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 profiled 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.
Modern technologies have made it possible to make low-rise buildings lighter and cheaper, and their construction time has been significantly reduced. These advantages attract many, but those who want to get not a temporary shelter, but a real home, try to use materials such as brick and concrete. In this case, monolithic flooring is often performed on corrugated sheets, since such technology can be used with buildings of any shape and size.
In this article we will tell you what is the difference between this type of overlap and the classic version, and also describe the technology for its creation.
The use of corrugated sheeting allows you to get something that standard technology lacks - a ceiling that practically does not require additional processing. This can be seen by looking at the first picture in the article. In general, this technology can be represented as pouring slabs using permanent formwork. The classic solution involves dismantling the base panels used to hold the concrete during the process of strengthening.
The difference of this technology does not in the least prevent it from developing, since its features make this approach attractive for the construction of garages, terraces and outbuildings.
Overlapping with corrugated sheets receives higher strength due to the fact that the metal profile allows you to give the concrete a shape that better resists deformation, and therefore has higher reliability. This is achieved thanks to the stiffening ribs formed by the profile. As studies show, a floor with a ribbed cross-section requires much less reinforcement, and the consumption of concrete is lower, although the strength is in no way inferior to a conventional structure.
Despite the fact that corrugated sheets make it possible to obtain concrete slabs that are relatively light in weight, such floors can only be used in houses with brick walls or those built from concrete blocks. 
Before planning the installation of such an overlap, you need to attend to at least a preliminary strength calculation. It is advisable that this issue be dealt with by a professional, otherwise unexpected difficulties may arise at the pouring stage.
Preparing for pouring
Before starting work, you need to make sure that the monolithic flooring on corrugated sheets is fully calculated and all possible loads are determined. The base for it is metal columns and beams, the parameters of which also need to be determined, and this is very difficult to do without first calculating the loads on the floor.
It is worth saying that the pitch of the beams and the distance between them also depend on what kind of corrugated sheeting you plan to use. The greater the height of the profile, the smaller the pitch of the beams is chosen, since the strength of this concrete pour will not be too high.
As an example, let’s assume that the beam laying step is no more than 3 meters, and the grade of material used is TP-75, while the sheet thickness is 0.9 mm. To determine the length of the corrugated sheet, you will need to take into account that it should rest not on two, but on three beams. This will prevent the sheet from bending in the future. Pouring concrete in this case will also be simplified, since short spans the pressure will be less.
Attaching a sheet to a metal base is not easy. As a rule, for this it is best to use special self-tapping screws with a reinforced drill. Ceilings on corrugated sheets can even be made with 32 mm fasteners. The presence of a reinforced drill allows the self-tapping screw to easily enter the channel, even if it has not been pre-drilled, which is why such fasteners are also called armor-piercing.
It is best to tighten screws using a screwdriver or drill set to low speed, since the number of attachment points can be quite large.
It is better to fasten in every place where the corrugated sheet comes into contact with the base beam, since the load on such a structure will be very high. One has only to remember that the ceiling on corrugated sheets is poured from concrete, which is 2.4 times heavier than water, and it becomes clear that it is necessary to make a very reliable formwork.
The joints of individual sheets should also be recorded. For this purpose, smaller self-tapping screws are suitable, for example 5.5, 25 mm long. They need to be screwed in increments of 25 mm. After the corrugated sheeting is prepared, you can begin preparing the reinforcement.
Preparation of reinforcement
Reinforcement is an internal frame that allows concrete to withstand heavy compressive and bending loads. In this case, experts recommend counting on the fact that the monolithic flooring on corrugated sheets will not receive additional strength due to permanent formwork, which means that reinforcement must be done wisely.
The volumetric structure is created from longitudinal rods 12 mm thick, laid in each of the depressions of the profiled sheet. In addition, “top” reinforcement is used, which is performed along the ridges of the profiled material. In this case, there are not only longitudinal components made from 10 mm reinforcement, but also transverse ones, which can be made from 6 mm rods.
The elements of the reinforcement frame are connected by a weld or using steel wire. The first option is attractive because the structure is quite strong, and such a connection is made quickly, but wire is still preferable.
When covering with corrugated sheets, it is better to mark the openings for stairs to the second floor, as well as communication channels in advance, and then perform formwork around them. In this case, after completion of the work, there will be no need to carry out any additional procedures to make the opening. All you need to do is cut out a thin sheet of perforated metal.
The formwork is made of wood, since it is simple and cheap, and the boards themselves need to be protected with film or roofing felt, since this will allow them to be used in the future for other needs.
Pouring concrete
To create floors, it is better to use a fairly high grade of concrete, for example, M350. It may also be designated as the B-25 class. Maximum strength will be achieved only if the pouring is carried out continuously, which means that it is necessary to ensure the delivery of the required amount of the mixture to the work site. It’s better not to experiment with homemade concrete, since it won’t bring much benefit in cost, but it will take a lot of time to prepare.
It’s easier to order ready-mixed concrete, as well as special equipment for pouring. As a rule, a concrete pump or conveyor belt performs well in such situations. Using a concrete pump is advisable if the mixture has high mobility, so this point should be discussed with the solution supplier.
The ceiling over the corrugated sheet is poured continuously, after which it is leveled. It is worth noting that before pouring concrete, you need to install additional supports that will not allow the corrugated sheet to bend under the weight of the mixture being held. These supports are placed in the center of the spans between the beams and are removed only after the composition has gained grade strength.
To gain strength, artificial stone will require at least 28 days under normal hardening conditions. Pouring must be done at positive air temperatures, since as the thermometer drops, the time it takes for concrete to gain strength increases. In an ideal situation, after 11 days of hardening, concrete will gain up to 80% of its brand value.
When a monolithic ceiling over corrugated sheets is created in hot and dry weather, it is worth additionally moistening the poured composition, since due to the loss of a large amount of water, its surface may begin to crack. This will negatively affect the strength of the material.
If frosts may occur during work, it is better to immediately order a mixture that has antifreeze additives. Such concrete gains strength even at low temperatures, and the use of a number of special methods will significantly reduce the time required for its hardening. Of course, various additives can increase the cost of the composition, so it is better to carry out such work in late spring or summer.
Creating a "pie"
In addition to the concrete layer, experts also recommend using insulation, the installation of which is carried out after completion of the first stage of work. Overlapping with corrugated sheets allows the use of any type of material, but ideally two tasks should be solved at once: providing heat and sound insulation. Today there are a lot of similar materials, so the choice of a suitable option is determined by thermal engineering calculations and the ratio of price and characteristics.
Waterproofing is laid on top of the insulation and a reinforced screed is made, for which concrete of a lower grade, for example M250, is suitable. We will not describe the technology for creating a screed in this article, since it is already given on our website.
Difficult moments
One of the most important stages of work is theoretical calculation. The reliability of the entire structure depends on how correctly it is executed. If you are not an expert in this matter, then it is best to turn to a professional, since there are several important points in which a beginner can easily make a mistake:
- Choice of frame construction material. In fact, there are several types of profiles and you can’t rely on “maybe” in this case. An accurate answer about the appropriate formwork in which a monolithic floor will be created using corrugated sheets will only be given by analyzing the future design and performing difficult calculations.
- Type and thickness of corrugated board. The reliability of the formwork being created depends on this. If the thickness is too small, then unwanted deformations may occur, which will lead to a violation of the thickness of the slab, and therefore will affect its performance characteristics, and not for the better.
- Selecting the reinforcement section and calculating the structure of the internal frame. Above we gave an example of choosing reinforcement, but it only shows the relationship between these elements. To create a working project, you will need to think through in detail the technology for constructing a metal “skeleton”, as well as perform calculations of the behavior of the finished reinforced concrete slab under the influence of loads.
To summarize, we note that covering with corrugated sheets, the installation technology of which is described above, is not the only possible option. As an alternative, ordinary hollow-core panels can be used, and even the classic pouring of concrete into a special formwork. The use of corrugated sheeting is advisable in the case when work is carried out in a private building area and heavy equipment simply cannot get to the installation site of the slabs.
If the ceiling is poured over corrugated sheets using a concrete pump, then the range of supply of the solution can reach several tens of meters in a straight line.
A floor is a structure that is intended to divide a structure into sectors and floors and to construct a floor; as a result, the floor must have strength, reliability and durability, since the strength and reliability of the entire building as a whole depends on its technical properties and characteristics. Previously, concrete slabs were used for flooring, but they are heavy, and accordingly, installing and installing the slab requires a huge amount of physical labor. Moreover, it is necessary to have equipment with a high lifting capacity at the construction site, because the slab is carried with the help of powerful cranes. using corrugated sheets is a new technology that greatly simplifies the work of builders.
Corrugated sheet is a corrugated sheet made of galvanized steel. This material is coated with special agents that protect it from corrosion and other adverse environmental influences and improve the aesthetics of the product. Again, in this matter, concrete and reinforced concrete slabs do not have such indicators. Moreover, a reinforced concrete slab absorbs moisture well, which is quite difficult to dry, and accordingly, the building may have high humidity, and slabs with high humidity begin to mold. The advantage of corrugated sheeting is its resistance to high humidity. Corrugated sheet metal has a wide range of applications; this material is used for cladding walls, creating roofs, constructing hangars, fences, change houses and for constructing floors, which is not typical for a reinforced concrete slab. Another factor in favor of corrugated sheeting is that it can be used in any region of our country, while the slab does not have such indicators.
Types of profiled sheets:
N – for floors and roofs (load-bearing);
NS – for flooring and walls;
C – for walls
Requirements for a professional sheet:
- high reliability;
- special strength.
Material advantages
At the moment, corrugated sheets are the most optimal option for flooring, since they are not subject to negative environmental influences and do not deform under heavy loads. Moreover, it has a fairly low cost and has a wide range of colors and sizes. This is what makes corrugated sheets such a sought-after material.
Advantages and characteristics of profiled sheets:
- light weight;
- ease of installation;
- high strength;
- versatility;
- efficiency;
- long service life;
- unpretentiousness;
- ease of transportation.
The profile sheet makes it possible to obtain a ribbed floor, which significantly increases its strength and reliability, reducing the cost of reinforcement and concreting, in other words, for reinforcement and concrete. With a profiled sheet, it acts as formwork, which cannot be removed, and the metal frame serves as a support, while with a slab, formwork is required, even to cover the floor. Thanks to this technology, walls can be built from lightweight materials, since the entire load is transferred to the frame and not to the walls; by the way, the load is not transferred to the floor either.
On a note! Foam and aerated concrete blocks are perfect as materials for walls.
Another advantage is that the load passes evenly across the entire foundation, and not just on the column-type concrete foundation.
An important advantage in modern construction is the speed of construction of the building. According to the professional sheet, it’s quite simple. The work does not require a huge amount of special equipment and special equipment for the construction site. The only tool you need is a screwdriver. Accordingly, another advantage follows from this: the installation of the overlap can be completed in a few days. In other words, the construction period of the building is reduced.
Overlapping device
Tools that will be required during the work process:
- screws and screwdriver;
- drill and drill bits;
- wire and crochet hook;
- level;
- plumb line;
- roulette;
- square;
- If necessary, you will need a concrete mixer or a container for the solution.
Material calculation
Before starting construction work, it is necessary to make the correct calculation. The calculation of a monolithic floor using a profiled sheet is made on the basis of: the dimensions of the designed building, as well as the calculation of the loads on columns and beams. Based on the data obtained, the required dimensions of the frame elements are selected, and the required number of profiled sheets is calculated, the number of screws is calculated, and so on. You can do the installation of a monolithic ceiling yourself, but it is better to entrust the calculations to professionals.
Design calculation
In our example, the pitch of the beams is 3 m; to determine the amount of corrugated sheeting, it is necessary to calculate the support of the sheet on 3 beams to prevent deflection, which is possible. Moreover, you should calculate the number of 32 mm self-tapping screws, which will be fastened at each joint of the beam or corrugated sheet. By the way, it is better to calculate the screws with a margin, since some of them will fall, and accordingly, you will need to collect them. If you purchase more self-tapping screws than the required number, you don’t have to worry about the fallen one.
Advice! The screws come in increments of 40 cm; at the joints it is better to use 25 mm armor-piercing screws.
The calculation of concrete is influenced by the expected load of the floor, the dimensions of the beams and slabs, and the features of the work.
Monolithic floor technology involves reinforcing beams or support columns; in this case, cross-section pipes, metal or asbestos, are used. Metal I-beams or channels are used as beams. Reinforcement is an important component, so you should not skimp on it. Especially if you are building a multi-story building, where the monolithic ceiling is both the ceiling and the floor. In other words, you save on materials. Moreover, the corrugated flooring is quite strong and reliable; the monolithic ceiling allows you to make the floor also warm. A floor based on corrugated sheets protects against rodents and is not subject to rotting processes. In other words, you can put any of the finishing materials on the floor without worrying about it, that is, without worrying about its safety from the inside. If earlier reinforced concrete slabs were laid on the floor, which were often damp, and, accordingly, the floor too, then at the moment, construction technologies have reached a completely new level, which makes it possible to create a reliable and durable floor that will also serve as a ceiling during the construction of a multi-story building .
In order to install the ceiling, you must have drawings and strictly adhere to them. It is also better to order a drawing from professionals, but if you understand this issue, you can do it yourself. The drawing consists of a complete description of all the elements necessary for the ceiling, their sizes, and, of course, the actual drawing (drawing).
An important component is the correct selection of the necessary materials.
Filling the floor
It is better to carry out concreting over spans, especially if the building area is large, since you may simply not have time to pour the mortar in one day. If you do otherwise, cracks and deformations may appear, as a result of which the floor will lose its evenness and strength, and, accordingly, reliability. Before pouring the spans, it is necessary to have good reinforcement of the side parts of the structure and install support beams under the span that you plan to fill.
Remember! In cold weather, concrete can dry for one month or more, in warm weather it is reduced to 10 days. If you are pouring concrete in very hot weather, it must be watered to prevent cracking.
All finishing work is carried out after the concrete has completely hardened and the supports have been dismantled.
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?
Flooring made from corrugated sheets is 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 floors using profiled sheets does not fall on the wall, but on a completely strong and reliable metal frame.
When using corrugated sheet flooring as a building material for walls, we can recommend foam block or gas block, 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.
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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