Cl/SfB (23) E f 2 BRE CERTIFICATION LIMITED

CERTIFICATE NUMBER 152/09

ISSUED: NOVEMBER 2009 (Change of address January 2011)

CERTIFICATE OF ASSESSMENT PRODUCT Cobiax Concrete Flooring System SUPPLIED BY Hanson Building Products Ltd Birchwood Way Cotes Park Industrial Estate Somercotes Derbyshire DE55 4NH Tel: 01773 602 432 Fax: 01773 603 134 Email: uksales@hanson.biz Web: www.hanson.co.uk SUMMARY Cobiax Concrete Flooring System (Cobiax System) is used for the construction of voided suspended concrete floor slabs in buildings. The system (see Figure 1) comprises a steel reinforced pre-cast concrete biscuit with a steel wire cage containing plastic balls cast into its upper surface. Additional steel reinforcement is site fixed to the top of the cages and concrete poured in-situ. The plastic balls are maintained in position by the cage and form voids in the poured concrete. The voids formed by the Cobiax System reduce the volume of concrete from that required for a solid slab of the same thickness, thus saving both weight and materials. The product is used to produce a range of sizes and thicknesses of slab designed in accordance with BS 8110-1:1997 Structural use of concrete. Code of practice for design and construction. The characteristics of the product and its method of application have been reviewed with respect to the current Building Regulations, British and European Standards and other publications in the United Kingdom and Republic of Ireland in October 2009. The assessment is described in the following pages which form integral parts of this certificate and which should be read in its entirety. CONDITIONS OF USE 0.1 A structural engineer competent in the design of reinforced concrete structures shall

undertake the design, and oversight of, the installation of the floor and its temporary and permanent supporting structures.

0.2 Design dead and imposed loads shall be determined using BS 6399: Part 1 Loading

for buildings. Code of practice for dead and imposed loads

0.3 Floor slabs shall be individually designed for each application as two-way spanning reinforced concrete slabs in accordance with the requirements of BS 8110-1.

0.4 The performance of the system depends on correct installation. Cobiax System shall be installed strictly in accordance with the certificate holder’s installation instructions and the requirements of this certificate. The quality of installation achieved on site is not covered by this certificate. It is therefore recommended that the quality of installation and workmanship is subject to appropriate checks by a competent person for each installation.

STATEMENT Cobiax Concrete Flooring System is satisfactory for use within the stated conditions provided that it is used in accordance with the certificate holder's instructions and the requirements of this certificate.

CONFIRMATION For and on behalf of BRE Certification Director Date: 29 March 2011

1. TECHNICAL SPECIFICATION 1.1 Description of product and method of application

1.1.1 Cobiax System is used for the construction of voided suspended concrete floor slabs

in buildings. The system comprises a steel reinforced pre-cast concrete biscuit with a steel wire cage containing plastic balls cast into its upper surface. Steel reinforcement cast into the biscuits is a combination of high yield steel reinforcing bars and welded triangular lattice sections which provide a shear key between the pre-cast and the in-situ concrete. Additional steel reinforcement is site fixed to the top of the steel wire cages prior to placing concrete.

Table 1 Product dimensions Maximum ball diameter 450mm Minimum ball diameter 180mm Thickness of pre-cast concrete biscuit

50 to 70mm

1.1.2 The product is used to produce a range of sizes and thicknesses of slab designed in

accordance with BS 8110-1:1997 Structural use of concrete. Code of practice for design and construction. At the manufacturing plant a steel cage incorporating the plastic balls is cast into a concrete biscuit dimensioned and reinforced in accordance with structural design for each application.

1.1.3 The pre-cast units are transported to site, lifted into position and provided with

temporary support while top reinforcement and site placed concrete are added to complete the floor structure.

1.1.4 A structural engineer competent in the design of reinforced concrete structures shall

undertake the design, and oversight of the installation, of the floor and its temporary and permanent supporting structures.

1.2 Product components 1.2.1 Steel wire cage incorporating plastic balls Steel wire cages are manufactured from steel wire complying with the requirements

of BS 4449:2005+A2:2009 Steel for the reinforcement of concrete. Weldable

reinforcing steel. Bar, coil and decoiled product. Specification. Void formers used are High Density Polyethylene (HDPE) balls of a diameter to suit the structural design requirements.

1.2.2 Pre-cast concrete biscuits

Pre-cast concrete biscuits are manufactured by the certificate holder in accordance with the requirements of BS 8110-1 and BS 8500-1:2006 Concrete. Complementary British Standard to BS EN 206-1. Method of specifying and guidance for the specifier, and BS 8500-2:2006 Concrete. Complementary British Standard to BS EN 206-1. Specification for constituent materials and concrete, at a plant holding QSRMC ISO 9001 Certification (Plant Registered number 01509 – Hanson Premix).

1.2.3 Reinforcement in pre-cast concrete biscuits

Reinforcement is high tensile steel bars to BS 4449: 2005 or BS 4482: 2005 Steel wire for the reinforcement of concrete products. Steel reinforcement is supplied by a UK Certification Authority for Reinforcing Steels (CARES) accredited supplier. Lattice reinforcement is third party certificated. Intersig Type 1 as Komo certificate K7342/03.

1.3 Reinforcement and concrete placed in situ (outside the scope of this certificate) Steel reinforcement shall be supplied in the UK by a CARES accredited supplier and

in Ireland by a National Standards Authority of Ireland registered supplier. Concrete shall be supplied by a plant holding QSMRC ISO 9001 or BSI Kitemark certification.

2 PRODUCT PERFORMANCE 2.1 Cobiax System provides a satisfactory means of construction of voided suspended

concrete floor slabs in buildings. Where suitably weather protected the system can be used to provide flat roofs. Weather protection to roofs is outside the scope of this certificate.

2.2 Cobiax System floors can be installed in new buildings and may be suitable for

alterations to existing buildings. In all cases the structural design for the building shall be co-ordinated with the design of the Cobiax System slab.

2.3 Fire resistance of floors shall be determined by reference to the relevant clauses of

BS 8110-1. Clause 3.3.6 and Table 3.4 provide design guidance. 2.4 Cobiax used in accordance with the requirements of this certificate, is considered to

be as durable as traditional reinforced concrete construction in buildings. Project specific requirements can be met by reference to the relevant clauses of BS 8110-1. Clauses 3.3.3, 3.3.4, and 3.3.5 provide design guidance.

3. BUILDING REGULATIONS 3.1 Cobiax System, when used in accordance with this certificate and the certificate

holder’s installation instructions, can assist in demonstrating that the works within which the floor or roof slab is installed will meet the stated Requirements of the following building regulations and standards.

3.2 Building Regulations

The Building Regulations (England & Wales) 2000 (as amended) AD A Structure

AD B Fire Safety Volume 1 Dwelling Houses AD B Fire Safety Volume 2 – Buildings other than Dwelling Houses

Regulation 7 – Materials & Workmanship The Building (Scotland) Regulations 2004 Regulation 8 – Fitness and durability of materials and workmanship. Regulation 9: Section 1 – Structure Section 2 – Fire

The Building Regulations (Northern Ireland) 2000

Part B – Materials & Workmanship Part D – Structure Part E – Fire safety

The Building Regulations Ireland 2007 Part A – Structure Part B – Fire safety Part D – Materials and workmanship

3.3 CDM Regulations

The Building Construction (Design and Management) Regulations 2007 Construction (Design and Management) Regulations (Northern Ireland) 1995 (as amended)

The certificate should form part of the information used by the client, planning supervisor, designer and contractors to discharge their responsibilities under these regulations.

4. INSTALLATION 4.1 General The performance of the Cobiax System depends on correct delivery, storage and

handling in accordance with the certificate holder’s installation instructions. The quality of installation actually achieved on specific sites is not covered by this certificate. Therefore it is recommended that the quality of installation and workmanship is subject to appropriate checks by a competent person for each installation.

4.2 The pre-cast units are transported to site, lifted into position and provided with

temporary support while reinforcement and in-situ concrete are added to complete the floor structure. A structural engineer competent in the design of reinforced concrete structures shall undertake the design, and oversight of the installation, of the floor and its temporary and permanent supporting structures.

4.3 Installation shall be carried out only by installers trained, approved and monitored by

the certificate holder taking into account all relevant health and safety implications. 5. TECHNICAL INVESTIGATIONS 5.1 Examination of a design submitted by the certificate holder for a project confirmed

that it satisfactorily dealt with the design requirements related to the use of the Cobiax Concrete Flooring System for the construction of voided suspended concrete floor slabs in buildings. Assessment has been made of the product design, with reference to its application and practicality of installation which was found to be suitably addressed by the manufacturer’s installation instructions.

5.2 Quality Control Traceable quality records are maintained by the manufacturer. The manufacturer carries out checks at regular intervals to ensure the quality of the product is maintained within the defined product specification. BRE Certification undertakes regular monitoring of the factory production audits on the manufacture of the product against an agreed Quality Plan for the product.

5.3 Standards

The following standards have been referred to for this assessment:

BS 4449:2005+A2:2009 Steel for the reinforcement of concrete. Weldable reinforcing steel. Bar, coil and decoiled product. Specification

BS 4482: 2005 Steel wire for the reinforcement of concrete products BS 6399-1:1996

Loading for buildings. Code of practice for dead and imposed loads

BS 8110-1-1997 Structural use of concrete. Code of practice for design and construction.

BS 8500-1:2006

Concrete. Complementary British Standard to BS EN 206-1. Method of specifying and guidance for the specifier

BS 8500-2:2006

Concrete. Complementary British Standard to BS EN 206-1. Specification for constituent materials and concrete

BS EN 13369:2004+A1 : 2006

Common rules for precast concrete products.

BS EN 10080:2005 Steel for the reinforcement of concrete — Weldable reinforcing steel — General

6. CONDITIONS OF CERTIFICATE ISSUE 6.1 Validity

This certificate will be valid for a period of three years from the date of issue. It will remain valid in so far as: a. The materials and method of manufacture are unchanged or BRE

Certification has assessed any changes and found them to be satisfactory. b. The designs and specifications are unaltered from those examined by BRE

Certification. c. The certificate holder continues to have the product checked by BRE

Certification through factory production control procedures.

6.2 Health and Safety This certificate and the recommendations herein do not purport in any way to restate the requirements of the Health and Safety at Work Act 1974 or any statutory or common law duty of care which exists now or in the future: nor is compliance with these recommendations to be assumed as satisfying the requirements of the said Act or any existing or future statutory or common law duty of care.

6.3 Reference to Other Documentation Where reference is made in this certificate to any Act of Parliament, Regulation, Code of Practice, British or other Standard or other publications, it shall be construed as reference to such publication in the form in which it is in force at the date of issue of the certificate.

6.4 Patents BRE Certification makes no representational warranty that any patent or similar industrial property right is valid or that the manufacture, use, sale, lease or any other dealing or disposition of the product in whole or in part is not an infringement of any patent or industrial property right not owned by the certificate holder.

Figure 1 Cobiax composite voided floor Confirmation that a certificate is current may be obtained from the BRE Certification website (www.redbooklive.com)

Copyright BRE Global 2009

Top mesh

Lattice

Insitu concrete

Ball cage

Precast concrete

Bottom reinforcement