Advantages of Pre-Fabricated Corrugated Steel Flooring

The choice of corrugated steel flooring for pre-fabricated houses is gaining popularity due to its exceptional durability and rapid construction capabilities. In the following article, we'll provide insights on common flooring types used in industrial buildings and explain why deck mezzanine corrugated steel flooring is the ideal option for pre-fabricated steel structures.

If you are looking for more details, kindly visit our website.

1. Common Floor Types for Pre-Fabricated Steel Buildings

1.1 Concrete Floor

Concrete flooring is favored by many clients in pre-fabricated steel building projects, credited for its outstanding bearing capacity, remarkable durability, and effective fire resistance.

1.2 Cemboard Cement Sheet Floor

The cemboard cement sheet floor boasts significant advantages, including compact design, easy installation, and swift construction, making it a popular choice for mezzanine flooring, advanced renovations, and civil pre-fabricated buildings. These floors, composed of ultrafine materials like silica, cellulose fibers, and Portland cement, offer a certain degree of hardness and load-bearing capacity. However, their horizontal load-bearing ability is often underestimated, and they lack flexibility. Consequently, the use of cemboard cement sheet floors in pre-fabricated steel structures remains limited.

1.3 Pre-fabricated Lightweight Concrete Panel Floor

Many builders opt for pre-fabricated lightweight concrete panels, especially for residential constructions. Their lightweight nature makes them suitable for installation in buildings that have limited capacity for foundation modifications or weaker soil.

1.4 Deck Floor

The deck floor is a hybrid of reinforced concrete and corrugated steel deck flooring, commonly used in mezzanine and standard floors of pre-engineered buildings. The primary material in the corrugated steel floor deck is galvanized steel, providing exceptional durability and corrosion resistance. Additionally, its shiny appearance enhances the aesthetics of the buildings. The large wave structure of the corrugated iron flooring ensures it has high load-bearing capacity.

The corrugated steel floor deck is incredibly popular in pre-fabricated steel construction (Source: Pebsteel). The installation process for a deck floor is straightforward and lacks excessive complexity. Investors can construct several deck floors simultaneously without the need for traditional formwork used in concrete casting. This efficiency reduces construction time and conserves concrete usage, ultimately optimizing costs for investors. Presently, deck flooring is widely utilized in pre-fabricated steel frameworks, including showrooms, office buildings, factories, and warehouses.

2. Choosing PebDek® Corrugated Steel Floor for Mezzanine Combined Steel Floor

Pebsteel is recognized for its reputable and high-quality steel flooring systems. They use ASTM® A653 SS Grade 550 & Z180 (USA), producing two types of PebDek® products: PebDek® 55 (56mm high corrugated steel wave) and PebDek® 76 (76mm high corrugated steel wave). PebDek® corrugated steel flooring combines concrete and metal mesh for both mezzanine and standard floors, particularly suited for multi-story pre-fabricated steel structures. This combination not only helps reduce concrete material costs but also maintains adequate load-bearing capacity. Furthermore, the deck floor provides aesthetic appeal to the building while ensuring long-term durability.

Pebsteel not only provides optimal solutions regarding technology and affordability but also offers a ten-year structural warranty and a three-year warranty for all constructions.

The information above covers common floor types and highlights the benefits of deck flooring using PebDek® systems available at Pebsteel. For any inquiries, feel free to contact Pebsteel at [ protected] or +84 908 for complimentary advice and quotations.

What Is Form Decking? Types & Uses Of Steel Form Deck

Have you come across the term 'form deck' and wondered whether it's simply another term for composite floor deck? Does it hold a different meaning?

When pouring concrete, it's essential to have a solution that can support its weight. Essentially, a form deck provides temporary support to wet concrete while it sets. This article will lay out the basics of form decking.

At Western Metal Deck, we have been in the metal decking industry for three decades. After addressing daily inquiries about steel form decks versus composite floor decks, we felt it was high time to create a comprehensive article to address all inquiries.

This article will explore:

What Is Form Decking?

A form deck is a type of corrugated metal sheeting used as a form for structural concrete. Steel form decking supports the concrete slab during construction. This form is popular as it is economical and remains in place once the concrete is cured, as opposed to removable wood forms.

Steel Form Deck Versus Wood Forms

Construction tasks often necessitate quick placement of concrete. Many jobs require thousands of cubic yards of concrete, which can weigh between 140 and 150 pounds per cubic foot. Thus, substantial weight must be managed by a fitting concrete form.

The type of concrete form utilized will be influenced by the size and volume of concrete being poured. In multi-story buildings, the form must span from beam to beam, supporting the concrete weight effectively—something wood forms cannot accomplish.

Steel decking supports significantly more weight than wood while being cost-efficient. When dealing with large areas requiring shoring and heavy-weight support, steel form decking outperforms wood forms.

Advantages of steel form decking include:

• Rapid and simple installation
• Cost-effective
• Reduces the need for temporary wood deck shoring
• Eliminates time spent removing temporary supports
• Acts as a work platform during concrete pouring and preparations

Steel Form Decking vs. Composite Floor Deck

Steel form deck and composite floor deck serve similar purposes in supporting wet concrete; however, they have a key distinction. Steel form decking alone does not enhance the floor's strength, while composite floor decking actively contributes to increasing floor system strength.

Composite floor decks incorporate embossments in the vertical ribs of the metal decking, allowing the concrete to bond seamlessly as it cures. This results in a composite metal floor deck, substantially increasing floor strength without additional weight.

In contrast, steel form decking merely supports the concrete’s weight without any bonding. It does not contribute to the floor's strength and typically should not be utilized for spans greater than six inches.

For extended spans, composite floor decking is more suitable, and it works effectively for slabs ranging from 3.5 to 7.5 inches deep.

Additional reading:
What is custom hot rolled rebar and Why Do We Use Them?

With competitive pricing and timely deliveries, KAIYAO aims to be your trusted supplier and partner.

Uses And Applications Of Steel Form Deck

Wet concrete lacks strength and can be unwieldy. To develop desired strength and durability, it must cure appropriately. Steel form decks primarily serve as temporary shoring for concrete while it sets. This solution is optimal when a concrete composite isn't crucial.

Steel form decking usually spans 2 to 5 feet and features slab thicknesses between 3 to 6 inches, making it ideal for closely spaced supports, multi-story structures, and stairways.

This type of decking can also function as wall panels or metal siding, often seen in mini storage facilities. Notably, Shallow Vercor or Deep Vercor are popular choices for creating partition walls when shear panels are required.

When opting to pour concrete on a steel form deck, it’s critical to steer clear of certain pitfalls. Form decking cannot have a galvalume or zincalume finish, as this compatibility issue can lead to rapid rusting. Form decking should ideally have a galvanized substrate.

Corrugated materials can be engineered for use as form decking or designed for architectural applications; however, if they feature a galvalume or zincalume finish, it must be confirmed they were engineered specifically for form decking rather than as metal siding panels.

Types Of Steel Form Deck

Available in various depths, gauges, and finishes, form decking options vary depending on the region. Here are four common types:

Shallow Vercor Form Deck

• 9/16&#; Deep
• Gauge
  A maximum of 20 gauge thickness up to 26 gauge as the lightest option, with 22 gauge being the most accessible. Heavier or lighter gauges may be region-dependent.
• Steel Tensile Strength
  High tensile 80KSI steel
• Finish
  Galvanized G90
• Sheet Lengths
  12&#;, 16&#;, or 20&#; lengths for smaller jobs; larger jobs may require custom lengths with a lead time of 2-4 weeks.

Deep Vercor Form Deck

• 1 5/16&#; Deep
• Gauge
  Maximum of 20 gauge with options as light as 26 gauge; commonly 20 gauge.
• Steel Tensile Strength
  High tensile 80KSI steel
• Finish
  

  Galvanized G90, ASTM A653

• Sheet Lengths
  

  Available in 12&#;, 16&#;, and 20&#; with additional lengths for larger projects requiring a lead time of 2-4 weeks.

Vulcraft 1.0 C, CSV Conform

• 1&#; Deep
• Gauge
  A maximum of 20 gauge thickness, with lighter options as thin as 26 gauge.
• Steel Tensile Strength
  High tensile 80KSI steel
• Finish
  Galvanized G90
• Sheet Lengths
  Can be made to specific lengths based on project size with lead times required for larger projects.

Vulcraft 6 C, CSV Conform

• 9/16&#; Deep
• Gauge
  Maximum thickness of 20 gauge, with lighter choices as light as 26 gauge.
• Steel Tensile Strength
  High tensile 80KSI steel
• Finish
  Galvanized G90
• Sheet Lengths
  Size options available based on job size with 2-4 weeks lead time for custom orders.

If welding Verco or Vulcraft form decking of less than 22 gauge, be sure to use weld washers.

How Much Does Form Decking Cost?

Form decking typically ranges from $2 to $3 per square foot. Pricing varies based on the following factors:

• Gauge
• Job size
• Job location
• Market fluctuations in steel prices

For a deeper dive into metal decking costs, we recommend following:

Get A Quote On Form Deck

Steel form decking represents an excellent choice for concrete applications, given its affordability, ease of installation, and the fact it remains post pouring. If you believe steel form decking aligns with your project needs, we welcome you to explore your options further.

Once you determine the best steel form deck for your project, sourcing it can be challenging as it's a niche market with limited suppliers in various regions.

Let us save you the hassle of searching. We offer shipping across the United States and can have form decking on-site promptly. Should you require a quote for your metal decking, don't hesitate to reach out to us. Our extensive selection of form decking, roof and floor decks, gauges, and sheet lengths is at your disposal.

For more insights into metal decking, please check out our blog or YouTube channel.

For more information, please visit steel flooring panels.