection for the critical beam element
within the effective load width determined in the flexure and shear calculation. Use the full
unfactored dead and live load attributed to that element.
Deflection formulas for each of the systems are included in Section 7.5.3 Composite sections
properties and capacities.
The shear strength at a distance x from the support can be determined, after calculating V*/M* at
that point, as:
Vuc = Vuc1 + M0 (V*/M*)
where Vuc1 is given below:
Web-shear Cracking
Web-shear cracking can occur in regions of the beams near the supports that are uncracked due
to flexure. The capacity, Vuc, has been calculated in accordance with AS 3600 Clause 8.2.7.2 (b),
as for non-composite design, and checked against V* at d from the support. The results are
tabulated below.
Slab Zones
Punching shear should be considered when a concentrated load occurs over the infill section of the
Ultrafloor system, i.e. where there is no beam directly below the concentrated load. The procedure
for calculating punching shear is highlighted in Section 9.2 of AS 3600.
Ultrafloor manufacture four convenient sizes of prestressed concrete lintels to suit standard and
modular brickwork. Ultralintels have excellent durability and fire resistance properties. Ultralintels
are suitable for internal or external use in projects of exposure class A1, A2, B1 or B2. The
Ultralintels have been fire tested by CSIRO of North Ryde NSW in accordance with AS1530.4
1990. The structural strength of Ultralintels increases significantly when they act compositely with
the brickwork above.
Cross-sectional details of the lintels are provided at Section 4.1.5 of this manual. Load charts are
provided in the Ultralintel brochure, indicating the safe maximum span when Ultralintels are
installed in various configurations. The brochure also details how these lintels can be used to form
hobs on the slabs.
Loan / span tables included in this section allow design by professional engineers using normal
engineering principles. The tables have been calculated using Ultimate Limit State design, but in
the charts the engineer must enter the working load, namely the unfactored DL + LL. Allowable
working loads are nominated for various spans for lintels in their non-composite state and when
acting compositely with brickwork above.
! The minimum end bearing of Ultralintels on the brickwork is 100mm for spans up to 1200mm
and 150mm for longer spans assuming a minimum brick crushing strength of 20N/mm2.
! Ultralintels must be placed with the rough side on top to provide a key to the brickwork above.
! Ultralintels must be propped at intervals not exceeding 1500mm until the brickwork mortar is
mature.
90
These lintels must only be used with modular (90mm wide) brickwork and are suitable for use with
concrete floors.
To satisfy L/1000
18.5 9.5 5.6 3.7 2.6 1.9 1.4 1.1 - - - -
deflection
To satisfy L/300
26.1 14.5 8.8 5.5 3.7 2.7 2.0 1.5 1.2 - - -
deflection
2 courses of modular
22.7 17 13.6 7.8 4.9 3.2 2.2 1.5 1.1 - - -
bricks over the lintel
4 courses of modular
41 30.7 24.5 20.4 17.5 15.3 11.5 8.3 6.2 4.7 3.7 2.9
bricks over the lintel
6 courses of modular
63.1 47.3 37.8 31.5 26.9 23.6 20.9 18.8 17.1 13.7 10.7 8.6
bricks over the lintel
90
These lintels must only be used with Modular (90mm wide) brickwork and are suitable for use with
concrete floors.
900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
To satisfy L/1000
46.0 19.2 9.6 5.4 3.3 2.1 1.3 - - - - -
deflection
To satisfy L/300
60.8 45.2 28.8 19.0 11.8 7.8 5.4 3.8 2.8 2 1.5 1.2
deflection
2 courses of modular
46.0 25.3 20.2 16.4 10.2 6.7 4.6 3.3 2.4 1.7 1.3 1.0
bricks over the lintel
4 courses of modular
46.0 33.7 26.9 22.4 19.1 16.7 14.8 13.1 9.8 7.4 5.8 4.5
bricks over the lintel
6 courses of modular
62.4 46.7 37.3 31.0 26.6 23.2 20.6 18.5 16.8 15.3 14.1 11.8
bricks over the lintel
110
These lintels must only be used with standard (110mm wide) brickwork and are suitable for use
with concrete floors.
900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
To satisfy L/1000
10.2 5.7 3.2 2.0 1.4 - - - - - - -
deflection
To satisfy L/300
26.0 11.7 6.3 3.8 2.5 1.7 1.2 - - - - -
deflection
2 courses of modular
23.5 17.6 11.5 6.6 4.1 2.6 1.8 1.3 - - - -
bricks over the lintel
4 courses of modular
41.4 31 24.8 20.6 17.6 13.4 9.3 6.8 5 3.8 3 2.3
bricks over the lintel
6 courses of modular
63.2 47.3 37.8 31.5 27 23.6 20.9 18.8 14.3 11 8.6 6.8
bricks over the lintel
110
These lintels must only be used with standard (110mm wide) brickwork and are suitable for use
with concrete floors.
900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
To satisfy L/1000
41.3 25.1 12.6 7.1 4.3 2.8 1.8 1.2 - - - -
deflection
To satisfy L/300
41.3 32.0 26.0 18.9 13.8 10.2 7.0 5.0 3.7 2.7 2.0 1.5
deflection
2 courses of modular
41.3 26.3 16.6 11.4 8.3 6.2 4.6 3.2 2.3 1.7 1.2 -
bricks over the lintel
4 courses of modular
48.3 36.1 28.8 23.9 19.8 15.1 11.8 9.5 7.8 6.5 5.2 4.1
bricks over the lintel
6 courses of modular
64.3 48.1 38.4 32 27.3 23.9 21.2 17.3 14.2 11.9 10 8.6
bricks over the lintel
Construction details of the saddle supports are given in Section 8.3. Design of the steel saddle
beam should be designed in accordance with normal engineering principles. Saddles are usually
designed by Ultrafloors design engineers. The Ultrafloor beams supporting the steel saddle should
be designed for the load concentration as outlined in Section 7.7.2.
A grouping of two Ultrafloor beams is often required at each end of the saddle. In cases where two
Ultrafloor beams are insufficient to support the load concentration, structural steel beams are
required parallel to the Ultrafloor beams.
Note that consideration should be given to placing re-entrant corner reinforcement to reduce
likelihood of cracking in concrete.
7.7.2.1 General
The load/span tables in Section 7.1.1 do not consider concentrations of load such as load bearing
walls, column loads and saddle supports. Non-distributed loads must be investigated by analysis of
the structure in accordance with normal engineering principles. One or a combination of Ultrafloor
beams can then be selected to resist the design actions determined from the analysis.
No reference is made in AS 3600, but BS 8110.1 gives guidance on the transverse load
distribution within precast concrete slabs. With reference to Clause 5.2.2.2. Concentrated loads on
slabs without reinforced topping: the width of slab assumed to contribute to the support of
concentrated loads (including partitions in the direction of the span) should not exceed the width of
three precast units and joints plus the width of the loaded area or extend more than a quarter of the
span on either side of the loaded area. Refer also to Clause 5.2.2.3 Concentrated loads on slabs
with reinforced topping. The provisions of Clause 5.2.2.2 apply in all respects except that, instead
of three, the width of four precast units and joints may be allowed to contribute. Testing at the
University of Newcastle has verified that the transverse load distribution within Ultrafloor slabs is in
keeping with these guidelines.
1. Determine the effective width of slab as outlined in Section 7.7.2.3. An initial assessment
must be made as to the number of beams required in the grouping.
2. Determine the action effects on the slab using normal engineering principles.
3. Design the slab for flexure using the guidelines in Section 7.2.3 (composite state).
4. Design the slab for shear using the guidelines in Section 7.5.4.4.
The effective width of slab to consider for the transfer of concentrated loads to supports is
dependant upon the distance of the load concentration from the nearest support.
1. Case 1: a 1.5m
If the load concentration is greater than 1.5m from the support, one third of the total load is
apportioned to the central beam module.
If the load concentration lies in the region 1 1.5m half of the total load P is apportioned to
the central beam module.
3. Case 3: a<1.0m
If the load concentration is close to the support, only one Ultrafloor beam and contributing
topping width (module) contributes to the load transfer. When distance a < 1.0m, then full
load P is apportioned to one beam module.
Ultrafloor beams can be grouped together to transfer concentrated loads to supports. The load
distribution is again dependent upon the distance a from the support.
If the load concentration is greater than 1.5m from the support, the total load is apportioned
to each of the beam modules as illustrated below:
The critical beam element could be either the L section subject to P/4 or the T section
subject to P/6.
2. Case 2: a 1.5m
If the load concentration is close to the support, only the grouping of beams and contributing
topping width contributes to the load transfer. The total load P is divided equally into the
number of beams in the grouping.
In most circumstances, the number of beams in the grouping should not exceed two.
Cantilevered sections of slab can be achieved either with the Ultrafloor system or by tying precast
or in-situ cantilevered slabs into the Ultrafloor slab. The design and detailing of any cantilever must
be performed by a professional engineer.
! Unless the span of the cantilever is minimal, the tip of the cantilever should be propped during
construction. Determination of the maximum allowable cantilever span without propping can
be made using the negative cracking moment of the non-composite section included in
Section 7.5.1 relative to the applied moment from construction loads.
! If waterproofing is required at the line of an external wall over the slab, a hob can be cast onto
the slab as shown in Figure 7.7.3a and Figure 7.7.3b (refer also to the Ultrafloor Lintels and
Hobs Brochure where lintels can be cemented to the slab to form hobs).
In-situ and precast cantilevered slabs can be tied into an Ultrafloor slab. This situation is common
when external balconies meet an Ultrafloor slab at the external wall line.
! The FC formboard is set-down to the underside of the Ultrafloor beams for a distance equal to
half the span of the cantilever (ie set-down width = cantilever span / 2). The additional concrete
increases the area of concrete in the compression zone through the peak moment region.
! Top reinforcement must be designed and detailed to resist the induced stresses. Design
principles are the same as for a reinforced concrete cantilevered slab.
! If required, a throat can be formed under the Ultrafloor beams subject to architectural
constraints.
A detailed description of the design principles for continuous Ultrafloor slabs is contained in
Section 7.2.3.2.
The design of continuous Ultrafloor slabs is simplified by incorporating solid concrete block-outs in
the peak negative moment regions. This allows negative moment reinforcement to be designed
similarly to a conventionally reinforced continuous slab. The solid concrete block-outs are achieved
by dropping the formwork sheet to the underside of the Ultrafloor beams through the peak moment
regions to increase the concrete compression zone. Alternatively the Ultrafloor beams can be
designed to take the compression forces.
Negative moment reinforcement is designed over the supports using normal engineering
principles. Up to 30% moment redistribution is suggested in order to gain a further advantage by
making full use of the positive moment capacity. Further to this, if the Ultrafloor beams are
unpropped, the only negative moment for continuity design is that resulting from the live load (LL)
and superimposed DL only. This can then also be partially redistributed.
Ultrafloor recommends a maximum bar size of N16 for continuity design of slabs.
Buildings with a rise in storeys of more than four require special detailing to prevent progressive
collapse. Ultrafloor recommend the provision of horizontal continuity at each floor level. The floor
should be capable of resisting all negative bending moments specified by AS 3600.
Testing has been conducted at the University of Sydney on continuous Ultrafloor slabs. The
following detail was found to develop the full negative moment flexural capacity equivalent to a
reinforced concrete slab of the same depth and with the same reinforcement. It behaved in a
ductile manner with well-distributed cracks. Substantial rotation capacity over the wall was
demonstrated, sufficient to ensure that full moment redistribution would occur.
The British Standard BS 8110.1 gives guidance on designing for progressive collapse. Developing
catenary action through provision of horizontal ties is deemed adequate to prevent progressive
collapse. Alternate details to Figure 7.7.5a may be used through consultation of the requirements
of this standard.
Worley Fraser Pty Ltd of Melbourne provided the following appraisal of the Ultrafloor System in
relation to progressive collapse and earthquake design:
The use of Ultrafloor for the flooring system of a building does not impair the robustness of the
floor compared to a conventional slab system. As the Ultrafloor slab consists of a 98mm thick
in-situ slab, the floor is able to act as a diaphragm to distribute loads to key lateral restraining
elements. By introducing continuity to the Ultrafloor slabs, with top reinforcement over
supports, the redundancy of the structure is increased with the potential loss of a supporting
vertical member.
In the absence of detailed information in Australian codes of practice, information can be found
in the British concrete code, BS 8110, for guidance on robustness. BS 8110, unlike the
American and Australian concrete codes, provides an empirical design method to effectively
tie the structure together through a series of vertical and horizontal ties. This empirical design
method was developed by the Imperial College in London following the partial collapse of a
precast concrete wall frame at Ronan Point, London in 1968. This fully tied solution relies on
catenary action of the ties in the floor to suspend the floors during accidental removal of a key
vertical loadbearing element. These ties, in the form of N12 and N16 bar reinforcement, can
easily be accommodated within the in-situ slab of the Ultrafloor system. The Ultrafloor system
also has flexibility with the use of set-down boards so that an in-situ slab of full thickness could
be adopted around the perimeter, to accommodate the tie reinforcement.
Earthquake Loads
The Ultrafloor slab, with its in-situ 98mm thick concrete slab and mesh reinforcement, is ideal
to act as a diaphragm to distribute lateral loads through the floor plate to key lateral restraining
elements. Additional reinforcement can easily be accommodated in the slab should it be
necessary.
Pull-out bars or threaded reinforcement into ferrules from precast walls can be cast into the in-
situ slab to laterally restrain the wall as well as provide a means to transfer the lateral slab
forces to the wall. The adoption of Ultrafloor as the flooring system, compared to a
conventional slab, does not impair the strength or serviceability of the structure under
earthquake conditions.
The Ultrafloor beams can be used in projects of exposure class A1, A2, B1 and B2 without special
protection measures. Surface treatments are usually required in exposure class C. The topping
slab needs consideration as follows:
Reinforcing mesh is cast into the topping slab. The mesh is non-structural and is included to
control shrinkage cracking. The mesh is typically placed directly on top of the Ultrafloor beams with
the standard topping thickness. Bar chairs can be used to raise the reinforcing mesh if required.
! SL62 in most internal areas where a nominal degree of control over cracking is required.
! SL82 in external areas. Note the increased concrete cover and strength requirements included
in Section 7.8.2.
Note that some projects require a very strong degree of control over cracking. Heavier shrinkage
control reinforcement may be required. Contact the Ultrafloor technical department for advice.
Control joints are discussed in Section 8.6 and details are included in Section 10.
Quality concrete curing is the single most important factor in minimising the effects of plastic
shrinkage. All Ultrafloor slabs must be placed compacted and cured in accordance with standard
industry practice. Guidance notes for curing are included in Section 8.5.
7.8.2 Cover-to-Reinforcement
The minimum cover-to-reinforcement in internal areas is 20mm. Ultrafloor recommends the use of
25MPa topping concrete for normal internal applications (with traditional loadbearing wall
construction) with an SL62 shrinkage control mesh.
In external areas, cover to reinforcement concrete strength and size of mesh all need to be
increased to provide adequate corrosion protection.
Ultrafloor recommends the use of 25MPa concrete as in-situ topping for slabs in normal interior
environments and 32MPa for band beam systems. Concrete should have a target slump of 85mm.
The in-situ topping must be cured in accordance with standard industry practice such as flooding
with water, covering with plastic sheeting, or using suitable curing compounds.
Durability of the concrete may be increased by (a) lowering the water-cement ratio, (b) increasing
the cementitious content and (c) providing thorough wet curing.
Information regarding concrete strength and required covers for external and industrial areas is
included in Section 7.8.2. Further information regarding curing methods is included in Section 8.5.