Coltman Technical Specification
Coltman Technical Specification
SPECIFICATION
COLTMAN FLOORS & ROOFS EN 206-1[7]. The units are prestressed in the longitudinal direction only
Coltman’s floor and roof slabs are manufactured as individual using pretensioning wire, which is stress relieved and treated for
prestressed concrete units, typically 1200mm wide, placed side by side low relaxation.
with a cast insitu grouted joint to form a completed floor slab. Narrower The units are manufactured by a machine using the long-line slip
units may be used for non standard bay widths. The units are most form technique on heated steel beds within a factory environment.
commonly designed as simply supported, one-way spanning slabs, After the concrete achieves a compressive cube strength of at least
but cantilevers and continuous slabs may be specified. Where it is 30 N/mm2 the wires are detensioned and the casting is sawn to the
necessary to tie individual spans together, short slots are formed in the length of individual units whilst on the manufacturing bed. Units are
ends of units to permit the placement of cast insitu rebars as structural supplied as standard with plain sawn ends and if required with slots or
ties. In this case the precast units provide horizontal diaphragm action top-opened cores.
to transmit wind and sway forces to the stabilising parts of the building. Cross sectional and length tolerances are within the limits set out in
The cross-sectional profile of the units is either solid, of depths BS EN 1168[6] and are subject to stringent quality control checks.
ranging from 75 to 200mm, or with pre-formed longitudinal voids, Coltman’s floor and roof units, and composite slabs, can also be
known as ‘hollow core units’ of depths ranging from 150 to 250mm. designed and constructed according to BS 8110[8] (see page 7 for more
The units can be designed to act alone, or compositely with a cast details). Apart from the recommendations given in Eurocodes 0, 1 and
insitu topping, containing a steel mesh, typically 50 to 100mm in depth 2, all other information in this document also applies to design carried
(see page 6 for further details). out to BS8110.
The units are designed according to Eurocode 2 and the UK National CAMBER
Annex Documents (NAD); BS EN 1992, Part 1-1 for structural strength,
[1]
Pre-stressed units have an inherent upward camber and due allowance
Part 1-2[2] for fire resistance, and BS 8500-1[3] for durability. The units should be made in any finishes to cater for this particularly where rigid
are designed to comply with the serviceability requirements of BS EN insulation board, floating timber floor or waterproof membrane is to
1992-1-1[1] for tensile stress, cracking and deflection. be placed onto the top of the floor unit. In these situations a levelling
Service loads and ultimate load combinations are defined according screed will need to be applied by the Principal Contractor prior to the
to Eurocodes 1 and 0 and their UK NAD: BS EN 1991, Part 1 and BS EN
[4]
laying of the finish.
1990[5], respectively. Differential camber between adjacent units is not specified in the
The standard fire resistance is typically 60 minutes, but 90 and 120 Eurocodes or Product Standards. However, the recommendations
minutes is possible for the greater depths (see page 6 for given in BS 8110, Part 1[8] are specified, except for areas of floor where
further details). the adjacent spans of the units are of different lengths or where large
The design life of the units is 50 years. The durability of the units holes are to be formed within the middle third of the unit.
satisfies exposure classes from XC1 (internal), XC3 (external) to XD1 Consideration must also be given to both floor and ceiling finishes
(airborne chlorides)[3]. Certain aspects of the design and profile of the where floor spans are perpendicular as steps will occur between units.
units conform with the European Product Standard BS EN 1168[6]. The The camber of Coltman units will generally comply with the
natural frequency and thermal resistance of the units (or composite recommendations of BS EN 1992-1-1[1] and are predicted to be
slab) is available on request. approximately 1/300 of the span.
The units are manufactured with concrete having a characteristic
compressive cube strength of 55 N/mm2 at 28 days. The design
cylinder strength[1] fck = 45 N/mm2. Concrete production conforms to BS
DUAL BEARING
INTERNAL LOAD BEARING WALL In locations where the precast concrete units are to be supported on
walls less than 190mm thick then temporary props or other means of
bearing enhancement must be employed, designed and erected by
competent persons. Props and timber runners are to be positioned at
Gap due to camber to be bearing level to give lateral support to the wall during installation.
100 filled with ‘Dry Pack’ mortar
Minimum after installation of slabs. 140 In situ infill and
Minimum width of wall reinforcement by Coltman
SUPPORTS
The design of structural bearings on steelwork, concrete or load
bearing masonry is according to BS EN 1992-1-1[1]. This includes the Timber just below Props to provide
required bearing length, allowing for manufacturing and construction bearing level. lateral stability to
tolerances, and the ultimate bearing strength. The design bearing single skin load
length on steelwork is 75mm, precast concrete is 80mm, and cast bearing wall (must be
insitu concrete and masonry is 100mm. employed, designed
The precast units are positioned directly onto bearings without the and erected by
need for mortar or elastomeric strips, unless the Principal Contractor competent persons
considers that the levels of the bearing require a bedding material. other than Coltman)
Structural supporting walls for Coltman units are to rise from proper
foundations and the adequacy of all bearings is the responsibility of the THIS PROPPING METHOD IS FOR GUIDANCE ONLY
Principal Contractor.
The stability of the supporting structure must not be adversely
affected by the installation of the precast concrete units.
When designing bearings consideration must be given to the
standard method of fixing precast concrete units, particularly the
3
PROPPING 30
Consideration must also be given to the design and stability of lintels Minimum clearance
during the construction phase. It may be necessary dependent on type
of lintels to prop the inner skin until the construction is complete.
50 150
Lintels should be designed with the Shelf Angles to project 150mm minimum
construction phase loading in mind, as this a minimum of 50mm outstand leg
type of lintel does not achieve full load beyond top flange
capacity until construction is complete
Flange flush with top of slab
The inner skin should be propped
where there is sufficient masonry to
counterbalance the load imposed during the Infill concrete
construction phase.
Contact Coltman Technical Department at an early stage if any
The foregoing comments apply equally to other types of structures variation to this detail is to be considered.
with particular attention being required in the case of isolated piers
and walls or toothed walls where temporary means of support may FIXING
be required. Coltman installation crew are fully experienced and trained to
In all instances the temporary supports/propping should be handle and place precast concrete in accordance with the Code of
designed by a competent person and must be in position prior to the Practice for the Safe Installation of Precast Concrete Flooring and
installation of the precast concrete units. associated components[9].
Where precast concrete units are to be fixed within a steel frame Where erection is to be carried out by others than Coltman it is
building it is essential that sufficient structural steelwork, sheeting rails, the responsibility of the Principal Contractor to ensure that the fixing
purlins, bracings, etc., are omitted to allow for our standard crew is competent and capable of carrying out the work in accordance
fixing procedures. with the Code of Practice for the Safe Installation of Precast Concrete
Additional steel supports may be required where floor units are Flooring and associated components[9]. Copies of this code are
required to notch around columns, particularly around the perimeter of available upon request.
the building. Layout drawings are prepared for use during site erection and these
Any material placed between the strutural seating and the unit soffit should be followed carefully and accurately.
may result in a variation to our estimate.
GROUTING
STEEL SHELF ANGLE BEARING When fixing we include for filling the joints between units with Grade
Where precast concrete units are supported on steel shelf angles then C20/25 concrete, but not for screed or other finishes.
the outstanding leg of the angle should not be less than 150mm and
should project a minimum of 50mm beyond the top flange of the beam. MAKE UP
Each area of flooring is set out using standard units and may
incorporate reduced width units or insitu concrete strips to make up.
Any strips should be cast insitu during site erection, unless otherwise
specified. Stripping and disposal of formwork to be carried out by
others at no cost to Coltman.
Our estimate does not include for any insitu strips that may be
required adjacent to steel beams, or to the edge of any bay of units,
or for making good around pipes, stanchions or making up faces of
large openings.
CEILING FIXTURES
Recommended type of fixing for heavier loads. (Fire protection may
required by others)
Fixing Zone
Holes for large services, flues, soil and vent pipes and the like may be
formed during manufacture. Small holes may be drilled on site through Toggle or similar type fittings Tapcon or similar fixings may
the cores of the units. may be made into the areas be drilled into the area’s
Metal straps are used to trim larger duct openings subject to design directly below the cores. directly below the cores to
criteria and should be fire protected by the Principal Contractor. Expanding bolt type fixings are provide fixings for batton and
not recommended. plasterboard ceilings.
SCREED
A non-structural sand and cement or granolithic screed is normally laid
by the Principal Contractor over the floor (before plastering the soffit) 100 100
to provide a level surface for finishes. A minimum screed thickness of
40mm is suggested with due allowance being made for the camber of
units. It is strongly recommended that a light two-way reinforcing fabric 70
(steel mesh) is incorporated in the screed. Anti-crack reinforcement in
the screed should always be provided by the Principal Contractor over
supporting beams and walls.
Pre-stressed wire locations
SOFFIT
Soffits of Coltman units are suitable for the application of plaster 1. Shot fired fixings are not permitted
finishes. Small surface blemishes may be expected but the surface will 2. Service and ceiling loads must not exceed those shown on the slab
be free from large voids. Stopping off of air holes and rubbing down of general arrangement drawings
any casting bed marks are not included within our offer. 3. Fire protection may be required where a fixing penetrates the
The Principal Contractor is responsible for ascertaining the floor slab
suitability of our floor units, by inspection at our factory if an exposed 4. The adequacy of the fixing is the responsibility of others
soffit is required or if the soffit is to receive direct decoration.
The visual effect of differential camber as previously described
should be considered when an exposed soffit finish or direct
decoration is to be utilised.
The application of plaster should be carried out in accordance with
the recommendations of British Gypsum. We do not recommend direct
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FIRE RESISTANCE COMPOSITE
Coltman units are designed in accordance with BS EN 1992, Part1-2 Coltman units may be designed and constructed as composite slabs
and the UK NAD[2] to provide a load bearing, integrity and insulation with the addition of a structural cast insitu topping, containing a steel
fire resistance classes REI 60, REI 90 and RE 120 (i.e. 60, 90 and 120 mesh, typically 50 to 75mm in depth for hollow core units or up to
minutes fire resistance). The fire resistance may be enhanced further 125mm for solid units. Interface shear loops or dowels (typically 10
by the application of appropriate finishes. or 12mm diameter) may be required to be placed in the longitudinal
joints between units, projecting into the topping. Steel mesh, typically
SOUND INSULATION A142, is positioned at the mid-depth of the topping. The concrete
See Building Regulations Approved Document E [10]
and Robust Details topping should be placed in accordance with BS 8204 Parts 1 and
Part E, Resistance to the Passage of Sound[11]. 2[13]. A structural topping specification is available from our Technical
The thermal transmittance, RT value (m K/W) of the units, may be
2 o
Department upon request.
provided on request, and shall be according to BS EN ISO 6946[12].
Where the precast concrete units are forming a floor which is DISPROPORTIONATE COLLAPSE
separating individual dwellings, the following points should Requirements for disproportionate collapse must be specified by the
be considered: Project Engineer responsible for the overall design of the structure.
It is important that the project Architect ensures the precast floor Where structural ties are specified, they should be designed and
depth and average density is compatible with the intended floor and detailed by the Project Engineer. If the proposed ties are to be cast
ceiling finish, if full compliance with Building Regulations Part E[10] and or into details pre- formed within the precast units, the Project Engineer
Robust Details Ltd publication: Robust Details Part E, Resistance to the should check with Coltman that the proposed details are achievable.
Passage Of Sound[11] is to be achieved.
PRECAST CONCRETE STAIRCASES
TYPICAL END BEARING
Finish
Ceiling
Finish
Ceiling
7
Physical Appearance 4. BS EN 1991 Part 1-1:2002, Eurocode 1, General actions - densities,
Pre-stressed Floor Units: Grey solid or with longitudinal hollow cores self weight and imposed loads.
within depth of unit. 5. BS EN 1990:2002, Eurocode 0, Basis of Structural Design; and NA
Stair/General Precast Items: Grey solid units occasional protruding to BS EN 1990:2002, UK National Annex.
steel bearing cleats. 6. BS EN 1168:2005 +A3:2011, Precast concrete products - Hollow
core slabs.
Hazards 7. BS EN 206-1:2000, Concrete - Specification, performance,
Skin irritation or dermatitis unlikely when handling the product in its production and conformity.
solid form. Operatives should be aware of the abrasive nature of the 8. BS8500:1997, Structural use of concrete. Structural Use of
product. During cutting, drilling and other operations where dust is Concrete - Part 1: Code of practice for design and construction.
created there is a risk of inhaling dust containing silica compounds and 9. Code of Practice for the Safe Installation of Precast Concrete
steel filings, which if inhaled can lead to long term health hazards. The Flooring and Associated Components, Precast Flooring Federation,
airborne dust will irritate the eyes. Leicester, 2017.
10. Building Regulations, 2015, Resistance to sound: Approved
Area of Use Document E. Building regulation in England for the resistance to the
Precast concrete flooring, stair components and other general precast passage of sound and sound insulation.
concrete products for use in the construction industry. 11. Robust Details Part E, Resistance to the Passage of Sound, Robust
Details Ltd., Milton Keynes.
PPE/Precautions 12. BS EN ISO 6946:2007, Building components and building elements,
Gloves, suitable for handling abrasive material. Eye protection to Thermal resistance and thermal transmittance, Calculation method.
prevent dust or splinters getting into the eyes. Respiratory protection to 13. BS 8204-1:2003+A1:2009 Screeds, bases and insitu floorings.
be worn at all times when carrying out operations that generate dust. Concrete bases and cementitious levelling screeds to
Selection of respirator will depend upon proximity and concentration of receive floorings.
dust. Dust masks will normally be adequate unless working in 14. BS EN 13670:2009, Execution of concrete structures.
confined spaces. 15. NSCS-4:2010, National Structural Concrete Specification Edition 4,
CONSTRUCT, UK.
Spillage Requirements N/A
Storage Requirements N/A
Special First Aid N/A
GENERAL
The illustrations shown and details given in other parts of this brochure
also constitute part of the Standard Technical Specification. For further
details, please contact our Technical Department.
Our policy is one of continuous improvement, and we reserve the
right to change the specification without notice.
REFERENCES
Allowable clear span (m) for imposed live load (kN/m2) and floor usage
Self
Depth of weight
Type precast including Domestic/Residential/Offices Retail/Congregation Storage
unit (mm) infill
(kN/m2)
0.75 1.50 2.00 2.50 3.00 4.00 5.00 7.50 10.00 15.00
Solid K75 75 1.76 3.80 3.79 3.69 3.61 3.53 3.39 2.83 2.50 2.05 1.78
Solid L100 100 2.35 5.30 5.30 5.18 5.07 4.97 4.78 3.87 3.37 2.77 2.40
Solid Z150 150 3.53 7.69 7.47 7.34 7.13 6.90 6.49 5.87 5.11 4.20 3.66
Solid X200 200 4.71 9.66 9.43 9.28 9.14 8.88 8.41 7.69 6.85 5.64 4.91
Hollow Core A150 150 2.35 7.80 7.80 7.80 7.70 7.54 7.20 5.64 4.92 4.04 3.52
Hollow Core C200 200 2.94 10.30 10.16 9.96 9.76 9.58 9.26 7.43 6.48 5.33 4.64
Hollow Core E250 250 3.66 11.80 11.80 11.79 11.59 11.40 11.05 9.21 8.03 6.61 5.76
Data include 1.75 KN/m² for finishes
Allowable clear span (m) for imposed live load (kN/m2) and floor usage
Self weight
Depth including infill
Depth of
of and topping
Type topping Domestic/Residential/Offices Retail/Congregation Storage
precast (allowing for
(mm)
unit (mm) camber of
pcu)kN/m2)
0.75 1.50 2.00 2.50 3.00 4.00 5.00 7.50 10.00 15.00
75 75 3.67 3.80 3.80 3.80 3.80 3.80 3.80 3.80 3.80 3.79 3.43
Solid K75
75 100 4.29 3.80 3.80 3.80 3.80 3.80 3.80 3.80 3.80 3.80 3.56
100 75 4.29 5.30 5.30 5.30 5.30 5.30 5.30 5.30 5.10 4.57 4.10
Solid L100
100 100 4.91 5.30 5.30 5.30 5.30 5.30 5.30 5.30 5.12 4.90 4.53
150 75 5.45 7.80 7.62 7.48 7.35 7.23 7.00 6.79 6.35 5.96 5.36
Solid Z150
150 100 6.08 7.56 7.40 7.30 7.20 7.10 6.92 6.76 6.40 6.09 5.59
200 75 6.62 9.85 9.57 9.39 9.23 9.07 8.79 8.53 7.97 7.33 6.62
Solid X200
200 100 7.25 9.55 9.33 9.19 9.06 8.94 8.71 8.49 8.02 7.62 6.98
Hollow Core 150 50 3.72 7.80 7.80 7.80 7.80 7.80 7.63 6.87 6.32 5.37 4.68
A150 150 75 4.35 7.80 7.80 7.80 7.80 7.80 7.62 7.30 6.75 5.90 5.23
Hollow Core 150 50 4.29 7.80 7.80 7.80 7.80 7.80 7.56 6.92 6.38 5.51 4.80
High Density
D150 150 75 4.91 7.80 7.80 7.80 7.80 7.80 7.56 7.32 6.79 6.00 5.38
Hollow Core 200 50 4.33 10.30 10.30 10.28 10.13 9.99 9.58 8.55 7.89 6.71 5.85
C200 200 75 4.96 10.30 10.30 10.30 10.14 9.92 9.53 8.93 8.29 7.27 6.41
Hollow Core 250 50 5.03 11.80 11.80 11.80 11.80 11.73 11.32 10.14 9.39 8.06 7.03
E250 250 75 5.66 11.80 11.80 11.80 11.80 11.69 11.23 10.50 9.77 8.61 7.61
Data include 1.5 KN/m² for finishes above the topping and self weight of topping
NOTE: These tables are for guidance only. They do not allow for the effect of any service holes and consideration must be made for the effect of
camber, deflection, partitions or additional finishes / services. Tables are determined for 1 hour fire slabs design to Eurocode EC2, increased fire
rating and design to BS8110 can be provided by our Technicanl department on request.
9
Coltman Precast Concrete Limited.
London Road, Canwell,
Sutton Coldfield,
West Midlands B75 5SX UK
T: 01543 480482
E: [email protected]
W: coltman.co.uk