Jointless Steel Fibre Concrete Industrial Floors

Size: px

Start display at page:

Download "Jointless Steel Fibre Concrete Industrial Floors"

Tabitha Cook
6 years ago
Views:

1 Jointless Steel Fibre Concrete Industrial Floors Presented by: Darryl Eddy Twintec South Africa

2 CONTENT Meeting the demands of a modern warehouse Design and engineering considerations What applications are there? How are Jointless SFRC floors constructed? Case Studies

3 Meeting the demands of a modern warehouse

4 Meeting the demands of a modern warehouse

5 Meeting the demands of a modern warehouse Impact on Floor Slab Higher traffic levels Increased loads Faster movement of goods Increased flatness tolerances required Future-proofing an ideal floor would be perfectly flat and have no joints. UK Concrete Society TR

6 Meeting the demands of a modern warehouse Traditional flooring solution Minimal reinforcement Low grade concrete Un-skilled workers Close spaced induced contraction joints Simple formed construction joints Split responsibilities

7 Meeting the demands of a modern warehouse

8 Meeting the demands of a modern warehouse

9 Meeting the demands of a modern warehouse

10 Meeting the demands of a modern warehouse What is the solution? Reduce the number of formed joints Increase reinforcement level Minimise shrinkage Armour the formed joints Eliminate sawn contraction joints Select appropriate flatness specification Increase surface hardness Detailing to be industrial floor slab specific

11 Meeting the demands of a modern warehouse

12 Meeting the demands of a modern warehouse

13 Meeting the demands of a modern warehouse

14 Meeting the demands of a modern warehouse

15 Design and engineering considerations

16 Design and engineering considerations Design and engineering considerations Ground conditions Loading criteria Building layout Material properties Detailing Construction Sustainability

17 Design and engineering considerations Ground conditions Slab on Grade: Bearing capacity Settlement limits Improvement strategy Slab on Piles: Pile type and size Pile spacing Pile caps Contamination Detailed ground investigation essential

18 Design and engineering considerations Loading criteria UDL Static point loads Dynamic loads Line loads Temporary construction loads

19 Design and engineering considerations Building layout Access Building use Loading dock system Fixed penetrations Storage system Temperature control Hygiene requirements

20 Design and engineering considerations Material properties SFRC (TR34 Section 6.3) Historically Japanese beam test JCI-SF4 RILEM beam test now incorporated in EN FR value now used ( residual flexural tensile strength ) Specimens 150 x 150 supported over 500mm Notched at mid-span, 25mm deep Performance related to applied load and crack mouth opening displacement (CMOD)

21 Design and engineering considerations Material Properties - EN beam test

22 Design and engineering considerations Material Properties - BS EN beam test Each load is used to calculate a residual flexural tensile strength (fr1, fr2, fr3, fr4) Residual moment capacity can be calculated and used in design EN Fibres for concrete Part 1: Steel fibres Definitions, specifications and conformity 12 beams per result Mean value used from set of 12 Test results fibre type / dosage / concrete specific

23 Design and engineering considerations Material Properties CE Marking The fibre supplier is required to declare the quantity of fibres to achieve residual (post-cracking) flexural strength F R of 1.5N/mm 2 at CMOD of 0.5mm 1.0N/mm 2 at a CMOD of 3.5mm This requirement equates to a ratio of cracked to un-cracked moment resistance of

24 Design and engineering considerations Detailing Shrinkage control Elimination of pinch points Joint positions Panel sizes, aspect ratio

25 Design and engineering considerations

26 Design and engineering considerations

27 Design and engineering considerations

28 Design and engineering considerations

29 Design and engineering considerations

30 Design and engineering considerations Construction Pour methodology Available resources Local material supply Skilled labour Equipment Site conditions

31 Design and engineering considerations Sustainability Minimising the impact of design Minimising the impact of contracting Promoting the use of recycled materials Championing cement replacement Improved whole-life environmental performance of construction projects

32 What applications are there?

33 What applications are there? SFRC jointless ground floor slab on grade

34 What applications are there? Benefits Elimination of sawn induced joints Reduction in overall life cost Improved efficiency and operator comfort Greater flexibility Reduced maintenance cost Reduced programme time Improved tolerances

35 What applications are there?

36 What applications are there? SFRC jointless ground floor slab suspended on piles

37 What applications are there? Total volume of slabs suspended on piles with these methods throughout Europe since 1992 now exceeds 10,000,000m 2

38 What applications are there? Benefits Elimination of steel fixing Allows use of laser screed technology Increased panel size and reduction in number of joints Reduced construction programme Greater flexibility of use Reduced maintenance cost Improved tolerances

39 What applications are there?

40 What applications are there? SFRC high tolerance jointless ground floor slabs

41 What applications are there? Benefits Elimination of sawn induced joints Can be cast in large panels Reduction in overall life cost Improved efficiency and operator comfort Greater flexibility Reduced maintenance cost Reduced programme time Improved tolerances Aesthetic improvement Highest flatness tolerances achieved without remedial grinding

42 What applications are there?

43 What applications are there? Structural Raft Foundations

44 What applications are there? Structural Raft Foundations Benefits Elimination of all or most of the steel fixing Allows use of laser screed technology Increased panel size and reduction in number of joints Reduced construction programme Greater flexibility of use Reduced maintenance cost Improved tolerances

45 How are jointless SFRC floors constructed?

46 How are jointless SFRC floors constructed? Joint Installation

47 How are jointless SFRC floors constructed? Steel Fibre Integration

48 How are jointless SFRC floors constructed? Production Process Laserscreed Levelling

49 Case Studies

50 ProLogis Developments Distribution Facility, UK Design and construction of 48,384m 2 SFRC pile-supported ground floor slab

51 Case study: ProLogis Developments SFRC jointless pile supported ground floor slab Project Data Contractor: Winvic Construction Engineer: Nolan Associates Concrete Supplier: Hanson Fibre Type(s): AFT +1/60 Fibre Dosage: 45kg/m 3 Total Area: 48,384m 2 Slab Depth: 250mm Completion Date: September 2006 Awards: Concrete Society Concrete Performance Award

52 Al Azizia Panda United Ridayh, Kingdom of Saudi Arabia Design and construction of 71,900m 2 SFRC jointless ground bearing floor slab

53 Case study: Al Azizia Panda United SFRC jointless ground bearing floor slab New Image Required Project Data Consultant Engineer: WSP Middle East Ltd Concrete Supplier: Al Falwa Fibre Type(s): AFT +1/60 Fibre Dosage: 40kg/m 3 Total Area: 71,384m 2 Slab Depth: 190mm Completion Date: May 2007

54 Quinn Glass Cheshire, UK Design and construction of 52,000m 2 SFRC structural raft foundation slab

55 Case study: Quinn Glass Structural SFRC raft foundation slab Project Data Main Contractor: Quinn Glass Bottling Management Consultant Engineer: Babtie Engineering Concrete Supplier: Hanson Premix Fibre Type(s): AFT 1/50 & AFT +1/60 Fibre Dosage: 45kg/m 3 Total Area: 52,000m 2 Slab Depth: 400mm Completion Date: March 2005

56 Tesco Distribution Centre Livingston, Scotland Design and construction of 250,000m 2 SFRC jointless internal & external concrete floor slabs

57 Case study: Tesco Distribution Centre Internal & external SFRC jointless floor slabs Project Data Main Contractor: Taylor Woodrow Construction Consultant Engineer: W.A. Fairhurst & Partners Concrete Supplier: Twintec / Sitebatch Technologies Fibre Type(s): AFT 1/50 Total Area: 250,000m 2 Completion Date: October 2007

58 Renault Factory Tangier, Morocco Design and construction of 165,000m 2 SFRC jointless ground bearing floor slab

59 Case study: Renault Factory Internal SFRC jointless floor slab Project Data Main Contractor: Sogea Concrete Supplier: Lafarge (mobile batching plants) Fibre Type(s): AFT 1/50 Fibre Dosage: 35-40kg/m 3 Total Area: 165,000m 2 Slab Depth: mm Completion Date: April 2012

60 Shoprite Distribution Centre Centurion, South Africa Design and construction of 64,500m 2 SFRC jointless ground bearing floor slab

61 Case study: Shoprite, South Africa Internal SFRC jointless floor slab Project Data Application Type: SoG Logistics: ILS Consulting Engineer: WSP Consulting Civil Engineer: KLS Consulting Contractor: Stefanutti Stocks Concrete Supplier: Afrimix Fibre Type(s): AFT +1/60 Fibre Dosage: 40kg/m 3 Total Area: 64,000m 2 Slab Depth: 200mm Completion Date: September 2010

62 Metcash Distribution Centre Huntingwood, NSW, Australia Design and construction of 69,800m 2 SFRC jointless ground bearing floor slab

63 Case study: Metcash DC Internal SFRC jointless floor slab Project Data Application Type: Internal ground bearing freezer, ambient & fresh warehouse Main Contractor: Hansen Yuncken Consultant Engineer: Costin Roe Fibre Type(s): AFT Steel Fibres Total Area: 69,800m 2 Completion Date: November 2011

64 Al Madina Logistics Barka, Oman Design and construction of 16,500m 2 SFRC jointless ground bearing floor slab

65 Case study: Al Madina Logistics High tolerance internal SFRC jointless floor slab Project Data Application Type: Internal ground bearing warehouse Consultant Engineer: DG BIM Consulting Fibre Type(s): AFT 0.8/55 Total Area: 16,500m 2 Slab Depth: 175mm Completion Date: October 2011

66 SUMMARY SFRC suits the demands of a modern warehouse Good design guidance exists to validate SFRC SFRC can be used in any industrial application Jointless SFRC floors can be constructed anywhere SFRC must be delivered by experienced contractors (TR34 4 th edition section 12)

Performance Floors for Warehouses and Distribution Centres. Kevin Dare, Managing Director, Face Consultants Ltd.

Performance Floors for Warehouses and Distribution Centres Kevin Dare, Managing Director, Face Consultants Ltd. Performance Floors for Warehouses and Distribution Centres. Kevin Dare, Face Consultants