7.0 Design Information

ultrafloor DESIGN INFORMATION
7.0 DESIGN INFORMATION
7.1 Design Aids for Floor Slab

7.1.1 Load/Span Tables for Floor Systems
Design information and technical data has been provided for the 500 systems only. For details on
the 400 system, please contact the Ultrafloor Technical Department.
The following footnotes apply to all design tables shown below:
Design Criteria
Slab design is based on the following criteria:
! Simply Supported Greater spans can be achieved with extra topping and/or continuity.
! Fwrk Str strength of beams as formwork
! Slab Str strength of slab as composite prestressed slab
! Fwrk Defl serviceability of beams as formwork
! Slab Defl serviceability of slab under Dead and Live Load (deflection limit = L/250)
! LL Defl serviceability of slab under Live Load only (natural frequency limited to
a minimum of 5.0 Hz)
Beams as formwork are designed for 1.0kPa construction loading and 0.9kPa for stacked
materials. Once the topping reaches 15MPa, a stacking load of 4kPa has been allowed for. Slabs
supporting masonry walls are considered to be supporting a 2400mm high single brick wall. The
wall is deemed to be parallel to the beam span. A deflection limit of L/1000 is an additional design
criterion for slabs supporting masonry.
In addition to the self-weight of the concrete topping, the FC formboard has been designed to carry
a live load of 4kPa to cater for stacked materials, mounding of concrete and the workmen.
The following tables are all based upon 50mm topping concrete over top of beams, 25MPa
concrete topping and SL62 shrinkage control mesh.
SLAB SUPPORTING
130R-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
LIVE LIVE LOAD + 1.0 kPa SDL
(SDL 3.5kPa)
LOAD
BEAMS FREE SPANNING BEAMS PROPPED MIDSPAN BEAMS FREE SPANNING
kPa
ALLOWABLE DESIGN ALLOWABLE DESIGN ALLOWABLE DESIGN
SPAN (m) CRITERIA SPAN (m) CRITERIA SPAN (m) CRITERIA
1.5 4.00 Fwrk Str 5.90 Slab Str 4.00 Fwrk Str
Design Composite Slab
Properties Properties/m
Weight of slab: Area: 115344 mm2
2.89 kPa 7.5 3.95 Slab Str 3.95 Slab Str 3.60 LL Defl
Igross: 212.0 x E6mm4
Beam weight: 10.0 3.55 Slab Str 3.55 Slab Str 3.10 LL Defl
34 kg/m Mu: 31.7 kNm
15.0 2.50 Slab Str 2.50 Slab Str 2.30 LL Defl
ULTRAFLOOR TECHNICAL MANUAL September 2002 Edition Page 7-1

SLAB SUPPORTING
130C-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
(SDL 3.5kPa)
LOAD
kPa BEAMS FREE SPANNING BEAMS PROPPED MIDSPAN BEAMS FREE SPANNING

LL Defl
1.5 4.50 Fwrk Str 6.15 LL Defl 4.50 Fwrk Str

Design Composite Slab
Properties Properties/m 3.0 4.50 Fwrk Str 6.00 LL Defl 4.50 Fwrk Str
2 4.0 4.50 Fwrk Str 5.85 LL Defl 4.50 Fwrk Str

Weight of slab: Area: 121406 mm
3.02 kPa 5.0 4.50 Fwrk Str 5.75 LL Defl 4.50 Fwrk Str
Igross: 248.4 x E6mm4
Beam weight:
51 kg/m Mu: 57.34 kNm
10.0 4.50 Fwrk Str 4.70 Slab Str 4.20 Slab Str
15.0 3.50 Slab Str 3.50 Slab Str 3.20 Slab Str
SLAB SUPPORTING
150R-500 Ultrafloor System SLAB SUPPORTING
MASONRY WALLS
LIVE LOAD + 1.0 kPa SDL
(SDL 3.5kPa)
LIVE
LOAD
kPa


Design Properties Composite Slab
Weight of slab:
Properties/m 3.0 4.50 Fwrk Str 6.25 LL Defl 4.50 Fwrk Str
2.81 kPa 2 4.0 4.50 Fwrk Str 5.80 Slab Str 4.50 Fwrk Str
Area: 111724 mm
Beam weight: 4 5.0 4.50 Fwrk Str 5.35 Slab Str 4.50 Fwrk Str
Igross: 277.5 x E6mm
41 kg/m
Mu: 45.6 kNm
SLAB SUPPORTING
MASONRY WALLS
(SDL 3.5kPa)
LOAD
kPa

Design Properties Composite Slab 4.0 5.50 Fwrk Str 6.40 Slab Str 5.50 Fwrk Str
Weight of slab:
Properties/m
5.0 5.50 Fwrk Str 6.00 Slab Str 5.40 Slab Str
3.09 kPa Area: 127142mm2
Beam weight:
80 kg/m Igross: 372.8 x E6mm4
Mu: 57.4 kNm 15.0 3.60 Slab Str 3.60 Slab Str 3.40 Slab Str

SLAB SUPPORTING
MASONRY WALLS
(SDL 3.5 kPa)
LOAD
kPa
1.5 7.00 Fwrk Str 7.90 LL Defl 7.00 Fwrk Defl

Design Properties Composite Slab 4.0 7.00 Fwrk Str 7.55 Slab Str 6.85 Slab Str
Weight of slab:
Properties/m 5.0 7.00 Fwrk Str 7.35 Slab Str 6.60 Slab Str
3.52 kPa Area: 145000 mm2 7.5 6.50 Slab Str 6.50 Slab Str 5.95 Slab Str
Beam weight:
112 kg/m Igross: 728.5 x E6mm4 10.0 5.85 Slab Str 5.85 Slab Str 5.45 Slab Str
Mu: 89.5 kNm 15.0 4.60 Slab Str 4.60 Slab Str 4.30 Slab Str
SLAB SUPPORTING
MASONRY WALLS
(SDL 3.5 kPa)
LOAD
kPa

Design Properties Composite Slab
Weight of slab:
Properties/M
3.94 kPa 5.0 8.00 Fwrk Str 8.40 LL Defl 8.00 Fwrk Defl
Area: 162857 mm2
Beam weight: 7.5 8.00 Fwrk Str 8.10 LL Defl 7.60 Slab Str
142 kg/m Igross: 1255 x E6mm4
Mu: 147.7 kNm
Maximum unpropped spans for various

Ultrafloor configurations
130R 130 C 150R 150C 200C 250C
insitu topping 400 500 400 500 400 500 400 500 400 500 400 500
over rib board board board board board board board board board board board board
50 4.4 4.1 4.9 4.7 4.8 4.5 5.8 5.5 7.9 7.6 10.3 9.9
60 4.3 4.1 4.8 4.6 4.7 4.4 5.6 5.4 7.7 7.4 10.1 9.7
70 4.2 4.0 4.7 4.5 4.6 4.3 5.5 5.3 7.6 7.3 9.9 9.6
100 4.0 3.7 4.5 4.2 4.3 4.0 5.2 5.0 7.2 6.9 9.5 9.1
60 + setdown
3.9 3.6 4.5 4.2 4.1 3.7 5.1 4.8 6.8 6.5 8.6 8.1
clips
Note : These spans are based on the weight of the wet concrete plus a 1.0 kPa construction
loading only.

7.1.2 Design Checklist Ground Floor Construction
The following steps are involved in the design of the Ultrafloor system when used in ground floor
construction and may be used as a checklist by the design engineer:
1. Determine the design live load for the floor. Refer to AS1170.1 SAA Loading Code, Part 1:
Dead and live loads and load combinations.
2. Determine the available lines of support, for example masonry dwarf walls, retaining walls,
bearers and piers, etc.
3. Determine the maximum span between the available lines of support nominated in Step 2.
4. Select an Ultrafloor system using the load / span tables in Section 7.1.1. Input the design
live load and the maximum span.
a) Use the left-hand part of the design table if all internal partitions and walls that are
supported by the floor are of lightweight construction (timber or metal stud).
b) Use right-hand part of the design table if the floor supports non-loadbearing brick walls
of height up to 2.4m.
5. Are the spans such that the load / span tables indicate the need for propping?
YES: Refer to Section 8.2 for details of propping.

NO: Continue to Step 6.
6. Does the floor support any concentrated loads due to columns or loadbearing walls bearing
on the floor?
YES: Refer to Section 7.7.2 for details regarding design for concentrated loads.
7. Is the slab to be supported on Ultrafloor bearers and masonry piers?
YES: Refer to Section 7.3 for details regarding design of Ultrafloor bearers.
8. Does the slab need to be designed as continuous to achieve larger spans for the selected
system than allowed by the span tables?
YES: Refer to Section 7.7.4 for details regarding designing for continuity.
9. Does the floor contain any cantilevered sections of slab?
YES: Refer to Section 7.7.3 for details regarding designing cantilevers.

10. Does the slab contain voids for stairs or penetrations?
YES: Refer to Section 8.3 for details regarding trimming voids with saddle supports.

11. Does the floor include any external areas?
YES: Refer to Section 7.8 for details regarding design for durability.
12. Does the floor require wet area set-downs in the finished floor level?
YES: Refer to Section 8.4.3 for details regarding wet area set-down.
13. Are control joints required to control movement and cracking?
YES: Refer to Section 8.6 for details regarding control joints.

14. Refer to Section 8.1.1 and the construction details in Section 10 for common details for
supporting Ultrafloor systems in ground floor construction.
A similar checklist for multi-storey construction follows in Section 7.1.3.

7.1.3 Design Checklist Multi-Storey Construction
The following steps are involved in the design of the Ultrafloor system when used in multi-storey
construction and may be used as a checklist by the design engineer:
1. Determine the design live load for the floor. Refer to AS1170.1 SAA Loading Code, Part 1:
Dead and live loads and load combinations.
2. Determine the available lines of support, for example load bearing walls, steel or concrete
beams etc.
3. Determine maximum span between the available lines of support nominated in Step 2.
4. Select an Ultrafloor system using the load / span tables in Section 7.1.1. Input the design live
load and the maximum span.
a) Use the left-hand part of the design table if all internal partitions and walls that are
supported by the floor are of lightweight construction (timber or metal stud).
b) Use the right-hand part of the design table if the floor supports non-loadbearing brick
walls of height up to 2.4m.
5. Are the spans such that the load / span tables indicate the need for propping?
YES: Refer to Section 8.2 for details of propping.

6. Does the floor support any concentrated loads due to columns or loadbearing walls bearing
on the floor?
YES: Refer to Section 7.7.2 for details regarding design for concentrated loads.
7. Does the building need to be designed for progressive collapse or earthquake design?
YES: Refer to Section 7.7.5 for details regarding progressive collapse.

8. Does the slab need to be designed as continuous to achieve larger spans for the selected
system than allowed by the span tables?
YES: Refer to Section 7.7.4 for details regarding designing for continuity.
9. Does the floor contain any cantilevered sections of slab?
YES: Refer to Section 7.7.3 for details regarding designing cantilevers.

10. Does the slab contain voids for stairs or penetrations?
YES: Refer to Section 8.3 for details regarding trimming voids with saddle supports.

11. Does the floor include any external areas?
YES: Refer to Section 7.8 for details regarding design for durability.
NO: Continue to Step 12
12. Does the floor require wet area set-downs in the finished floor level?
YES: Refer to Section 8.4.3 for details regarding wet area set-down.
13. Are loadbearing lintels required over door or window openings?
YES: Refer to Section 7.6 for details regarding designing Ultralintels.

14. Is the slab required to have a high fire resistance level?
YES: Refer to Section 5 for details regarding fire resistance levels.

NO: Continue to Step 15
15. Is fire and/or sound insulation required at internal or external walls?
YES: Refer to Section 8.9.3 for details regarding fire and sound separation.
16. Are control joints required to control movement and cracking?
YES: Refer to Section 8.6 for details regarding control joints.

17. Refer to Section 10 for common details for supporting Ultrafloor systems on load bearing
masonry, steel beams, reinforced concrete beams and post tensioned band beams.

7.2 Design Procedures in General

7.2.1 General
The Ultrafloor system consists of prestressed concrete beams, which act as formwork to support
the weight of a concrete topping and construction loads. When the topping has cured, it acts
compositely with the beams to form a slab capable of supporting the superimposed loads.
The design method is based on Limit State design principles as well as the following Australian
Standards:
AS 3600 2001, Concrete structures.
AS 1170 2002, SAA Loading Code, Part 1: Dead and live loads and load combinations.
AS 3610 1995, Formwork for concrete.
The design process is in two stages: [1] the Ultrafloor beams as formwork, and [2] the composite
slab under design loads. At each stage, checks must be made for strength and serviceability.
The Ultrafloor beams may be simply-supported or continuous. In either case, the composite slab
may be designed as simply-supported, or, by the addition of negative moment reinforcement over
internal supports, as continuous. The load tables in this manual are for the simply-supported slab
condition. It is for the design engineer to design each continuous slab individually.
Verification of the behaviour of the Ultrafloor system (particularly of properties such as ductility,
longitudinal shear transfer, transverse shear capacity, the distribution of line loads across beams,
fire resistance etc) has been carried out by extensive testing, as referred to in Section 3.4.
7.2.2 Non-Composite State
7.2.2.1 As Formwork
A. LOADING
Formwork loads for strength are taken from AS 3610 as:
Case 1: 1.25 G + 1.5 QUV (Stage 2)

1.25 G + 1.0 QC
Case 2: 1.25 G + 1.5 QUV + 1.5 M3 (Stage 3)
where G = DL = Beam + fibre cement + wet concrete load
Quv = Construction LL = 1.0 kPa
QC = Construction LL = 3.0 kPa over 1.6m x 1.6m
M3 = Stacked material = 0.9 kPa (4.0kPa once the in-situ topping

reaches a minimum compressive strength of 15MPa)

B. DESIGN
The beams are checked for strength and serviceability criteria. If the beams are propped as
formwork, then they are designed as a series of simply-supported beams, spanning between
props.
1. Bending strength is checked under the above loads against the non-composite capacities
for ultimate moment given in the tables of Section 7.1.1.
2. Shear strength is also checked under the above loads. The shear capacity is the minimum
of the flexure-shear and web-shear capacities.
3. Flexure-shear strength at various locations along the beam using the decompression
moment and shear force at each point.
The flexure-shear strength at x from the support can be determined, after calculating V*/M*
as that point, as:
Vuc(flexure) = Vuc1 + M0 (V*/M*)
where Vuc1 is in tabulated in Section 7.5.2.1 and M0 is found from Figure 7.5.2.1a.
Web-shear strength for the non-composite case is also tabulated in Section 7.5.2.1.
A minimum length of bearing of 60mm is to be used so that the theoretically unstressed

length of tendon, Lp/10 = 56mm from the end, is outside the shear design region. Note: the
bearing length used in testing was only 40mm.
4. Deflection is checked, under DL prestress hogging, against a limit of L/360. AS 3610

requires L/270 for Class 3 formwork.
5Gl 4 Pel 2
formwork =
384 EI nc 8 EI nc
where L = clear unpropped span
Inc = beam moment of inertia, non-composite
e = eccentricity of centroid of prestress below the neutral axis
P = prestressing force
E = Youngs elastic modulus (noting that Ultrafloor beams reach
a compressive strength of typically 50MPa after 48 hours.
5. The working moment due to Quv and G (factored accordingly) must be less than the cracking
moment of the Ultrafloor beam.
7.2.2.2 As Bearers
Design principles are similar to those for formwork except that the design loads are as per
AS 1170.1 2002, SAA Loading Code, Part I: Dead and live loads and combinations.

[A] ULTIMATE MOMENT CAPACITY, MU

The published Ultrafloor ultimate moment capacities are based on strain compatibility calculations
using the AS 3600 stress block with a maximum concrete compressive strain of 0.003 and an
average maximum concrete compressive stress of 0.85 fc. Refer to Section 7.5.1 for a tabulation
of Mu values. (Note: For the beams acting as formwork the ultimate neutral axis parameter ku is
sometimes greater than 0.4, the strength reduction factor has been taken as 0.8, these capacities
have been confirmed by testing in accordance with Clause 21.2 of AS 3600).
[B] SHEAR STRENGTH

In the non-composite state, Clause 8.2.5 (c)(i) of AS 3600 explicitly can be applied to Ultrafloor
beams not exceeding 250mm deep, so that again shear reinforcement is not required if V* < Vuc.
The shear capacity of non-composite beams has been verified by testing at Sydney University.
[C] NON-COMPOSITE DESIGN SHEAR CAPACITY, Vucn.

The ultimate shear capacities of Ultrafloor are based on the minimum of flexure-shear capacity and
web-shear capacity in accordance with Clause 8.2.7.2 of AS 3600.
Flexure-shear cracking could occur in regions of the beams which are cracked in flexure.
BS 8110 would only require this to be checked where M* > M0, the decompression moment.
Ultrafloor load tables are based on a check for flexure shear capacity, in accordance with
Clause 8.2.7.2 of AS 3600, at numerous sections from the critical section, d from supports, to
the midspan of the beams as formwork.
The ultimate shear strength, Vuc, is taken as
Vuc = 1 2 3 bv d0 [Apt fc / (bv d0)]0.33 + V0
where 1 = 1.1(1.6 - d0 / 1000) 1.1
2 =1
3 = 1 (note that the shear enhancement of 2d0/av permitted under AS 3600 for
strut action has not been adopted. To do so would require increased
anchorage length)
V0 is the shear associated with a moment equal to the decompression moment,

M0, under the applied load distribution.
ie V0 = M0 V*/M*
To calculate the decompression moment, M0
Pe Pe e
Mo = Zb +
A Zb
where Zb = I/yb and yb = distance from bottom to centroid;
A prestress force, Pe, equal to 85% of the jacking force has been used to allow for immediate
losses, plus shrinkage and creep losses, at 30 days.

To determine the decompression stress, the prestress force Pe is taken to develop linearly from
zero at Lp/10 from the end of the beam, to full prestress at Lp from the end of the beam. Lp is taken
as 60 times the strand diameter, in accordance with AS 3600 Clause 13.3.2.
Since V0 can vary with the location along the span, the load distribution, and the length of bearing,
it is not possible to determine a specific Vuc for each beam.
To assist designers in checking shear, Section 7.5.2.1 of this manual can be used. This enables
the shear strength at any location to be easily calculated once the designer has determined V*/M*
at that location.
The shear strength at x from the support can be determined, after calculating V*/M* at that point,
as:
where Vuc1 is tabulated in Section 7.5.2.1
Web-shear cracking could occur in regions of the beams near the supports which are uncracked.
It has been checked in accordance with AS 3600 Clause 8.2.7.2.(b), (or by testing) but at a
distance from the support equal to the height of the centroid from the bottom of the beam. This is
the location required by BS 8110 and is more conservative that at d. The results are tabulated in
Section 7.5.2.1.
A minimum length of bearing of 60mm has been set so that the theoretically unstressed length of
tendon, Lp/10 = 56mm from the end, is outside the shear design region. The bearing length used
in testing was only 40mm.
7.2.3 Composite State
In the composite state, the Ultrafloor system is considered as a slab. In accordance with
Clause 8.2.5(c)(ii) of AS 3600, shear reinforcement is not required if V* < Vuc.
7.2.3.1 Simply-Supported Design
[A] UNPROPPED SLABS
Loading
Composite loadings are based on AS 1170.1. For strength this is as below:
1.25 G + 1.5 Q where G = DL = Slab DL + Applied DL (eg. partitions)
Q = LL as in AS 1170 Part 1
Design
The composite slab is checked for strength and serviceability.
1. Bending strength is checked under the above loads against the composite design moment
capacity described below.

Composite Design Moment Capacity, Mu

The published Ultrafloor ultimate moment capacities are based on strain compatibility
calculations using the AS 3600 stress block with a maximum concrete compressive strain of
0.003 and an average concrete compressive stress of 0.85 fc.
Refer to Section 7.5.3 for a tabulation of Mu values.(The approach of adding stresses is

conservative as, due to creep, the non-composite stresses are considerably redistributed
across the full section.The ultimate moment capacity therefore becomes close to that of a slab,
which was composite throughout its whole load history).
2. Shear strength is also checked under the above loads. The shear capacity is the minimum of
flexure-shear and web-shear capacities. The method of calculations is the same as for the
non-composite situation, however the tables and figures in Section 7.5.4.4 are used.
3. Longitudinal shear should also be checked at the interface of the Ultrafloor beams and the
topping from Clause 8.4.3 of AS 3600.
Vuf = 5 bf d fct < 0.2 fc bb fd
where 5 = 0.2 conservatively
bf = width of shear interface
fct = 0.4 fc and is based on the weaker concrete, generally the topping.
In an unpropped slab, the unfactored slab self-weight is not included in the longitudinal shear
calculation.
4. Deflection is checked for a number of criteria.
Relevant section properties, composite or non-composite, are used depending on the condition
of the slab in relation to the type of deflection being calculated. For the composite condition, an
average value of E can be used throughout based on fc = 45MPa for the full section. Note that
the Ultrafloor beams reach a compressive strength of typically 50MPa after 48 hours.
a) Springiness
Deflection of the composite section is checked under LL only against a limit of L/1200. This
is to guard against springiness with tendons rebounding.
b) Long Term
Loads are categorised as follows:
Sustained Before partitions -I Slab DL prestress
After partitions - II 0.4 LL typically (as varied by AS 1170.1)
- III Applied DL (partitions, ceiling etc)
Non-sustained - IV 0.7 LL typically (as varied by AS 1170.1)
Short-term deflection = ST

c) Creep is calculated using the multiplier method of AS 3600 Clause 8.5.3.3.
CREEP = (2-1.2ASC/AST) x ST [due to I +II +III]
using 0.8 x prestress to account for losses; Icomposite with full service loads
d) Total Deflection is calculated from short-term deflection and creep, and checked as
follows:
TOTAL = ST [due to I + III + IV] + CREEP < L/250

e) Deflection After Partitions is calculated and checked as follows:
AFTER PARTITIONS = ST [due to III+ IV] + CREEP

< L/1000 for non-articulated masonry
< L/500 for articulated masonry
[B] PROPPED SLABS
Composite Design Moment and Shear Capacity

The principles are as per the unpropped case with the design capacities, Mu, and Vuc as given in
Sections 7.5.3 and 7.5.4.4. Applying the slab DL as a uniform load on the composite section is a
reasonable approximation to the central prop load.
Deflection
The principles are as for the unpropped case except that composite section properties are used for
all cases, and there is no deflection under construction loads at the midspan location.
7.2.3.2 Continuous Design
[A] UNPROPPED SLABS
Design
1. The composite slab is checked for strength and serviceability.
Bending strength is checked under the above loads against the composite design moment
capacity, similarly to a simply supported slab.
Positive Moments:
The design ultimate positive moment is calculated as a simply supported moment for 1.0 x self-
weight (of beams + wet concrete), plus a continuous slab moment for 0.25 x self-weight + 1.25 x
SDL + 1.5 x LL.

Negative Moments:
Negative reinforcement can be designed similarly to a conventionally reinforced continuous slab
by incorporating solid concrete blockouts over the peak negative moment regions as required.
Consideration can be given to using the Ultrafloor beams to carry the compression loads.
The design negative moment is only due to an effective load of 0.25 x self-weight + 1.25 x SDL
+ 1.5 x LL.
2. Ultrafloor slabs are designed for flexure shear to AS 3600 Clause 8.2.
The ultimate shear capacity, Vuc, at the external support of a continuous slab is checked in a
similar manner to a simply supported slab, from AS 3600 Clause 8.2.7.2.(a). To determine the
decompression stress, the prestress force is taken to develop linearly from zero at Lp/10 from
the support to full prestress at Lp from the support, where Lp = 60 times the strand diameter.
Vuc = 1 2 3 bv d0 [(Ast+Apt) fc / (bv d0)]0.33 + V0
At internal supports, where the slab is in tension at the top, Vuc is calculated from AS 3600
Clause 8.2.7.1, where Ast is the area of top reinforcement.
Vuc = 1 2 3 bv d0 [Ast fc / (bv d0)]0.33
3. Longitudinal shear should also be checked at the interface of the Ultrafloor beams and the
topping from AS 3600 Clause 8.4.3.
Vuf = 5 bf d fct < 0.2 fc bf d
where 5 = 0.2 conservatively
bf = width of shear interface
fct = 0.4fc and is based on the weaker concrete, generally the topping
In an unpropped slab, the slab unfactored self-weight is not included in the longitudinal shear
calculation.
[B] PROPPED SLABS
Positive Moments
During the non-composite stage, ie under self-weight, FRC and wet concrete loads, the beams are
designed in the same way as for a propped simply supported slab design at the same stage (ie for
formwork design). The maximum span with one row of props is double that span obtained for the
unpropped case as no continuity is considered.
For the composite stage the Design Moment Capacity, Mu is as tabulated in Section 7.5.3.
The design positive moment is calculated as a continuous slab moment for the total factored DL +
LL. The central prop load is approximated by including slab DL as a uniform load on the composite
section.

Negative Moments
Negative reinforcement can be designed similarly to a conventionally reinforced continuous slab by
incorporating solid concrete blockouts over the peak negative moment regions. Consideration can
be given to using the Ultrafloor beams to carry the compression loads.
The design negative moment is due to total factored DL + LL.
[C] DEFLECTION CALCULATIONS
Short-Term Deflection
1. Calculate the deflection at beam placement.
pre = P.eNC.L2/(8EB INC)
swt+frc = 5wswt + frc.L4/(384 EB INC)
If propping is to occur then it would normally be at this level. A pre-camber could be applied using
the propping. Its effects could be accounted for by increasing the load of the in-situ concrete
applied to the composite slab by an amount equivalent to the reaction from the pre-camber.
Deflection at beam placement = pre - swt+frc
2. For unpropped beams calculate the deflection of the beams under wet in-situ concrete.
wetcon = 5w wetcon. L4 / (384 EB INC) [= zero for propped beams]
3. Calculate the cracking moment at salient locations on the slab.
For a continuous composite slab a model needs to be developed which accounts for the
effects of cracking, and uses an effective moment of inertia.
Over Supports fc = 25MPa in the topping concrete
fct = 0.6fc = 3MPa
a) If the Ultrafloor beams are discontinuous over the supports
Mcr = fct.Zgt where Zgt = section modulus of the gross

section over the support at the top
b) At locations where the Ultrafloor beams are prestressed
Mcr = Zgt[fct + P/Ag] P.e
where P = effective prestress force
Ag = gross slab section area
e = eccentricity of prestress force from the neutral axis

At Midspan fc = 70MPa
fcb = 0.6fc = 5.01 MPa
Mcr = Zgb[fcb + P/Ag] + P.e
4. Calculate the cracked moment of inertia at salient points in the slab.
Icr = bd3/3 + n Ast(d - dn)2
where dn = k.d
k = [(n.p)2 + 2n.p] n.p
n = 8.5 for fc = 25MPa (topping)
= 6.0 for fc > 50MPa (beams)
5. It is necessary to estimate the location of the regions of cracked and uncracked section of slab.
When the slab is continuous a model needs to be developed which accounts for the effects of
cracking, under serviceability loads, and uses an effective moment of inertia.
Serviceability load is defined at DL* + sLL, where s is given in AS 1170 Part 1 and is
generally 0.7.
! If the beams are unpropped, then the DL to be used is only that which is superimposed,
i.e. it does not include the weight of the beams, FRC or in-situ concrete. This is because
the cracked sections under serviceability load are generally over the supports, and, in an
unpropped situation, the moments at supports are only due to superimposed loads. The
beam self-weight, FRC and in-situ concrete weight has been taken by the beams alone
(non-composite) when the in-situ concrete is placed.
! If the beams are propped, then the DL to be used includes the in-situ concrete but not the
weight of the beams or FRC. This assumes that the props hold the beams at their
installation level. Although strictly speaking the prop reaction is a point load, it is
acceptable to consider the deflection under the in-situ concrete load as being due to a
uniform load on the full composite slab after prop removal. Unless the propping induces a
pre-camber, the in-situ concrete is the only load transferred onto the composite slab from
the non-composite stage. If a precamber is introduced by the propping, then the DL must
be increased by an amount to give an equivalent moment to the that produced by the prop
reaction from precambering.
An elastic analysis can be used, with a uniform stiffness, as an estimate of Ms (moments under
serviceability loads) at the salient points. Areas of cracked section can be located where
Ms > Mcr.
6. Calculate the effective moment of inertia at the salient points, using the relationship in
AS 3600 1994 Clause 8.5.3.1:
Ief = Icr + (Ig Icr) (Mcr/Ms)3

7. Model the slab with I = Ief ie varying throughout the span, to calculate short-term serviceability
deflections, serv and moments. This is not strictly accurate as the location of the cracked
sections derived in step 5 was based on uniform stiffness. An iterative process could be
undertaken to recalculate Ieff using moments derived from the step 7 model as Ms, and then re-
run the model with the revised Ieff.
If it is desired to ascertain the immediate deflection after prop removal less conservatively, then
Ms could be based on DL only to calculate Ieff. However, Ieff would need to be reassessed with
full serviceability load, for use in calculating short-term deflection including LL.
However, it should be remembered that many factors make calculation of deflections of precast,
prestressed composite systems an estimate only. Examples are:
Age of the beam at time of installation.
Whether the plank is hogging or deflecting while it is in storage.
The effect of construction loads on the plain plank, and whether it cracks during construction.
The age of the composite system when permanent dead loads are applied.
The differential shrinkage of topping and plank.
The inherent stiffness of some superimposed dead loads, compared to the flexibility of the structure,
causing redistribution of those dead loads.
The possibility of some service loads causing undue vibration, especially when the prestressing has
been designed to balance the effect of long-term loads, which theoretically leads to zero deflection.
The location, magnitude, timing and duration of service loads applied during the life of the structure,
and whether any of them cause the composite system to crack.
The restraint to shrinkage by the topping reinforcement and plank, and the distribution of the resultant
shrinkage cracks.
8. Calculate short term deflection as:
short term = serv ( pre - swt+fre - wetcon)
LONG-TERM DEFLECTION
Creep
Creep calculations require the determination of the sustained loads, which act on the composite
section. Sustained loads are taken as DL = l.LL from AS 1170 pt 1, where l is generally 0.4.
This loading will be less than the short serviceability loading of DL + sLL where s is generally
0.7. It is therefore necessary to use the cracked regions and properties determined for the short
term loading case.
Creep occurs under sustained loads and under prestressing loads (basically another type of
sustained load), and is calculated by factoring up the short-term deflection caused by these loads.

Short-term deflection under sustained loads, short term sust is determined from the elastic analysis of
step 5 above, using sustained loads DL + l.LL. Prestress deflection to be factored for creep is
calculated on the composite section as:
pre short term for creep = P.ecomp.L2/(8EavIcomp)
The creep factor can be calculated from AS 3600 Clause 8.5.3.3 as:
C = [2-1.2 Asc / Ast] > 0.8
Therefore,
creep = C [ short term sustained 0.8 pre short term for creep]
and long-term deflection
LT = short term + creep
SUGGESTED DEFLECTION LIMITS
1. Short-Term L/360
2. Long-Term
Total L/250
Deflection After Construction Masonry Partitions:
Articulated partitions L/500
Non-articulated partitions L/1000
3. Springiness
We recommend the natural frequency of the slab be kept to a minimum of 5.0 Hz. This is to guard
against springiness with tendons rebounding.

7.3 Designing Ultrafloor Bearers

7.3.1 General
Ultrafloor prestressed beams can be used as bearers to support Ultrafloor systems in ground floor
construction. The bearers can be supported on isolated and/or engaged piers. The 170R bearer
section has been developed specifically for this purpose. It courses with two courses of standard
brickwork. When high loads or large spans need to be designed for, double 170R bearers are the
preferred option for ease of construction. The commercial range of beams are very efficient for this
purpose, however, particular care is required to achieve correct levels on the supporting piers, as
these beams do not course easily with brickwork.
Ultrafloor bearers shall be designed to suit the applied loads and the required span between
supports by a professional engineer. The necessary properties and engineering information for the
non-composite beam sections is contained in Section 7.5.1 and are repeated in the bearer data
sheets in this section. Deflection information and load/span tables for the common bearer sections
follow. Construction details for Ultrafloor bearers are included in Section 8.1 as well as Section 10
of this manual.

7.3.2 170R Bearer Design Information
80 Weight 41 kg/m
Moment capacity (Mu) 13.0 kNm
Shear Capacity (Vuc) See Section 7.5.2.1

6 4
Second moment of area (gross) 41.8 x 10 mm
130
Youngs modulus of elasticity (Ec) 33840 MPa
Total long term deflection

= 1.235E-14 * L + 2.0198E-08 * L + 3.353(DLslab + wall) + 2.041 * LL
(including shrinkage and creep)
Long term deflection after construction of walls

= 8.669E-15 * L + 2.0198 E-08 * L + 2.353 * DLslab + 3.353 * wall + 2.041 *LL
Notes:
1. L = Beam span (mm).
2. DLslab = Dead load deflection of bearer due to slab loads (mm).
3. wall = Dead load deflection of bearer due to wall loads (mm).
4. LL = Live load deflection of bearer (mm).
5. The self-weight of the bearer has been allowed for in these deflection formulae.
170R Load / Span Table using Uniformly Distributed Loads

Total Working Allowable Span (mm)
Load (kN/m) Deflection limit L/250 Deflection limit L/500 Deflection limit L/1000
5 3050 2400 1900
10 2450 1950 1550
15 2050 1700 1350
20 1800 1550 1250
25 1600 1450 1150
30 1350 1350 1100
35 1150 1150 1050
40 1000 1000 1000
45 900 900 900
50 800 800 800
Notes:
1. Allowable spans are based on the total working load being in the proportion of 60% Dead
Load and 40% Live Load.
2. Self-weight is allowed for in the tables.

7.3.3 150C Bearer Design Information
200 Weight 80 kg/m
Shear capacity (Vuc) See Section 7.5.2.1

6 4
Second moment of area (Igross) 64.8 x 10 mm
250 Youngs modulus of elasticity (Ec) 33840 MPa

= 1.588E-14 * L + 1.4732E--07 * L + 3.1(DLslab + wall) + 1.94 * LL
Long- term deflection after construction of

= 1.075E-14 * L + 1.4732E-07 * L + 2.1 * DLslab + 3.1 * wall + 1.94 * LL
walls including shrinkage and creep)
Notes:
2. Dlslab = Dead load deflection of bearer due to slab loads (mm).
150C Load / Span Table using Uniformly Distributed Loads

5 3350 2600 2000
10 2800 2150 1650
15 2450 1950 1500
20 2250 1750 1350
25 2050 1650 1300
30 1850 1550 1200
35 1600 1500 1150
40 1400 1400 1100
45 1250 1250 1100
50 1150 1150 1050
55 1050 1050 1000
60 950 950 950
65 900 900 900
70 800 800 800
75 750 750 750
Notes:
1. Allowable spans are based on the total working load being in the proportion of 60% Dead
Load and 40% Live Load.


200 Weight 112 kg/m

6 4
Second moment of area (Igross) 157 x 10 mm

= 7.486E-15 x L - 1.1272E - 07 * L + 3.025(DLslab + wall) + 1.91 * LL
Long term deflection after construction of = 5.011E-15 * L - 1.1272E - 07 * L + 2.025 * DLslab + 3.025 * wall + 1.91*LL
walls(including shrinkage and creep)
Notes:

5 4900 4000 3300
10 4000 3250 2650
15 3550 2850 2350
20 3200 2600 2100
25 3000 2400 1950
30 2700 2300 1850
35 2300 2150 1750
40 2050 2050 1700
45 1800 1800 1600
50 1650 1650 1550
55 1500 1500 1500
60 1400 1400 1400
65 1300 1300 1300
70 1200 1200 1200
75 1100 1100 1100
80 1050 1050 1050
85 1000 1000 1000
Notes:
1. Allowable spans are based on the total working load being in the proportion of 60% Dead Load and
40% Live Load.


200 Weight 142 kg/m

6 4
Second moment of area (Igross) 306.3 x 10 mm

= 5.155E -15 * L - 3.845E - 07 * L + 2.967(DLslab + wall) + 1.887 * LL
Long- term deflection after construction of

= 3.417E -15 * L - 3.845E - 07 * L + 1.967 * DLslab + 2.967 * wall + 1.887* LL
walls(including shrinkage and creep).
Notes:

5 6750 5900 5250
10 5500 4700 4150
15 4750 4100 3550
20 4200 3700 3200
25 3750 3400 2950
30 3450 3200 2750
35 3200 3050 2600
40 3000 2900 2450
45 2750 2750 2350
50 2500 2500 2250
55 2250 2250 2200
60 2100 2100 2100
65 1950 1950 1950
70 1800 1800 1800
75 1700 1700 1700
80 1600 1600 1600
85 1500 1500 1500
Note:
1. Allowable spans are based on the total working load being in the proportion of 60% Dead Load and
40% Live Load.

7.4 Designing Ultrashell Band Beam Systems

7.4.1 Description
A further innovation to the Ultrafloor slab system is to replace the formwork also in conventional
band beams by using specially precast flat soffit shell-beams in a system known as Ultrashell as
shown in Section 4.3.2. Its design is described in Section 7.4.7 below along with further diagrams.
No fibre-cement formboard is used in this instance. It can be post-tensioned or reinforced for
further strength capacity.
The standard Ultrafloor beams and slab therefore are supported by primary beams that have been
created using the same concept designed to reduce formwork and reinforcement placing.
7.4.2 Design Synopsis
In order to achieve full cost savings in the structure, it is imperative to make use of the structural
capacity of the band system, rather than merely seeing it as a substitute for formwork.
Structural testing (refer to Section 3.4) has shown conclusively that in the concreted state, full
composite action occurs, resulting in a monolithic band beam that carries the required design
actions. Propping is required during concreting until a minimum concrete compressive strength of
22MPa is achieved. For the calculation of propping to the band beams during construction, the
cracking moment (Mcr) is never exceeded (for most cases 1.5m to 1.8m centres is normally
sufficient).
To determine the capacity of the Ultrashell system, one calculates it in the usual manner in
accordance with the relevant codes of practice using the quantities of 9.3mm diameter strand at a
particular effective depth.
NB: For a quick preliminary calculation, use the following equation:

Mu = Aps x dp / 800
where Aps = cross-sectional area of pre-tensioned strand (mm2)
dp = effective depth to strand (mm)
Mu = ultimate bending moment capacity (kNm)
Refer to Section 7.5.1 for properties (non-composite) of the range of Ultrashell sections and
Section 7.5.2.2 for the properties of the prestressing strands.
For most normal spans (6-8m) and normal loadings (2-4kPa) very little, if any, additional bottom
reinforcement is required over and above the Ultrafloor band beam systems. Top steel and ties
would generally be the only additional requirement.
7.4.3 Fire Rating
In the Ultrashell sections, the cover to the bottom strand is effectively 35mm. The minimum floor
thickness is in the range 190mm to 290mm. This results in a fire rating of at least three hours if the
system is used for structural benefit, namely an FRL of 180/180/180. For greater fire resistance (eg
4 hours), extra cover (eg 40mm) is required.

7.4.4 Dimensional Considerations
In selecting the dimensions of the Ultrashell system, it is important to remember that the system is
modularised and is built up as such.
Ultrashell rib-slab comes in modules of 600mm and 1200mm widths and depths of 100mm,
150mm, 200mm and 250mm. Therefore band depths are determined by adding the above options
to the slab depth.
7.4.5 Design of Conventionally Formed Band Beams
The use of conventionally formed band beams with Ultrafloor slabs has been extensive prior to the
introduction of the Ultrafloor band systems. The minimum embedment of Ultrafloor beams into a
conventional band beam is 150mm for internal spans and 250mm for edge beam embedment.
2Y12 ties are typically placed between each Ultrafloor beam.
7.4.6 Design of Ultrashell System
It is usual that the 600mm wide Ultrashells are used in order to make the lifting on site easier, and
it is furthermore usual that two 600mm widths are used to form a 1200mm band beam as shown in
Figure 7.4.6a. It is only where greater load capacity is required that an Ultrashell band of wider
than 1200mm would be designed.
Floor depths vary depending on the topping slab depth, namely by adding 100, 150, 200 or 250
millimetres of depth for the precast band beam profile. The minimum recommended topping depth
is 60mm and hence the least band beam thickness is 160mm.
The bending moment capacity can be calculated by considering that each 600mm module has
8 x 9.3mm diameter prestressing strands (six bottom and two top). An approximation method
described at Section 7.4.2.
Figure 7.4.6a: Typical Ultrashell Band Beam System

7.4.7 Ultrafloor Band Systems at Columns
Figure 7.4.7a shows how the Ultrafloor band beam systems are constructed relative to a structural
column.
Figure 7.4.7b is a cross-sectional view showing the suspension reinforcement.
Figure 7.4.7a: Ultrashell Band System Relative to Columns
Figure 7.4.7b: Section A-A of Figure 7.4.7a

7.5 Section Properties & Design Capacities

7.5.1 Non-Composite Section Properties
Residential Range of Beams
b
UNITS 130R 150R 170R
Depth of section (a) mm 130 150 170
Width of section (b) mm 130 130 130
Depth of flange (c) mm 70 100 70
Mass of section kg/m 34 41 41
2
Gross area mm 13470 16440 16790
4 6 6 6
Second moment of area (I Gross) mm 18.5x10 29.5x10 41.8x10
Youngs Elastic Modulus (Ec) MPa 33840 33840 33840
pos
Positive moment capacity (Mu ) kNm 6.1 8.4 10.6
pos
Positive cracking moment (Mcr ) kNm 4.7 6.1 8.2
neg
Negative moment capacity (Mu ) kNm 3.8 7.7 8.4
neg
Negative cracking moment (Mcr ) kNm 2.2 4.4 4.8
See Section
Shear capacity (Vuc) kN
7.5.2.1
Commercial Range of Beams
b
UNITS 130C 150C 200C 250C
Depth of section (a) mm 130 150 200 250
Width of section (b) mm 190 250 250 250
Depth of flange (c) mm 70 100 150 200
Mass of section kg/m 51 80 112 142
2
Gross area mm 21530 34270 47180 56850
4 6 6 6 6
Second moment of area (I Gross) mm 31.2x10 64.8x10 157.1.0x10 306.3x10
Youngs Modulus (Ec) MPa 33840 33840 33840 33840
pos
Positive moment capacity (Mu ) kNm 12.1 18.2 39.6 61.9
pos
Positive cracking moment (Mcr ) kNm 8.7 12.1 23.2 42.1
neg
Negative moment capacity (Mu ) kNm 10.3 15.8 24.7 27.8
neg
Negative cracking moment (Mcr ) kNm 5.6 9.00 12.8 15.1
See
Shear capacity (Vuc) kN Section
7.5.2.1

Ultrashell Range of Beams
UNITS S600/100 S600/150 S600/200 S600/250

Depth of section (a) mm 100 150 200 250
Width of section (b) mm 595 595 595 595
Depth of flange (c) mm 65 70 70 70
Mass of section kg/m 120 150 185 220
2
Gross area mm 49781 65791 79791 93791
4 6 6 6 6
Second moment of area (I Gross) mm 34.4x10 113.1x10 269.3x10 523.3x10
Youngs Modulus (Ec) MPa 33840 33840 33840 33840
pos
Positive moment capacity (Mu ) kNm 13.7 29.9 60.4 81.2
pos
Positive cracking moment (Mcr ) kNm 11.5 22.9 39.9 59.0
neg
Negative moment capacity (Mu ) kNm 8.0 23.2 32.0 39.0
neg
Negative cracking moment (Mcr ) kNm 4.4 13.1 18.9 25.7

7.5.2 Non-Composite Section Design Notes
7.5.2.1 Shear Capacity
The shear strength at x from the support can be determined, after calculating V*/M* at that point,
as:

where Vuc1 is given below:
BEAM 130R 150R 170R 130C 150C 200C 250C
Vuc1 8.89 10.85 12.04 17.45 24.08 30.17 37.94
Figure 7.5.2.1a: Decompression Moment Diagram

for Non-Composite Section
Note: M0 is constant at M0(max) when x + bearing exceeds 558mm.
If it is preferred, then Mo can be calculated as M0 (max).(x + bearing 56)/502.
With x in mm, when x + bearing < 558.
Web-shear Cracking
Web-shear cracking could occur in regions of the beams near the supports that are uncracked. It
has been checked in accordance with AS 3600 Clause 8.2.7.2(b), (or by testing) but at a distance
from the support equal to the height of the centroid from the bottom of the beam. This is the
location required by BS 8110 and is more conservative that at d. The results are tabulated below.
BEAM 130R 150R 170R 130C 150C 200C 250C
Vuc1(web) 14.24 20.65 18.90 26.84 48.35 69.49 89.63
A minimum length of bearing of 60mm has been set so that the theoretically unstressed length of
tendon, Lp/10 = 56mm from the end, is outside the shear design region. The bearing length used in
testing was only 40mm.

7.5.2.2 Properties of Tendons
The tendons used for prestressing the Ultrafloor components comply with Clause 6.3 of AS 3600
and the structural design properties are as follows:
Material Type and Standard 7-wire super strand AS 1311

Nominal Diameter 9.3mm
2
Area 54.7 mm
Minimum Breaking Load 102 kN
Minimum Tensile Strength (fp) 1860 MPa
Yield Strength of Tendons = 0.85 x fp (for stress-relieved wire)
3
Modulus of Elasticity 195 x 10 MPa
7.5.3 Composite Section Properties and Capacities
The following notes apply to all of the design data presented below:
1. Beam span L in mm.
2. LL is the deflection due to Live Loads.
3. DL is the deflection due to Superimposed Dead Loads. The self-weight of the floor is already
included in the formula.
4. The calculation of LL and DL also include the summation of all point and distributed loads.
Beams may be grouped together to resist the applied loads. The applied loads shall be
apportioned to a beam configuration on the basis of the relative stiffness. Refer to Section
7.7.2 for details.
5. All deflections are in millimetres (mm).

Beam Configuration 1 130R/500 System

Section bending capacity (Mu) 18.4 KNm
Section stiffness (EI) 3.42E+12 Nmm
Section area 66900 mm
Section weight 1.68 kN/m
Floor weight 2.89 kPa

Section Shear Capacity Vuc See Section 7.5.4.4
Unpropped Deflections:
Long term deflection = 5.5038E-14 * L - 8.974E-07 * L + 1.5* LL + 3.0 * DL
Deflection after construction of walls = 1.279E-14 * L - 6.1529E-07 * L + 1.5 * LL + 2.0 * DL
Propped Deflections:
Long term deflection = 2.5840E-14 * L - 8.9742E-07 * L + 1.5 * LL + 3.0 * DL
(props removed after wall is constructed);
(props removed before wall is constructed).

Section bending capacity (Mu) 17.1 kNm
Section stiffness (EI) 2.79E +12 Nmm
Long term deflection
= 2.1197E-14 * L - 9.5414E-07 * L + 1.5 * LL + 3.0 * DL
Deflection after construction of walls
(props removed after wall is constructed); = 1.3211E-14 * L - 6.7555E-07 * L + 1.5 * LL + 3.0 * DL

(props removed before wall is constructed)

= 1.5262E-14 * L - 9.4173E-07 * L + 1.42 * LL + 2.8 * DL
= 8.1777E-15 * L - 6.5670E-07 * L + 1.42 * LL + 2.8 * DL
(props removed after wall is constructed);

(props removed before wall is constructed).

Beam Configuration 1 130C/500 System

Unpropped Deflections
Propped Deflections
= 2.2125E-14 * L - 1.2020E-06 * L + 1.5 * LL + 3.0 * DL
= 1.4525E-14 * L - 9.7865E-07 * L + 1.5 * LL + 3.0 * DL
(props removed after wall is constructed)
= 1.0678E-14 * L - 9.7865E-07 * L + 1.5 * LL + 2.0 * DL

Section bending capacity (Mu) 32 kNm
Propped Deflections
(props removed after wall is constructed) = 1.0617E-14 * L - 8.9769E-07 * L + 1.4 * LL + 2.74 * DL


Long term deflection 2.0092E-14 * L - 1.1867E-06 * L + 1.45 * LL + 2.88 * DL
Deflection after construction of walls =
= 7.8238E-15 * L - 9.5922E-07 * L + 1.45 * LL + 1.88 * DL
Propped Deflections
= 1.4828E-14 * L - 1.1867E-06 * L + 1.45 * LL + 2.88 * DL



Propped Deflections
= 1.1845E-14 * L - 7.3977E-07 * L + 1.5 * LL + 3.0 * DL




= 7.5601E-15 * L - 6.9787E-07 * L + 1.5 * LL + 2.0 * DL
Propped Deflections
= 1.5278E-14 * L - 7.6626E-07 * L + 1.5 * LL + 3.0 * DL
= 9.3328E-15 * L - 6.9787E-07 * L + 1.5 * LL + 3.0 * DL


Section bending capacity (Mu) 14.3 KNm

= 6.2348E-15 * L - 6.1551E-07 * L + 1.45 * LL + 1.87 * DL
Propped Deflections
= 1.1917E-14 * L - 6.8683E-07 * L + 1.45 * LL + 2.87 * DL



Propped Deflections
= 1.4531E-14 * L - 6.8967E-07 * L + 1.5 * LL + 3.0 * DL
= 9.2406E-15 * L - 5.9647E-07 * L + 1.5 * LL + 3.0 * DL



Propped Deflections
= 1.1997E-14 * L - 6.0402E-07 * L + 1.38 * LL + 2.71 * DL
= 6.9661E-15 * L - 5.0938E-07 * L + 1.38 * LL + 2.71 * DL
Deflection after construction of walls = 5.3109E-15 * L - 5.0938E-07 * L + 1.38 * LL + 1.71 * DLL


Propped Deflections
6.1478E-15 * L - 5.0617E-07 * L + 1.44 * LL + 2.85 * DL
(props removed after wall is constructed) =



Section bending capacity (mu) 62.7kNm
Section weight 2.47 Kn/m
Propped Deflections
= 8.1024E-15 * L - 6.2902E-07 * L + 1.5 * LL + 3.0 * DL
= 5.1732E-15 * L - 4.6786E-07 * L + 1.5 * LL + 3.0 * DL

Section bending capacity (mu) 58.4 kNm

Propped Deflections
= 6.9303E-15 * L - 5.7363E-07 * L + 1.4 * LL + 2.76 * DL
= 4.1082E-15 * L - 4.0973E-07 * L + 1.4 * LL + 2.76 * DL


Section bending capacity (mu) 45.8 kNm
Propped Deflections
= 6.5541E-15 * L - 5.7223E-07 * L + 1.45 * LL + 2.87 * DL
= 3.8390E-15 * L - 4.0715E-07 * L + 1.45 * LL + 2.87 * DL



Section weight 2.76kN/m
Propped Deflections
= 4.7798E-15 * L - 6.3519E-07 * L + 1.39 * LL + 2.73 * DL
= 2.9079E-15 * L - 3.9928E-07 * L + 1.39 * LL + 2.73 * DL



Propped Deflections
= 4.5441E-15 * L - 6.6243E-07 * L + 1.43 * LL + 2.82 * DL
= 2.7272E-15 * L - 4.2340E-07 * L + 1.43 * LL + 2.82 * DL


Section bending capacity Mu) 77.4 kNm

Propped Deflections

7.5.4 Composite Section Design Notes
7.5.4.1 Design for Flexure (Concentrated Loads)
1. Determine the imposed bending moment M* due to all loads imposed on the section of slab
under consideration (concentrated and distributed loads plus self-weight).
2. The total imposed ultimate moment can be proportioned to each of the beam elements within
the effective load width as outlined in Section 7.7.2. The moment capacity of each beam
element within the effective load width is checked against the composite moment capacity
tabulated in Section 7.5.3.
Composite beam elements of this shape are referred to as Beam Configuration 1 or BC1
3. If M*(BC1) < Mu (BC1) then section is OK in flexure.
If M*(BC2) < Mu (BC2) then section is OK in flexure.
If M*(BC3) < Mu (BC3) then section is OK in flexure.
4. If a grouping of two beams is insufficient to resist the flexure actions, a structural steel or
concrete beam should be used to support the load concentration.
7.5.4.2 Design for Shear (Concentrated Loads)
1. Determine imposed ultimate shear force V* due to all loads imposed on the section of slab
under consideration (concentrated and distributed loads plus self-weight).
2. The total imposed shear force can be proportioned to each of the beam elements within the
effective load width as outlined in Section 7.7.2. The shear capacity of each beam element
within the effective load width is checked against the composite shear capacities contained in
Section 7.5.4.4.
3. If a grouping of two beams is insufficient to resist the shear actions, a structural steel or
concrete beam should be used to support the load concentration.
4. Punching shear should be considered as outlined in Section 7.5.4.5.

7.5.4.3 Deflection Calculation
Refer to Section 7.2 for the principles adopted for deflection calculation.
1. Determine the dead load deflection and the live load deflection for the critical beam element
within the effective load width determined in the flexure and shear calculation. Use the full
unfactored dead and live load attributed to that element.
2. Long-term deflections can be calculated using formulas of the form.
Term1*L^4 + Term2*L^2 + Term3*LL + Term4*DL
Deflection formulas for each of the systems are included in Section 7.5.3 Composite sections
properties and capacities.
7.5.4.4 Shear Strength
The shear strength at a distance x from the support can be determined, after calculating V*/M* at
that point, as:
Vuc = Vuc1 + M0 (V*/M*)
where Vuc1 is given below:
BEAM 130R 150R 130C 150C 200C 250C

Vuc1
500 system (BC1) 14.989 17.79 26.47 32.95 40.52 49.12
Figure 7.5.4.4a: Decompression Moment Diagram

for 500 System Composite Section
Note: Mo is constant at Mo(max) when x + bearing exceeds 558mm.
If it is preferred, then Mo can be calculated as Mo(max).(x + bearing 56)/502.
With x in mm, where x + bearing < 558.

Web-shear Cracking
Web-shear cracking can occur in regions of the beams near the supports that are uncracked due
to flexure. The capacity, Vuc, has been calculated in accordance with AS 3600 Clause 8.2.7.2 (b),
as for non-composite design, and checked against V* at d from the support. The results are
tabulated below.
BEAM 130R 150R 130C 150C 200C 250C

Vuc(web)
500 (BC1) 20.19 24.84 33.25 47.46 60.39 73.52
7.5.4.5 Punching Shear Guidance
Slab Zones
Punching shear should be considered when a concentrated load occurs over the infill section of the
Ultrafloor system, i.e. where there is no beam directly below the concentrated load. The procedure
for calculating punching shear is highlighted in Section 9.2 of AS 3600.
Band Beam Zones

To calculate the punching shear capacity in the Ultrashell band system, normal calculations for
post-tensioned or reinforced bands are performed, ignoring any enhanced contribution from the
Ultrafloor beams. This produces a slightly conservative result, as clamping action of the beam in
the column zone is known to increase the capacity.

7.6 Designing Ultralintels

7.6.1 Introduction
Ultrafloor manufacture four convenient sizes of prestressed concrete lintels to suit standard and
modular brickwork. Ultralintels have excellent durability and fire resistance properties. Ultralintels
are suitable for internal or external use in projects of exposure class A1, A2, B1 or B2. The
Ultralintels have been fire tested by CSIRO of North Ryde NSW in accordance with AS1530.4
1990. The structural strength of Ultralintels increases significantly when they act compositely with
the brickwork above.
Cross-sectional details of the lintels are provided at Section 4.1.5 of this manual. Load charts are
provided in the Ultralintel brochure, indicating the safe maximum span when Ultralintels are
installed in various configurations. The brochure also details how these lintels can be used to form
hobs on the slabs.
Loan / span tables included in this section allow design by professional engineers using normal
engineering principles. The tables have been calculated using Ultimate Limit State design, but in
the charts the engineer must enter the working load, namely the unfactored DL + LL. Allowable
working loads are nominated for various spans for lintels in their non-composite state and when
acting compositely with brickwork above.
! The minimum end bearing of Ultralintels on the brickwork is 100mm for spans up to 1200mm
and 150mm for longer spans assuming a minimum brick crushing strength of 20N/mm2.
! Ultralintels must be placed with the rough side on top to provide a key to the brickwork above.
! Ultralintels must be propped at intervals not exceeding 1500mm until the brickwork mortar is
mature.
Some typical construction details are illustrated below:
Figure 7.6.1a: Typical Ultralintel Detail

7.6.2 90 x 90mm Modular Prestressed Lintel
90
These lintels must only be used with modular (90mm wide) brickwork and are suitable for use with
concrete floors.
SAFE WORKING LOADS (kN/m)

Based on the strength of the lintel only
CLEAR OPENING (mm)

900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
To satisfy L/1000
18.5 9.5 5.6 3.7 2.6 1.9 1.4 1.1 - - - -
deflection
To satisfy L/300
26.1 14.5 8.8 5.5 3.7 2.7 2.0 1.5 1.2 - - -
deflection

Based on the composite strength of the lintel and brickwork only
To satisfy L/2000 CLEAR OPENING (mm)

deflection 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
2 courses of modular
22.7 17 13.6 7.8 4.9 3.2 2.2 1.5 1.1 - - -
bricks over the lintel
41 30.7 24.5 20.4 17.5 15.3 11.5 8.3 6.2 4.7 3.7 2.9
63.1 47.3 37.8 31.5 26.9 23.6 20.9 18.8 17.1 13.7 10.7 8.6
The following notes apply to all Ultrafloor lintels:

1. All lintel design and selection must be performed by a Professional Engineer.
2. Characteristic compressive strength of brick unit must be 20MPa minimum.
3. Mortar must be Classification M3 in accordance with AS3700-1998. Ratio of cement to sand
must be 1:6 or better.
4. Complete courses of bricks must be used until the required number of courses is achieved.
All vertical and horizontal joints must be completely filled with mortar.
5. Lintels must be placed rough side up.
6. Composite lintels must be propped at 1500mm centres until brickwork has matured. In hot
weather the surface of the lintel must be moistened to provide a good key.
7. The lintel must have a minimum bearing of 100mm for spans less than 1200mm and 150mm
for spans greater than 1200mm assuming a minimum brick crushing strength of 20N/mm.
8. The self-weight of the lintel has been allowed for in the calculations.

7.6.3 170 x 90mm Modular Prestressed Lintel
90
These lintels must only be used with Modular (90mm wide) brickwork and are suitable for use with
concrete floors.

CLEAR OPENING (mm)
900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
To satisfy L/1000
46.0 19.2 9.6 5.4 3.3 2.1 1.3 - - - - -
deflection
To satisfy L/300
60.8 45.2 28.8 19.0 11.8 7.8 5.4 3.8 2.8 2 1.5 1.2
deflection


deflection 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
46.0 25.3 20.2 16.4 10.2 6.7 4.6 3.3 2.4 1.7 1.3 1.0
46.0 33.7 26.9 22.4 19.1 16.7 14.8 13.1 9.8 7.4 5.8 4.5
62.4 46.7 37.3 31.0 26.6 23.2 20.6 18.5 16.8 15.3 14.1 11.8


7.6.4 80 x 110mm Standard Prestressed Lintel
110
These lintels must only be used with standard (110mm wide) brickwork and are suitable for use
with concrete floors.

CLEAR OPENING (mm)
900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
To satisfy L/1000
10.2 5.7 3.2 2.0 1.4 - - - - - - -
deflection
To satisfy L/300
26.0 11.7 6.3 3.8 2.5 1.7 1.2 - - - - -
deflection


deflection 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
23.5 17.6 11.5 6.6 4.1 2.6 1.8 1.3 - - - -
41.4 31 24.8 20.6 17.6 13.4 9.3 6.8 5 3.8 3 2.3
63.2 47.3 37.8 31.5 27 23.6 20.9 18.8 14.3 11 8.6 6.8


7.6.5 170 x 110mm Standard Prestressed Lintel
110
These lintels must only be used with standard (110mm wide) brickwork and are suitable for use
with concrete floors.

CLEAR OPENING (mm)
900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
To satisfy L/1000
41.3 25.1 12.6 7.1 4.3 2.8 1.8 1.2 - - - -
deflection
To satisfy L/300
41.3 32.0 26.0 18.9 13.8 10.2 7.0 5.0 3.7 2.7 2.0 1.5
deflection


deflection 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200
41.3 26.3 16.6 11.4 8.3 6.2 4.6 3.2 2.3 1.7 1.2 -
48.3 36.1 28.8 23.9 19.8 15.1 11.8 9.5 7.8 6.5 5.2 4.1
64.3 48.1 38.4 32 27.3 23.9 21.2 17.3 14.2 11.9 10 8.6


7.6.6 Using Ultralintels as Hobs

The Ultralintels are bonded to the top of the concrete slab so as to create an upstand or hob of
the desired height. Waterproofing is achieved by extending the bitumen coating or suitable
membrane up the external face of the hob. Refer to details C13.1.1 and C13.1.2
7.7 Other Design Principles

7.7.1 Design of Saddle Supports
Construction details of the saddle supports are given in Section 8.3. Design of the steel saddle
beam should be designed in accordance with normal engineering principles. Saddles are usually
designed by Ultrafloors design engineers. The Ultrafloor beams supporting the steel saddle should
be designed for the load concentration as outlined in Section 7.7.2.
It should be propped during construction.
A grouping of two Ultrafloor beams is often required at each end of the saddle. In cases where two
Ultrafloor beams are insufficient to support the load concentration, structural steel beams are
required parallel to the Ultrafloor beams.
Note that consideration should be given to placing re-entrant corner reinforcement to reduce
likelihood of cracking in concrete.
7.7.2 Designing for Concentrated Loads
7.7.2.1 General
The load/span tables in Section 7.1.1 do not consider concentrations of load such as load bearing
walls, column loads and saddle supports. Non-distributed loads must be investigated by analysis of
the structure in accordance with normal engineering principles. One or a combination of Ultrafloor
beams can then be selected to resist the design actions determined from the analysis.
No reference is made in AS 3600, but BS 8110.1 gives guidance on the transverse load
distribution within precast concrete slabs. With reference to Clause 5.2.2.2. Concentrated loads on
slabs without reinforced topping: the width of slab assumed to contribute to the support of
concentrated loads (including partitions in the direction of the span) should not exceed the width of
three precast units and joints plus the width of the loaded area or extend more than a quarter of the
span on either side of the loaded area. Refer also to Clause 5.2.2.3 Concentrated loads on slabs
with reinforced topping. The provisions of Clause 5.2.2.2 apply in all respects except that, instead
of three, the width of four precast units and joints may be allowed to contribute. Testing at the
University of Newcastle has verified that the transverse load distribution within Ultrafloor slabs is in
keeping with these guidelines.

7.7.2.2 Concentrated Loads Design Procedure
Design for concentrated loads should be performed by a professional engineer.
1. Determine the effective width of slab as outlined in Section 7.7.2.3. An initial assessment
must be made as to the number of beams required in the grouping.
2. Determine the action effects on the slab using normal engineering principles.
3. Design the slab for flexure using the guidelines in Section 7.2.3 (composite state).
4. Design the slab for shear using the guidelines in Section 7.5.4.4.
5. Check deflection using the guidelines in Section 7.2.3 (composite state).
7.7.2.3 Proportioning of Loads / Effective Width of Slab
The effective width of slab to consider for the transfer of concentrated loads to supports is
dependant upon the distance of the load concentration from the nearest support.
Figure 7.7.2a: Structural Model of Slab Span
A. STANDARD CONFIGURATIONS OF ULTRAFLOOR BEAMS
1. Case 1: a 1.5m
If the load concentration is greater than 1.5m from the support, one third of the total load is
apportioned to the central beam module.

2. Case 2: 1.0m a < 1.5m.
If the load concentration lies in the region 1 1.5m half of the total load P is apportioned to
the central beam module.
3. Case 3: a<1.0m
If the load concentration is close to the support, only one Ultrafloor beam and contributing
topping width (module) contributes to the load transfer. When distance a < 1.0m, then full
load P is apportioned to one beam module.

B. GROUPING OF ULTRAFLOOR BEAMS
Ultrafloor beams can be grouped together to transfer concentrated loads to supports. The load
distribution is again dependent upon the distance a from the support.
1. Case 1: a < 1.5m
If the load concentration is greater than 1.5m from the support, the total load is apportioned
to each of the beam modules as illustrated below:
The critical beam element could be either the L section subject to P/4 or the T section
subject to P/6.
2. Case 2: a 1.5m
If the load concentration is close to the support, only the grouping of beams and contributing
topping width contributes to the load transfer. The total load P is divided equally into the
number of beams in the grouping.
In most circumstances, the number of beams in the grouping should not exceed two.

7.7.3 Design for Cantilevers
Cantilevered sections of slab can be achieved either with the Ultrafloor system or by tying precast
or in-situ cantilevered slabs into the Ultrafloor slab. The design and detailing of any cantilever must
be performed by a professional engineer.
7.7.3.1 Ultrafloor Cantilevers
When Ultrafloor is to be used to form the cantilevered section of slab:

! The FC formboard is dropped to the underside of the Ultrafloor beams either side of the
support wall for a distance equal to half of the span of the cantilever i.e.
set-down width = cantilever span + support width.
! The additional concrete increases the area of concrete in the compression zone through the
peak moment region.
! Unless the span of the cantilever is minimal, the tip of the cantilever should be propped during
construction. Determination of the maximum allowable cantilever span without propping can
be made using the negative cracking moment of the non-composite section included in
Section 7.5.1 relative to the applied moment from construction loads.
! Top reinforcement needs to be designed and detailed as shown in Figure 7.7.3a,

Figure 7.7.3b, Figure 7.7.3c and Figure 7.7.3d to resist the induced stresses. Design principles
are the same as for a reinforced concrete cantilevered slab. The negative bending capacity of
the Ultrafloor beam is typically ignored. If required for cover provisions, the top steel can be
designed and detailed for placement under the shrinkage control mesh and between the
Ultrafloor beams.
! If waterproofing is required at the line of an external wall over the slab, a hob can be cast onto
the slab as shown in Figure 7.7.3a and Figure 7.7.3b (refer also to the Ultrafloor Lintels and
Hobs Brochure where lintels can be cemented to the slab to form hobs).
Figure 7.7.3a: Typical Ultrafloor Cantilever 1 (without step-down)

Figure 7.7.3b: Typical Ultrafloor Cantilever 2 (without step-down)
Figure 7.7.3c: Typical Ultrafloor Cantilever 3 (with step-down)
Figure 7.7.3d: Typical Ultrafloor Cantilever 4 (with step-down)

7.7.3.2 In-situ and Precast Cantilevers
Figure 7.7.3e: Typical Cantilevered Balcony Plan

(for sections see Fig 7.7.3f and Fig 7.7.3g)
In-situ and precast cantilevered slabs can be tied into an Ultrafloor slab. This situation is common
when external balconies meet an Ultrafloor slab at the external wall line.
! The FC formboard is set-down to the underside of the Ultrafloor beams for a distance equal to
half the span of the cantilever (ie set-down width = cantilever span / 2). The additional concrete
increases the area of concrete in the compression zone through the peak moment region.
! Top reinforcement must be designed and detailed to resist the induced stresses. Design
principles are the same as for a reinforced concrete cantilevered slab.
! If required, a throat can be formed under the Ultrafloor beams subject to architectural
constraints.

Steps at the line of the wall over are easily accommodated.
Figure 7.7.3f: Section A-A through Typical Cantilever Balcony
Figure 7.7.3g: Section B-B through Typical Cantilever Balcony

7.7.4 Design for Continuity over Supports
A detailed description of the design principles for continuous Ultrafloor slabs is contained in
Section 7.2.3.2.
The design of continuous Ultrafloor slabs is simplified by incorporating solid concrete block-outs in
the peak negative moment regions. This allows negative moment reinforcement to be designed
similarly to a conventionally reinforced continuous slab. The solid concrete block-outs are achieved
by dropping the formwork sheet to the underside of the Ultrafloor beams through the peak moment
regions to increase the concrete compression zone. Alternatively the Ultrafloor beams can be
designed to take the compression forces.
Negative moment reinforcement is designed over the supports using normal engineering
principles. Up to 30% moment redistribution is suggested in order to gain a further advantage by
making full use of the positive moment capacity. Further to this, if the Ultrafloor beams are
unpropped, the only negative moment for continuity design is that resulting from the live load (LL)
and superimposed DL only. This can then also be partially redistributed.
Ultrafloor recommends a maximum bar size of N16 for continuity design of slabs.
7.7.5 Design for Progressive Collapse
Buildings with a rise in storeys of more than four require special detailing to prevent progressive
collapse. Ultrafloor recommend the provision of horizontal continuity at each floor level. The floor
should be capable of resisting all negative bending moments specified by AS 3600.
Testing has been conducted at the University of Sydney on continuous Ultrafloor slabs. The
following detail was found to develop the full negative moment flexural capacity equivalent to a
reinforced concrete slab of the same depth and with the same reinforcement. It behaved in a
ductile manner with well-distributed cracks. Substantial rotation capacity over the wall was
demonstrated, sufficient to ensure that full moment redistribution would occur.
Figure 7.7.5a: Typical Progressive Collapse Detail

The British Standard BS 8110.1 gives guidance on designing for progressive collapse. Developing
catenary action through provision of horizontal ties is deemed adequate to prevent progressive
collapse. Alternate details to Figure 7.7.5a may be used through consultation of the requirements
of this standard.
Worley Fraser Pty Ltd of Melbourne provided the following appraisal of the Ultrafloor System in
relation to progressive collapse and earthquake design:
Progressive Collapse / Robustness

There is currently very little information in the Australian loading code AS 1170.1, the
Australian concrete code AS 3600 and the Building Code of Australia (BCA) regarding
robustness or progressive collapse. Previous editions of the BCA (1990 and 1993) have
provided some specific requirements for precast concrete floors on loadbearing walls in the
New South Wales Appendix. States other than NSW had no progressive collapse
requirements. The current edition of the BCA makes no reference to progressive collapse,
neither in the main text nor in the separate State requirements.
The use of Ultrafloor for the flooring system of a building does not impair the robustness of the
floor compared to a conventional slab system. As the Ultrafloor slab consists of a 98mm thick
in-situ slab, the floor is able to act as a diaphragm to distribute loads to key lateral restraining
elements. By introducing continuity to the Ultrafloor slabs, with top reinforcement over
supports, the redundancy of the structure is increased with the potential loss of a supporting
vertical member.
In the absence of detailed information in Australian codes of practice, information can be found
in the British concrete code, BS 8110, for guidance on robustness. BS 8110, unlike the
American and Australian concrete codes, provides an empirical design method to effectively
tie the structure together through a series of vertical and horizontal ties. This empirical design
method was developed by the Imperial College in London following the partial collapse of a
precast concrete wall frame at Ronan Point, London in 1968. This fully tied solution relies on
catenary action of the ties in the floor to suspend the floors during accidental removal of a key
vertical loadbearing element. These ties, in the form of N12 and N16 bar reinforcement, can
easily be accommodated within the in-situ slab of the Ultrafloor system. The Ultrafloor system
also has flexibility with the use of set-down boards so that an in-situ slab of full thickness could
be adopted around the perimeter, to accommodate the tie reinforcement.
Earthquake Loads
The Ultrafloor slab, with its in-situ 98mm thick concrete slab and mesh reinforcement, is ideal
to act as a diaphragm to distribute lateral loads through the floor plate to key lateral restraining
elements. Additional reinforcement can easily be accommodated in the slab should it be
necessary.
Pull-out bars or threaded reinforcement into ferrules from precast walls can be cast into the in-
situ slab to laterally restrain the wall as well as provide a means to transfer the lateral slab
forces to the wall. The adoption of Ultrafloor as the flooring system, compared to a
conventional slab, does not impair the strength or serviceability of the structure under
earthquake conditions.

7.8 Design for Durability

7.8.1 Shrinkage Control Reinforcement
The Ultrafloor beams can be used in projects of exposure class A1, A2, B1 and B2 without special
protection measures. Surface treatments are usually required in exposure class C. The topping
slab needs consideration as follows:
Reinforcing mesh is cast into the topping slab. The mesh is non-structural and is included to
control shrinkage cracking. The mesh is typically placed directly on top of the Ultrafloor beams with
the standard topping thickness. Bar chairs can be used to raise the reinforcing mesh if required.
Figure 7.8.1a: Typical Arrangement
Figure 7.8.1b: Arrangement with Bar Chairs
Ultrafloor recommend the use of the following shrinkage control meshes:
! SL62 in most internal areas where a nominal degree of control over cracking is required.
! SL72 in tiled areas.
! SL82 in external areas. Note the increased concrete cover and strength requirements included
in Section 7.8.2.

Note that some projects require a very strong degree of control over cracking. Heavier shrinkage
control reinforcement may be required. Contact the Ultrafloor technical department for advice.
Control joints are discussed in Section 8.6 and details are included in Section 10.
Quality concrete curing is the single most important factor in minimising the effects of plastic
shrinkage. All Ultrafloor slabs must be placed compacted and cured in accordance with standard
industry practice. Guidance notes for curing are included in Section 8.5.
7.8.2 Cover-to-Reinforcement
The minimum cover-to-reinforcement in internal areas is 20mm. Ultrafloor recommends the use of
25MPa topping concrete for normal internal applications (with traditional loadbearing wall
construction) with an SL62 shrinkage control mesh.
In external areas, cover to reinforcement concrete strength and size of mesh all need to be
increased to provide adequate corrosion protection.
Ultrafloor recommends the following:
Cover Concrete Strength Shrinkage Control

Exposure Class
(mm) (MPa) Reinforcement
A1 20 25 SL62
A2 30 25 SL72
B1 40 32 SL82
B2 45 40 SL82
7.8.3 Site Concrete
Ultrafloor recommends the use of 25MPa concrete as in-situ topping for slabs in normal interior
environments and 32MPa for band beam systems. Concrete should have a target slump of 85mm.
The in-situ topping must be cured in accordance with standard industry practice such as flooding
with water, covering with plastic sheeting, or using suitable curing compounds.
Durability of the concrete may be increased by (a) lowering the water-cement ratio, (b) increasing
the cementitious content and (c) providing thorough wet curing.
Where greater concrete durability is required, for example in marine environments, it is

recommended that the water/cement ratio be reduced to no more than 0.45 in conjunction with a
cementitious content of at least 350kg/m3. In addition, thorough wet curing is crucial in order to
achieve a concrete matrix of low enough permeability to resist the penetration of the corrosive
chloride ions.
Information regarding concrete strength and required covers for external and industrial areas is
included in Section 7.8.2. Further information regarding curing methods is included in Section 8.5.

7.0 Design Information

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ultrafloor DESIGN INFORMATION

7.0 DESIGN INFORMATION

7.1 Design Aids for Floor Slab

The following footnotes apply to all design tables shown below:

ULTRAFLOOR TECHNICAL MANUAL September 2002 Edition Page 7-1

ALLOWABLE DESIGN ALLOWABLE DESIGN ALLOWABLE DESIGN

1.5 4.50 Fwrk Str 6.15 LL Defl 4.50 Fwrk Str

2.0 4.50 Fwrk Str 6.10 LL Defl 4.50 Fwrk Str

2.5 4.50 Fwrk Str 6.05 LL Defl 4.50 Fwrk Str

2 4.0 4.50 Fwrk Str 5.85 LL Defl 4.50 Fwrk Str

ALLOWABLE DESIGN ALLOWABLE DESIGN ALLOWABLE DESIGN

1.5 4.50 Fwrk Str 6.45 LL Defl 4.50 Fwrk Str

2.0 4.50 Fwrk Str 6.40 LL Defl 4.50 Fwrk Str

2.5 4.50 Fwrk Str 6.30 LL Defl 4.50 Fwrk Str

1.5 5.50 Fwrk Str 6.80 LL Defl 5.50 Fwrk Str

2.0 5.50 Fwrk Str 6.75 LL Defl 5.50 Fwrk Str

2.5 5.50 Fwrk Str 6.65 LL Defl 5.50 Fwrk Str

3.0 5.50 Fwrk Str 6.60 LL Defl 5.50 Fwrk Str

ULTRAFLOOR TECHNICAL MANUAL September 2002 Edition Page 7-2

1.5 7.00 Fwrk Str 7.90 LL Defl 7.00 Fwrk Defl

2.0 7.00 Fwrk Str 7.85 LL Defl 7.00 Fwrk Defl

2.5 7.00 Fwrk Str 7.75 LL Defl 7.00 Fwrk Defl

3.0 7.00 Fwrk Str 7.70 LL Defl 7.00 Fwrk Defl

1.5 8.00 Fwrk Str 8.90 LL Defl 8.00 Fwrk Defl

2.0 8.00 Fwrk Str 8.80 LL Defl 8.00 Fwrk Defl

2.5 8.00 Fwrk Str 8.75 LL Defl 8.00 Fwrk Defl

3.0 8.00 Fwrk Str 8.65 LL Defl 8.00 Fwrk Defl

Maximum unpropped spans for various

ULTRAFLOOR TECHNICAL MANUAL September 2002 Edition Page 7-3

7.1.2 Design Checklist Ground Floor Construction

YES: Refer to Section 8.2 for details of propping.

7. Is the slab to be supported on Ultrafloor bearers and masonry piers?

9. Does the floor contain any cantilevered sections of slab?

YES: Refer to Section 7.7.3 for details regarding designing cantilevers.

10. Does the slab contain voids for stairs or penetrations?

ULTRAFLOOR TECHNICAL MANUAL September 2002 Edition Page 7-4

11. Does the floor include any external areas?

13. Are control joints required to control movement and cracking?

YES: Refer to Section 8.6 for details regarding control joints.

A similar checklist for multi-storey construction follows in Section 7.1.3.

ULTRAFLOOR TECHNICAL MANUAL September 2002 Edition Page 7-5

7.1.3 Design Checklist Multi-Storey Construction

YES: Refer to Section 8.2 for details of propping.

YES: Refer to Section 7.7.5 for details regarding progressive collapse.

9. Does the floor contain any cantilevered sections of slab?

YES: Refer to Section 7.7.3 for details regarding designing cantilevers.

10. Does the slab contain voids for stairs or penetrations?

ULTRAFLOOR TECHNICAL MANUAL September 2002 Edition Page 7-6

11. Does the floor include any external areas?

13. Are loadbearing lintels required over door or window openings?

YES: Refer to Section 7.6 for details regarding designing Ultralintels.

14. Is the slab required to have a high fire resistance level?

YES: Refer to Section 5 for details regarding fire resistance levels.

15. Is fire and/or sound insulation required at internal or external walls?

16. Are control joints required to control movement and cracking?

YES: Refer to Section 8.6 for details regarding control joints.

ULTRAFLOOR TECHNICAL MANUAL September 2002 Edition Page 7-7

7.2 Design Procedures in General

AS 3600 2001, Concrete structures.

AS 3610 1995, Formwork for concrete.

7.2.2 Non-Composite State

Formwork loads for strength are taken from AS 3610 as:

Case 1: 1.25 G + 1.5 QUV (Stage 2)

Case 2: 1.25 G + 1.5 QUV + 1.5 M3 (Stage 3)

Vuc(flexure) = Vuc1 + M0 (V/M)

Vuc(flexure) = Vuc1 + M0 (V/M)