hanson omnia brochure flooring system
DESCRIPTION
Brochure flooring precast concreteTRANSCRIPT
FLOORING SYSTEMSOmnia and Cobiax
Hanson Building Products
Omnia
System overview 4
Benefits 5
Construction details 6-7
Bearing details 8
Temporary support 9
Cobiaxdeck
System overview 10
Benefits 11
Design and construction 12-13
Nationwide service 14
The Omnia system from Hanson BuildingProducts is a pre-cast floor panel thatprovides the direct equivalent of an in-situslab but provides the facility to combine pre-cast and in-situ concrete.
Cobiaxdeck is a development that combinesthe advantages of Omnia wideslab flooringwith Cobiax void forming technology tocreate a long-spanning, biaxial deck systemwithout beams.
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FLOORING SYSTEMSOmnia and Cobiax
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.
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The system displaces non-working
deadload through the incorporation of
hollow spheres between the upper and
lower layers of reinforcement.
Cobiaxdeck
Omnia
The Omnia flooring system is equallysuitable for steel and concrete framedstructures and masonry buildings
SYSTEM OVERVIEWOmniaThe Omnia system provides major benefits over alternativeswhen used as fully participating permanent formwork.
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The basic Omnia product is theOmnidec panel which incorporatesthe distinctive triangular Omnialattice girder.
The Omnia girder is attached to anindividually designed lower layer ofreinforcement and wet concrete is thenpoured to create the Omnidec panel.
The triangular lattice girder providesthe panel with its stiffness during thetemporary condition and ensures abond between the pre-cast and in-situ concrete.
It also serves to provide support forthe upper mesh reinforcement(supplied by the contractor) and isused as the anchor point when liftingpanels into position on site.
Each Omnidec panel is designedand manufactured to order, eachwith its own specific shape andstructural capacity.
Unlike pre-stressed concrete flooringsystems, Omnidec panels are wet-cast into pre-formed shapes that buttjoint together on site.
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Omnia benefitsStructural strengthsCan 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
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
Design flexibilityIrregular 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
Competitively pricedSystem 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
Quality serviceFactory-manufactured to consistent quality standards
Complies with all relevant standards
Where Omniacan be usedThe Omnia system is suitable for use onsteel and concrete framed structures aswell as masonry structures
Commercial and IndustrialHotels, factories, warehouses and retail structures
Public buildingsHospitals, schools, fire and policestations, prisons.
ResidentialLow and high rise apartment blocks,student accommodation blocks, hostels etc
Car ParksSingle level or multi-storey complete with ramps
CONSTRUCTION DETAILSOmnia
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DimensionsEach Omnia panel is designed andmanufactured to suit its location. Sizes are, therefore, infinitely variable.
Panels are cast onto steel bedsaccurately set and split into individualpanel lengths.
The beds are 2.40m wide whichdetermines the maximum width ofpanel. However, every contract mayhave a proportion of non-standard widths.
ToleranceFor standard 2.40m wide panels, thewidth is controlled and the dimension is virtually exact.
For non-standard panel widths withformed edges and at the bearing ends,the panels are cast within thetolerances allowed, usually to ±10mm.
Panel depthsThe precast concrete panels can beprovided at 50, 60 and 75mm asrequired by the structure’s specific fireand exposure conditions.
ConstituentsThe Omnia lattice girders are cast intothe precast concrete panel at centresfrom 600mm down to 120mm toprovide stability in the temporary condition.
By increasing the amount, size andheight of the lattice girders, the panelscan be made to span great lengthswithout temporary propping.
Each panel is designed to cope with its specific loading condition and isreinforced with bars from 8 to 16mmplaced at 50 to 300mm centres.
With over 11 million permutations oflattice girder, steel reinforcement andconcrete available, it is possible tocope with the most onerous of loadingand exposure requirements.
Maximum SpansThe maximum span of any Omnia panel is a result of a number of factorsincluding 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. Hanson’s Omniadesign team can provide designs attender stage to determine the mostcost-effective span/depth ratio.
Appearance and shapeAll Omnia panels are cast to length onsteel moulds. Long edges are formedwith a chamfer to the underside sothat, when placed adjacent to eachother, the effect of a bird’s mouth jointcan be seen at regular intervals on thesoffit.
Holes for services etc. can be neatlycast into the panels during manufacture.
Special side forms are introduced atcasting stage enabling panels to beproduced to suit the shape of thebuilding and it is, therefore, possible tocater for structures with complex floorlayouts.
Ends of panels are formed with squareforms to provide a suitable surface atthe lines of bearing.
Soffit qualityThe steel moulds used for casting ensurea high quality finish suitable for directdecoration with paint or textured finish.
As no pre-stressing wires are used inthe manufacture of the Omnia panels,the soffit is also flat with no camber.
Omnidec
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The Omnicore variation
Accessories
Omniedge
All products in the Omnia system utilise the Omnia lattice girder, reinforcingsteel and dense concrete. Omnidec is the basis for the product range withvariations and accessories as shown below:-
A precast concrete panel reinforcedwith steel bars and incorporating theOmnia lattice girder to providestrength in the temporary condition(i.e. during erection). Reinforced in-situ concrete is placed over thepanel to create a solid concretehomogeneous slab.
Typically used for spans from 1.0m up to 6.50m, providing slab depths
from 135mm to 250mm, at whichpoint Omnicore should beconsidered to reduce overall deadweight on the structure.
However, on civil engineeringstructures, slab depths occasionallyexceed 750mm. Slabs can also becast using lightweight aggregate toreduce self-weight.
Similar to Omnidec except that inbetween the lattice girders, lengthsof polystyrene are cast into the topof the precast section to reduce theamount of in-situ required andtherefore the weight of thecompleted slab.
Typically used for spans of 6.00mand over, providing slab depths from250mm upwards.
Reductions of 20 - 45% in slabweight can be expected.
Omniedge is a galvanised steel edgeshutter cast into the edges of theprecast panels at the factory.
Generally it is used on masonrystructures and is a competitivemethod of providing an edge shutterto the completed slab.
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BEARING DETAILSOmnia
Bearing on steelwork
Bearing on in-situ concrete
Bearing on masonry
Omnia panels are suitable for use on concrete andsteel framed structures and on masonry buildings.
Panels require a nominal bearingof 55mm.
Panels bearing at differential levels mayrequire a compressible bitumenised stripto prevent point bearing and excessivegrout loss.
Shelf angles must be of such a length asto allow the end of the panel to pass thetop flange during placing, and be set at aheight that will allow continuity.
Support panels on the formwork and casta fully homogeneous slab. The OMNIA preferred option.
When supported on ‘half-cast’ beams,links must be so arranged to allow65mm nominal bearing.
Where less than 65mm bearing isavailable, a suitable temporary prop mustbe in place before placing the panel andleft in place until the in-situ portion hasreached working strength.
Panels are usually detailed to take the full bearing of the internal skin of masonry,allowing the use of ‘Omniedge’ edgeformwork (see page 7).
Two OMNIA panels can be supported on140mm wide load bearing blockworkwith a 20mm gap between.
Where less than 60mm bearing is availableeg. on 100mm walls, temporary props shouldbe in place prior to placing the panels.
TEMPORARY SUPPORTConstruction
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Unpropped
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 aresult of a combination of lattice height,lattice top bar diameter and the number oflattice girders cast into the panels.
Spans up to 4.0m regardless of slab depthwill generally be designed to be erectedwithout props.
Depending on the depth of the slab, spansof over 6m can be designed to be erectedwithout propping and spans over 7m can be designed to be erected ‘post-propped’ (see below). Please check with Hanson formaximum spans using Omnicore, as theintroduction of the polystyrene limits the abilityof the panel to span with reduced propping.
No props are required, except for localised supports around openings etc.These will be identified on the Omnia layout drawings.
Post-propped
Panels are self-supporting, but will require one row of props placed mid-span prior to placing materials, particularly the in-situ concrete.
One row of propsplaced mid-span
Continuous head timber
Prop
ProppedProps are typically spaced at 2.50mcentres, although these centres can beextended to suit the contractorsrequirements.
Examples are spans in the 7m – 11m range.
OMNIA panels can also be designed to cope with the loads transferred from temporary props, therebyeliminating the need for ‘back-propping’ on lower floors.
Temporary props shall remain in position inaccordance with the requirements of therelevant code of practice, and whilst their
spacing will be shown on the Omnia panellayout drawings, the actual design of theprops will be responsibility of others.
Panel lowered onto supports
2.50m Max
Overall Maximum slab depth post-propped span
150mm 5.80m
175mm 6.80m
200mm 7.00m
225mm 7.20m
250mm 7.50m
Overall Maximum slab depth unpropped span
150mm 3.95m
175mm 4.40m
200mm 4.85m
225mm 5.40m
250mm 6.10m
SYSTEM OVERVIEWCobiaxdeck
Cobiaxdeck combines the establishedadvantages of the Omnia system withspherical void forming technology toenable the construction of light weight,biaxial floor slabs with column gridsranging from 6m up to 18m withoutbeams.
The resultant overall slab depth will bedetermined by the arrangement and spacingof the columns as well as the ultimate loading.
The combination of these technologiesallows the construction of buildings withwide open spaces, providing for greaterflexibility with internal design.
The absence of beams also means areduction in the overall floor zone which, in some instances, can allow space for the construction of an additional floor.
The use of void forming technologyreduces the volume of concrete in thefloor slab by displacing non-workingdeadload.
The reduced weight can impact on thedesign and reduce the cost of foundations and the system is ideal foruse where ground conditions are poor or piling is required.
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Cobiaxdeck benefitsBiaxial design
No need for support beams
Reduced structural zone
Resource effective
Fewer columnsWide open spaces
Greater design flexibility
Reduced costsFaster build
Reduced in-situ concrete
FoundationsLighter weight slabs means reduced costs for foundations
Ideal for poor ground conditions or piling
Thermal performanceDesign allows thermal mass to be exploited
Lower heating/cooling costs
Quality serviceFactory produced quality
Complies with all relevant standards
WhereCobiaxdeck can be usedSuitable for all types of buildings but isideal for larger scale projects including:
Shopping centresand supermarkets
Office complexes and high-rise commercial buildings
Schools and universities
Hospitals
Hotels
Apartment blocks
Industrial buildings
Multi-storey car parks
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DESIGN & CONSTRUCTIONCobiaxdeck
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StructuralprinciplesCobiaxdeck provides the potential forsavings on materials, floor depth, slabweight, foundations and build-time ifincorporated at the design stage of thecontract.
The Cobiax system of biaxial design inconjunction with the void formingsystem allows for a considerablereduction in the volume and weight ofthe slab without compromising thisability to maintain biaxial strength.
The Cobiaxdeck system provides a verycost-effective alternative to achieve therequired deflection criteria in long spanapplications.
Hollow spheres, manufactured fromrecycled polyethylene, are used as voidformers. They are held in place, relativeto the soffit and to each other, inlightweight steel cages.
Additional Space
Conventional construction Cobiaxdeck construction
Absence of beams in the Cobiaxdeckstructure offers the potential for anadditional floor (or floors).
Weight savings impact on floor slabs,vertical elements and foundationdesign, effectively reducing costs.
Less excavation
The utilisation of the spheres providesweight saving of between 20-30%compared to an equivalent solid concrete slab.
The extremely efficient biaxial design canalso enable savings to be made on theweight of reinforcement required for theultimate loads on the floor slab, as well asthe size of columns and foundationssaving up to 50% structural concrete.
CobiaxdeckoptionsThe Wet-Method is the name given to the system where the ball and cagematrices are fully bonded to thereinforced precast concrete at the factory.
The precast panels include 2 layers of reinforcement.
The panels are placed onto preparedfalsework, splice bars are threadedinto place and shear connectorslaced around the columns to pre-setshear ladders already cast into thepanels.
The top layers of reinforcement arethen placed across the whole of theassembly before concreting.
The Dry-Method is the name given tothe system where the precast panel issent to site for placing without the Balland Cage matrix attached. Only one layerof reinforcement is included in theprecast panel.
The 2nd layer of bottom steel and theshear connector bars are laid intoposition on top of the precast panel.
The Ball and Cage assemblies are sent to site separately and are placed inposition. The top steel is then placed andtied down to the lattice girder to prevent‘floating’.
The In Situ-Method is the name givento the system where the voided biaxialslab is created on traditional formworkwith no precast concrete involved.
DesignCobiaxdeck is a solutions driven systemand Hanson’s engineering team workwith the client throughout each project tomaximise the benefits and achieve anideal solution.
Hanson provide a full design serviceincluding all aspects of the biaxialconstruction, panel and loosereinforcement layout drawings for all 3 options.
Soffit qualityIf the Cobiaxdeck option includes aprecast Omnia element, this is cast onsmooth flat steel casting beds giving a first class soffit ready for directdecoration.
Thermal massThe thermal mass in a Cobiaxdeck slabcan significantly reduce the energyrequirement of the building once in use.This can be achieved passively, throughsolar gain and night cooling, or activelythrough the use of fluid circulation wherereduction figures of up to 66% of theenergy needed to heat and cool thebuilding have been achieved.
SustainabilityThe void forming technology and theabsence of beams in the structure,combined with the reduction in thenumber of support columns required,reduces the volume of the concrete usedin the building effectively reducing theCO2 omissions produced during themanufacturing process.
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Wet-Method
Dry-Method
In Situ-Method
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SERVICENationwide
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]
The Floors and Precast Division of Hanson Building Products operates from various plants located throughout the UK.
Hoveringham
Derby
Somercotes
Omnia production
Hanson Building Products Floors and precast locations
15
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0870 6097094Hanson Building ProductsHanson House14 Castle HillMaidenheadSL6 4JJ
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Email: [email protected]: www.hanson.com/uk/sustainability OM 02 | Dec 2010