Permanent formwork from corrugated sheets for floors calculation

Ceilings made of corrugated sheets with permanent formwork

When constructing a monolithic reinforced concrete floor, corrugated sheets act as permanent formwork.
A reinforcement frame made of metal rods is laid on top, and concrete of the required grade is poured. The entire structure rests on longitudinal metal beams made of I-beams or channels. Thus, the monolithic floor transfers the load acting on it to the load-bearing columns and foundation. By preventing concrete from spreading, corrugated sheeting acts as additional external reinforcement. The frame structure becomes more rigid and stable.

To save on labor-intensive and expensive ceiling finishing, it is recommended to choose sheets with double-sided polymer coating. In this case, the ceiling surface becomes resistant to any external influences.

The choice of grade of corrugated sheeting is of great importance. The sheet must withstand enormous loads from the weight of concrete. It is recommended to choose brands “N” or “NS”, with a high fin height, and a trapezoidal wave shape.

The advantages of this kind of ceilings include affordable price, reliability and durability. The downside of a corrugated ceiling is that it doesn’t look very attractive.

You can build a monolithic ceiling using corrugated sheets with your own hands, for example, for a garage. Before starting work, you need to prepare documentation. All measurements and calculations must be made by a specialist. It is necessary to calculate the dimensions of supporting structures, the diameters and number of reinforcement bars, and select the grade of corrugated sheeting. Only after this can a building permit be obtained.

You can carry out installation work yourself. If it is necessary to insulate the room, then foam blocks or aerated concrete are used as an additional ceiling. These materials will serve as insulation materials.

What is permanent formwork?

First, let's figure out what permanent formwork is and why it is needed.

Permanent formwork is a frame for pouring mortar. After pouring and drying the solution, such formwork is not removed; it becomes part of the resulting structure (monolithic slab).

Permanent formwork performs the following functions:

• does not allow the mixture to spread and “gives” it a certain shape;
• strengthens the resulting structure.

Remember how in childhood we sculpted figures from raw sand using plastic molds? The plastic form here plays the role of formwork. If we don’t remove it, it will be permanent formwork.

That is, we install formwork into which we pour concrete. It dries and takes the formwork shape. We get a monolithic slab, which is additionally reinforced with corrugated sheets. It tolerates horizontal loads well.

Load-bearing corrugated sheets are most often used as permanent formwork. It can support the weight of the concrete pour. But wood is not suitable for such formwork - it is not durable and strong enough.

The formwork can also be removable . It performs only one function - it gives a certain shape to the concrete solution. When the concrete has dried, the formwork is removed. It can be used repeatedly.

But in this case, corrugated sheeting is almost never used, because there are many difficulties with it. Before installation, it must be lubricated with a special compound so that the material does not stick to the concrete. You also need to remove it carefully - if you damage it, the formwork will turn out to be disposable.

Types and costs

There are different types of submissions. Profiled sheets H75, H60 belong to the category of the most durable products. Their cost can reach 700-900 rubles/m². However, there are also less durable varieties on sale. Before using them in a particular type of construction, it is necessary to consider whether such materials are suitable in this case.

It should be noted that the dimensions of corrugated flooring may vary. Products on sale are available in widths of 80, 90, 100 and 110 cm. Sizes may vary depending on manufacturer standards. The length can be 75, 85 and 100 cm. Dimensions affect the cost of the material. There are products on sale whose thickness is 0.45-1 mm. The thicker the sheet, the stronger the structure will be. The manufacturer's documentation should definitely be considered when choosing corrugated sheets.

Most often, during construction work, corrugated sheeting of grade H75 and a thickness of 0.9 mm is used. To correctly calculate the length of the material, you need to measure the distance between the three beams. This will help create a durable structure that will not sag.

Removal of formwork and installation of interfloor ceilings

When installing the main floors, the formwork is removed. Removal of the side surfaces is permitted when the main floor has completely hardened and formed a solid structure. It is necessary to carefully check the entire surface from all sides.

The strength of a concrete structure is determined by the following indicators:

• Load-bearing elements whose span is less than 2 meters account for 50%.
• Slabs with a span of 6 meters or more – 70%.
• Reinforced types of structures no more than 25%.

How to determine the strength of hardened concrete of an installed interfloor slab?

The concrete surface increases the strength of the coating from the moment the last layer is poured over time:

• 3rd day strength is about 30%.
• Day 7 increases to 60%.
• Day 14 is 80% or more.
• Day 28 is around 100%.
• Day 90 increases by 30%.

The duration of hardening of the concrete floor depends on the air temperature and the level of ambient humidity. There are special additives that help speed up the hardening process of concrete on the surface of the floor.

Corrugated sheeting and its advantages

Profiled sheets have a number of advantages, which made it so popular in the construction industry. These include:

1. Versatility. As already noted, profiled sheets are used in a wide variety of construction areas as roofing, cladding material, as fences, and so on.
2. Anti-corrosion resistance. During manufacturing, each sheet is coated with a special anti-corrosion solution, which increases the service life of the material to 30 years or more.
3. Ease. The weight of the profiled sheet is a maximum of 8 kg, which significantly reduces the load on the supporting structure.
4. Transverse and mechanical strength. Corrugated sheeting can withstand a lot of weight, this is especially true when constructing a roof.
5. Manufacturability during operation. The material is easy to process and easy to install.
6. Acceptable price. The cost of corrugated sheeting is very affordable; it is one of the cheapest building materials.
7. Convenient transportation and storage. It will not be difficult for you to transport corrugated sheets from the store to the construction site yourself. After all, it is not heavy. You can store corrugated sheets in the packaging for two weeks, and if the packaging is opened, the period is not limited at all.
8. Fireproof and environmentally friendly material. Does not burn and does not emit harmful substances or odors.
9. Aesthetic appearance. You can choose profiled sheets of any size and color, allowing you to harmoniously incorporate it into your exterior.
10. Persistence. The material is resistant to various weather conditions and is not afraid of the sun, rain or snow. In addition, corrugated sheeting is resistant to acid and alkali influences. Moss or lichens can never be found on its surface, as often happens with other floors.

Creating a flat roof from corrugated sheets

Creating a flat roof from corrugated sheets with insulation

Flat roofing made of corrugated sheets is a modern and cost-effective solution. The most positive quality of such a roof is its price; it is affordable to every developer. The basis for this type of roof is the covering of the topmost floor of the building. Such roofs are most often called: “Without attics”. They help protect the structure from weather conditions. A flat roof will last you a long time.

Carrying out installation work

The preparatory stage consists of drawing up a project and forming a resource base for installation work. Here, among other things, the provision of tools, equipment and consumables (personal protective equipment, fasteners, etc.) must be provided.

Formwork installation

Laying of corrugated sheets on a metal frame ceiling is carried out with fixation using self-tapping screws with a drill-shaped tip.

Armor-piercing screws for metal (with drill) Source prom.st

This way you won’t have to make holes or recesses first, and the panels will be fixed faster. The pitch between hardware is maintained within 400 mm. In places where edges overlap, the distance is reduced to 250 mm. The use of rivets is recommended here. Such a frequent position of the screws is necessary so that the formwork is guaranteed to cope with the pressure from the heavy concrete mortar.

Finally, the forming structure is limited by the vertical sides. Here you can use a board with a height in accordance with the design thickness of the monolith. After this, you can begin to reinforce the floor using the corrugated sheet.

Reinforcement

The reinforcing frame is assembled from iron rods with a diameter of 12 mm. They fit into each of the waves of the steel base. If necessary, blanks with a cross section of 6 mm are added across the profile line. The elements can be connected using a welding machine or knitting wire. Another option is to lay the finished lattice on top of the base reinforcement on anchors or special pads.

An example of longitudinal reinforcement of a floor using a profiled sheet without reinforcementSource blogspot.com

Works with concrete

Pouring formwork from corrugated sheets for one span with reinforcement cage is carried out in one go. The best option here would be a factory-made solution and concrete mixing equipment (pump, conveyor). Before doing this, it is worth installing additional temporary supports under the corrugated sheet in the center between the base posts to be on the safe side. This reduces the likelihood that the profile sheet will bend.

The solution is used grade M350 and higher. As the cement mass dries and hardens, it releases moisture, meaning the monolith will be lighter, and excess columns can be dismantled. In summer this is done approximately every 10-12 days, in winter every month.

With concrete you will need to perform the following steps step by step:

• evenly distribute the solution over permanent formwork made of corrugated sheets for floors;
• remove air from the mixture, thereby compacting it (you can pierce it with a reinforcing rod, but it is better to use special equipment);
• level the surface using the rule.

Mechanized pouring of screed using corrugated sheetsSource strojdvor.ru

For proper drying of concrete, it is further necessary to create and maintain conditions close to optimal. In particular: relative humidity – 50-60%, temperature – +15-+22 degrees Celsius, absence of drafts and dynamics. More often, installation work is carried out in the summer, so in the heat, periodic moistening of the surface will be required due to the excessively rapid water loss of concrete. The top of the concrete floor is covered with corrugated sheeting with plastic film. In winter, a solution with antifreeze additives is used so that the composition does not freeze at subzero temperatures.

In this video, a specialist talks in detail about the features of corrugated sheet floors and answers user questions about the technology of monolithic floors with permanent steel formwork:

Part two of the video about the features of ceilings using corrugated sheets:

Types of formwork

Today there are more than twenty types of formwork for concrete mixtures. But they all have one common function - holding the liquid construction mixture in a given circuit. The structure is used until the solution completely hardens and turns into a monolith.

In simple terms, we can say that concrete formwork is a barrier that can be molded into different shapes to confine the cement mixture to a specific space. The latest changes to regulatory construction documents were made in 2003. And all design requirements are contained in GOST R 52085.

Formworks are classified according to:

• Type of structure. Moreover, it is easier to divide them into vertical (which includes foundations, walls, and columns) and horizontal. The latter include floors and platforms.
• Constructions. They are panel, sliding, flexible, pneumatic, block, fixed and lifting-adjustable.
• Material. They are made of steel or aluminum, wood and plastic. There are also combined options.

Metal formworkSource fundamentaya.ru

• Climatic characteristics. There are regular or insulated designs. But there are also structures that are capable of heating the solution inside themselves.
• Turnover. Formworks are divided into disposable and reusable.

An important point for many developers is the origin of the contour. In private construction, in most cases, a disposable, self-made product is used. To do this, craftsmen use available materials - bars and boards, as well as suitable sheet metal.

All construction organizations give preference to structures made industrially. In this case, the finished concrete formwork is reusable.

Briefly about the main thing

Corrugated sheeting for installing permanent formwork under floors is used as a load-bearing type due to the high profile wave.

Advantages of the material: resistance to aggressive operating conditions, durability, high strength.

The structure of the ceiling using a corrugated sheet is represented by a construction pie: support pillars, three beams, a steel sheet, longitudinal and additional reinforcement on anchors, concrete mortar.

Before installing the floors, it is important to correctly draw up a project with engineering calculations. The thickness of the screed along the corrugated sheet is approximately 1/30 of the length of one span (this ranges from 1.5 to 6 meters)

The thickness of the screed along the corrugated sheet is approximately 1/30 of the length of one span (this ranges from 1.5 to 6 meters).

Before pouring the concrete screed, it is recommended to install temporary supports between the base pillars to prevent deformation of the permanent formwork.

Flooring made of corrugated sheets and concrete

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

Design features

This design is a solid slab concreted on corrugated sheeting. The supports for it can be brick walls and concrete, a steel frame and reinforced concrete elements.

Monolithic systems can have different designs, for example, ribbed and beamless.

Ribbed, in turn, can be:

• with slabs on corrugated sheets. The frame for them is beams supported by columns. The span varies between 4–6 m. As for the thickness of the slab, it depends on the level of load, as well as the dimensions. However, the most common thickness is in the range of 60–160 mm.
• with secondary beams in addition to the slabs. The thickness of the slabs here is no more than 120 mm. The cost of a monolithic floor in this case is higher, and moreover, its installation requires more time.

Beamless structures are based on a solid slab supported by columns.

On a note

If the surface to be concreted has openings, then reinforcement is additionally welded into the openings around them to reinforce the monolithic mass.

Load calculation

The minimum thickness of the monolithic floor, the number and cross-section of reinforcement, as well as other parameters are determined based on the calculation of the loads acting on the structural element.

Types of loads acting on the floor:

• Permanent - those that create the weight of the building box, all partitions in the structure, roof
• Variables - can change: this is the mass of finishing elements, the weight of utility networks, furniture, people

The ability to withstand certain loads directly depends on the thickness of the reinforced concrete monolith, as well as the cross-section and amount of reinforcement, and the grade of concrete. In order for a monolithic reinforced concrete floor to withstand a load of 500 kilograms per square meter, the thickness must be 20 centimeters.

Factors affecting the accuracy of calculations:

• Concrete grade
• The size of the design forces that act on a unit area of ​​the slab
• Concrete slab thickness
• Slab width and length

In accordance with the calculated loads, the cross-section of the reinforcement is determined that can withstand tensile forces and bending moments. It is very difficult to independently calculate a monolithic reinforced concrete floor, but you can try using special formulas or find an online calculator on the Internet.

When calculating a monolithic floor, the thickness of the slab is very important. And not always the thicker the better. Much depends on the span - the distance between columns or walls. Typically, for a private house, the floors are poured with a thickness of 15 to 20 centimeters.

If you plan to take more than 18 centimeters, the decision must be justified by accurate calculations, because the load on it increases in proportion to the increase in the thickness of the slab. Thus, before you start designing and installing a monolithic floor, drawings must be drawn up.

Materials

Profiled sheet N-75

As permanent formwork, it is most advisable to use profiled sheets of grade N (load-bearing) and NS (universal) with a wave height (corrugations) of at least 44 mm and with additional stiffening ribs in the upper part of the corrugations. This material is intended for floors with horizontal placement and at a slight angle. Sheets from H44 to H156 are suitable for permanent formwork. The height of the corrugation proportionally affects the distance between the load-bearing beams of the floor. The higher the wave, the larger the area the monolithic structure under the corrugated sheet will have, and the pitch between the supports will also increase.

The reinforcement used to create the reinforcing frame should have an optimal thickness of 10-12 mm. Metal rods are designed to increase the resistance of a monolithic floor to heavy loads and deformations.

Steel beams are mainly made of I-beams and channels. To create support columns, metal pipes with a round or square cross-section are used.

Concrete production is carried out in specialized factories, from where the solution, ready for laying, is delivered to the site using specialized equipment - concrete mixers. In order for the corrugated flooring to be of high quality and especially durable, the grade of the concrete mixture should not be lower than M300. The composition of the concrete complies with SNiP 3.03.01-87.

Overlapping device

Overlapping according to profiled sheet

For floors, corrugated sheeting with additional stiffening ribs is suitable. The height of the wave must be at least 60 mm, and the thickness of the sheet without external protective coating must be at least 0.7 mm. The only exception to this rule is the creation of an attic floor, since it bears significantly less load than the interfloor.

Before carrying out work, the ceiling is calculated using a profiled sheet, taking into account the following characteristics:

• Dimensions of the building.
• Loads on beams and columns.

When calculating a monolithic floor using a profiled steel sheet, data on cracking in the lower part of the structure are not taken into account. It is imperative to remember about the likelihood of ribs being crushed or deformed during operation. The calculation of the top part of the slab is carried out taking into account all the data, as is done when designing traditional precast concrete structures. Since during operation there is a possibility of slab deflection, the possible size is determined based on the calculated permanent and temporary loads on the structure.

Analysis of this data allows you to select the optimal dimensions of the metal frame. Installation of the structure is very simple, and it can be done without the help of specialists. But the calculation should always be carried out by professionals, since any mistake can lead to the fact that the structure simply cannot withstand the load during operation.

Installation of beam structure

The technology for installing a monolithic floor using corrugated sheets involves the use of beams and columns. Metal pipes, I-beams and channels are suitable for this purpose. The distance between adjacent beams is determined based on the size and shape of the sheet profile. If the profile height is significant, the pitch between the beams can be reduced.

Corrugated sheeting for monolithic floors

The corrugated sheeting is attached to the base of the beam with self-tapping screws with a reinforced drill, which makes it possible not to drill holes in the channel or I-beam. Experts call such self-tapping screws “armor-piercing”, which corresponds to their technical characteristics. Fastening is carried out only in places where the corrugated sheet comes into contact with the beam. Additional fixation is carried out at the joints of the sheets. Here you can use 25 mm self-tapping screws. The pitch between the screws should be about 40 cm. The width of the sheets is butted with an overlap, and the length of the sheets is butted. The corrugations of the sheet should be oriented downwards. At the construction stage, the rigidity of the steel profiled sheet and its compliance with the calculated design parameters must be checked.

Next, the structure is reinforced. The reinforcement is laid in corrugations in the longitudinal and transverse directions. The reinforcement is knitted with wire. It is not recommended to use welding to create a reinforcement cage. Fixatives are used to form a protective layer. A protective layer is necessary in order to minimize the risk of reinforcement coming out of concrete and being exposed to negative environmental factors. The type and size of the clamps are selected depending on the design thickness of the protective layer. After creating the metal structure, you can fill the floor with concrete.

Frame installation

For this purpose, additional supports are used. The minimum thickness of the floor should be 7–8 cm. Concreting is best done across spans. After the concrete has completely hardened on one span, additional supports are removed. The time it takes for concrete to fully mature can vary greatly depending on the ambient temperature. In the warm season, the structure dries completely in about 10 days. At sub-zero temperatures this may take more than a month.

In accordance with SNiP 3.03.01-87, before concreting, the surface of the corrugated sheet must be cleaned of any dirt, oils, debris, cement dust, etc. The surface is washed with water immediately before pouring the concrete mixture. The mixture is poured in layers that should not have breaks or changes in thickness. The concrete is compacted using vibrators. When performing this work, it is necessary to ensure that the tool does not impact the corrugated sheet, reinforcement and other structural elements. The next layer is poured only after the previous one has set.

Advantages of concrete floors on corrugated sheets

• Rigidity.
  The rigidity of the material allows it to become an excellent permanent formwork that can withstand the weight of liquid concrete.
• Uniform load.
  When using load-bearing corrugated sheeting for floors, the weight load is evenly distributed over the entire frame, which makes it possible to lighten the walls and foundation
• Extra strength.
  The stiffening ribs of corrugated flooring act as additional external reinforcement, which gives the interfloor concrete floor high strength with less thickness (compared to removable formwork technology).
• Convenience and speed of installation.
  The construction of the floor does not require special equipment with a high load-bearing capacity (unlike ready-made concrete slabs). Fastening of corrugated sheets to a metal frame is carried out in an accelerated time. You can fill large areas at once. No effort is required to remove the formwork.
• Aesthetic appearance of the ceiling.
  Formwork made from corrugated sheets has a neat appearance from the outside, so in buildings of a certain type (warehouses, industrial workshops, etc.) the ceiling will not require additional finishing.
• Fire safety.
  A concrete floor protected by a metal sheet is fireproof.

Considering these advantages, it can be said without exaggeration that the use of monolithic permanent formwork made of corrugated sheets can significantly reduce the cost of construction without compromising the strength and durability of the building structure.

A lightweight foundation instead of a monolithic slab, prefabricated walls made of sandwich panels or aerated concrete blocks instead of brickwork or reinforced concrete slabs, columns instead of load-bearing walls, a ceiling that does not require finishing - these are cheaper solutions, which are also easy and quick to install.

Thanks to their use, it is possible to construct buildings in a very short time with the efforts of a small number of workers.

Types of metal formwork

The production of metal formwork involves the production of several types of structures, the choice of which depends on the design assignment and the upcoming construction volumes. In most cases, the three most popular options are used.

Beam-transom

An excellent solution for the construction of prefabricated monolithic or monolithic structures of floors, foundations, columns, load-bearing walls.

Beam-transom technology allows you to fill complex structures with certain bending curvature values. The equipment is popular for the construction of objects with elements of architectural decoration.

The formwork is lightweight, easy to install, and can be disassembled quickly. There is the possibility of repeated use without additional cleaning of the shields between cycles. The main advantage is that it can be used in combination with other formwork systems.

Large-shield

The shields are large in size. The structure is prefabricated, reinforced with vertical and horizontal stiffening ribs.

The main task of application is to form large and tall vertical structures. Large-panel formwork is used for concreting walls, because the structure is able to withstand significant load forces created by concrete. By using additional elements, it becomes possible to form a long and tall structure.

Professional builders use adjustable large-panel formwork, because installation and dismantling of the system requires the use of special equipment.

The basis of the set consists of large shields connected to each other with special fasteners. During installation, jacks are used to help adjust the position of each panel.

Small shield

The formwork kit consists of:

• panels in direct contact with concrete mortar;
• supporting elements fixing the panels in the required positions;
• fastenings.

The small panel formwork system allows the casting of structures up to fifteen meters in height. It is often used when constructing a foundation, because after the concrete has hardened, the panels can be easily removed and used at the next site.

One of the advantages of such formwork is its versatility. The system can be used not only for the construction of residential buildings, but also for the construction of outbuildings.

Separately, the high economic effect is noted - the formwork is used repeatedly, fully recouping its own costs and helping to quickly begin to make a profit.

Monolithic floor without supporting beams

Scheme of a frequently ribbed prefabricated monolithic floor.
Installation of interfloor floors without supporting beams is carried out with the support of corrugated sheets and reinforced weave directly on the embedded columns and walls of the building with temporary supporting props, allowing workers to move freely along the spans and holding the weight of unhardened concrete.

In this case, the metal sheet is attached to the mortgages using a metal anchor, and the reinforced frame is welded to the mortgages at all points of contact on all columns.

The organization of hatches in the ceiling or any interruptions in the line of support of the ceiling frame on columns is excluded. The monolith must be located from column to column or from wall to column without interruption.

This type of installation is most widely used at the room-attic level, where the load on the ceiling is significantly less than in living rooms.

Calculation of loads on interfloor floors

Calculation of loads when determining the thickness of the ceiling to be poured must be carried out by designers. The calculation must take into account:

• if necessary, the installation of partitions on the floors, and even a lightweight partition made of plasterboard puts pressure on the floor weighing 50 - 70 kg per square meter. m area;
• finding furniture and other household belongings;
• movement of people living in this building and the simultaneous presence of guests of the owners in this premises;
• the safety margin of the structure, after taking into account the above points, should be another third of what the original calculation was.

For reference: the minimum thickness of a monolith floor should be 50 - 60 mm, the maximum 200 - 250 mm.

Is it possible to use corrugated sheets for formwork?

Corrugated steel is a popular building material for roofing and cladding work. This material has acquired its practical use due to its quality. It is very durable and adds the necessary rigidity to the monolith. In order to make a monolithic interfloor ceiling or a flat roof, the best material for formwork is a profiled sheet.

Formwork made of corrugated sheets

Corrugated sheeting can withstand enormous loads due to its load-bearing capabilities. When working with this material, you can significantly save on concrete and reinforcement of the monolith. This is especially suitable for industrial buildings and complexes.

Main stages of installation

Before calculating the length of a corrugated sheet, it is worth considering that its support must be provided immediately by 3 support beams, 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 a 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 is better not to mix concrete yourself - it would be 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.

Making permanent formwork with your own hands

Let's consider the process of creating permanent formwork from sheet materials with independent cutting using the example of EPS (extruded polystyrene foam).

Unfold the sheets into fragments corresponding to the width and length of the compacted trench. From the remnants, cut out strips for sides 20–25 cm high. The total length of the sides should correspond to the double perimeter of the trench + 20% for overlap at corner points.

Place the sheets in the trench so that the sides rest on the EPS layer and do not touch the ground. Secure the sheets at the corners by piercing the material with plastic ties of the SVT system.

Place the halves of plastic ties between the vertical sheets and secure them together. If the system does not click tightly enough, tighten the connections with pliers.

Install reinforcing bars above and below the horizontal ties. To ensure that the metal is embedded in the thickness of the concrete, place pieces of polystyrene foam under the rods. Special grooves on plastic ties will help maintain the same distance between the reinforcement bars throughout the entire foundation.

Tie the rods together with thin wire, folded 2-3 times. In the same way, the reinforcement can be tied to plastic ties.

Build up the foundation with whole sheets of EPS, having previously attached narrow strips of the same material to them using plastic clips. Place the prepared sheets as shown in the figure

When installing, pay attention to the location of the grooves and ridges on the sheet.

Attach the vertical sheets to each other with ties, install and tie the reinforcement using the technology described above. You should get at least two plastic reinforcement belts, approximately at a distance of 10 cm from the top and bottom edges of the sheet.

Attach locking plates to the sharp ends of the plastic ties and trim off the ends that remain free.

Fill the reinforced formwork with cement-sand mortar

To prepare concrete, you can use your own concrete mixer, but you will need a lot of solution. If you doubt that you can pour the entire foundation in a day, it is better to use the services of an industrial concrete mixer tank.

Remove air bubbles with a construction vibrator and level the concrete surface. In this case, it is impossible to expel the air with a reinforcing rod, since the metal will damage the formwork, easily piercing the EPS sheet.

After the foundation concrete has completely hardened, you can continue pouring the walls using the same technology, but such a foundation can also be used with other materials.

Video: technology for building a house with permanent formwork from particle blocks

https://youtube.com/watch?v=Aqg7_Xdw5aE

When giving preference to one of the permanent formwork options, consider not only your financial capabilities and labor costs, but also the purpose

For example, in areas with swampy soil you should not use blocks based on wood chips, and in cold regions you should pay attention to a material with a minimum thermal conductivity coefficient. In this case, you can quickly build a warm house without extra financial costs.

Installation stages and features

The arrangement of reinforced concrete floors using profiled sheets involves three main stages:

• installation of formwork from corrugated board;
• creation and installation of a reinforcing frame;
• pouring concrete mixture.

Installation of formwork

Installation of permanent formwork from corrugated sheets

Fastening of metal sheets to beams is carried out using 32 mm armor-piercing self-tapping screws. To prevent sagging of corrugated sheet formwork under the weight of concrete, temporary racks are installed, which are located between the main beam supports. The number of additional supports depends on the thickness of the corrugated metal, the height of the corrugation and the area of ​​the interfloor ceiling. The racks are removed after the concrete has completely hardened.

Frame installation

The load-bearing characteristics of a monolithic interfloor ceiling made of corrugated sheets are increased by installing an additional “skeleton”, for the manufacture of which reinforcement and reinforcing mesh are used. Reinforcing elements are laid in waves of profiled sheets. The effect of using this method is improved by installing small supports that lift the reinforcement to a height of up to 20 mm.

Installation of reinforcement cage

Installation of reinforcement located between the beams is carried out in continuous sections. In areas where corrugated sheets are laid directly on the load-bearing wall and on the outer I-beams, the reinforcement is brought to the very edge of the corrugated sheet. A maximum deviation of no more than 20 mm is allowed, otherwise the load created by the concrete will be redistributed on the metal sheets.

Reinforcing mesh with cells 200x200 mm can be created directly on site. For its manufacture, metal rods with a diameter of 3 mm are used, and the connection at the joints is carried out by welding or galvanized wire. Often a ready-made version of the mesh is used. The reinforcing belt is laid on profiled sheets. The distance between the mesh and the metal is at least 15 mm.

Pouring concrete mixture

Before starting concreting the coating, the working surface is prepared. Formwork made from corrugated sheets is cleaned of existing contaminants, washed with water and dried. To supply the concrete mixture, one of the mechanized methods is used. Can be used:

• concrete pump stationary or mobile;
• band conveyer;
• a special construction tub that is lifted by a crane.

Additional supports for corrugated formwork

This technology involves pouring concrete mixture in one go. Leveling over the entire surface is done using a construction trowel. The concrete layer is compacted using a deep vibrator. Dry cement is used to “ironize” the surface and protect it from external influences. If it is not possible to immediately fill the entire floor area from profiled sheets, then concrete is laid in each span and in several stages. When concreting in stages, deadlines should be fixed in order to dismantle additional supports in time.

In accordance with regulatory requirements, the thickness of the concrete layer must cover the upper part of the wave:

• In a beamless ceiling, the minimum thickness is 250 mm (measured from the bottom edge of the profile).
• In the beam version - 70-80 mm (the height of the profile is not taken into account).

Weather conditions affect the features and nuances of the fill. To prevent the appearance of cracks that violate the integrity of the concrete structure, the surface requires constant care in the form of regular moistening and covering with moisture-absorbing materials until 70% strength is reached. Concreting is carried out at positive air temperatures, not lower than +5°C. Complete hardening in the summer season at an ambient temperature of 20°C occurs in 10-14 days.

If the temperature drops to 0°C and below, then, according to the standards, special anti-frost additives are introduced into the concrete mixture. Although this composition is more expensive, it guarantees the successful completion of concrete work. When the air temperature drops, the concrete surface needs additional insulation. In this case, the period of complete hardening increases to 28 days.

Pouring concrete over corrugated sheets

Rules for reinforcing floors and pouring concrete

Laying reinforcement

Pouring concrete

Pouring is best done with a concrete pump - this way the pouring will take place quickly, in one step, and the structure will be absolutely monolithic. It’s better not to skimp on concrete - buy a ready-made solution, or prepare it yourself in a concrete mixer, cement of at least M400. For better compaction of the concrete, it is necessary to go over it with an internal vibrator.

Advantages and disadvantages

The advantages of this technology are quite obvious

• Uniform pressure is created on the walls along the entire perimeter.
• The cost of a monolith is less than that of ready-made reinforced concrete slabs, the formwork of the covering slabs is dismountable, and the materials can be reused.
• There is no need to use lifting equipment (crane).
• The ceiling can be made non-standard, of almost any shape, if the house design requires it.

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 sheetProfiled rolled metal of type H has the greatest load-bearing capacity, which allows it 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.

https://youtube.com/watch?v=deCQDPEjbgo

Table No. 3 Corrugated sheeting 2 meters

C8 corrugated sheet (width 1200/1150mm, length to size up to 8000mm) Profiled sheet MP20 (width 1150/1100mm, length to size up to 8000mm)

Tips for working with concrete

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 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.

When concreting floors, various types of formwork are used, but one of the most common in recent years is permanent formwork made from corrugated board. Preventing concrete from spreading during the hardening process, corrugated formwork is also an additional external reinforcement. It partially compensates for the tensile forces that act on the lower reinforcing mesh. This greatly increases the strength and load-bearing capacity of the floor.

In addition, a monolithic slab with a corrugated sheet having a modern protective and decorative coating allows, in some cases, to do without expensive ceiling finishing.

Contents of the article

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Advantages of overlapping with corrugated sheets

Overlapping with corrugated sheets is characterized by the following advantages:

1. Low cost of material and installation work. Since installing the ceiling is easy with your own hands, financial costs remain minimal. The material itself is sold at an affordable price.
2. Possibility of implementing any architectural solutions and installation of different geometric shapes.
3. The pouring process is relatively simple and eliminates the need for formwork. The use of ridges reduces the consumption of concrete mixture, which also has a positive effect on the final cost of the work.
4. Even an inexperienced beginner can complete the installation of the system.
5. The finished floor is lighter than a reinforced concrete structure with removable formwork, while the strength properties remain at the highest level. As a result, the system does not place large loads on the foundation and remains an effective solution for old buildings. With the help of a profiled sheet, you can achieve proper distribution of effort.
6. Being an indispensable component of a monolithic structure, corrugated sheeting takes on the role of a reinforced frame.
7. The thickness of the floor is determined by the location of its operation. In order for them to meet the required standards, a number of calculations need to be performed.
8. The finished slab has good strength, and the presence of a metal profile strengthens the structure and gives an increased degree of rigidity.
9. There are different brands and types of corrugated sheets available in the market. This expands your choice and allows you to find the best option for any application.
10. The material is characterized by increased resistance to ignition. Fire resistance indicators are 30 minutes, and if we are talking about a monolithic system with a reinforced span - 45 minutes.
11. The ceilings between floors are characterized by reinforced formwork, which allows you to install the ceiling without a finishing layer or other installation work.
12. Corrugated sheets are indispensable for rooms with a metal frame. To connect the columns, reinforcement is used, making the frame rigid and resistant to various negative influences.

Due to its light weight, rigidity and resistance to corrosion processes, corrugated sheeting is very popular and is used for the construction of buildings for various purposes.

When bound to the concrete mixture, it takes on part of the loads on the floor slabs. The monolithic element is fixed on a lightweight supporting frame, which reduces the cost of forming foundations and purchasing wall materials. The lungs are used as them. The concrete solution is poured onto corrugated sheets without the use of complex formwork.

If you follow the basic rules of operation and maintain the structure on time, it will demonstrate better strength and resistance to negative influences.

Also, slabs based on corrugated sheets are characterized by minimal weight and look neat. By installing such a solution in your home, you don’t have to worry about finishing or insulating layers.

The material is convenient to use and easy to transport.

Installation

During the installation process, metal pipes with a square or round cross-section can act as columns. And for beams they use metal channels and I-beams. It is extremely important to be extremely careful when selecting corrugated sheets for floors. Based on the category, an acceptable beam section and laying step are selected. That is, a smaller pitch is necessary for metal profiles with a higher height. And for a high-precision calculation of the inter-beam pitch, you can talk to an employee of the corrugated sheet manufacturing company.

You can even show an example of correct calculations. For example, the inter-beam laying step is 300 centimeters. We purchased corrugated sheets of type TP-75 with a sheet thickness of 0.9 millimeters. To find the required length of the material, you should take into account its support on 3 beams. This will make it possible to avoid sheet sagging.

It is better to secure sheets with beams with 32 mm self-tapping screws, which are also called armor-piercing. Such fasteners are distinguished by the presence of a reinforced type drill, which will allow you to make channels without the need to use a drill. Fastenings are made at the junction of the beam and the corrugated sheet. If the product is laid on 3 beams, then it should be fixed to them at 3 points, and if on 2, then at 2 points, respectively. Here it is possible to use the aforementioned armor-piercing screws, but 25 mm. The step between their placement should be 400 mm. This will be the last step of the formwork process.

The next stage is reinforcing the slab. This process will make it possible to strengthen one material at the expense of another, which has greater strength. Reinforcement of corrugated sheets is carried out with wire. Such a frame, which will be located inside the structure, will allow the concrete to withstand heavy loads. The volumetric structure is formed by longitudinal rods with a thickness of 12 millimeters. They are laid along the channels of profiled sheets.

After the reinforcement has been completed, you can safely begin laying concrete. The pouring thickness should not be more than 80 millimeters. It would be best to use a composition of the M-25 or M-350 brand. But before pouring, it is necessary to prepare the corrugated sheet. More precisely, it is necessary to install boards under it to prevent subsidence under the weight of the concrete composition. Such supports should be removed as soon as the concrete mass dries.

It should be added that concreting is best done in one attempt. But if the area of ​​work is very large, and there is no confidence that it can be completed in a day, then it is better to fill along the span.

The drying time of the concrete mass will depend on the weather and temperature indicators. If the weather conditions are good and quite warm, the process will take no more than 10 days. By the way, if it’s hot, the concrete needs to be constantly moistened. If work is carried out in the cold and damp season or in winter, the drying process period increases to 4 weeks.

How to make an overlap using a profiled sheet, see the video below.

Installation instructions for formwork

Above are general instructions for installing formwork of any type. But when assembling forms for foundations, walls and ceilings, there are special nuances that you definitely need to know about.

Foundation

When installing formwork for strip foundations, panels made of boards or plywood are often used. It is these elements that bear the main load exerted by the concrete solution.

The strength and service life of the entire building depends on how correctly the formwork for the foundation is assembled, since the foundation is its basis. Before starting the construction of the foundation, it is necessary to carry out a number of preparatory measures.

At the initial stage, it is necessary to familiarize yourself with the requirements of the project, in addition, it is necessary to take into account the climate. It is advisable to carry out work at positive temperatures, that is, in late spring or summer, when frosts are unlikely

If you plan to build the most common version of formwork from boards, then the procedure should be as follows:

• On the prepared site, the corners of the foundation to be poured are marked. The remaining elements will be attached to these bars;
• the distance between the bars is measured and, depending on the results obtained, boards are assembled from the boards;
• they knock together the shields using bars, which should remain on the outside of the forms;

• shields are made in duplicate, since these elements are installed opposite each other;
• The shields are sealed, in addition, their internal surface is treated, it should be as smooth as possible;

the shields are installed between the corner bars, securely fastening the elements to each other. From the outside they are strengthened by installing slopes. The spacing of these elements depends on the thickness of the foundation and ranges from 0.5 to 1 meter. Inside, the boards are fastened by installing ties.

The inside of the assembled formwork forms is lined with thick polyethylene film or roofing felt, and the waterproofing material is secured with self-tapping screws. This will help prevent the solution from leaking out through the cracks. It is recommended to pour crushed stone or sand at the bottom of the molds so that the liquid from the solution does not absorb into the soil too quickly;

Before pouring the solution, you must once again check the horizontal and vertical positions of the installed elements.

Stan

When assembling formwork for erecting walls, the installation technology differs little from the technology for assembling foundation forms. Two types of wall formwork are used:

• small-panel - assembled from relatively small panels of laminated plywood or plastic. This equipment is suitable for the construction of small objects, for example, low-rise buildings;
• large-panel – characterized by the presence of large-area shields. Used for the construction of large objects, for example, multi-storey buildings.

The distance between the panels depends on the thickness of the walls. When assembling forms, you should take into account the need to leave openings for windows and doors. The panels are dismantled after the concrete solution has completely hardened.

Floors

When installing floor formwork, horizontal forms are assembled at height. The installation option depends on the planned ceiling height. Most often, structures on telescopic racks are used; they can be used if the ceiling height does not exceed 4.5 meters.

Tripods are mounted at the bottom of the racks for stability, and universal forks are attached to the top. These forks are used to secure the support beams, on top of which the cross beams are laid.

The horizontal part of the form, the deck, is laid on top of the beams. And along its perimeter, vertical sides are installed, their height depends on the design thickness of the floors.

Fixed

Installation of permanent formwork is simpler than assembling adjustable forms. To assemble permanent formwork, special blocks of foamed polystyrene are produced. Other material options are used much less frequently - reinforced concrete, wood concrete, metal.

Expanded polystyrene blocks are installed on a pre-prepared base. If this is wall formwork, then they are placed on a ready-made foundation, covered with a layer of waterproofing. The blocks are placed on top of reinforcement bars protruding from the foundation. The lateral connection of adjacent blocks occurs due to the fastenings available on them.

So, installation work on formwork assembly is an extremely important stage in the construction of a building. Not only the appearance of the cast structure, but also its strength characteristics directly depends on the quality of the work performed.

Therefore, installation must be carried out with special attention and all technological requirements must be carefully followed.

Floor calculation rules

Interfloor ceilings based on corrugated sheets, which have been so popular in recent years, are reliable and durable, but this cannot be done without preliminary calculations. Only a specialist should make such calculations, since the reliability and safety of the future structure depends on this

Separately, it is worth paying attention to the selection of corrugated sheeting, its thickness, type of wave, and design loads. The same applies to the section of beams, installation of a reinforcing belt and temporary supports that are necessary for pouring concrete

It is recommended to use round or square pipes as columns; for beams you can use an I-beam or channel. The pitch of such beams will depend on the height of the profile section.

Corrugated sheet roofing device.

For example, a floor structure where the pitch of the beams is 3 m requires a 0.9 mm TP75 profiled sheet. In this case, the planning is calculated in such a way that the sheet rests not on 2 beams, but on 3, ensuring the reliability of the entire structure. The deflection in this situation will be minimal.

The corrugated sheeting is attached to the floor beams using metal screws, which have dimensions of 5.5 * 32 mm. The sheet is fixed to the beam in each wave, which guarantees the rigidity of the surface, that is, the entire monolithic floor. To connect the profile at the joints, self-tapping screws with a cross-section of 5.5 * 25 mm are used, which must be installed in increments of 400 mm.

Lightweight covering using corrugated sheets: calculations and manufacturing

Another type of monolithic flooring is lightweight with corrugated sheets. It involves the use of a steel profiled cast with a polymer and zinc coating as a base. But not every professional sheet is suitable for this task.

As you know, corrugated sheeting differs in profile, having different shapes and corrugation heights. The higher the corrugation, the higher the rigidity of the floor. Despite the fact that such sheets are metal, they are reliably protected from corrosion. Even in the factory, they are coated with polymer paints and a special zinc layer.

Also pay attention to the brand of corrugated sheeting. So, “C” means “wall”, and “NS” means “universal”

Only sheets of the “N” grade are suitable for the ceiling device, which means “load-bearing”.

This is what such an overlap looks like in cross-section:

Before pouring concrete, so that it adheres reliably to the base, special notches are made along the entire surface of the profiled sheet - “reefs”. Concrete penetrates into them, and this increases its adhesion.

The corrugated sheets themselves act as something like a frame, and therefore there are not as many reinforcement rods as in a classic monolithic slab. Either I-beams or channels are used as beams.

If desired or necessary, you can insulate the ceiling, giving it thermal insulation properties and sound insulation:

A high-quality floor constructed in accordance with all the rules will last at least 100 years! Do you still have questions about installing a monolithic floor? Ask us, we will be happy to answer them!

Marking

Concrete slabs are marked with special markings, and you must pay attention to them. The letters in the marking indicate the type of slab itself, so PNO are lightweight flooring slabs, and PC are floor slabs

NV means internal flooring. Next, the letters on the marking are followed by numbers according to which the dimensions are indicated, namely length and width. The very last figure is the loads that are permissible. So, the number 8 means that the permissible load is about 800 kilograms per square meter.

When choosing the type of slabs, it is very important to pay attention to the fact that in general they differ in structure. So, according to the cross section, they can be hollow, solid or ribbed. Hollow-core slabs have gained the greatest popularity, this is due to their low mass, so they can be easily transported and installed

The voids can have a round or oval shape and are made of heavy concrete

Hollow-core slabs have gained the most popularity, this is due to their low weight, so they can be easily transported and installed. The voids can be round or oval in shape and are made of heavy concrete.

Due to the fact that the variety of slabs is large, they can be selected based on their main purpose, as well as on various natural features.

As for the process of reinforced flooring, it occurs with standard meshes, as well as with the use of knitted reinforcement. The diameter of the welded reinforcement rod is about 3 mm or even more, and the diameter of the knitted reinforcement is 6 mm or more.

Prefabricated and prefabricated monolithic slabs

Factory-made slabs are one of the most popular solutions in the construction of a residential building. They are very convenient - a homeowner with minimal experience in construction can carry out most of the work with his own hands. However, it must be taken into account that a crane is often required to install the slabs.

The disadvantage of ready-made elements for floors is their standard sizes, which are not suitable for all basements. The maximum slab length is only 9 m. Therefore, if your basement has distances exceeding this value, you will have to choose a different type of floor. If for some reason only prefabricated slabs are available to you, you can get out of the situation by installing additional load-bearing walls.

Factory-made stoves also have important advantages. Firstly, the ceiling made of such slabs does not need to be additionally insulated - it already has a thermal insulation system built into it. Secondly, they are characterized by a high degree of fire resistance.

Prefabricated slabs

Quite often the choice is made in favor of prefabricated slabs. They are ready-made factory-produced reinforced concrete products. There are different types of slabs: solid (also known as solid), hollow-core and ribbed. Solid and hollow-core slabs are more often used to install floors between floors, while ribbed slabs have industrial and household purposes. A serious disadvantage of prefabricated slabs is the fact that they cannot be installed with your own hands without a truck crane. This significantly increases the construction budget.

Scheme of laying factory reinforced concrete slabs.

In addition, this type of flooring has other disadvantages that impose certain restrictions on the work. Manufacturers produce only standard slab sizes, and their lengths are often too short or long for a basement.

The slabs are installed on a layer of mortar up to 20 mm thick. At the end, the seams are also filled with cement

It is important to note that you should not delay the processing of seams. This is due to the fact that they quickly become clogged with debris, which is difficult to clean out.

To install such a structure, a truck crane is required.

Prefabricated monolithic slabs

Prefabricated monolithic floor slabs are no less often used. The installation of such floors involves laying blocks between the beams and then pouring them with concrete. This allows you to make the design unified.

Scheme of a prefabricated monolithic floor.

Prefabricated monolithic floors structurally consist of 4 elements:

1. A reinforced concrete beam that serves as a load-bearing base.
2. Gas silicate, ceramic, concrete or polystyrene concrete block liner, which plays the role of a frame.
3. Reinforcement mesh.
4. Layer of monolithic concrete.

The main convenience of a prefabricated monolithic slab is that a truck crane is not required for its installation. Workers can install it with their own hands. The installation process will not take much time.

Installation of a prefabricated monolithic structure.

How is installation carried out?

Reinforcement

The internal metal frame in monolithic concrete provides compressive work, which ensures the original strength of the slab. The volumetric reinforcement structure is formed from a flat welded mesh with cells 15 x 15 cm and longitudinal sections of reinforcement laid on the bottom of each stiffener, which are united by vertical connections with ligation wire or welding. The volumetric dressing step is 20 cm. The ends of the metal rods and mesh are welded to the beams and columns.

For reinforcement, a steel rod with a diameter of 10 - 12 mm (grade A 400C) is taken. The mesh can be created from longitudinal rods with a diameter of 12 mm and transverse rods with a diameter of 0.6 cm. In order for the corrugated sheet to become an external reinforcement, notches (“reefs”) are created on the profile that adhere it to the concrete.

The steel inside the slab is protected by a layer of concrete up to 4 cm thick. To create it, special plastic clamps are used that lift the metal rods above the surface of the bottom of the stiffeners by 20 - 40 mm. The top of the reinforcement is also covered with concrete by 20 - 40 mm.

Specifics of reinforcement

Thanks to reinforcement, the strength characteristics of one material are increased with the help of another, which has increased rigidity. If we talk about corrugated sheets, the reinforcement is done with steel wire. The power circuit located inside the structure allows the concrete to withstand increased loads.

Longitudinal rods with a diameter of 12 mm form the frame. Laying is carried out along the channels of the sheets. The frame parts are attached to each other by welding or wire.

When the corrugated formwork is constructed, you can begin concreting

Consumables and tools

To make a monolithic structure you will need the following materials :

1. Concrete. You can use heavy concrete on fine-grained or regular filler and light concrete on porous filler. The class of heavy mixtures in terms of compressive strength is not less than B15, the class of light mixtures is not less than B12.5. The remaining characteristics of concrete must comply with SNiP 2.03.01-84. 2.2.
2. Steel corrugated sheets of grades N and NS.
3. Steel rod reinforcement of class A-II and A-III, wire reinforcement - class Vr. It is recommended to use A 400C reinforcement with a cross-sectional diameter of 10.8 mm.
4. Rivets and construction screws, rigid self-tapping screws.

To work you need to prepare:

• concrete mixer;
• sand;
• shovel;
• Master OK.

You will also need a tool for fastening materials.

Differences between profile coating and regular coating

The main difference between roofing with a corrugated sheet and a conventional one is the ability to create an almost ready-made structure for the ceiling, which does not require finishing or modification in the future.

The advantage of the profile sheet is that the dimensions of the structure can be adjusted to the desired level and profile, which increases the stability and strength of the entire structure.

Find out all the information about steps for stairs made of porcelain stoneware here.

Foam blocks or aerated concrete can be used as an additional floor covering on the walls: these materials will serve not only as floors, but also as insulation. The main load on the frame can be reduced by applying pressure to the foundation. The most common and inexpensive is the columnar frame, the installation of which takes little time. Covering a building with corrugated sheets can reduce labor costs, time and finances several times.

It is possible that information about interesting cantilever staircases will be useful to you.

Types of additional wall coverings.

If concrete is poured into hollows of corrugated sheeting 2-4 cm high, then you can feel the savings of the concrete mixture compared to dense pouring of corrugated metal. Corrugated sheeting allows you to achieve the most rigid floor structure in combination with concrete pouring. This also greatly saves time on the construction of floors, since there is no need to pour concrete onto wooden formwork and wait for the mixture to harden.

Options for protective coating of corrugated sheets

When choosing corrugated sheeting, you need to check with the manufacturer what kind of protective coating is present in this product. The strength and quality of corrugated board depends on this.

1. Zinc coating is inexpensive, but also the most fragile.
2. An alloy of aluminum and silicon provides higher protection and can last up to several years.
3. Polyester is a very high quality material. Resistant to negative external factors.
4. Polyester with Teflon provide enhanced protection. A large selection of colors is also available.
5. A mixture of PVC with other substances provides enhanced protection.
6. PVDF is a very high quality coating and durable.

Corrugated sheet

Formwork using corrugated sheets will be more expensive than wood-based construction, but also much more reliable. The system elements are installed in the following order:

• beam for formwork (channel No. 16 or I-beam No. 20);
• corrugated sheeting - laid so that the edges of the sheet are perpendicular to the direction of the supporting beam;
• reinforcement.

Next, the assembled metal structure is filled with concrete solution and compacted.

Diagram of corrugated sheeting for formwork

Permanent formwork for ceilings made of corrugated sheets is made on the basis of the following brands:

• “H” – for horizontal floors;
• “NS” – universal.

The height of the profile sheet is calculated for each floor individually.

As a rule, sheets of grades H60-H75 are used.

The use of metal sheets in formwork makes it possible to obtain a durable floor, save on reinforcement, reduce the weight of the structure, and therefore reduce the load on the foundation.

Formwork made from corrugated sheets - features of manufacturing composite slabs

In construction there is such a term as “composite slab”. This is a steel concrete slab that uses corrugated sheets for floor formwork. Corrugated sheeting can withstand the weight of reinforcement and concrete mixture, while the rigidity of the profile itself allows it to be used as additional external reinforcement. In addition, for the reinforcement cage rods, it is possible to use reinforcement of a smaller cross-section, which significantly reduces the cost of constructing floors of this type.

The height of the corrugation and the thickness of the corrugated sheet in such structures are interrelated with the distance between the load-bearing beams. The use of profiled sheets with a higher profile height and higher load-bearing capacity allows you to increase the distance between floor beams when developing a project. And with a short span, you can use a thinner and cheaper corrugated sheet with a lower corrugation height.

It should be taken into account that although the length of profiled sheets can reach 12 meters or more, it is better to support them not on two, but on three beams with a support in the middle of the sheet. This will prevent sagging or deformation of the corrugated sheets due to uneven load on the formwork during the concreting of the floor. The corrugated formwork sheeting must be attached to the support beams in each wave. This will significantly increase the rigidity of the composite slab at the stage of hardening of the concrete mixture

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.

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.