Lighter Flat Slab Structures

with BubbleDeck
CI/SfB
(23) Eq4
Part 1 February 2006
P r o d u c t
I n t r o d u c t i o n
Reinforcing mesh, top
Recycled plastic hollow Bubble void former
Reinforcing mesh, bottom cast into
optional 60mm concrete biscuit
Want to know more?
BubbleDeck Technical Manual
BubbleDeck Design Guide
Interactive CD ROM with
BubbleDeck slab calculator
are also available
upon request
Email: [email protected]
Tel: 01691 774242
Advantages
Design Freedom
Reduced
Dead Weight
Longer Spans
Green and
Sustainable
Fast
Construction
Wh a t i s t h e Bu bbl e De c k

S y s t e m?
T h e e n g i n e e r i n g s o l u t i o n t h a t r a d i c a l l y
i mp r o v e s b u i l d i n g d e s i g n a n d p e r f o r ma n c e
wh i l e r e d u c i n g t h e o v e r a l l c o s t .
BubbleDeck is a revolutionary method of virtually eliminating concrete from the middle of a floor slab not performing any
structural function, thereby dramatically reducing structural dead weight. BubbleDeck is based on a new patented technique
- the direct way of linking air and steel. Void formers in the middle of a flat slab eliminates 35% of a slabs self-weight
removing constraints of high dead loads and short spans.
Incorporation of recycled plastic bubbles as void formers permits 50% longer spans between
columns. Combination of this with a flat slab construction approach spanning in two
directions the slab is connected directly to insitu concrete columns without any beams -
produces a wide range of cost and construction benefits including:-
Design Freedom flexible layout easily adapts to irregular & curved plan layouts.
Reduced Dead Weight - 35% removed allowing smaller foundation sizes.
Longer spans between columns up to 50% further than traditional structures.
Downstand Beams eliminated quicker & cheaper erection of walls and services.
Load bearing walls eliminated facilitating MMC with lightweight building envelopes.
Reduced concrete usage 1 Kg recycled plastic replaces 100 Kg of concrete.
Environmentally Green and Sustainable reduced energy & carbon emissions.
The overall floor area is divided down into a series of planned individual elements, either 3 or
2.4 metres wide dependant upon site access, which are manufactured off-site using MMC
techniques. These elements comprise the top and bottom reinforcement mesh, sized to suit
the specific project, joined together with vertical lattice girders with the bubble void formers
trapped between the top and bottom mesh reinforcement to fix their optimum position. This
is termed a bubble-reinforcement sandwich which is then cast into bottom layer of 60mm
pre-cast concrete, encasing the bottom mesh reinforcement, to provide permanent formwork
within part of the overall finished slab depth.
On site the individual elements are then stitched together with loose reinforcement simply
laid centrally across the joints between elements. Splice bars are inserted loose above the pre-cast concrete layer between
the bubbles and purpose made mesh sheets tied across the top reinforcement mesh to join the elements together. After the
site finishing concrete is poured and cured this technique provides structural continuity across the whole floor slab the
joints between elements are then redundant without any structural effect to create a seamless floor slab.
BubbleDeck has proved to be highly successful in Europe since its invention ten years ago. In Denmark and Holland over 1
million square metres of floors have been constructed in the last seven years using the BubbleDeck system in all types of
multi-storey buildings.
B u b b l e D e c k

i s a s i mp l e s o l u t i o n t h a t e l i mi n a t e s n o n - wo r k i n g
d e a d l o a d i n f l o o r s wh i l e f u l l y r e t a i n i n g s t r e n g t h .
BubbleDecks
height saving
allowed 2
floors to be
added
during
construction
Temporary Support Propping on parallel beams at 1.8
to 2.4 metre spacing
Placing Elements Semi pre-cast elements mechanically
lifted into position
Joint Reinforcement Insert loose bottom splice bars
and tie top mesh across joints between elements
Shear Reinforcement Insert loose bars across columns
Edge reinforcement Insert edge bars and hairpins
around slab perimeter
Perimeter shuttering Fix shuttering to bottom pre-cast
concrete layer & tie to top mesh reinforcement
Soffite shuttering Prop plywood across tolerance joints
between element bays and between elements & columns
Preparation Seal joints between elements, clean and
moisten bottom pre-cast concrete layer
Concreting Pour, vibrate and float 10mm max.
aggregate in-situ concrete
Temporary works Remove, typically after 8 10 days,
according to specific site advice.
Finishing no further work required, the slab is complete
unless requirement for exposed soffite
BubbleDeck

is a two-way
spanning hollow
deck in which
recycled plastic
bubbles serve the
purpose of
eliminating
non-structural
concrete
S i mpl e s i t e i n s t a l l a t i on
(DECK TYPE A)
T h e a p p r o p r i a t e B u b b l e D e c k s l a b v e r s i o n i s b e s p o k e e n g i n e e r e d t o s u i t b u i l d i n g
c o n f i g u r a t i o n , s p a n l e n g t h b e t we e n s u p p o r t s , a p p l i e d l o a d i n g s a n d v e r t i c a l
a l i g n me n t o f s u p p o r t s . I n d i c a t i v e s p a n s , b a s e d o n o u r s t a n d a r d 2 0 mm c o n c r e t e
c o v e r t o b o t t o m r e i n f o r c e me n t me s h p r o v i d i n g 1 h o u r f i r e r e s i s t a n c e , a r e g i v e n
a s a g u i d e t o wh a t c a n b e a c h i e v e d .
BubbleDeck can be supplied in 3 types of
manufactured elements:
Type A Filigree Elements, where the bottom of the
bubble-reinforcement sandwich includes a 60mm thick pre-cast
concrete layer acting as permanent formwork within part of the
finished slab depth replacing the need for soffite shuttering. The
elements are placed on temporary propping, loose joint, shear &
edge reinforcement added, perimeter and tolerance joints shuttered and then the
remaining slab depth concreted.
Most commonly specified being suitable for the majority of new-build projects. Requires fixed or
mobile crane to lift into position due to weight of manufactured
elements as delivered to site.
Type B - Reinforcement Modules
comprising pre-fabricated bubble-
reinforcement sandwich elements.
The modules are placed on
traditional site formwork, loose joint,
shear & edge reinforcement added and then
concreted in 2 stages to the full slab depth.
Suitable for suspended ground floor slabs and alteration /
refurbishment projects, particularly where site access is
extremely restricted. Can be manually lifted into position.
Type C Finished Planks, delivered to the building site as complete
pre-cast factory made slab elements with the full concrete thickness. These
span in one direction only and require the inclusion of supporting beams or walls
within the structure.
Version Slab Bubbles Span Cantilever Span Completed Site Concrete
Thickness (Multiple bays) Maximum Length (Single bays) Slab Mass Quantity
mm mm metres metres metres Kg/m
2
m
3
/m
2
BD230 230 180 5 8.1 2.2 5 6.3 370 0.11
BD280 280 225 7 10.1 2.7 6 7.8 460 0.14
BD340 340 270 9 12.5 3.3 7 9.6 550 0.18
BD390 390 315 10 14.4 3.8 9 11.1 640 0.21
BD450 450 360 11 16.7 4.5 10 12.5 730 0.25
Bu bbl e De c k

s l a b v e r s i ons
E l e me n t t y p e s
These are only a few of many projects with
BubbleDeck floors.
For many others and new projects see our
WEB site: www. BubbleDeck-UK.com
Le Coie Housing
The largest BubbleDeck structure so far erected in Great Britain was
completed 6 weeks ahead of programme. The structure comprises 7,800m
2
of
BubbleDeck floor slabs between 3 and 6 stories high supported on in-situ
reinforced concrete columns. Over 400,000 of savings were realised as a
direct result of incorporating BubbleDeck into this project, amounting to a
3% saving off the TOTAL project cost.
The Main Contractor subsequently found the BubbleDeck system
benefits continue throughout the whole construction process with
faster and cheaper erection of external & internal walls plus fast
and easy installation of services below the flat soffites.
Chris Dunne, Project Architect, commented:- Our original
solution for Le Coie was a steel frame with Bison floor planks &
structural concrete topping in the 5 to 6 storey areas, with load
bearing blockwork supporting a composite metal deck in the lower sections.
The BubbleDeck technique not only saved a considerable sum but simplified
the buildings structure, removing my co-ordination headache of getting
services around or through beams required with a traditional solution. We
were also able to eliminate all load bearing walls down the middle of each
flat, required to support the short spans of composite metal decks, giving
more internal space and fantastic flexibility.
I will definitely consider BubbleDeck
for use on my future projects.
S e l e c t e d Bu bbl e De c k

pr oj e c t s
Media City
This 32.000 m
2
building was
constructed with great
transparency, revealing a huge
open atrium. This atrium is the fulcrum and heart of the
building. The spaces are formed in soft, organic
shapes that allow light to spill onto every
single workplace in the building.
To achieve these wide, open, internal
spaces a BubbleDeck structure of
post tensioned 390mm deep
floor plates, achieving 16 metre
spans between columns was
selected - dramatically reducing
structure dead weight and
enabling long spans. The flexibility
of BubbleDeck also facilitated
construction of the soft flowing, organic
shapes forming the floors around the
central atrium.
Millennium Tower
Originally designed with hollow core planks, late in the
design stage it was determined that BubbleDeck would
realise considerable cost and time savings. Adopting
BubbleDeck also reduced the structural floor zone
depth due to omission of beams, lowering the
overall buildings height.
Another consideration was the lack of storage
space on the building site which is located close to
major arterial roads and streets. The floors were on
average erected, cast and completed in half the
time - 4 days instead of 8 days it would have
taken to construct with hollow core planks. Half
way through constructing the structure it was
decided to add another 2 floors which was made
possible within the overall height of the original building
due to BubbleDeck reducing structural floor depth.
City Hall and Offices
BubbleDecks superior cantilevering ability
achieved 3.3 metre cantilevers from a
280mm deep slab with 7.5 metre internal
spans between columns. The building
provides a City Hall and financial centre
for Danske Bank containing 4,000 m
2
floor area. The slender slab without any
beams secures maximum light from the
facades, which is enhanced by an internal
atrium. This project won Building of the
Year 2004 award for offices and
commercial buildings.
BubbleDeck

is the ONLY
light flat slab
system officially
certified for U.K. use
having been granted
Dutch Technical
Certificate CUR 86,
recognised in the
Building Regulations
as equivalent to
an Agrment
Certificate.
A BubbleDeck slab has the same applied load carrying capacity with
only 50% of the concrete required for a solid concrete slab, or with
the same slab thickness has twice the load carrying capacity using
65% of the concrete required by a solid concrete slab.
Schematic design basic principle
As a general guide for project scoping purposes the maximum achievable
spans for each BubbleDeck slab depth is usually determined by deflection
limitations. This criteria is controlled by the ratio of span / effective depth
(L/d) stipulated in BS8110 or EC2 and modified by applying a factor of 1.5,
permitted to take account of BubbleDecks dramatically lower dead weight
than traditional solid flat slabs.
L/d 30 for simply supported floors (single spans)
L/d 39 for continuously supported floors (multiple spans)
L/d 10.5 for cantilevers.
The effective depth of a BubbleDeck slab is the overall depth less standard
20mm concrete cover (achieving 1 hour fire resistance) from the bottom
mesh reinforcement to underside of the slab. Where 90 minute fire
resistance is required deduct 25mm off overall slab depth, or for 120
minute fire resistance deduct 30mm off overall slab depth. In the case of
spanning onto columns without beams use the longest dimensions
between columns, where the slab will span onto walls or beams use the
shortest span dimension.
As an example for BD280 slab version, with 1 hour fire
resistance, d is 260mm so 39xd indicates a maximum 10.14
metre continuously supported (multiple bay) span; 30xd
indicates a maximum 7.8 metre simply supported (single bay)
span, and 10.5xd indicates a maximum 2.73 metre cantilever is
potentially feasible. This basic principle has been verified for
dead loadings up to 4.5 Kn/m2 following full calculations on
many projects as a generally reliable indication. We can refine
this estimation method by full calculation and we would be
pleased to give you advice on a specific project.
Post tensioning
When mega spans are required
(above 15 metres) we can provide
a PostTensioned (PT)
BubbleDeck solution. The above
deflection limits can be
increased by up to 30% more
with post-tensioned
BubbleDeck slabs.
S ol i d de c k c ompa r i s on
Carrying capacity
Slab Dead load
Relative values in % of solid slab
Carrying capacity 25 50 25
Dead load 75 50 40
Dead load / Carrying capacity 3:1 1:1 1.5:1
Absolute values in % of solid slab
Carrying capacity 100 200 100
Slab dead load 100 65 50
Utility value of 300 200
concrete increased
A BubbleDeck has twice the capacity with 65% concrete and the
same capacity with 50% concrete compared to a
solid slab.
Solid slab BubbleDeck

BubbleDeck

same thickness same capacity

floors make a
substantial
contribution to
reducing carbon
emissions arising
from construction.
By virtually eliminating concrete in the middle of a slab BubbleDeck
makes a significant contribution to reducing environmental impact.
Guidance from the ODPM requires the direct environmental effects of buildings
to be considered, including usage of natural resources and emissions resulting
from construction. Not only is concrete usage reduced by up to 50% within a
buildings structure but knock-on benefits can be realised through reduced
foundation sizes. BubbleDeck can make a big contribution towards achieving
BREEAM targets.
Every 5,000 m
2
of BubbleDeck floor slab can save:-
1,000 m
3
site concrete.
166 ready mix lorry trips.
1,798 Tonnes of foundation loads or 19 less piles.
1,745 GJ energy used in concrete production & haulage.
278 Tonnes of CO
2
green house gas emissions.
Data based on typical 4,500 m
2
Office Building with 7.5 x 7.5 metre multiple
spans between in-situ or precast concrete columns.
Assumptions:
1) Lightweight external envelope (curtain walling or equal).
2) Typical office live load 2.5 kN/m
2
+ 1.5 kN/m
2
for lightweight partitions, computer floor, finishes & services.
3) Overall stability braced by stair / lift core shear walls in both cases.
4) Energy from materials transport cement 50 miles, aggregate 10 miles (to ready mix plant) and concrete 5
miles (to site).
BubbleDeck structures are also Sustainable with the system allowing frame re-use for future
purposes. The envelope and all internal work can be removed from a BubbleDeck building
and the original frame simply refitted for a new purpose. The two way spanning nature of
BubbleDeck slabs allows any internal layout to be reconfigured to new uses within the
original design load parameters.
Slab Site Concrete Site Concrete Total Slab Embodied CO
2
Depth Volume Quantity Dead Load Energy Emissions
(mm) m
3
/ m
2
m
3
(Tonnes) (Giga Joules) (Tonnes)
Solid Slab 310 0.31 1,395 3,376 3,278 522
BubbleDeck 230 0.11 495 1,758 1,707 272
BD SAVES 80 0.20 900 1,618 1,571 250
Cons i de r t h e be n e f i t s
Gr e e n c r e de n t i a l s
We provide two alternative Service Options covering provision of design, detailing, drawing production,
element manuifacture and supply of all components to site completely ready for construction:-
Option A Full Floor Design by BubbleDeck (BD)
1. Initial Enquiry & consultation / advice / meetings (FOC).
2. Schematic design of Deck Type and Report (FOC).
3. Quotation for Detail Design, Drawing Production, Element Manufacture & Supply, based on estimated amount
of reinforcement required per m
2
(FOC).
4. Acceptance of Quotation and order / payment for Detail Design
and Drawing Production.
5. Detail Design of BubbleDeck floors by BD, Detail Design of all
other elements (foundations, columns, external envelope &
roof) by Clients Agents or others.
6. Submission of Detail Design to Clients Agents & Building
Control for approval.
7. Production of manufacture and site installation
drawings by BD, including pre-cast elements ready
for manufacture and all required loose
reinforcement.
8. Submission of Production Drawings to Clients
Agents for approval.
9. Adjusted Quotation, based on final amount of
reinforcement per m
2
.
10. Acceptance of Adjusted Quotation & Order for
Element / Reinforcement manufacture,
production & supply to site.
11. Advice to Clients Main Contractor & Agents on Site Installation & Construction.
12. Manufacture of Elements & supply to Site.
13. Advice to Main Contractor during Site Installation & Construction.
14. Site Inspections of Erection, Loose Reinforcement and signoff by BD prior to final
concrete pour.
Option A under-written by BDs 2M Professional Indemnity Policy and Product Guarantee.
Option B Structure & BubbleDeck Floor Design by Clients Agents
1. Initial Enquiry & consultation / advice / meetings (FOC).
2. Advice on Deck Type, element layout and design (FOC).
3. Quotation for Element Production & Supply, based on Clients Agents estimated reinforcement per m
2
(FOC).
4. Detail Design of BubbleDeck floors and all other elements (foundations, columns, external envelope & roof)
by Clients Agents or others.
5. Submission of Detail Design to BD for review & comment.
6. Production of manufacturing drawings by BD, production of site installation drawings by Clients Agents,
including all required loose reinforcement.
7. Submission of site installation drawings to BD for review & comment.
8. Adjusted Quotation, based on final amount of reinforcement per m
2
.
9. Acceptance of Adjusted Quotation & Order for Element / Reinforcement manufacture, production
& supply to site.
10. Advice to Clients Main Contractor & Agents on Site Installation & Construction.
11. Manufacture of Elements & supply to Site.
12. Site Inspections and sign off by Clients Agents prior to final concrete pour.
Option B under-written by BDs Product Guarantee.
The
BubbleDeck

system is based
upon the patented
integration
technique - the
direct way of
linking air and
steel.
WEB: www. Bubbl eDeck- UK. com
B U B B L E D E C K
S e r v i c e opt i on s
Contact Name:
Company:
Address:
Town: Post Code:
Tel No:
Fax No:
Email: Web Site: www.
Project Name: Project Town:
Please Contact Me/Us [ ]
I would like advice on a specific project [ ]
Please send me your full Data Pack [ ]
Please call to arrange a CPD Presentation [ ]
Please send me your Technical Manual [ ]
Please send me your Design Manual [ ]
Please send me your BubbleDeck Interactive CD-ROM [ ]
Includes: Slab Calculator, Technical Manual. Design Manual and Video.
Other: [Please write your requirements below]
This page is designed to be photocopied. Please complete your details on the form below,
then either use our FREEP0ST service (Stamp not required) by putting the form in a
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BubbleDeck UK
4 Firs Close
St Martins
OSWESTRY
SY11 3LT
Email : [email protected] Tel: 01691 774242
Please complete the form below, thank you:
UK Office
4 Firs Close, Ellesmere Road,
St Martins, Nr Oswestry,
Shropshire, SY11 3LT
Telephone: +44 (0)1691 774242
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E-Mail: [email protected]
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White Lodge, Wellington Road,
St. Saviour, JERSEY, C.I., JE2 7TE
Telephone: +44 (0)1534 725402
Facsimile: +44 (0)1534 739115
E-Mail: [email protected]
www.BubbleDeck-UK.com
C o n t a c t d e t a i l s