MDEK S100™ is a newly developed at pan prole that

provides unmatched performance in composite slab

construction. MDEK S100™ is used in both concrete

and steel frame construction and utilizes patented

technology to achieve superior spanning capabilities,

less deection, greater composite strength and better

re performance than similar proles.

MDEK S100™ can deliver cost savings when used in the

following types of construction:

• Concrete frame buildings

• Residential construction

• Multi-level carparks and Multi-storey buildings.

• Commercial buildings.

• Shopping centres.

MDEK S100™

Structural Decking Introduction

M Metal is a Singapore-based manufacturer of high quality steel and non-steel roong and walling products. We also manufacture Galvanised Hi-Tensile steel decking - RF55® and MDEK S100™.

We started the company in 2007 in response to what we saw was a growing industry need for a responsible supplier, which believes in the value of forging partnerships with stakeholders in order to deliver innovative, reliable and customized solutions. It is our breadth and depth of specialized knowledge, combined with our stakeholders’ awareness of their client needs, which results in a win-win collaboration.

Our sense of responsibility extends to workplace safety. We strongly believe that good safety equates good business. Through regular training sessions, we make sure that our workers, and also those of our contractors, are able to do a good job safely.

Staffed by experienced professionals with an in-depth knowledge of the industry and who are motivated by the company’s vision - to be the industry’s preferred building solutions provider from concept to completion - we aim to be a game-changer in Singapore’s building industry.

Table 1 : MDEK S100™ MATERIAL AND SECTION PROPERTIES

Base Metal Self Weight Steel Grade Zinc X-Sectional 2nd Moment Thickness kg/m2 (MPa) Coating Area of Area (+ve) (BMT) mm mm2/m cm4/m

1.00 17,55 550 Z275 2153 230.32

1.20 21.06 500 Z275 2584 298.77

1.50 26.32 450 Z275 3230 408.64

Greater spanning capacitiesMDEK S100™ is designed to provide larger unpropped spanning capabilities compared to other structural decking available in the market. This is achieved through the rib design where the stiffness and symmetry are optimised.

Stronger composite strengthMDEK S100™ composite slab is able to resist larger imposed loads . Every rib is fully embedded in concrete, developing strong interlocking actions with the concrete.

Higher Fire Resistance PerformanceExtensive re tests have been conducted at Exova Warringtonre UK. Tests results showed that MDEK S100™ composite slabs can achieved re resistance up to 240 min with only a single layer of top reinforcement.

Feature & Benets of MDEK S100™

Specification and Design Data of MDEK S100™

* Base metal thickness (BMT) is the metal thickness used in the design. This thickness excludes the thickness of the zinc coating.

* A zinc coating of 275 g/m2 (both sides) is sufcient in non-aggressive environment. But the specication may be varied depending on service conditions – EN1994-1-1 Cl 4.2(3).

Dimension in mm

3

300

46 46

100

mm

Table 4 : Minimum Concrete thickness above ribs, hc

Non-composite beam Composite beam Action Action

40mm 50mm

MDEK S100™ composite slab is designed in accordance to EN1994-1-1, EN1993-1-3. The design method is based on m&k values. Data about longitudinal shear capacity have been obtained from full scale tests conducted in Imperial College, UK.

The minimum overall depth of the composite slab Dcs, shall be determined according to the conditions indicated in the table below. – EN1994-1-1 9.2.1.

For full composite slab design, please contact our technical department for more information.

Span Table Notes• The tables above denote maximum allowable centerline to centerline span (in mm) between supports.• Density of wet concrete is assumed at 2450 kg/m3.• Loading congurations during the various construction stages are considered in accordance with EN1994.• Construction load of 1.5kPa is adopted.• The deection limit adopted is Span/130. For exposed soft, a deection limit of Span/240 is recommended.

• A minimum bearing width of 50mm of the permanent steel support and 125mm ange width have been considered.• Care must be exercised when placing concrete to avoid mounding.• Wide ply strips, of 300mm wide, shall be provided to prevent any concentrated loads being applied to the sheeting to avoid direct point loading of the sheet overlap ribs and unsupported edges of the sheeting.• For continuous application, please contact our technical department.

MDEK S100™ is developed to work as unpropped formwork during the construction stage. MDEK S100™ formwork design is based on EN1993-1-3. The span table below shows the maximum unpropped span for MDEK S100™ installed in single spans. The table should be read in conjunction with Span Table Notes below.

Formwork Design

Composite Slab Design

Table 3 : MDEK S100™ Maximum un-propped span

Span Base Metal Slab Thickness (mm)

Thickness (BMT) 150 175 200 250

Single span 1.0mm 3900 3750 3600 3400

MDEK S100™ Single span 1.2mm 4400 4200 4050 3800

Single span 1.5mm 4850 4660 4490 4200

Table 2 : Factored load combinations for strength & deflection calculations

Construction Design Imposed Permanent Load Imposed Variable Load

Stage Criterion Decking Wet Concrete Construction Storage

1A Strength 1.35 - 1.5 -

1B Strength 1.35 - - 1.5

2A Strength 1.35 1.35 1.5 -

2B Deection 1.0 1.0 - -

Composite slab set up.

Composite slab tested to failure.

Formwork test set up.

Formwork tested to failure.

The recommended location for re reinforcement is shown in gures below. Typically, the mesh or rebars are laid with the longitudinal rebars evenly spaced between the ribs support by the distribution rebars (cross bars). Contribution of MDEK S100™during re resistance design has been extensively tested at Exova Warringtonre, UK. Exova Warringtonre is accredited through the Singapore Accreditation Council.

Fire resistance for

MDEK S100™ composite slab is

designed in accordance to

EN1994-1-2.

For Type B & D Mesh For Type A Mesh

For more information, please contact our technical department

After 240min of test. Underside of re furnace.

After 30 mins of test,Start of the re test.

5

Fire Resistance Design

^ based on what is the standard dimension available in the market.

Deck Rib Height, hp Diameter, d Min Stud Height, Recommended

Profile (mm) (mm) hsc = hp+2d (mm) Studs Height^, hsc

Trapezoidal 40 19 40+2*19 =78 100mm

RF55® 55 19 55+2*19 = 93 100mm

MDEK S100™ 100 19 100+2*19 =138 140mm

Table 5 : Recommended Shear Standard height, hsc

• Minimum Height of Shear Connectors, hsc The nominal height of a shear stud hsc, should extend not less than 2d above the top of the steel deck, where d is the diameter of the shank. - EN1994-1-1 6.6.5.8 (1).

The table below illustrates the minimum height of a shear connector depending on the type of prole steel deck used in composite slab composite beam design.

Savings in beam weight can be achieved when the composite slab

is effectively anchored to the steel beam. The slab will then act as

a compression ange whilst the steel beam acts as a tension

member.

Composite beams are normally hot rolled or fabricated steel

sections acting compositely with the concrete slab. Composite

interaction is achieved by the attachment of shear connectors to

the top of the beam. These connectors generally take the form of

headed studs and can be welded in the workshop or on-site

through the decking. It is recommended the shear studs to be

welded on site, as this will allow for continuity of the decking

sheets and more economical designs. The shear connectors are

required to provide sufcient longitudinal shear connection

between the beam and the concrete so that they act together

compositely.

Composite slabs

and beams are most

commonly used in

commercial and industrial

buildings due to the speed

and economy of construction.

Design of Shear Connectors

• Shear Connectors Location Details

Some proles on the market (typically trapezoidal prole) have a

central location of the lapping rib which creates a ‘preferred’ and a

‘non-preferred’ side of the rib to place the shear stud to obtain

optimum capacity of the shear stud. This creates unnecessary

complexity for sub contractors on site to determine the optimum

placement of the stud.

For MDEK S100™ the centre of

the pan is at and thus allows the

shear studs to be placed centrally

in the pan.

Composite Steel Beam Design

Table 6 : Minimum Composite Slab thickness (Based on 19mm x 100mm shear connector)

Profile Rib Height Min hc Shear connector hsc Min Conc. Cover Min Slab thk = (A) (B)^ (C) (D) Greater of (A+B) ; (C+D)

Trapezoidal 40 50 100 20 120

RF55® 55 50 100 20 120

MDEK S100™ 100 50 140 20 160

^ from Table 4

• Minimum Composite Slab Thickness

The minimum composite slab thickness with composite beam action depends on the height of the shear connectors and the concrete cover over the shear connectors.

EN 1994 6.6.5.2 (2) recommends the following concrete cover over the shear connectors: • Not less than 20mm, or • As recommended by EN 1992-1-1, Table 4.4 for reinforcing steel, whichever is greater.

Typically for a MDEK S100™ composite slab, 19mm (d) x 140mm (L) shear connectors are used in the composite beam design. With 20mm concrete cover over the connector, the minimum MDEK S100™ composite slab shall be; • hsc + 20mm, or • hp + 50mm, whichever is greater (EN1994-1-1 9.2.1)

However, if cover is not required the top of the connector maybe ush with the upper surface of the concrete slab. This shall be determined by the structural engineer.

* Minimum concrete shall be determined by the structural engineer.

7

Panels are delivered to site or specied storage area, in strapped bundles. If not required for immediate use, bundles should be neatly stacked clear of the ground with a fall for drainage and protected by waterproof covers. Do not allow rain or condensation to be trapped between panels. Length manufactured according to shop drawings.

To minimize damage to the sheets, break open bundles only when installation is due to commence. Check to ensure that any temporary supports required are in place prior to installing the decking.

When lifting, it is recommended that appropriate lifting equipments are used. Unprotected chain slings can damage the bundle during lifting. When synthetic slings are used there is a risk of severing them on the edges of the decking sheets.

If timber packers are used, they should be secured to the bundle before lifting so that when slings are released they do not fall to the ground. Bundles must never be lifted using the metal banding.

Concrete should be placed in a manner that minimizes the permanent deection of the decking. When concreting is poured in the same direction as the span of the decking it should be placed rst over the supports where the decking is continuous, followed by the mid span region and nally the areas above the end supports. When concrete is being poured transversely to the decking ribs, it should be placed rst at the edge where a decking sheet is supported by the under lap of an adjacent sheet. This will help ensure that the longitudinal seams between sheets remain closed.

When a steel deck composite slab is to be poured in conjunction with a band beam, it is the contractor’s responsibility to ensure that the temporary ply used to form the concrete beam is positioned, held & secured sufciently to form the beam to engineer’s details. The steel deck must pass the ply form of the beam a minimum of 50mm. Care must be taken that the steel deck does not penetrate into the band beam to such an extent that it fowls the internal reinforcing used in the band beam.

We can provide comprehensive design advice and information pertaining to the application, handling & installation of MDEK S100™ structural steel decking and edge form. Please contact M Metal if you require technical support.

Storage And Handling

Concrete Placing9

• Laying of Decking

Panels should be accurately aligned, side laps fully lapped and the gap between abutting ends kept to a minimum.

Provision should be made so that all panels have full end and intermediate bearing support on the building framework of a minimum of 50mm unless other stated on the structural drawings. The decking must be continuous over all intermediate temporary supports without intermediate splicing or joining. Sheeting shall only terminate at ends into a permanent support (i.e. steel beam or concrete beam).

Note: Wide ply strips, of 300mm width, may be positioned above the header bearers to assist in dispersing the load and minimize any local deformation of the decking due to the headers.

Temporary props should only be removed after the slab has reached sufcient strength (at least 75% of the specied 28 day strength). The full design load may only be applied once the slab has achieved its 28 day strength.

The propping supports shall be effectively rigid such that their vertical deection during the construction phase can be ignored. It is the contractor’ responsibility to ensure that the vertical props have sufcient strength to withstand the construction load, are braced and secured appropriately to withstand all incidental and construction loads.

• Temporary Propping

Provide temporary propping during concrete placing & curing in accordance with the engineers’ drawings. It should be placed at the correct centers prior to laying the decking sheets.

Generally timber or steel bearers with a minimum dimension of 75mm x 75mm are used on vertical props. The use of wider bearers can be considered to reduce visible marks in the decking after concrete has hardened and the props are removed. The props should be installed so as to prevent settlement during loading by the wet concrete and other construction loads.

One at a time, all shores to complete oors should be rst loosened and then tightened to ensure equal loads in all props before casting of the next oor over. Repeat this process for each oor to be cast.

Propping generally consists of substantial timber or steel bearers supported by a line of props, adjusted to prevent settlement of the working levels during the concrete placement and curing. Propping shall be designed to support the weight of wet concrete and construction loads.

Where the underside of the deck is to remain exposed as a feature, a wide ply form strip attached to the bearers will minimize marking. Strips of 300mm wide are commonly used.

Propping shall not be removed until the concrete has achieved sufcient strength to support the designed superimposed loads.

Installation Guidelines

• Fasteners and Clips The decking must be positively xed to the supporting structure, in order to avoid movement and excessive deection during the pouring of concrete.

When xing to a steelwork support structure, shot red pins or self drilling/tapping fasteners should be used. Provide 1 fastener in each pan at every support. Place the xings in the at areas of the pans adjacent to the ribs or between the utes.

In the case of other support systems, such as brickwork, blockwork and concrete, the decking must be temporarily held in place against wind and other effects until the concrete is poured.

Place two MDEK S100™ Sheeting side by side (Female and Male Rib) and press them together to form a complete rib. Place a MDEK S100™ rib clip on top, the clip shall hook on to the male rib and press down to snap to the female rib. The clips should be install at both ends of the decking and one at the midspan.

Fixing panels to masonry supports may not be necessary if concrete is placed immediately after panels are laid. If xing is required to prevent movement due to wind or for safety reasons during placement of concrete, the panels should be secured to the temporary timber bearers by nailing.

• Reinforcement

Place all reinforcement in strict accordance with the structural engineer’s drawings and specication.

• Concrete Placement

The specied grade of concrete and any chemical admixtures must be in accordance with EN 1992 and the structural engineer’s drawings and specication. The deck must be clear of any excess dirt, grease or debris as this inhibits bonding between the deck and concrete reducing the oor slab capacity.

Ensure that the concrete is applied evenly over the decking surface, as mounding of the wet concrete will cause excessive local loading and deection.

Female rib Male rib

Fixing point over intermediate support

Fixing point at end supports

PRESS DOWNSNAP ON

MDEK FIXING CLIP

MDEK FIXING CLIP

FASTENER

• Cutting & Penetrations

Panels are supplied at the required lengths to minimize on-site cutting. Where necessary, panels can be cut using a power saw with an abrasive disc or a metal cutting friction blade. When cutting, panels should be turned over with the ribs downwards.

Where holes are to be cut for pipes etc, the use of hole-saw is recommended. Should it be necessary to provide a hole through the oor decking, the sheeting should only be cut after curing of the concrete cured (i.e. the concrete has reached a minimum of 75% of its design strength). Before the actual concrete pour, any openings should be boxed out with timber shuttering or dense polystyrene blocks.

For isolated openings at right angles to the deck span, M Metal offers the following guidelines which must always be checked and approved by the structural engineers:

• Penetrations up to 200mm square may be acceptable without additional reinforcement.

• Penetrations between 200mm & 500mm square may require additional reinforcement to trim the opening, designed in accordance. • Penetrations greater than 500mm square typically require trimming steelwork support to be supplied by the fabricator.

• A close group of penetrations transverse to the prole direction should be considered as single large penetration.

• Permanent Loading

Do not place permanent loads, including masonry walls, on the concrete structure until the concrete has cured and all props have been removed.

• Construction Loading

Maximum construction has been designed in accordance to EN1994-1-1. Do not place construction loads, including plant and equipment, on the concrete structure, which exceeds the design capacity of the structure. Seek permission for such loads.

Applying loads on decking

11

Lapping two piecesFor External corner For Internal corner

Cut ‘V’ in top & bottom ange

Bend corner of Edge Form to the required angle

Bend Edge Form to the required angle

Lapping two pieces

Bend corner of Edge Formto the required angle

Slit top & bottom anges square

Accessories – Edge form/Flashings An easy & economical method of forming up the edges of concrete slabs is to order the edge form from M Metal. It is custom made from galvanized steel in lengths of about 3 metres long.

The bottom edge of the form is slipped between the decking, and the beam or wall below. The top edge is restrained from movement during concrete placement, by the installation of galvanized straps minimally 20-25mm wide every 600mm, usually fastened by hex head self drilling screws or pop-rivets.

Typical Isometric View of Edge Form Installation

Mechanical and electrical services can be hang from the soft of MDEK S100™ composite slab easily. The installation method and consideration is similar to that of a conventional RC slab.

* The above accessories are for illustration and suggestion only. Please contact M Metal Pte Ltd for more information.

MDEK Fixing Clips

Cut ‘V’ in top

For Internal corner

SSlit top & bottomanges square

Hanging of Mechanical & Electrical Services

BE

AM

BE

AM

TYPICAL MDEK S100 STEEL FRAMING PLAN

SLAB EDGE

BE

AM

BE

AM

BE

AM

BE

AM

BE

AM

BE

AM

BEAM

BEAM

BEAM

BEAM

BEAM

BEAM

BEAM

BEAM

BE

AM

BE

AM

BE

AM

BE

AM

BE

AM

BE

AM

COLUMN

BEAM

BEAM

1

MDEK 100 GALVANIZED STRUCTURAL DECKING

7

5

7

2

4 6

3

Below are some typical construction details for the use of MDEK S100™. These are also available electronically from M Metal for use where appropriate.

Please contact our Project/ Supply & Installation Department for assistance.

Construction Details

Section 1

Section 2

Tie-back Strap at 600mm c/c Concrete

Galv. Edgeform

Rebar Mesh

Shear Studs(indicative only)to installer’s detail Main Beam

MDEK S100™ Galv. Structural Decking

13

Section 3

Section 5

Section 6

Section 4

15

Section 7

Proposed detail for difference in steel beam level

Proposed detail for concrete frame construction

• EN1992-1-1:2008 Design of concrete structures – General rules and rules for buildings.

• EN1993-1-1:2010 Design of steel structures – General rules and rules for buildings.

• EN1993-1-3:2010 Design of steel structures – General rules – supplementary rules for cold-formed members and sheeting.

• EN1994-1-1:2004 Design of composite steel & concrete structures – General rules and rules for buildings.

• EN1994-1-2:2009 Design of composite steel & concrete structures –Structural re design.

• AS 1397 – 2001 Steel sheet & strip– Hot-dip zinc-coated or aluminium/zinc coated.

• Heavy Engineering Research Association (HERA), Auckland, New Zealand Design Properties of 1.0mm MDek S100 in AS1397-G550, 1.2mm MDek S100 in AS1397-G500 and 1.5mm MDek S100 in AS1397-G450 material proled steel deck Document SSTR-058.

• Fire Engineering Assessment of Composite Slabs Constructed Using 1.0 mm MDek S100, Document SSTR-059, Heavy Engineering Research Association, Auckland, New Zealand.

• Fire Engineering Assessment of Composite Slabs Constructed Using 1.2 mm MDek S100, Document SSTR-060, Heavy Engineering Research Association, Auckland, New Zealand.

References