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Suspended Flooring - Technical Overview

Suspended flooring, (also known as RIB and BLOCK) is used as a safe, easy to install, customisable (not to mention cost effective) way of creating floors for a wide array of buildings. Most commonly used in residential, light commercial and light industrial applications, Custom Crete’s Suspended Flooring product has successfully been used in hundreds of buildings of all types.

Custom Crete works closely with the appointed structural Engineer and the building contractor to ensure the required scope of work is correct and delivered on time for the project.

The process of designing a flooring system is relatively simple, but must be carried out by a recognised structural Engineer who is authorised to conduct such work and be able to “sign off” on the completed flooring job.

Step 1 - Purpose

Ascertain for what purpose the floor will be used. Click on the icon to download the pdf document showing a table of Intensity of nominal imposed floor loads for occupancies other than industrial and storage (SANS 0160-1989). This will assist you in best identifying your particular project’s load bearing requirements.

Download
Click here to download the Load Categories

STEP 2 - Beam and block configuration selection

Determine the beam and block configurations. These configurations are largely dependent on the required span widths. The table shown below gives the nominal live load for the various configurations.

Nominal Live Load (kN/m2), Qn (SABS 0160-1989)   

SPAN WIDTH in mm

Load Tables  2000  2500 3000 3500 4000 4500 5000 5500 6000 6500
112 Deck Block 4mmØ x 4  17.70  11.40  6.90  4.20  2.40 1.20         
112 Deck Block 4mmØ x 5  19.10  14.60  9.30  5.90  3.80  2.30        
112 Deck Block 4mmØ x 6  20.50  15.80  11.60  7.60  5.10  3.30        
112 Deck Block 5mmØ x 4    15.50  12.10  8.00 5.40   3.50        
112 Deck Block 5mmØ x 5    17.00  13.60  10.60  7.30  5.10        
112 Deck Block 5mmØ x 6    18.50  14.90  12.30  9.20  6.60        
202 Deck Block 4mmØ x 4    14.50  11.40  8.60  5.70  3.70        
202 Deck Block 4mmØ x 5    14.50  11.40  8.60  5.70  3.70        
202 Deck Block 4mmØ x 6    16.80  13.40  10.90  9.10  7.30  5.20  3.60    
202 Deck Block 5mmØ x 4    16.60  13.20  10.80  9.00  7.50  5.50  3.90  2.60  
202 Deck Block 5mmØ x 5      14.50  11.90  9.90  8.40  7.10  5.70  4.20  3.00
202 Deck Block 5mmØ x 6         12.90  10.80  9.20  7.90  6.80  5.60  4.20

Detailed load tables for each configuration are supplied below, click on the labelled icon to show detailed load tables. (The black shaded box is the recommended configuration for a particular span and load requirement).

Download  Download  Download  Download  Download 
Load Category 1 -
Live Load 1.5 kN/m2
Load Category 1 -
Live Load 2.0 kN/m2
Load Category 1 -
Live Load 3.0 kN/m2
Load Category 1 -
Live Load 4.0 kN/m2
Load Category 1 -
Live Load 5.0 kN/m2

 

Load Tables 4mm x 4 strands 4mm x 5 strands  4mm x 6 strands  5mm x 4 strands  5mm x 5 strands  5mm x 6 strands 
112 Deck Blocks  Download  Download  Download  Download  Download  Download
202 Deck Blocks  Download  Download  Download  Download  Download  Download

 

STEP 3 - Design

Once the maximum span widths and load requirements are understood, the Engineer would then design the entire floor beam, block and reinforcing steel components into a technical (normally Autocad) diagram that would resemble the following example.

Layout and Beam Lengths Rib and Block Quantities


STEP 4 – Manufacture

Custom Crete uses the designs received from the Engineer and manufactures the beams as per the required lengths and quantities. Typically this process takes a week or more depending on the size of the order. Always allow two weeks from time of order to delivery, to ensure there is no standing time for the project.

STEP 5 - Installation

Once the components of the floor have been delivered to site, the installation can commence. The following sequence of pictures highlights the major steps involved in installing the flooring components.

Step 1 - Place Beams using deckblock as spacer Step 2 - Place all beams Step 3 - Support the Beams
Step 4 - Place Deckblocks as per Engineer Plan Step 5 - Place REBAR - Y12s and Electirical Conduits Step 6 - Place Ref Weld mesh - Slab is now ready for Concrete topping