Decking floor

DECKING FLOOR

Decking floors: Concepts and applications

Decking floors, often referred to as decking, are a composite flooring system that integrates steel with reinforced concrete. Specifically, this product comprises cold-rolled metal sheets serving as the base, topped with a reinforced concrete slab, and supported by a structural steel beam system beneath. Notably, it can be placed on concrete beams or masonry walls.

As a composite material in construction, the decking combines the load-bearing properties of steel with the durability of reinforced concrete. In this synergy, the steel structure provides rigidity while the concrete slab enhances the system's overall strength. Alternatives like cement board replacing steel sheets are also recognized as composite materials in the construction sector.

The main structure of decking

Load-bearing framework:

• The load-bearing system typically utilizes I-beams, flat trusses, and supporting columns. These beams are manufactured from hot-rolled steel or welded composite steel, in combination with I-beam steel or concrete columns. This framework supports the load from secondary beams, transferring it efficiently to the columns.
• Primary load-bearing beams segment the work area into smaller sections of less than 10 meters, with secondary beams further dividing the deck into smaller panels. The spacing between secondary beams depends on several factors, including applied load, sheet wave height, and beam dimensions. Generally, the distance between secondary beams ranges from 0.6m to 1.5m.

Decking sheets:

• Deck sheets, typically featuring a wave profile, play a critical role in the structural framework by providing robust support.

• These sheets range in thickness from 0,75mm to 1,5mm, with common usages falling between 0,75mm and 1mm. The typical height of the sheet profile ranges from 40mm to 80mm. To prevent corrosion, the metal sheets are galvanized on both sides.

• The elastic limit of the sheets is approximately 300N/mm², equivalent to 30kg/cm². Ribs are often incorporated on the surface of the sheets to enhance friction between the sheets and concrete.

Reinforced concrete layer:

• The reinforced concrete layer in the composite flooring system integrates seamlessly with the deck sheet, creating a resilient structure capable of withstanding substantial loads.

• The thickness of this concrete layer must be no less than 80mm from the top of the metal sheet. Additionally, the concrete thickness over the ribs of the sheet must not be less than 40mm to protect the reinforcement and prevent damage from impact.

• Within the concrete, the placement of steel reinforcement bars is meticulously designed to manage moments at support points and spans, ensuring the structural integrity and safety of the flooring system.

Key advantages and disadvantages of decking

Advantages:

• High load capacity: Decking combines wave sheets with concrete to deliver exceptional load-bearing capabilities of up to 20kN/m², which can be enhanced with lightweight mesh for added resistance to external impacts.

• Large span capability: Decking can span distances of up to 10 meters, providing expansive interior spaces without the need for numerous columns.

• Fire resistance: The composite flooring can withstand fire for up to 120 minutes, with simple reinforcement using steel mesh. Fire resistance can be adjusted based on the thickness and type of concrete utilized.

• High durability: Decking sheets are double-galvanized to protect against damage, ensuring long-lasting performance in moderate weather and light exposure conditions.

• Cost efficiency: Employing deck floors can lead to savings of 7% to 12% compared to other construction methods, thanks to rapid installation (up to 50% faster than projects using alternative materials). Foundation costs can also decrease by at least 20% due to the lightweight nature of the sheets and beams.

• Time efficiency: Quick installation translates to time savings of 7% to 12% compared to alternative construction solutions, eliminating the need to remove formwork after achieving strength.

• Environmental benefits: The use of recycled materials reduces reliance on raw materials, as steel is 100% recyclable, minimizing waste and simplifying foundation complexities.

• Reusability: After use, the decking system can be dismantled, allowing for the reuse of most beam and column structure.

Disadvantages:

• Shape-cutting limitations: Current deck rolling machines can only produce flat shapes, resulting in rectangular panels after processing.

• Thickness limitations of raw sheets: Deck machines can handle sheets with a maximum thickness of 1.6mm.

• Limited flexibility with floor shapes: Not suitable for round, curved, or sloped configurations, potentially leading to material wastage.

• Unsuitable for highly acidic environments: A thorough assessment is essential before use in environments with high acid concentrations.

• Rusting concerns: Rust may develop in areas exposed to rainwater, necessitating regular maintenance to mitigate this issue.

Applications of decking in industrial projects:

• Residential construction: Decking is widely used in residential projects, from apartments to townhouses, due to its load-bearing capacity and design flexibility.
• Industrial and office spaces: Frequently utilized as office floors and multi-story parking in industrial parks, such as Advance Multitech Industrial Park, and office centers like Kim Tin MDF.
• Commercial projects: Commercial buildings often incorporate decking in multi-story constructions, including notable structure like Bitexco Tower and Diamond Plaza in Ho Chi Minh City, as well as UHD Tower and New Skyline Tower in Hanoi (Vietnam). These iconic projects feature steel and concrete composite structure.
• International projects: Globally, decking has found extensive application in major constructions, including the Federal Building in Brooklyn (New York) and the SDS in Skilton, alongside the Atlantic Center project.

We specialize in decking design, production, and installation services

With over a decade of experience, LEXFAS COMPANY LIMITED proudly stands as a reputable provider specializing in the design, production, and installation of:
✦ Decking and grating floors for construction and industrial projects
✦ Viglacera precast autoclaved aerated concrete AAC panels
✦ Lightweight concrete panels, ALC flooring, concrete panels, EPS concrete, etc.

Product advantages:
✔ Lightweight and cost-effective structural solutions - Rapid installation
✔ Excellent thermal insulation, fire resistance, and soundproofing properties
✔ Superior moisture and impact resistance
✔ Easy processing, flexible manufacturing, and environmentally friendly

Applications: Roofing, walls, partitions, flooring, window and door canopies, and more.

We continuously strive to deliver products that embody: "Safety - Quality - Timeliness - Competitive Price."

Contact us today for a free consultation!