Composite Floor Decks

Transcription

1 Studwelders Composite Floor Decks Steel Floor Decking Systems

2 Studwelders Limited A history that dates back to 1952 and a reputation that s second to none. Studwelders Limited was originally formed in In 1987 the Directors decided to further expand its already established welding expertise into associated product areas. Today the Company is firmly established within the Construction Industry as one of the market leaders in the Design, Installation and Studwelding of Steel Floor Decking Systems. Studwelders realises the importance of technical expertise and speed of communication within todays fast track construction industry, therefore, it s Design and Draughting department based in Chepstow is supported by state of the art computer systems. Although its centre of operations is based at Chepstow the company s self sufficient installation and welding teams install throughout England, Wales, Scotland, Channel Islands, Isle of Man and Isle of Wight. The safety of these teams is ensured by the erection of netting by Studwelders in house Safety Net Division. Throughout its period of growth Studwelders has continued to develop its own welding technology and products, including sole UK distribution of KÖSTER welding products. The company s target for success has been summarised by the Directors in the statement, Only through first class quality and service can we become the customers first choice. Studwelders new corporate headquarters.

3 Contents Page Operations Design 2 Contracts 4 Fibredeck 9 Projects Projects 10 Flooring Profiles MetFloor MetFloor MetFloor Health & Safety Safety Net Division 16 Studwelding Associated Products 17 1

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5 Design Analytical Design & Draughting Full in-house Design & Draughting Department Project specific design teams Some 2000 projects totalling 5 million square metres of decking have been designed and completed over the past 10 years Latest network IT hardware Windows based Composite Floor Design Software developed by the Steel Construction Institute Analytical Design can be produced for both BS 5950 and Eurocodes Full support from our Technical Department All drawings are computer generated using AutoCAD LT Ability to receive and transmit drawings by 3

6 Contracts Management Studwelders procedures and control systems have been optimised over the past ten years to ensure: Detailed pre-planning On site interfacing problems are minimised Programme issues are resolved immediately Quality standards are maintained Safety standards are adhered to Customer communication is constantly maintained Auditable records and information systems Contract management prepares fully detailed: - Method Statements - COSHH and Risk Assessments All sites are visited prior to commencement of installation 4

7 All projects prior to commencement are fully programmed including: - Phasing of the works - Drawing submission - Materials delivery - On site installation Notice of material deliveries are issued for all deliveries Contract management attend where necessary all progress meetings Upon completion the works are inspected and a Completion/ Handover Certificate issued Manuals and as-built drawings are issued upon completion All management staff are NEBOSH accredited 5

8 Contracts Netting, Installation & Welding The companies installation teams are the front line in creating customer relationships and demonstrating professionalism. Studwelders have invested heavily in training and equipping its installation staff. Today these self-sufficient installation teams are the backbone of Studwelders Limited. All Installation, welding and netting teams are directly employed and are fully trained holding the following certificates: CITB Banksman and Slinging Powered Access Forklift ECITB Safety Passport All site staff are provided with: Adequate gloves and protective clothing, Safety boots, Eye protection conforming to the specification in BS 2092:1987 Ear defenders, hard hats and high visibility clothing Full safety arrest systems in the form of safety netting are supplied by our in house Safety Netting Division 6

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10 Contracts Concreting To compliment our floor decking products we now offer a complete floor slab construction by adding the supply and laying of reinforced concrete. This single point solution allows integrated deck slab design with associated trade interface and programme advantages. 8

11 fibredeck NO MESH FLOORDECK SYSTEM Fibredeck is a composite floor system that uses a combination of Fibermesh micro-synthetic fibres and Novocon steel fibres to provide a 3 dimensional fibre reinforced concrete. Traditionally composite metal deck construction has utilised mesh fabric reinforcement. This involves the delivery, lifting and installation of wire mesh on to floors prior to pouring concrete. This method is a costly and time consuming use of equipment and manpower. Fibredeck provides a solution where reinforcement is mixed within the concrete delivered, ready to pump on-site. Fibermesh Novocon Benefits of Fibredeck The combination of Novocon Steel and Fibermesh micro-synthetic fibres provide a unique technical solution for composite metal decks. Fibermesh micro-synthetic fibres are proven to reduce plastic shrinkage, settlement cracking and the explosive spalling tendency of concrete during fires. Novocon Steel Fibres provides load bearing capabilities, increased toughness and long term crack control. Independent testing proves that Fibredeck provides equivalent or superior performance to traditional welded wire fabric solutions. Up to 20% on site Programme savings. No lifting/manual handling of mesh reinforcement. Easier concrete placement - no trip hazard from mesh. No lapping and spacer products required. No onsite storage requirements. 9

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13 Projects A measure of Studwelders success is the number, size and quality of the projects under construction and completed. The company s major achievements can be summarised in the following projects: Platinum Point at Leith Docks, Edinburgh - 44,000 m 2 St George s Island in Manchester - 40,000 m 2 The Eagle Centre in Derby - 110,000 m 2 The Glasshouse in Nottingham - 25,000 m 2 Faslane Naval Base Regeneration at Helensburgh - 55,000 m 2 Mass House in Birmingham - 25,000 m 2 Stratford City - 400,000 m 2 11

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15 MetFloor 55 The ultimate in lightweight steel decking for all multi-rise buildings MetFloor 55 is a traditional dovetail re-entrant composite floor deck. Its profile provides an excellent mechanical key into the concrete slab, offering a strong shear bond performance augmented by stiffeners located in the profile trough. MetFloor 55 presents a virtually flat soffit and a relatively thin slab is required to meet fire design requirements. Metfloor Cover width 600mm Shear studs MetFloor 55 has a wide trough which gives you great flexibility and efficiency when placing shear studs. Composite beams fire performance Even for two hours fire rating, the top flange of the steel beam does not require fire protection when used with MetFloor 55 composite deck. Under floor services Services are easy to attach to MetFloor 55, with the ribs presenting a dovetailed recessed groove in the concrete slab at 150mm centres. This provides the perfect connection for service hangars via a wedge nut or similar device. Slab s fire performance Because the dovetail has a very small opening very little heat is transferred through the slab if there is a fire. So when you design for fire purposes you will need a smaller slab depth. 13

16 MetFloor 60 The ultimate in lightweight steel decking for all multi-rise buildings With the launch of the entire CMF MetFloor range, solutions to composite flooring just got better. MetFloor 60 has exceptional spanning capabilities and reduced concrete usage. The result - a highly cost-effective, attractive, and easy-to-install floor solution. Its highly developed product range has been created with over 30 years experience in the composite metal flooring market. Metfloor Cover width 600mm MetFloor 60 also provides great acoustic performance it is engineered with optional closed ends - and excellent fire protection, with no need for filler blocks. The profile is designed with trough stiffeners and side laps positioned to guarantee centrally placed shear studs. And with a cover width at just 600mm, the lightweight, easy-to-handle MetFloor 60 sheets ensure safer on-site working conditions. Long-span capability The smarter profile designs of MetFloor 60 delivers exceptional unpropped spanning capability, helping to reduce structural steel components and costs Less concrete usage As it needs less concrete volume for any slab depth, MetFloor 60 delivers a more sustainable solution and helps reduces costs too Enhanced shear-stud interaction Enhanced design profile guarantees central shear-stud positioning to optimise composite action, so reducing the need for on-site checking Excellent acoustic and fire performance Manufactured with closed ends to give exceptional fire protection and acoustic performance, while simplifying installation Safer manual handling With a cover width of 600mm sheets are lightweight, making them safer and easier to handle 14

17 MetFloor 80 The ultimate in lightweight steel decking for all multi-rise buildings With the launch of the entire CMF MetFloor range, composite flooring solutions just got better. MetFloor 80 has exceptional spanning capabilities and reduced concrete usage. The result - a highly cost-effective, attractive, and easy-to-install floor solution. Its highly developed product range has been created with over 30 years experience in the composite metal flooring market. Metfloor Cover width 600mm MetFloor 80 also provides great acoustic performance it is engineered with optional closed ends - and excellent fire protection, with no need for filler blocks. The profile is designed with trough stiffeners and side laps positioned to guarantee centrally placed shear studs. And with a cover width at just 600mm, the lightweight, easy-to-handle MetFloor 80 sheets ensure safer on-site working conditions. Long-span capability The smarter profile designs of MetFloor 80 delivers exceptional unpropped spanning capability, helping to reduce structural steel requirements and costs Less concrete usage As it needs less concrete volume for any slab depth, MetFloor 80 delivers a more sustainable solution and helps reduces costs too Enhanced shear-stud interaction Enhanced design profile guarantees central shear-stud positioning to optimise composite action, so reducing the need for on-site checking Excellent acoustic and fire performance Manufactured with closed ends to give exceptional fire protection and acoustic performance, while simplifying installation Safer manual handling With a cover width of 600mm sheets are lightweight, making them safer and easier to handle 15

18 Health & Safety Studwelders Safety Net Division Studwelders Health and Safety Policy recognises the need to constantly develop its methods of working to minimise and remove risk. One of the key company edicts is that all staff will be protected by safety netting To ensure that its teams and customers receive this protection Studwelders has formed its own in house Safety Net Division Design of safety netting systems The erection and removal of safety netting in accordance with BS 1263 Parts 1 & 2. Erection and removal of debris netting for internal protection Sale of safety netting inclusive of border cords and ties Studwelders Safety Net Division has erection teams operating nationally, each team of two men being complete with its own vehicle, tools and safety nets All staff are CITB FASET trained installers 16

19 Studwelding One stop shop for stud welding products and equipment A large stock of the full range of stud welding products is maintained, including standard size plain and threaded anchors Non-standard items can be manufactured to customer requirements High performance Compact Stud Welding equipment is available either from stock or on short delivery Training operatives, including certification, can be combined with the supply of equipment Stud welding with ceramic ferrule Stud welding with shielding gas Short-cycle stud welding with or without shielding gas The stud is placed against the workpiece The stud is lifted off,while the current is flowing, thus creating an arc The arc melts the surfaces of the stud and workpiece The stud is plunged into the weld pool A cross-sectional joint is achieved 17

20 Whilst Studwelders Composite Floor Decks Limited have taken every care to ensure the accuracy of the information, data or advice contained in this brochure, no liability in respect of such information or advice whether given negligently or not, can be accepted by the company. Studwelders Composite Floor Decks Limited retain the right to amend the technical specifications of any range of profiles without prior notice. Copyright 2009 Studwelders Limited Designed by Plum Design & Advertising Ltd. Photographs: Conder Structures, Rowecord Engineering and Electra Studios Studwelders Composite Floor Decks Limited Millennium House Severnlink Distribution Centre Newhouse Farm Industrial Estate Mathern, Chepstow Monmouthshire NP16 6UN T F info@studwelders.co.uk