Hanson Building Products

Omnia and Cobiax

FLOORING SYSTEMS

Omnia and Cobiax

FLOORING SYSTEMS
Omnia System overview Benefits Construction details Bearing details Temporary support 4 5 6-7 8 9

The Omnia system from Hanson Building Products is a pre-cast floor panel that provides the direct equivalent of an in-situ slab but provides the facility to combine pre-cast and in-situ concrete. Cobiaxdeck is a development that combines the advantages of Omnia wideslab flooring with Cobiax void forming technology to create a long-spanning, biaxial deck system without beams.

Cobiaxdeck System overview Benefits Design and construction Nationwide service 10 11 12-13 14

The Omnia flooring system is equally suitable for steel and concrete framed structures and masonry buildings

Omnia
All Omnia products incorporate the triangular Omnia lattice girder that is attached to a lower layer of reinforcement before wet concrete is poured to create the Omnia panel.

Cobiaxdeck
The system displaces non-working deadload through the incorporation of hollow spheres between the upper and lower layers of reinforcement.

Omnia
SYSTEM OVERVIEW
The Omnia system provides major benefits over alternatives when used as fully participating permanent formwork.

The basic Omnia product is the Omnidec panel which incorporates the distinctive triangular Omnia lattice girder. The Omnia girder is attached to an individually designed lower layer of reinforcement and wet concrete is then poured to create the Omnidec panel. The triangular lattice girder provides the panel with its stiffness during the temporary condition and ensures a bond between the pre-cast and insitu concrete. It also serves to provide support for the upper mesh reinforcement (supplied by the contractor) and is used as the anchor point when lifting panels into position on site. Each Omnidec panel is designed and manufactured to order, each with its own specific shape and structural capacity. Unlike pre-stressed concrete flooring systems, Omnidec panels are wetcast into pre-formed shapes that butt joint together on site.

Omnia benefits
Structural strengths
Can be designed to withstand most loading conditions Can be designed to cope with rigorous exposure conditions Can be designed to protect against fire for long periods Each panel is designed to suit its specific location Progressive collapse conditions economically provided

Where Omnia can be used

The Omnia system is suitable for use on steel and concrete framed structures as well as masonry structures

Fast installation
Large panels mean less lifts Panels are lifted into place without the need for slings Large areas of floor can be erected in a short space of time Commercial and Industrial
Hotels, factories, warehouses and retail structures

Design flexibility
Irregular and complex shapes manufactured to suit contract requirements Service holes and cut-outs accurately formed during manufacture Smooth flat soffit can take direct decoration and top surface can be power-floated reducing depth of overall floor zone Exposed soffit can be used to provide thermal-mass Single or two-way spanning design possible Public buildings
Hospitals, schools, fire and police stations, prisons.

Competitively priced
System costs compare favourably with those of traditional formwork Decorated soffit can be left exposed, negating suspended ceilings In-situ topping can be power-floated negating extra finishing screed

Residential
Low and high rise apartment blocks, student accommodation blocks, hostels etc

Quality service
Factory-manufactured to consistent quality standards Complies with all relevant standards

Car Parks
Single level or multi-storey complete with ramps

Omnia
CONSTRUCTION DETAILS

Dimensions Each Omnia panel is designed and manufactured to suit its location. Sizes are, therefore, infinitely variable. Panels are cast onto steel beds accurately set and split into individual panel lengths. The beds are 2.40m wide which determines the maximum width of panel. However, every contract may have a proportion of non-standard widths. Tolerance For standard 2.40m wide panels, the width is controlled and the dimension is virtually exact. For non-standard panel widths with formed edges and at the bearing ends, the panels are cast within the tolerances allowed, usually to 10mm. Panel depths The precast concrete panels can be provided at 50, 60 and 75mm as required by the structures specific fire and exposure conditions. Constituents The Omnia lattice girders are cast into the precast concrete panel at centres from 600mm down to 120mm to provide stability in the temporary condition.

By increasing the amount, size and height of the lattice girders, the panels can be made to span great lengths without temporary propping. Each panel is designed to cope with its specific loading condition and is reinforced with bars from 8 to 16mm placed at 50 to 300mm centres. With over 11 million permutations of lattice girder, steel reinforcement and concrete available, it is possible to cope with the most onerous of loading and exposure requirements. Maximum Spans The maximum span of any Omnia panel is a result of a number of factors including the span/depth ratio, temporary condition requirements, preferred method of propping (if allowed). Spans of up to 14m are possible, subject to satisfying deflection criteria, but the normal maximum panel length is approx. 11.0m. Hansons Omnia design team can provide designs at tender stage to determine the most cost-effective span/depth ratio.

Appearance and shape All Omnia panels are cast to length on steel moulds. Long edges are formed with a chamfer to the underside so that, when placed adjacent to each other, the effect of a birds mouth joint can be seen at regular intervals on the soffit. Holes for services etc. can be neatly cast into the panels during manufacture. Special side forms are introduced at casting stage enabling panels to be produced to suit the shape of the building and it is, therefore, possible to cater for structures with complex floor layouts. Ends of panels are formed with square forms to provide a suitable surface at the lines of bearing. Soffit quality The steel moulds used for casting ensure a high quality finish suitable for direct decoration with paint or textured finish. As no pre-stressing wires are used in the manufacture of the Omnia panels, the soffit is also flat with no camber.

All products in the Omnia system utilise the Omnia lattice girder, reinforcing steel and dense concrete. Omnidec is the basis for the product range with variations and accessories as shown below:-

Omnidec
A precast concrete panel reinforced with steel bars and incorporating the Omnia lattice girder to provide strength in the temporary condition (i.e. during erection). Reinforced in-situ concrete is placed over the panel to create a solid concrete homogeneous slab. Typically used for spans from 1.0m up to 6.50m, providing slab depths from 135mm to 250mm, at which point Omnicore should be considered to reduce overall dead weight on the structure. However, on civil engineering structures, slab depths occasionally exceed 750mm. Slabs can also be cast using lightweight aggregate to reduce self-weight.

The Omnicore variation

Similar to Omnidec except that in between the lattice girders, lengths of polystyrene are cast into the top of the precast section to reduce the amount of in-situ required and therefore the weight of the completed slab. Typically used for spans of 6.00m and over, providing slab depths from 250mm upwards. Reductions of 20 - 45% in slab weight can be expected.

Accessories
Omniedge
Omniedge is a galvanised steel edge shutter cast into the edges of the precast panels at the factory. Generally it is used on masonry structures and is a competitive method of providing an edge shutter to the completed slab.

Omnia
BEARING DETAILS
Omnia panels are suitable for use on concrete and steel framed structures and on masonry buildings.

Bearing on steelwork

Panels require a nominal bearing of 55mm.

Panels bearing at differential levels may require a compressible bitumenised strip to prevent point bearing and excessive grout loss.

Shelf angles must be of such a length as to allow the end of the panel to pass the top flange during placing, and be set at a height that will allow continuity.

Bearing on in-situ concrete

Support panels on the formwork and cast a fully homogeneous slab. The OMNIA preferred option.

When supported on half-cast beams, links must be so arranged to allow 65mm nominal bearing.

Where less than 65mm bearing is available, a suitable temporary prop must be in place before placing the panel and left in place until the in-situ portion has reached working strength.

Bearing on masonry

Panels are usually detailed to take the full bearing of the internal skin of masonry, allowing the use of Omniedge edge formwork (see page 7).

Two OMNIA panels can be supported on 140mm wide load bearing blockwork with a 20mm gap between.

Where less than 60mm bearing is available eg. on 100mm walls, temporary props should be in place prior to placing the panels.

Construction
TEMPORARY SUPPORT
The greater the stiffness of the panel, the greater the distance it will span without propping. The stiffness is as a result of the Moment of Inertia created by the lattice girder. The value of the Moment of Inertia is a result of a combination of lattice height, lattice top bar diameter and the number of lattice girders cast into the panels. Spans up to 4.0m regardless of slab depth will generally be designed to be erected without props. Depending on the depth of the slab, spans of over 6m can be designed to be erected without propping and spans over 7m can be designed to be erected post-propped (see below). Please check with Hanson for maximum spans using Omnicore, as the introduction of the polystyrene limits the ability of the panel to span with reduced propping.

Unpropped
Overall slab depth Maximum unpropped span

150mm 175mm 200mm

3.95m 4.40m 4.85m 5.40m 6.10m

No props are required, except for localised supports around openings etc. These will be identified on the Omnia layout drawings.

225mm 250mm

Post-propped
Overall slab depth Maximum post-propped span

Continuous head timber Prop One row of props placed mid-span

150mm 175mm 200mm 225mm

5.80m 6.80m 7.00m 7.20m 7.50m

Panels are self-supporting, but will require one row of props placed mid-span prior to placing materials, particularly the in-situ concrete.

250mm

Propped
Props are typically spaced at 2.50m centres, although these centres can be extended to suit the contractors requirements. Examples are spans in the 7m 11m range. OMNIA panels can also be designed to cope with the loads transferred from temporary props, thereby eliminating the need for back-propping on lower floors.
2.50m Max Panel lowered onto supports

Temporary props shall remain in position in accordance with the requirements of the relevant code of practice, and whilst their

spacing will be shown on the Omnia panel layout drawings, the actual design of the props will be responsibility of others.

Cobiaxdeck
SYSTEM OVERVIEW
Cobiaxdeck combines the established advantages of the Omnia system with spherical void forming technology to enable the construction of light weight, biaxial floor slabs with column grids ranging from 6m up to 18m without beams. The resultant overall slab depth will be determined by the arrangement and spacing of the columns as well as the ultimate loading. The combination of these technologies allows the construction of buildings with wide open spaces, providing for greater flexibility with internal design. The absence of beams also means a reduction in the overall floor zone which, in some instances, can allow space for the construction of an additional floor. The use of void forming technology reduces the volume of concrete in the floor slab by displacing non-working deadload. The reduced weight can impact on the design and reduce the cost of foundations and the system is ideal for use where ground conditions are poor or piling is required.

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Cobiaxdeck benefits
Biaxial design
No need for support beams Reduced structural zone Resource effective

Where Cobiaxdeck can be used

Suitable for all types of buildings but is ideal for larger scale projects including:

Fewer columns
Wide open spaces Greater design flexibility

Reduced costs
Faster build Reduced in-situ concrete
Shopping centres and supermarkets

Foundations
Lighter weight slabs means reduced costs for foundations Ideal for poor ground conditions or piling

Thermal performance
Design allows thermal mass to be exploited Lower heating/cooling costs

Office complexes and high-rise commercial buildings

Quality service
Factory produced quality Complies with all relevant standards
Schools and universities Hospitals Hotels Apartment blocks Industrial buildings Multi-storey car parks

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Cobiaxdeck
DESIGN & CONSTRUCTION

Conventional construction

Cobiaxdeck construction
Additional Space

Structural principles
Cobiaxdeck provides the potential for savings on materials, floor depth, slab weight, foundations and build-time if incorporated at the design stage of the contract. The Cobiax system of biaxial design in conjunction with the void forming system allows for a considerable reduction in the volume and weight of the slab without compromising this ability to maintain biaxial strength. The Cobiaxdeck system provides a very cost-effective alternative to achieve the required deflection criteria in long span applications.

Less excavation
Hollow spheres, manufactured from recycled polyethylene, are used as void formers. They are held in place, relative to the soffit and to each other, in lightweight steel cages.

Absence of beams in the Cobiaxdeck structure offers the potential for an additional floor (or floors).

Weight savings impact on floor slabs, vertical elements and foundation design, effectively reducing costs.

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The utilisation of the spheres provides weight saving of between 20-30% compared to an equivalent solid concrete slab. The extremely efficient biaxial design can also enable savings to be made on the weight of reinforcement required for the ultimate loads on the floor slab, as well as the size of columns and foundations saving up to 50% structural concrete.

The Dry-Method is the name given to the system where the precast panel is sent to site for placing without the Ball and Cage matrix attached. Only one layer of reinforcement is included in the precast panel.

Design
Cobiaxdeck is a solutions driven system and Hansons engineering team work with the client throughout each project to maximise the benefits and achieve an ideal solution. Hanson provide a full design service including all aspects of the biaxial construction, panel and loose reinforcement layout drawings for all 3 options.

Cobiaxdeck options
The Wet-Method is the name given to the system where the ball and cage matrices are fully bonded to the reinforced precast concrete at the factory. The precast panels include 2 layers of reinforcement.
Dry-Method

Soffit quality
The 2nd layer of bottom steel and the shear connector bars are laid into position on top of the precast panel. The Ball and Cage assemblies are sent to site separately and are placed in position. The top steel is then placed and tied down to the lattice girder to prevent floating. If the Cobiaxdeck option includes a precast Omnia element, this is cast on smooth flat steel casting beds giving a first class soffit ready for direct decoration.

Thermal mass
The thermal mass in a Cobiaxdeck slab can significantly reduce the energy requirement of the building once in use. This can be achieved passively, through solar gain and night cooling, or actively through the use of fluid circulation where reduction figures of up to 66% of the energy needed to heat and cool the building have been achieved.

The In Situ-Method is the name given to the system where the voided biaxial slab is created on traditional formwork with no precast concrete involved.
Wet-Method

The panels are placed onto prepared falsework, splice bars are threaded into place and shear connectors laced around the columns to pre-set shear ladders already cast into the panels. The top layers of reinforcement are then placed across the whole of the assembly before concreting.

Sustainability
The void forming technology and the absence of beams in the structure, combined with the reduction in the number of support columns required, reduces the volume of the concrete used in the building effectively reducing the CO2 omissions produced during the manufacturing process.

In Situ-Method

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Nationwide
SERVICE

The Floors and Precast Division of Hanson Building Products operates from various plants located throughout the UK.
A specialist design and manufacturing facility for Omnia systems is located at Somercotes, Derbyshire. Standards All products are manufactured in accordance with relevant British/ European/Trade Association Standards. All Hanson Building Products sites are quality assured to BS EN ISO9001:2000 We operate environmental management systems at all our production sites in accordance with the methodology set out in the BS EN ISO14001:2004. All products are manufactured in accordance with BES 6001 - the Framework Standard for Responsible Sourcing of Construction Products. Other precast concrete products Jetfloor Beam and Block Staircases Hollowcore Bridgedeck Culverts Bespoke solutions For Omnia and Cobiax solutions please contact us at: Hanson Building Products Birchwood Way Cotes Park Industrial Estate Somercotes Derbyshire DE55 4NH Tel: 08706 097094 Fax: 01773 603134 Email: [email protected]

Hoveringham

Derby

Hanson Building Products Floors and precast locations

Omnia production

Somercotes

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Our companies and products

Hanson UK is split into three business lines Hanson Quarry Products, Hanson Cement and Hanson Building Products. We also offer a range of contracting services. For detailed information on all areas of Hanson and our products visit: www.hanson.com/uk

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UKAS

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Hanson Building Products Hanson House 14 Castle Hill Maidenhead SL6 4JJ Website: www.hanson.com/uk

Floors and Precast Division

0870 6097094

Hanson - A global business

Hanson is one of the world's largest suppliers of heavy building materials to the construction industry. We produce aggregates (crushed rock, sand and gravel), ready-mixed and precast concrete, asphalt and cement-related materials and a range of building products including concrete pipes, concrete pavers, tiles and clay bricks We are part of the HeidelbergCement Group, which employs 70,000 people across five continents, has leading positions in concrete and heavy building products and is the global leader in aggregates. Hanson Building Products is the UKs largest brick and aircrete block producer. We also produce aggregate blocks, bagged aggregate and cement products, renders, pavers, pre cast floors and stairs, SUD systems and prefabricated building systems. The division incorporates London Brick, Thermalite, Red Bank, Cradley, Formpave and Structherm.

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OM 02 | Dec 2010

Email: [email protected] Web: www.hanson.com/uk/sustainability