Construction today is developing at a fairly rapid pace, and all this is due to the fact that new building materials have begun to be used, which have a number of the most remarkable characteristics. Reinforced concrete slabs in which corrugated sheeting is used also play an important role, because such flooring can be used in the construction of houses, terraces, and non-residential buildings.
In the case of the construction of floors, the construction stage is especially important when it is necessary to draw up a project and make the necessary calculations. It is also necessary to have special knowledge that will allow you to select the appropriate dimensions of corrugated sheets, as well as select reinforcement sections.
The difference between a conventional floor and a corrugated floor
The most basic difference between corrugated flooring and conventional flooring is that in the second case a formwork system is used. With it, a completely finished ceiling can be obtained, and its appearance will not require any modification or finishing.
Overlapping with corrugated sheets has a number of advantages, for example:
There is a variety of sizes of profile “waves”, and the cross-section of the ceiling can ultimately be ribbed.
Low consumption of concrete solution.
Durability of the floor thanks to the ribs of the corrugated sheet.
The load is distributed on the foundation, which is why working with the material becomes simple and accessible.
In addition, if we talk about the weight of this structure, it will not be so large, which allows the use of lighter material to build walls - and this is an undoubted advantage of corrugated sheeting. Maximum attention will have to be paid to the foundation, since it is it that takes on most of the load. In order to give it even more strength, it is necessary to use as much concrete mortar as possible, and in the case when a corrugated flooring is used, concrete is consumed in smaller quantities, and each part of the foundation will take the load from its side on the metal frame.
Carrying out installation work. Floor calculation
In order to do this work, you will first need to calculate the monolithic floor, since the construction of the facility, as well as the installation of the floor, will depend on the accuracy of the calculation.
In this case, it is very important to take into account the size of the object, as well as to calculate all the necessary loads created by the ceiling.
As for the technology of corrugated flooring itself, it includes the reinforcement of columns, which are in their own way supporting, as well as beams. In this case, pipes consisting of asbestos or other metal are often used. These pipes, or rather their cross-section, can have any shape. Channels and metal I-beams can act as beams.
In this case, a very important concept is the laying step, which in this case will largely depend on some factors - such as the size and shape of the sheets, and the greater the height of the profile, the smaller the beam pitch will be. For example, if the size of the flooring is TP-75, and the thickness of the sheet is 1 m, then the laying step will be approximately 3 m.
Overlapping with corrugated sheets has some recommendations, and they must be followed when performing work.
– So, in order to avoid deflections on the profiled sheets, you need to lay three beams, and then fasten them with self-tapping screws, and place them at three appropriate points. The joints are similarly secured with self-tapping screws.
– In order to secure the sheets to the base, it is recommended to use self-tapping screws.
After the corrugated sheet formwork has been constructed, you can proceed to the process of pouring M350 concrete, but before doing this, it is necessary to prepare the corrugated board accordingly. To do this, additional sticks should be installed in the center of the distances between the beams, which will serve as a kind of supports to support the corrugated sheet. After the concrete solution has hardened, the supports can be removed.
It is very important to remember that pouring the mortar must be done in one span, since it will be very difficult to completely concrete it during the entire working day. In addition, you will have to wait until the concrete can gain the required strength, and its maturation in cold weather can take up to one month. And in order for concrete to mature quickly in hot weather, it must be constantly moistened with water.
Reinforcement of a monolithic floor
A two-span floor is the most common floor plan used for a two-story house. This means that the ceiling is carried out according to the principle: there are load-bearing walls around the perimeter of the house, and one is located in the middle. The only differences are in the size of the house, as well as in the way the opening for the stairs is located.
For each size of house there is its own version of such an overlap. As a structural scheme, it is necessary to take one in which the ceiling will rest only on three longitudinal walls, and as for the transverse walls, they are load-bearing. Thus, you can:
– save on materials due to the dimensions of the foundation for self-supporting walls;
– eliminate the dependence of reinforcement on the length of the house, as well as on the width of the staircase opening.
It should be noted that this scheme is designed for cases where the slab rests on three walls, and not on four.
The second step is to select materials to complete all the necessary work.
Concrete class B25, which is heavy.
Steel fittings (steel grades 35GS, 25G2S).
Clamps consisting of smooth rods of class A240C.
It is also necessary to determine the protective layer of concrete for the lower reinforcement, which is assumed to be 30 millimeters. The size of such a layer for the upper reinforcement will be 20 mm.
The standard loads on the floor are assumed to be as follows:
– floor structure and live load – 150 kilograms per square meter.
– weight of partitions – 50 kilograms per square meter.
The ceiling is not designed for the fact that any racks will subsequently rest on it; only support of the staircase landing is allowed.
Features of slab reinforcement
When reinforcing a slab, it is necessary to take into account a number of features, since they affect the work process.
So, for the lower reinforcement of the first layer, it is necessary to lay 10 diameters on the wall from wall to wall (if the diameter is 12 mm, then it is necessary to place it on the wall 120 mm). In this case, the end of the reinforcement is not brought to the edge by 15 mm.
After the first layer of reinforcement has been laid, it is necessary to tie the reinforcement of the hidden beams, which will form the frame for the staircase opening.
For the lower reinforcement of the second layer, it is necessary to lay distribution reinforcement, which is smooth and is part of class A240C. This reinforcement is placed on the wall, just like the reinforcement of the first layer. It is necessary to ensure that all smooth reinforcement ends in so-called “legs”, bends, 48 mm long.
For the upper reinforcement, the first layer must be laid parallel to the middle wall, the step is 200 mm. The reinforcement is smooth, and you need to treat it the same way as with the reinforcement of the lower layer.
For the upper reinforcement of the second layer. This layer should be laid perpendicular to the first, and then tied using wire twists.
After everything is ready, you need to leave the formwork for 28 days, and only then remove it.
Advantages of reinforced floor slabs
Floor reinforcement is a very important detail in many structures. They can be used for both public buildings and residential buildings. Reinforcement as a process has many advantages, among which there is no need to use construction equipment. Another undeniable advantage is that this method involves the manufacture of floors for rooms with non-standard dimensions, and it can have absolutely any complexity. Walls and columns act as support for such floors, thanks to which the house acquires a more free layout. The third advantage is that the structure is very durable, and much stronger than wooden floors. Reinforced floors have qualities such as fire resistance, and they can even withstand high voltages.
In order to mount such an overlap, it is very important to make the correct calculations, to calculate the optimal thickness, which is in full accordance with the thickness of the span - like 1:30. In order for the reinforcement to be of the highest quality, you will need monolithic slabs, mesh, and knitted reinforcement.
Marking
Concrete slabs are marked with special markings, and you need to pay attention to them. The letters in the marking indicate the type of slab itself, so PNO are lightweight flooring slabs, and PC are floor slabs. NV means internal flooring. Next, the letters on the marking are followed by numbers according to which the dimensions are indicated, namely length and width. The very last figure is the loads that are permissible. So, the number 8 means that the permissible load is about 800 kilograms per square meter.
When choosing the type of slabs, it is very important to pay attention to the fact that in general they differ in structure. So, according to the cross section, they can be hollow, solid or ribbed. Hollow-core slabs have gained the most popularity, this is due to their low weight, so they can be easily transported and installed. The voids can be round or oval in shape and are made of heavy concrete.
Due to the fact that the variety of slabs is large, they can be selected based on their main purpose, as well as on various natural features.
As for the process of reinforced flooring, it occurs using standard meshes, as well as using knitted reinforcement. The diameter of the welded reinforcement rod is about 3 mm or even more, and the diameter of the knitted reinforcement is 6 mm or more.
Multi-span beam slabs
These slabs are reinforced using welded rolled mesh, in the process the rolls are rolled out across the beams, which are secondary. In places where the extreme spans are located, an additional mesh is applied, and instead of it, rods can be laid, which in the process are tied to the main mesh. In order to maintain economy of reinforcement, you can use welded mesh that will overlap each other.
If narrow welded mesh is used during the reinforcement process, then they must be laid in two layers, and the directions must be perpendicular.
Pressure reinforcement that operates in both directions is designed in the same way as support reinforcement for beam slabs.
Monolithic beamless floors
If the floor is beamless, then it is reinforced in a similar way, and as a result, the slabs rest on the columns. In this case, there is a need for additional reinforcement using flat frames or rods that are located along the axes of the column. In order to determine the need for materials, it is necessary to make a calculation.
In the case of separate reinforcement, other reinforcement is installed.
If thick monolithic foundations are used, they are reinforced using special reinforced concrete blocks, which are assembled from special meshes, as well as from flat frames. Then the process of their installation is carried out, a gap occurs, which is equal to the width of the reinforced block, and horizontal meshes are installed in the resulting gap along all levels of the blocks.
Dismantling a brick partition
Floor slab installation technology - technical requirements
Construction of a foundation made of FBS blocks
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Monolithic corrugated flooring: calculation and installation
Modern technologies make it possible to carry out construction work cheaper and faster. The most popular now is monolithic flooring on corrugated sheets, which allows not only to reduce the cost and construction time, but also to significantly reduce the labor intensity of the work. The technology is applied to buildings of any shape and size; it is quite competent and scrupulous to calculate the floor using corrugated sheets.
Tools and materials for work
When working with monolithic floors, the following tools and materials will be useful to you:
Profile base
- cement;
- sand;
- capacity;
- concrete mixer;
- shovel;
- corrugated sheeting;
- self-tapping screws;
- fittings;
- formwork;
- Master OK.
What is corrugated sheeting and where is it used?
Corrugated sheet is a galvanized steel corrugated sheet. This material acquires its waviness by cold rolling. Sometimes an additional anti-corrosion coating is also applied to the material, which further increases its visual appeal..
Corrugated flooring is used for cladding walls, creating roofs, building fences, fencing, hangars and change houses. The following types of corrugated sheets produced by the modern industrial sector can be distinguished:
- type C – profile for walls;
- type NS is used for flooring and wall construction;
- N – load-bearing type, used for roofing (both flat and single- and double-slope) and floors.
Load-bearing corrugated sheet
Type H profiled metal products have the highest load-bearing capacity, which allows them to be used for roofing. The profile height is also the highest among other varieties. For example, in profile H35-1000-0.7 – 35 is the height of the corrugated sheet in millimeters, 1000 is the width, and 0.7 is the thickness.
Specifics of material calculation
When making calculations, it is imperative to take into account the dimensions of the building, the weight of the entire structure, as well as the load factor on the floor and the parameters of the foundation of the house. The types of metal supports and columns will be selected in accordance with the construction parameters.
The corrugated sheet ceiling will have the thickness required by the level of operational load. The formwork parameters and the cross-section of the metal fastening rods also depend on the degree of load, as well as on the length of the span between the support beams.
The corrugated floor covering, which includes a profile and a slab, will have a width in the proportion of 1:30 (relative to the span length).
Structural design
Before starting construction work, it is necessary to prepare all design documents in accordance with SNiP II-23-81. Due to the fact that it is extremely difficult for developers without special engineering education to carry out structural calculations carried out using these documents, special software was created with the help of which anyone can create working documentation and perform all calculations. By the way, using the same program you can make drawings of formwork and reinforcement, as well as calculate the total costs of materials.
Without first completing the work with documentation and calculations, it is not recommended to build a monolithic floor using corrugated sheets, because in this case there is a high probability that the likely load on the floor or roof (flat or with slopes) will be calculated incorrectly, as a result of which either the building or itself will be deformed profiled sheet
In addition, it is worth calculating in advance the step between the support beams, which varies depending on the type of corrugated sheet (for example, type H, used for a flat roof, requires frequent steps between the support beams, because the height of this profile is higher than the others - as much as 35 mm.) . This is due to the fact that the strength of the concrete pour will be low.
After all the calculations have been made, you can begin to build a monolithic floor using corrugated sheets, which you can actually do yourself, but for this you will need special tools and high-tech equipment.
Installation of monolithic flooring on corrugated sheets
Finished ceiling - bottom view
The main stage of constructing a reinforced concrete floor is preparing and pouring the formwork. The finished monolithic structure can later be used as a ceiling that does not require additional finishing or decoration.
The second important link of a monolithic floor is profiles. It is thanks to them that a ribbed section is achieved, which significantly increases the level of reliability of the ceiling. Also, thanks to the use of profiles, it is possible to reduce the cost of reinforcing the structure, which will reduce the overall construction costs.
The ceiling made of corrugated sheets is, in fact, a permanent formwork, the support for which is precisely the metal frame. Due to the fact that the overall structure has impressive weight and strength, lighter materials can be used for the walls without fear for the strength of the building, because a metal frame is responsible for it.
The load is transferred to the flat part of the frame, which further lightens the load on the walls and foundation. Thus, you can even save additional money and build a cheap and quickly erected column foundation.
Main stages of installation
Before calculating the length of a corrugated sheet, it is worth considering that its support must be provided by 3 support beams at once, so that in the future the sheet does not bend or deform.
Profile fastening
Fixing the profile with self-tapping screws
If the calculations were a preliminary stage, then the first stage will be attaching the sheets to the metal base. This is done using self-tapping screws with a reinforced drill. In this case, the fastener can freely enter the channel even when the hole was not made there specifically.
Fastenings must be made wherever the corrugated sheet comes into contact with the support beam, because the total load on the structure will be quite high.
Reinforcement
The next stage of work is reinforcement. Reinforcement is a frame that helps the concrete pour to withstand heavy loads. The structure of the reinforcement will consist of 12 mm longitudinal rods laid in each of the waves of corrugated sheeting. If you need to further strengthen the structure, you can add transverse reinforcement bars (6 mm thick). The reinforcement frame is connected by welding or steel wire.
Strengthening the structure
Filling of floors
The next stage is pouring the floors. The grade of concrete must be the highest, in addition, the entire pour must be done at one time. It’s better not to mix concrete yourself - it’s safer to order ready-made concrete and pour it using special equipment (concrete pump and conveyor).
Pouring the solution
Alignment
After pouring the ceiling, it must be carefully leveled. First you need to add several supports to insure the corrugated sheet from deflection under the weight of the concrete pour. Additional supports are installed between the main support beams.
As soon as the concrete gets stronger (this will take almost a month), the supports can be removed. Pouring is done only at temperatures above zero, because at sub-zero temperatures there is a high probability that it will take even longer to dry.
If for some reason work has to be carried out at a very low temperature, it is worth buying concrete with additional additives that will help the mixture strengthen.
If you have to work in dry and hot weather, then in order to prevent cracks from appearing, the poured composition will need to be periodically moistened. If frost may occur during work, it is recommended to order a mixture with special additives. It can gain the necessary strength even at low temperatures.
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Monolithic flooring on corrugated sheets: calculation, design
It is difficult today to imagine construction that could do without the use of concreting. Reinforced concrete structures are present in the foundations of buildings and in interfloor ceilings. It would not be amiss to note that in the process of constructing objects for various purposes, monolithic concrete is increasingly being used instead of precast reinforced concrete. This applies to a greater extent to buildings with a metal frame.
In individual construction, monolithic flooring on corrugated sheets is especially common. This solution is suitable, for example, for structures with non-standard spans or a large number of holes and openings. The operating load range is quite wide. During operation, permanent formwork for corrugated sheet floors also acts as additional external reinforcement, since it does not allow the concrete to spread during the hardening process. This significantly increases the strength characteristics of the structure being built and its load-bearing capacity.
This design is a cake consisting of the following layers:
- beams;
- corrugated sheeting;
- flexible reinforcement laid out along the wave;
- vertically installed rod anchor;
- reinforcing mesh;
- screed according to the profiled sheet.
Advantages of monolithic flooring using corrugated sheets
- Organizational and financial costs when installing corrugated flooring are not particularly high.
- They can have almost any geometric shape and size.
- Pouring the floor over corrugated sheets is less labor-intensive and does not require the installation of formwork. The ridges of a profiled metal sheet significantly reduce concrete consumption, which often becomes an important argument in favor of choosing this solution.
- Installation of the system is quite simple, and even a beginner can handle it.
- Due to the relatively light weight of the profiled sheets, a monolithic floor weighs less than traditional reinforced concrete structures with collapsible formwork. And this despite their fairly high strength. Thus, such a system acts on the foundation with less force, which allows it to be used effectively when repairing dilapidated buildings. In addition, the profiled sheet allows you to achieve an even distribution of all forces on the foundation.
- Corrugated sheeting, having become part of a monolithic structure, actually performs the functions of the main reinforcing frame.
- The structural thickness of the concrete floor over corrugated sheeting may vary depending on the location of application, and therefore requires preliminary calculation.
- Installation takes significantly less time.
- The finished floor slab on corrugated sheets is no less durable than other analogues. Moreover, the metal profile makes the entire structure even more rigid and reliable.
- Corrugated flooring may vary in type and brand.
- The ceiling is fire-resistant: the fire resistance of a single-span slab with external open reinforcement is approximately half an hour, and in the case of multi-span monolithic structures reinforced along the span - from 45 minutes.
- Interfloor metal floors have special formwork reinforcement, which makes it possible to immediately obtain a ceiling that does not require additional finishing or modification.
- Constructions of this type are especially often used for buildings with a metal frame. The columns are connected to the ceiling through reinforcement, which makes the frame more rigid and stable.
Design features
This design is a solid slab concreted on corrugated sheeting. The supports for it can be brick walls and concrete, a steel frame and reinforced concrete elements.
Monolithic systems can have different designs, for example, ribbed and beamless.
- Ribbed, in turn, can be:
- with slabs on corrugated sheets. The frame for them is beams supported by columns. The span varies between 4–6 m. As for the thickness of the slab, it depends on the level of load, as well as the dimensions. However, the most common thickness is in the range of 60–160 mm.
- with secondary beams in addition to the slabs. The thickness of the slabs here is no more than 120 mm. The cost of a monolithic floor in this case is higher, and moreover, its installation requires more time.
- Beamless structures are based on a solid slab supported by columns.
On a note
If the surface to be concreted has openings, then reinforcement is additionally welded into the openings around them to reinforce the monolithic mass.
Floor calculation
- The technology of covering using a corrugated sheet comes down to the installation of formwork from a metal profile, on top of which a reinforcing frame is built.
- The load acting on the concrete slab is transferred through the monolithic ceiling via metal beams to the support beams and foundation.
- The type and brand of corrugated flooring, the cross-section of metal reinforcement elements and the dimensions of the concrete shelf depend on the length of the span between the supports and the operating load. To calculate the thickness of a slab, its ratio to the span is most often used, equal to one to thirty. That is, with a span length of 6 meters, the thickness of the concrete layer should be at least 20 cm.
- The calculation of a monolithic floor using corrugated sheets is based on the design loads it experiences, as well as the weight of existing structures and the dimensions of the building being constructed. These parameters determine what the profile and cross-section of the metal support beams of the frame, columns, and the characteristics of the foundation should be.
- Systems of this type are classified as structurally responsible objects, therefore installation work begins only after the preparation of the appropriate design documentation. The latter, as well as the calculation of strength characteristics, is carried out on the basis of the relevant SNiP, in particular those relating to steel or reinforced concrete (concrete) structures.
- Such a calculation is quite complex and time-consuming, so designers, as a rule, resort to the help of special programs. Working documentation for a monolithic concrete floor using corrugated sheets includes a plan, drawings of formwork, reinforcement (mainly in dwg format), as well as a specification of materials.
Do-it-yourself monolithic ceiling on corrugated sheets
Preparation
Pouring concrete using a profiled sheet requires a technically competent approach to the initial stage of work. Pre-requisite:
- calculate efforts based on the exact dimensions of the future building,
It is very important to check with the manufacturer in advance the performance characteristics of the profiled sheets.
- calculate the material from which the frame is made with the required safety margin;
- choose the type of metal profile, determine the sheet size and material thickness;
- carry out a calculation of the range of reinforcement that is intended for the construction of a load-bearing frame.
Thus, the preparatory calculation stage makes it possible to find out what assortment and nomenclature of metal beams and columns are needed. For columns, steel pipes with a profile section are used as the base material. Metal channels are used to make beams. The stability of the entire structure depends on the accuracy of the calculation of the monolithic system.
On a note
The pitch of the beams depends mainly on the type of corrugated sheeting used, more precisely on the height of its profile. The larger it is, the smaller the beam pitch is chosen.
Installation of formwork
When choosing the length of corrugated sheeting, a number of important points are taken into account:
- to prevent the sheet from bending in the future, there should be three supports instead of two;
- with short spans it will be easier to pour concrete, since the pressure will be less.
To attach a profiled sheet to a metal base, special self-tapping screws equipped with a reinforced drill are usually used. Thanks to this reinforcement, the self-tapping screw easily penetrates the channel. Moreover, it is not at all necessary to drill it in advance. It’s not for nothing that such fasteners are also called armor-piercing.
Considering the fairly large number of fastening points, use a screwdriver or drill set to low speed to tighten the screws.
The structure is under the influence of very high loads; just remember that concrete (most often M-350 grade) for pouring is almost 2.5 times heavier than water. The reliability of the formwork largely depends on the method of fastening the corrugated sheets. It is recommended to fasten the sheets in places of contact with the beam with armor-piercing self-tapping screws in increments of about 40 cm. In places of overlap, individual sheets should also be fixed to each other. Fastening is carried out with smaller self-tapping screws and a smaller pitch - about 25 mm. Having completed laying the profile, they begin to reinforce the floor using corrugated sheets.
Specifics of reinforcement
The presence of permanent formwork does not provide the slab with additional strength, while during operation the concrete is exposed to large loads in both bending and compression. To avoid possible complications, an internal frame is constructed from metal rods, which are placed in the depressions of the corrugated sheet. “Upper” reinforcement is also performed by laying pipes along the crests of the sheets. Thus, a volumetric reinforcement frame is created from longitudinal and transverse components. Its elements are either welded or connected with steel wire.
Pouring concrete
- Before concrete work begins, the corrugated sheeting is reinforced with additional supports, which are installed between the support beams in the middle of the spans. The corrugated sheet will then not bend under the weight of the retained concrete mixture. The supports are removed no earlier than the fill has time to gain brand strength.
- Concrete is poured in stages, since concreting the entire volume at once is problematic. It is recommended to concrete a specific span within a working day.
- The concrete must stand until it reaches working strength. In the summer it ripens, that is, it gains the brand value by about 80%, in 10–11 days, in the winter – in a month. Since concrete takes much longer to gain strength at sub-zero temperatures, it is recommended that pouring be carried out in the warm season.
- In hot weather, the concrete surface is moistened with water to prevent it from cracking and to ensure the maturation of the composition.
If frosts are possible when installing a monolithic system, then it is better to initially choose a mixture with anti-frost additives. This concrete mixture gains strength even at negative temperatures. In addition, a number of special technologies can significantly reduce its setting time. Of course, the cost of the composition increases.
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Flooring made of corrugated sheets and concrete
The use of progressive construction methods and the use of modern materials increases the pace of construction of new buildings. Flooring using profiled sheets is in demand today and is popular in the construction of objects - terraces, garages, residential buildings, enterprises.
Traditionally, concrete slabs were used to cover objects. With their help, high-rise buildings were built. Lifting of heavy slabs was carried out by lifting equipment, and heavy physical labor of workers was used. Flooring made from corrugated sheets reduced the labor intensity of operations. Would you like to know how to use corrugated sheets for floors? You can do this work yourself by reading the material in the article.
Currently, during individual construction, during the installation of floors, monolithic flooring is increasingly being done using corrugated sheets
Basic information
Pouring floors with a corrugated sheet base is the creation of a monolithic slab with increased strength and a margin of safety. In production, galvanized profiled sheet is used, a material with polymer protection, which is the basis. It performs the function of a stationary formwork, filled with concrete mortar. Metal frames absorb the force load.
Floors based on corrugated sheets and concrete mortar, if calculated correctly and in accordance with all design rules, have a long service life and high strength. Compliance with all necessary requirements and proportions determines the reliability of the building and the safety of the people in the building.
Advantages of corrugated sheets
When planning to use corrugated sheeting for overlapping structures, you should familiarize yourself with the characteristics of this material, namely:
- wide range of applications. Profiled sheets are used as facing and roofing material, as well as for the purpose of arranging fences;
- corrosion resistance. The production technology of corrugated sheets involves the application of a special anti-corrosion coating, which increases the service life up to 25 years;
Floors of this type are used in the construction of multi-storey public and industrial buildings with non-standard spans
- light weight. The weight of the profiled sheet does not exceed 8 kilograms, which reduces the load on the load-bearing structure;
- machinability and manufacturability. Sheets of material are easy to attach and can be cut;
- increased strength. Corrugated sheeting can withstand increased forces;
- acceptable price. Low cost has made it a material accessible to the masses;
- aesthetics. The different colors of corrugated sheets allow them to harmoniously fit into the exterior;
- transportability. Light weight and compact dimensions make it easy to transport the material;
- environmental friendliness;
- resistance to natural factors. Corrugated sheeting is not affected by weather conditions. Has increased resistance to alkaline and acidic environments.
Features of monolithic design
The interfloor ceiling made of corrugated sheets differs from the conventional structure by special formwork reinforcement, which makes it possible to obtain a finished ceiling that does not require additional finishing.
The ability to use various types of profiled sheets when constructing floors is quite an important advantage
Advantages:
- the possibility of reducing the consumption of concrete mixture associated with the presence of “waves” of various sizes;
- reducing the amount of reinforcement material;
- increasing the strength of the base;
- reducing the weight of the structure;
- uniform load redistribution;
- the possibility of using lightweight wall materials, including foam and aerated concrete blocks.
Profiled sheets for floors have been used relatively recently. The method of covering with corrugated sheets involves the use of formwork and concrete. In a short period of time, the technology has become in demand.
One of the distinctive points is the possibility of constructing a column foundation for the structure, replacing the traditional strip one. The load that each column will bear is transmitted only by a specific part of the frame.
The monolithic reinforced concrete base is a solid slab concreted on a profiled sheet. Structural supports – brick walls, concrete, reinforced concrete elements, steel frame. The slab is poured in a span of 1.5 to 6 meters in length. The size of the concrete shelf above the surface of the sheets is determined by calculation and is at least 30 mm. If there are openings in the concrete surface, strengthen the monolithic mass around them by welding additional reinforcement at the holes.
The corrugated sheet used as reinforcement must have galvanized or some other coating that will provide it with resistance to corrosion
Preparatory stage
In order to qualitatively pour a concrete floor over corrugated sheets, it is important to approach the initial stage of work technically competently. Calculate the effort taking into account the exact dimensions of the building. To avoid making mistakes when performing calculations, check the performance characteristics of the profiled sheets with the manufacturer.
The preparatory stage plays a decisive role and requires a special approach, engineering knowledge and the ability to perform the necessary calculations. Before starting installation you should:
- Calculate the material required for the manufacture of a frame with the necessary safety margin.
- Select the type of profile sheet, determine the dimensions of the sheet and the thickness of the material.
- Calculate the range of reinforcement intended for the manufacture of a load-bearing frame.
The calculation part allows you to determine the assortment and nomenclature of columns and metal beams. The base material used for the columns is steel pipes with a profile section. Beams are made of metal channels. The accuracy of the calculation of a monolithic foundation determines the stability of the object’s structure.
Monolithic floors should be built strictly according to developed and approved drawings and plans
The work technology involves reinforcing beams and support columns. Metal pipes of various sizes and asbestos supports are used. A metal channel or I-beam is used as beams.
Depending on the size of the corrugations on the sheet, the pitch of the beams changes. As the wave height increases, the spacing between the beams decreases. For example, the distance between the beams for a profile sheet of grade TP-75 with a thickness of 0.9 mm is 3 meters.
Control that the sheets do not sag by installing them on three support beams. Fasten with self-tapping screws equipped with a reinforced drill. Remember the need to fix the joints, ensure the interval between armor-piercing screws is 40 centimeters.
After completing the formwork, proceed to reinforcing the floor using corrugated sheets.
Specifics of reinforcement
Thanks to reinforcement, the strength characteristics of one material are increased with the help of another, which has increased rigidity. If we talk about corrugated sheets, the reinforcement is done with steel wire. The power circuit located inside the structure allows the concrete to withstand increased loads. Longitudinal rods with a diameter of 12 mm form the frame. Laying is carried out along the channels of the sheets. The frame parts are attached to each other by welding or wire.
When the corrugated formwork is constructed, you can begin concreting
If the formwork made of corrugated sheets and metal profiles has been installed and reinforcement has been completed, proceed to pouring concrete. Use concrete mix grade M350. Sequence of events:
- Before pouring concrete, reinforce the corrugated flooring with additional beams - supports installed along the axes of the spans. They will support the base during the process of pouring the solution. After the mixture has hardened, dismantle them.
- Carry out concreting in stages. During working hours, try to concrete a specific span, since it is problematic to immediately fill the entire volume with concrete.
- Allow the concrete to cure until it reaches working strength. The ripening cycle in summer is 10 days, and at negative temperatures – one month.
- Moisten the concrete surface with water during the hot season. This will prevent cracking and ensure maturation of the composition.
If the calculations are made correctly, profile sheets are selected, a reinforcement frame is installed and concreting is done, then the strength of the structure will be at the proper level.
Possible risks
Being universal, corrugated sheet ceilings have disadvantages. During the work process, unforeseen moments may arise:
- increased consumption of concrete solution;
- insufficient rigidity of the floor structure;
- failure to meet construction deadlines;
- unforeseen increase in the estimated cost of construction of the facility.
When installing and pouring, it is not advisable to save on the services of designers and qualified specialists. A complex and important design requires a high level of engineering calculations and the development of a detailed work plan.
Nuances
Remember that the power-bearing sheets of corrugated sheets, which support the increased mass of concrete, do not tolerate errors. Pay attention to the calculations. If necessary, seek help from builders.
Only if you have convenient tools, use high-quality materials, components and a professional approach to the work, can you make a concrete floor using corrugated sheets.
Originally posted 2016-11-29 08:56:40.
pobetony.ru
Overlapping according to profiled sheets: calculation and installation
Modern construction technologies make it possible to use various materials when building a house, each of which has its own advantages and disadvantages. Traditional materials, such as brick, wood and concrete blocks, are gradually beginning to give way to others, more practical, functional, and reliable. Increasingly, in the construction of residential buildings and other buildings, roofing using corrugated sheets is used.
The starting material for the production of corrugated sheets is galvanized steel.
This design represents the following “pie”:
- metal beams from I-beams or channels;
- A special corrugated sheet for floors is laid on the support beams, which is secured with metal screws. These are special self-tapping screws that can even pass through a channel without additional drilling, which is not possible with other fastening methods;
- From above, the future ceiling is reinforced using a profiled sheet with a reinforced belt consisting of metal rods. The mesh is fixed with knitting wire and additional fasteners made of metal and plastic;
- Next, the concrete mixture is poured. But instead of concrete, you can also use moisture-resistant plywood, OSB boards, and in some cases foam concrete blocks are used.
Before installing the floors, it is necessary to correctly select the material that will be used for the beams. Corrugated sheeting for the ceiling and reinforcement for the armored belt are selected according to the appropriate brand. At this stage, the help of a specialist is necessary, since all calculations regarding loads can only be performed using special programs. Amateur action in the absence of experience and knowledge can cause a collapse.
Advantages of ceilings using corrugated sheets
Table of types and areas of application of corrugated sheets.
A ceiling device based on a profiled metal sheet is distinguished by the fact that formwork is used for pouring, which allows you to obtain a completely finished ceiling that will not require additional finishing. The technology itself consists of laying a profiled galvanized sheet on metal beams, reinforced with rods with a cross-section of 8-10 mm. After this, temporary supports are installed and the structure is filled with concrete.
Monolithic interfloor slabs on corrugated sheets have many advantages:
- the rigidity and strength of the resulting floor, which can withstand significant loads;
- Concrete consumption when pouring is significantly less, as are reinforcement materials. At the same time, reliability remains high;
- the profile metal sheet in this case acts not only as the most reliable basis for the entire floor, but also as a convenient permanent formwork that reinforces the entire structure as a whole.
- One of the advantages is that the corrugated flooring has much less weight than other materials, that is, its load on load-bearing walls and other building elements is less. Loads are transferred for the most part not to the walls, but to the metal frame of the floor.
Corrugated sheeting can withstand any load.
Corrugated sheeting can withstand any load without losing flexibility and strength.
Other materials can be used together with the profiled sheet, although concrete pouring is most often used, as it is the simplest and most reliable. You can lay foam concrete, aerated concrete blocks, OSB boards, moisture-resistant plywood and other building materials on corrugated sheeting.
Another big advantage is that corrugated flooring perfectly distributes the load on the foundation of the building. The use of this design makes it possible to use a lightweight foundation for the construction of a residential building; for example, instead of a strip foundation, it is quite possible to build a regular column foundation, which is much more economical.
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Floor calculation rules
Interfloor ceilings based on corrugated sheets, which have been so popular in recent years, are reliable and durable, but this cannot be done without preliminary calculations. Only a specialist should make such calculations, since the reliability and safety of the future structure depends on this. Separately, it is worth paying attention to the selection of corrugated sheeting, its thickness, type of wave, and design loads. The same applies to the section of beams, installation of a reinforcing belt and temporary supports that are necessary for pouring concrete.
The higher the profile of the metal sheet, the greater the distance between the beams.
Corrugated sheet roofing device.
For example, a floor structure where the pitch of the beams is 3 m requires a 0.9 mm TP75 profiled sheet. In this case, the planning is calculated in such a way that the sheet rests not on 2 beams, but on 3, ensuring the reliability of the entire structure. The deflection in this situation will be minimal.
The corrugated sheeting is attached to the floor beams using metal screws, which have dimensions of 5.5 * 32 mm. The sheet is fixed to the beam in each wave, which guarantees the rigidity of the surface, that is, the entire monolithic floor. To connect the profile at the joints, self-tapping screws with a cross-section of 5.5 * 25 mm are used, which must be installed in increments of 400 mm.
A private builder may deviate from standard solutions. Thus, the connection to the configuration and size of interior spaces is a thing of the past, giving way to new technologies. A monolithic ceiling using a profiled sheet allows you to cover any area, even if it is oval in shape.
The technology for carrying out the work will not require serious organizational and financial costs. When installing a monolithic ceiling on corrugated sheets an additional range of benefits is realized:
- the system does not require the installation of formwork and is relatively easy to assemble, which even beginners can do;
- lower weight compared to traditional structures, which reduces the load on the foundation;
- the corrugated sheet becomes part of the ceiling and serves as the main reinforcing frame;
- the finished coating can be covered with plasterboard or left in its original form;
- pouring the working solution is less labor-intensive;
- the structural thickness of the floor may vary depending on the application areas, which requires calculation;
- shorter work deadlines;
- the finished slab is not inferior in strength characteristics to other analogues;
- the ability to use different types and brands of profiles;
- fire resistance.
The embedded parts are made of metal and contribute to the uniform distribution of loads. During installation, welding work is required
Monolithic flooring on corrugated sheets - preparation
The finished covering is at the same time the floor of the room above or the ceiling of the room below - it is both a load-bearing and enclosing structure.
The quality of construction of a monolithic slab affects the safety of operation of the entire house, which is why it is so important to corresponding range of preparatory activities:
- calculation of the load-bearing structure and load-bearing capacity. Mistakes made at this stage lead to sagging of the slabs over long spans, an increase in the thickness of the slab, followed by an increase in labor costs and financial costs;
- calculation of materials;
- to support the floor, it is necessary to provide special mortgages and “pockets” in the walls and pillars, which must be noted in the drawing.
To correctly calculate the thickness of the slab, you must consider the following:
- arrangement of partitions - even a lightweight plasterboard construction creates a load of 50-70 kg/m²;
- Do not forget about the payload from the equipment of the room. In private construction it is accepted at 150 kg/m²;
- the safety margin must exceed the design value by a third;
- installation of vertical rod anchors will provide reliable adhesion of the corrugated sheet to the concrete. Additional elements are welded to the purlin flange during installation;
- Detailed recommendations for the design of monolithic floors and calculations are specified in the STO 0047 -2005 standard.
The maximum thickness of the monolithic floor varies between 200-250 mm, the minimum - 50-60 mm.
Technology
The installation of a monolithic floor using corrugated sheets can be implemented as follows:
- placing the structure on concrete or metal beams (channel/I-beam) in increments of 3.0 m;
- installation on the internal shelf of an I-beam, the pitch is a multiple of the sheet length, for example, 1.2-1.5 m;
- construction without supporting beams.
Carrying out work
The master must take into account the specified sequence of actions if he creates a monolithic ceiling with his own hands
Laying corrugated sheets on supporting beams:
- According to the drawing, an I-beam is placed in pockets or inserts. Embedded support corners are used when working on concrete columns or walls;
- A profiled sheet is installed on the I-beam; the corrugation should be oriented with the expansion down. When working, self-tapping screws are used. Fastening is carried out at the joints and in places where the beams are accustomed;
- longitudinal reinforcement is “lowered” into each rib (190-200 mm pitch) and connected to a transverse rod placed on top of the sheet in vertical sections. The size of the finished cells is 150-150 mm;
- supports are evenly mounted between the beams, which will avoid deflection of the corrugated sheet;
- filling is implemented;
- pockets or mortgages are sealed;
- after 25-30 days, the supports are dismantled and further work is carried out.
Laying on the inner flange of an I-beam:
- I-beams rest on mortgages or pockets;
- material is laid out on the inner flange of the beam. Laying is carried out along the length of the sheet, that is, with corrugations across the span of beams. The structure is fixed with self-tapping screws;
- The reinforcement is laid and the filling is carried out to cover the entire thickness of the I-beam. Filling in sections is acceptable.
Installation without support beams
Installation is carried out with the support of corrugated sheets and reinforcement on the walls with temporary supporting supports and embedded columns. The design allows workers to move along the spans and supports the weight of the pour..
Sequencing:
- the sheet is fixed on the mortgages with a metal anchor;
- the reinforcement is welded to the embedded parts and columns at all points of contact;
- the ceiling must not contain holes. The monolith should be placed from wall to column or between columns without interruption;
- how to fill the ceiling? It is recommended to pour concrete at one time.
An I-beam is a standard profile used in the construction of structural elements. The cross-section of the beam resembles the letter “H”, which provides high strength and rigidity, however, it is inferior to the channel in terms of resistance to torsion
This type of organization of work is advisable to use in the construction of floors between the floor and the attic, which is due to lower loads.
Choosing material
Corrugated sheeting is a corrugated sheet made of galvanized steel, which can be coated with additional coating.
Materials with the following markings may be available for sale:
- “N” - load-bearing profiled sheet for roofing and ceilings;
- “NS” - load-bearing for flooring and walls;
- "C" is for walls.
Decoding of the marking is carried out in the indicated manner.
For product H35-1000-0.7:
- “N” - type of profiled sheet:
- 35 – profile height (wave or trapezoid), mm;
- 7 – metal thickness, mm;
- 1000 – width (working/useful), mm.
For the construction of monolithic floors, the choice should be as follows:
- marking “N” (has a high load-bearing capacity), in the construction of less critical structures, profiled sheet “CH” is used;
- if the span length is less than 5.50 m, the minimum thickness is taken as 0.80 mm;
- if the span is more than 5.50 m – 0.90 mm;
- reinforcing bar d0-12.0 mm;
- concrete not lower than M300;
- self-tapping screws M5.5 x 32.0/35.0 mm – fix the corrugated sheet on the supporting beams;
- for the technology of installation on load-bearing metal beams - I-beam 12.
You can separately note such material as corrugated sheet H60. Its use is advisable if the structure will accept high operating loads.
Price
If a professional team is engaged in the construction of a monolithic floor, the price is as follows:
- lightweight structures - from 4 t.r./m²;
- solid monolith 0.25 m – from 5 t.r./m².
Profiled sheet H60 can be used for installation of floors without monolithic concrete, non-insulated and insulated wall structures, permanent and temporary fences
Doing the work yourself will require lower costs, however, it is recommended to entrust the calculation part to professionals, which will require additional costs.
Floors erected on corrugated sheets are a modern and justified solution for frequent construction. The technology is accessible to any master, does not involve significant costs and reduces the time required to complete the work.
The installation of a monolithic ceiling on corrugated sheets is available to everyone; you can see this from the video:
When concreting floors, various types of formwork are used, but one of the most common in recent years is permanent formwork made from corrugated board. Preventing concrete from spreading during the hardening process, corrugated formwork is also an additional external reinforcement. It partially compensates for the tensile forces that act on the lower reinforcing mesh. This greatly increases the strength and load-bearing capacity of the floor.
In addition, a monolithic slab with a corrugated sheet having a modern protective and decorative coating allows, in some cases, to do without expensive ceiling finishing.
Calculation of a monolithic floor using a profiled sheet
The device of a monolithic ceiling on corrugated sheets is a formwork made of a metal profiled sheet with a reinforcing frame made of metal rods laid on top of it.
This structure rests on longitudinal metal beams. Thus, a monolithic floor using a profiled sheet transfers the load acting on the floor to the supporting structures of the frame and the foundation of the building.
Monolithic flooring on corrugated sheets - dimensions of a specialized sheet with ribs for better concrete fixation
The profile of the corrugated sheet formwork, the cross-section of the metal reinforcement bars and the thickness of the monolithic floor are determined by the operational load and the span between the support beams. The thickness of the slab is usually determined ratio 1:30. That is, if the span length is 6.0 m, then the concrete layer must be at least 200 mm.
The calculations take into account the dimensions of the future building, the design loads on the floors and the weight of the building structures themselves. All this affects the choice of cross-section and profile of metal beams and columns of the frame, as well as the characteristics of the building foundations.
Monolithic flooring on corrugated sheets is a particularly critical building structure, so installation of such structures is carried out only if design documentation for construction is available. Design documentation for monolithic flooring on corrugated sheets and calculation of the strength of metal structures are carried out on the basis SNiP II-23-81 “Steel structures” And SNiP 2.03.01-84 “Reinforced concrete and concrete structures”.
Drawing of a monolithic floor using corrugated sheets
Since these calculations are quite complex and time-consuming, when developing detailed construction documentation and calculating loads, designers use special software, including a computer-aided design system CAD. The working documentation includes drawings of formwork for a monolithic ceiling on corrugated sheets, drawings of reinforcement, all necessary calculations and specifications of materials.
At the design stage, technical and economic calculations are also carried out. They confirm how justified it is to use a monolithic floor on corrugated sheets for this particular structure, the price of which is slightly higher than the cost of monolithic reinforced concrete structures with conventional collapsible formwork.
If you are confident in your abilities and want to independently calculate a monolithic floor using a profiled sheet, then I advise you to use the 1987 manual. Don't let its age bother you - little has changed in construction over the years. At the moment, this is the most detailed and accurate existing instructions on this topic.
You can download the manual from the link: " " (right-click on the link and in the menu that appears, click on "Save as...", then select a folder on your hard drive and enter a name). If you are using a modern browser (almost any other than Internet Explorer), then you can simply open the link in a new tab.
However, you must understand that incorrect calculation of the overlap is not only additional costs, but also a real danger to life. Therefore, if you have not encountered such calculations before, for the sake of your safety, I strongly recommend that you contact professional designers.
Two possible layouts of sheets for a monolithic ceiling using a profiled sheet, measuring 9 by 12 meters
It is most advisable to use corrugated sheets for floors of non-standard sizes with a large number of different technological openings. In these cases, the cost of producing individual panel formwork is high and there is no possibility of its repeated use.
Monolithic flooring on corrugated sheets - technology for performing work
After the installation of metal floor beams is completed, formwork from profiled sheets is installed. They are laid with an overlap in one or two waves and attached to the upper flanges of the supporting metal structures. In places where there are overlaps, the corrugated sheets are connected using rivets.
Then they begin laying the reinforcement. Before starting reinforcement, it is necessary to set the end formwork to the design height of the slab. The installation of reinforcing cages, meshes and individual rods is carried out in accordance with the working drawings of the reinforcement.
In this case, it is necessary to ensure the required thickness of the protective layer of concrete using special plastic clamps. For large areas of floors, after laying the reinforcement, special guides are installed, dividing the floor into several concreting zones.
At the next stage, they begin to supply the concrete mixture. Typically, stationary or mobile concrete pumps are used for these purposes. The composition of the concrete mixture used must correspond SNiP 3.03.01-87. Typically, when concreting floors, the following ratio of components is used.
Today, in the process of modern individual housing construction, as a rule, reinforced concrete floors, especially monolithic flooring on corrugated sheets, are becoming increasingly popular when constructing floors.
During concreting, corrugated sheeting is used as permanent formwork, and during operation it provides external reinforcement.
What is it, how is it different and what advantages does it have in comparison with standard floors, how is it installed?
Floors made from corrugated sheets are used in a wide variety of areas of construction work: construction of garages, terraces and other buildings.
Floors: profile or reinforced concrete?
A monolithic ceiling on corrugated sheets, in contrast to reinforced concrete, which involves pouring using specially designed formwork, helps to obtain a finished ceiling upon completion of the work, which does not require additional modifications and/or finishing. Corrugated sheeting, as already noted, will provide reinforcement.
The possibility of using various types of profiled sheets when equipping floors should be noted as a very important advantage, since the section can be made ribbed if desired or necessary. Due to this moment, the strength and reliability of the floor significantly increases, and it is also possible to reduce the consumption of reinforcement and concrete during the construction process.
The construction of a floor using a corrugated sheet implies that the flooring in question performs the function of permanent formwork, to which concreting will be applied in subsequent stages, and a metal frame consisting of metal columns and beams will be perceived as a support. This design allows (one might even say requires) the use of lightweight building materials of low strength during the installation of walls.
Emerging loads on the frame
This technology has gained the right to exist due to the fact that the load of interfloor ceilings using a profiled sheet does not fall on the wall, but on a completely strong and reliable metal frame.
When using corrugated sheet ceilings as a building material for walls, we can recommend foam blocks or gas blocks, which are also used for thermal insulation.
Interfloor ceilings made from profiled sheets have another equally significant advantage.
The construction of a large building involves the use of a strip foundation, which requires significant costs for building materials.
But the previously noted transfer of loads to the frame, which entails the possibility of lightening the walls, leads to a decrease in loads on the foundation. As a result, instead of a material-intensive strip foundation, you can choose another type of foundation (for example, a column foundation), which will cost significantly less money and time, and perhaps even less labor costs. It is worth noting that in a column foundation, each individual column will bear the load only from one column of metal frames.
At the head of such a foundation, it is necessary to cut out a small grillage, the cross-section of which is calculated using data on the thickness of the walls and the expected spacing between the foundation columns.
Thus, analyzing the above, the installation of floors using corrugated sheets entails a significant reduction in the costs of labor and financial resources, as well as temporary ones, because the process of constructing a building is significantly accelerated.
Installation of floors using profiled sheets
The design of monolithic floors on corrugated sheets must be carried out in accordance with the requirements of SNiP 2.03.01-84 “Reinforced concrete and concrete structures”, SNiP II-23-81 “Steel structures”.
Initially, regardless of whether corrugated sheeting is chosen as a building material or not, planning must necessarily include the calculation of the future floor, which requires data such as:
- exact dimensions of the structure being built;
- calculations of loads that are carried out directly by the floor.
Using the specified data, you can correctly determine the dimensions of metal columns, beams, etc.
Columns are usually made of metal pipes of both round and square sections. For the production of blocks, the presence of metal I-beams and channels is often used.
It is worth paying attention: the distance between the beams during the laying process and the determination of their cross-section are directly dependent on the type of profiled sheet used in the flooring device. The greater the height of the wall profile sheet, the smaller the step between the beams.
In order to independently perform the most accurate and correct calculation of the beam laying step, it is better to contact either the distributor or the corrugated sheeting manufacturer for the required information. They can provide information on the necessary parameters of the building material, the main types of profiled sheets, their characteristics, load-bearing capacity, etc.
Let's consider an approximate calculation
Let's take the following data as a basis: the gap between the beams is 3 m, the profiled sheet of the TP-75 brand is chosen, the thickness is 0.9 mm.
- The highest quality fastening of corrugated sheeting to the metal bases of beams is considered to be the use of 32 mm self-tapping screws with a reinforced drill (the so-called armor-piercing ones), through which it becomes possible to drill channels without first using a drill.
- Fixation must be carried out at each joint of the profiled sheet and the ceiling beams. Therefore, if the corrugated sheet is laid on 3 beams, then it should be fastened at 3 points, if laying is carried out on 2 beams - at 2 points.
- In addition to fixing the profiled sheets to the beams, it is also necessary to secure them at the joints. For this, you can also use the indicated armor-piercing screws, but shorter ones, for example, 25 mm. They are screwed in at a distance of approximately 400 mm from each other.
- When the installation of corrugated formwork is completed, the next step is concreting. Regarding ceilings, you must always take into account its minimum thickness, which, as a rule, is no more than 8 cm, excluding the thickness of the profiled sheets themselves. Concreting is recommended to be used with concrete grade M-25 (other designation is M-350).
- Before laying concrete, it is necessary to prepare profiled sheets. To do this, at the bottom, in the center of each span, between the beams, temporary supports should be installed (sticks can be used as them) from the floor directly to the profiled sheet. These actions help prevent the possibility of subsidence of the corrugated sheet under the load of laid concrete. Once the concrete solution has dried, the stick supports can be removed.
Do not forget that the essence of the profiled sheet during subsequent operation is reinforcement. Therefore, the thickness of the concrete masonry is calculated based on the strength and deformation of the corrugated sheet. The minimum is 30 mm; if there is no concrete screed, the calculation is 50 mm. The profiled sheet is laid with wide corrugations down. If the hole size across the deck is up to 500 mm, it is necessary to reinforce the floor in the form of longitudinal rods. In the opposite case, it is necessary to provide additional elements of the beam cage along the contour of the hole in order to transfer the load from the weakened areas to the purlins.
First of all, it is necessary to determine the required length of the corrugated sheet, for which it is best to take into account the support not according to the standard version on 2 beams, but on 3 - this will allow for the deflection of the profiled sheet during operation.
Please note: if laying concrete is carried out in several passes, it is necessary to take into account how many days a particular area has dried. Then additional supports from under the spans with dried concrete will be removed in a timely manner. Please keep in mind that concrete will reach 80% strength no earlier than 10 days from the date of installation, provided the weather is warm. During the cold season, concrete masonry can take up to one month to dry out.
In hot weather conditions, during the period of flooring on corrugated sheets, the concrete should be regularly wetted, which will prevent premature accelerated evaporation of moisture as a result of strong heating of the profiled sheets due to the high ambient temperature.
Like many other construction works, the technology for implementing a monolithic floor using corrugated sheets is not particularly difficult and does not require specially acquired skills.
The most important stage is the development of the theoretical part, which includes:
- determination of the frame material of a metal structure;
- correct determination of types and sizes of profiled sheets;
- competent calculation of the sections of reinforcement required in the process of manufacturing the frame, etc.
An important factor is the availability of the necessary tools:
- screwdriver and self-tapping screws, preferably 32 with a drill;
- drill and presence of drills;
- rule;
- crochet hook and wire.
These include various levels, a plumb line, a string, a square and a tape measure. If concrete is poured manually, you will need a concrete mixer and a container for the solution.
If the entire direct construction process can be completed independently, then it is still recommended to entrust the calculations for each parameter to a highly qualified professional.
The installation of corrugated flooring should be carried out strictly according to developed and approved plans and drawings, in accordance with the above requirements.
However, in order to prevent all sorts of errors and inaccuracies when performing construction work, you can invite a team of qualified specialists, but it is first recommended to inquire about their reputation and reviews about them.
When constructing frame buildings, one of the methods for constructing interfloor slabs or coverings is a monolithic slab on corrugated sheets. Its essence lies in the fact that a profiled sheet is laid over the finished floor beams, onto which a reinforcing frame is mounted, into which concrete is poured. In this case, the corrugated flooring acts as permanent formwork. The concept “non-removable” speaks for itself; after the concrete has gained strength, the formwork is not removed, but remains in the building frame structure.
For formwork, it is advisable to use a corrugated sheet with a wave height (corrugations) of at least 44 mm with additional stiffening ribs in the upper part of the wave, the so-called load-bearing one. Such a profiled sheet is marked with the letter H, which means that it is intended for horizontal installation and installation at an angle. The general marking of a profiled sheet with a wave height of 75 mm is H75, where “H” is the load-bearing sheet, 75 is the wave height. For permanent formwork, profiled sheets ranging from H44 to H156 are used. 
There is also a profiled sheet marked “C” - wall, which is mounted only vertically, and “NS” - universal. In addition to the functions of permanent formwork, load-bearing corrugated flooring, due to its geometric shape, is an additional reinforcement of the reinforcement frame of the flooring made of corrugated board. It perceives the deflection forces that the reinforcement holds and partially compensates for them. This makes it possible to reduce the cross-section of the reinforcement and the thickness of the concrete, compared to the design of a slab made from removable formwork. The greater the height of the corrugation of the profiled sheet, the greater the distance between the load-bearing beams of the floor, acting as the base on which the ceiling rests on the corrugated sheet. All these parameters should be determined by a preliminary calculation, depending on the loads on the slab, and its participation in the stability of the frame of the entire building. Also, in industrial buildings, warehouses, workshops, where it is planned to perform a monolithic ceiling on corrugated sheets, a decorative coating of a profiled sheet, laid with the painted side down, can serve as the final finishing of the ceiling. This significantly reduces the cost of interior decoration. 
Project documentation
The corrugated sheet ceiling is one of the most important and critical structures of the entire building. Carrying out construction and installation work on concreting such structures is unacceptable without developed working drawings, with all the accompanying calculations. In general, the calculation of the building frame is a very important moment in the design, on which the strength, durability and, most importantly, the safety of the structures being built will depend. Calculating flooring using corrugated sheets is a rather complex and time-consuming process. Therefore, if you want to get a high-quality structure as a result, be sure that at one “wonderful” moment it will not collapse, and at the same time not incur extra costs, it is better to contact a specialized architectural bureau. It would also be a good idea to ask them to show the relevant permits for design work and a SRO certificate. The main regulatory documents regulating the calculation and design of this structure are SNiP II-23-81 “Steel structures” and SNiP 2.03.01-84 “Reinforced concrete and concrete structures”.
In order to speed up calculations, designers use specialized computer programs, which also allow them to minimize errors. One of such software products is the CAD system - a computer-aided design system. The final set of working drawings for corrugated flooring should include: - formwork drawing - which indicates the method and attachment points of the formwork;
- reinforcement drawing - with dimensions and diameter of reinforcement;
- specifications - indicating the total quantity of materials used.
Sequence of work
After the frame of the lower floor has been erected, the floor formwork made of corrugated sheets is installed. In this case, the direction of the corrugated sheet wave should be perpendicular to the frame beams. The profiled sheet is laid with an overlap on another sheet in one or two waves. The sheets are fastened together with rivets and secured to the supporting beams on which they rest.
The next stage is the installation of frames made of reinforcement. First of all, an end board is placed on the formwork for corrugated flooring to the height of the calculated thickness of the flooring along the corrugated flooring, which prevents the concrete from spreading. Then the reinforcement frame is knitted and laid in the design position. To maintain the thickness of the protective concrete layer between the reinforcement and the formwork, plastic clamps intended for this purpose are placed on the frame. If the corrugated flooring to be concreted is large in area and cannot be completed continuously at one time, cut-off meshes are placed in the reinforcement frame to construct working joints. The construction of the working seam is made strictly perpendicular to the horizontal plane of the slab. 
This is followed by laying the concrete. This process is carried out using concrete pumps, mobile on trucks or stationary. Concrete of the required plasticity, calculated and specified in the project, is supplied from a concrete pump through a steel concrete pipeline, and is evenly distributed over the concreting area using a flexible hose. It is possible to lay concrete using special buckets, so-called shoes. They received this name because of their shape, where the back of the tub is open for loading concrete, and the front, from which concrete is supplied, is closed, and an opening gate with a supply tray is equipped at the end. In this case, the concrete is unloaded into these buckets, delivered to the place of installation by a crane, after which the concrete worker opens the gate and the concreting is carried out directly. 
When the corrugated flooring area is large, in order to evenly distribute the load on the formwork, concreting is done in a checkerboard pattern. If all the loads are correctly calculated, the type and cross-section of the reinforcement, the grade of concrete are selected correctly, the technological sequence of work and subsequent care of the concrete are followed, then the result is the structure you need, with balanced costs, ready for long-term and safe operation.