Stairs Flooring Precast Concrete

Charcon Flooring Flexible quality flooring solutions at all levels

02 Delivering value through construction materials

With a wealth of technical expertise, and a range of high quality engineered structural stairs, landings and flooring products, Charcon Flooring offers an efficient and versatile solution for any housing or commercial application.

04-0

7 Beam and block flooring A comprehensive flooring system composed of prestressed concrete beams with standard building blocks laid between them.

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9 Beamshield Plus flooring A suspended floor insulation system for domestic and commercial applications.

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1 Tetris flooring A suspended insulation flooring system designed for both domestic and commercial ground floor applications.

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5 Acoustic separating floors Flooring solution designed to limit or insulate against airborne sound.

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7 Hollowcore flooring Flooring units that offer the designer and contractor a flexible and economic answer to the challenges posed by flooring spans and widths.

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9 Accessories A range of flooring accessories.

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1 Stairs and landings Precast stairs and landings to suit most combinations of architectural design.

Aggregate Industries is the first company in the world to achieve a BES 6001:2008 Responsible Sourcing Certificate from BRE Global. All Aggregate Industries’ UK manufactured products have a certificated minimum rating of GOOD under the BES 6001 standard.

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www.charconflooring.com

04 Beam and block floors

Beam and block is a comprehensive flooring system composed of prestressed concrete beams with standard building blocks laid between them. Together with split course perimeter blocks and professional fixings, they add up, quite simply to a comprehensive flooring package.

From the supply of beams only to a complete structural floor, our client need only select those elements that meet their requirements.

Beams

Beams are prestressed and are available in various profiles, designed in accordance with BS8110 Part 1:1997 using grade C60 concrete and a cover to the reinforcement to satisfy the ‘moderate’ exposure condition as defined in BS8110 Part 1:1997. Prestressed beams are manufactured in standard lengths of 50mm increments.

Blocks

Infill blocks should be concrete or aerated concrete blocks generally 440x215x100mm and be minimum 3.5N/mm2 compressive strength and able to support a transverse load of 3.5kN on a span of 420mm (larger aerated floor blocks are available designed specifically for beam and block floors and can be used with prior consultation with our estimating department).

Blocks are100mm thick, solid and manufactured in accordance with BS6073: 1981. Block densities between 650kg/m3 and 2000kg/m3 are available.

Once all joists are in place and have been correctly spaced, infill blocks should be laid over the whole area.

Where blocks are built into walls of a higher strength than the infill block, then the general contractor must provide compatible perimeter blocks.

Split course blocks have a crushing strength of 7N/mm2.

A concrete cutting saw or block splitter will be required to cut the perimeter blocks and cut rows where necessary. To seal the joints a 4:1 sand cement grout should be brushed over the whole floor area. The floor now provides a safe working platform for following trades.

During further construction, never overload the floor with blocks as this could exceed design loadings.

Floor finishes

The top surface of the beam and block floor is suitable for the application of one of the following

(i) Sand/cement screed applied directly over the floor area

(ii) A timber T & G floating floor may be laid directly onto a continuous D.P.M. over a levelling screed on the beam and block floor

(iii) When additional insulation is required, a layer of insulation material is laid over the floor, which may be completed by either a sand/cement screed or T & G floating floor on D.P.M. A levelling screed is recommended prior to installing the insulation.

Benefits

• Easy to handle, quick to install. Beams and blocks can be easily handled by forklifts or cranes. Smaller lengths can be manhandled

• Provides immediate working platform. No need to wait for concrete slabs to cure. Grouted floors form an immediate base for following trades

• Simple all weather form of construction. There is no need to worry about frost damage to floors

• Draught proof, rot proof and fire resisting. The durability of solid concrete, but as simple to lay as timber

• Eliminates backfill and site compaction. Expensive backfill and compaction are not required. Subsequent ground heave problems are removed

• Good thermal insulation. Insulation values required by Building Regulations are easily achieved using the appropriate finishes.

Installation

1. Ensure bearings are level and clear of debris

2. Lay DPC and set out first beam in accordance with previously approved and issued layout drawings


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3. Position remaining beams using infill blocks at each end to ensure correct spacing

4. Ensure beams do not project into the cavity

5. Bed split course blocks between ends of beams and along parallel load bearing walls where shown on layout drawings

6. When all beams are in place complete the fixing of the infill blocks

7. A 4:1 sharp sand/cement grout must be thoroughly brushed into all the joists and a C30 concrete is required between multiple beams. The floor should be soaked with clean water prior to grouting if possible

Correct

250mm max overhang

Incorrect

Uneven ground/small bottom bearings/bearers out

of line = DAMAGE

8. Our floors achieve a fire resistance of one hour. This is enhanced by the application of suitable finishes.

General notes

No prestressed unit is to be cut or drilled without submission to our technical department.

Shot-fired fixings are NOT PERMITTED in beams or blocks.

Prestressed units have an inherent upward camber and due allowance should be made in any finishes to cater for this.

Differential cambers are likely to occur due to manufacturing/construction tolerances or where short and long units are adjacent or at change of direction of spans.

Some form of leveling screed by a general contractor is recommended for polystyrene and chipboard or ‘Floating’ floors to accommodate slight differences in camber and level between top of block and top of beam.

Garage floors require a reinforced C30 concrete screed.

Holes can be accommodated by the omission of blocks and made good with in situ concrete by the general contractor after the installation of services.

Place blocks on planks

no closer than 1.2m

centres measured

along the supports.

Position lower blocks

this way

Place blocks as close as possible to bearing walls.

Never double stack block packs.

Do not place packs of blocks mid span.

Span/4 Span/4Span/2

Max 2 stacks per span

12 blocks per stack


06 Beam and block floors

Prestressed concrete floor beams

MI04 beam

2 4 4 2 20 75 20

150

50

100

127

MR09 beam

2 4 4 2 20 123 20

50

100

150

Span load tables MI04 150mm deep beams typical application

Infill block density kg/m3

65mm screed finish 1.5kN/m2

Superimposed loadings kN/m2

Dry finishes 0.2kN/m2


Clear spans

1.5 2.0 2.5 1.5 2.0 2.5

Case S525 650 1350

4.80 4.54 4.29 4.80 4.80 4.50 4.52 4.27 4.07 4.80 4.80 4.80

Case S413 650 1350

4.80 4.80 4.70 4.80 4.80 4.80 4.80 4.78 4.55 4.80 4.80 4.80

Case S300 650 1350

4.80 4.80 4.80 4.80 4.80 4.80 4.80 4.80 4.80 4.80 4.80 4.80

Span load tables MR09 150mm deep beams typical application






Clear spans

1.5 2.0 2.5 1.5 2.0 2.5

Case S570 650 1350

5.88 5.57 5.29 6.30 6.30 5.95 5.52 5.26 5.03 6.29 5.91 5.58

Case S458 650 1350

6.30 6.10 5.82 6.30 6.30 6.30 6.09 5.80 5.55 6.30 6.30 6.15

Case S345 650 1350

6.30 6.30 6.30 6.30 6.30 6.30 6.30 6.30 6.28 6.30 6.30 6.30

175

MT10 beam

20 4 4

119 20 4 4

200

100

100

Span load tables MT10 200mm deep beams typical application






Clear spans

1.5 2.0 2.5 1.5 2.0 2.5

Case S570 650 1350

7.27 6.91 6.59 8.00 7.77 7.31 6.86 6.55 6.28 7.73 7.30 6.91

Case S458 650 1350

7.90 7.52 7.20 8.00 8.00 7.95 7.51 7.18 6.89 8.00 7.96 7.57

Case S345 650 1350

8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 7.73 8.00 8.00 8.00

175


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Prestressed concrete floor beams

CR94 beam

155

55

100

2 18

4 46 18

24

94

Span load tables CR94 typical application






Clear spans

1.5 2.0 2.5 1.5 2.0 2.5

Case S494 650 1350

4.20 3.95 3.55 5.14 4.71 4.38 3.91 3.52 3.18 4.63 4.31 4.05

Case S382 650 1350

4.72 4.46 4.23 5.50 5.27 4.91 4.41 4.19 4.00 5.20 4.86 4.57

Case S269 650 1350

5.49 5.18 4.94 5.50 5.50 5.50 5.17 4.92 4.71 5.50 5.50 5.34

CR130 beam

4 2 1882

42 18

100

55

155

130

Span load tables C130 typical application






Clear spans

1.5 2.0 2.5 1.5 2.0 2.5

Case S530 650 1350

5.00 4.72 4.49 6.00 5.56 5.19 4.69 4.46 4.26 5.50 5.14 4.84

Case S418 650 1350

5.54 5.24 4.99 6.00 6.00 5.74 5.22 4.97 4.75 6.00 5.71 5.39

Case S305 650 1350

6.00 5.98 5.70 6.00 6.00 6.00 5.99 5.71 5.47 6.00 6.00 6.00

MR09 beam

18 2 4 4 2

18124

100

55

155

172 51 35 5135

Span load tables MR09 typical application






Clear spans

1.5 2.0 2.5 1.5 2.0 2.5

Case S572 650 1350

5.84 5.53 5.26 6.80 6.46 6.05 5.51 5.25 5.02 6.44 6.03 5.69

Case S460 650 1350

6.39 6.06 5.78 6.80 6.80 6.61 6.07 5.79 5.54 6.80 6.62 6.26

Case S347 650 1350

6.80 6.78 6.49 6.80 6.80 6.80 6.80 6.53 6.26 6.80 6.80 6.80

C225 beam 90 18

5445 18

225

125

100

144

Span load tables C225 typical application






Clear spans

1.5 2.0 2.5 1.5 2.0 2.5

Case S534 650 1350

7.36 6.99 6.67 8.00 8.00 7.60 6.95 6.64 6.36 8.00 7.55 7.15

Case S420 650 1350

8.00 7.66 7.33 8.00 8.00 8.00 7.64 7.31 7.03 8.00 8.00 7.86

Case S307 650 1350

8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 7.94 8.00 8.00 8.00


08 Beamshield Plus Insulated floors

Beamshield Plus floor insulation system is a suspended flooring system for domestic and commercial applications to ground floors excluding garages. The system comprises prestressed concrete beams infilled with purpose designed high duty expanded polystyrene (EPS) panels from Springvale EPS Ltd topped off with a power floated reinforced structural screed finish.

From supply only of materials to a complete floor requiring the structural screed, our clients need only select those elements that meet their requirements.

Beams


EPS infill panels

Infill panels are used in place of standard building blocks between the beams and are manufactured in accordance with BS EN 13163: 2001.

• The insulation value of the EPS is more than three times greater than even the most efficient lightweight thermal block so no further insulation is required in the floor structure

• Because Beamshield Plus is positioned level with the top of the beam, there is no enroachment into the floor void

• The closed cell lightweight EPS panels are very easy to handle and their design facilitates a very rapid installation

• The shape of the panels has been carefully developed to eliminate cold bridging giving an average insulation thickness of approximately 200-300mm

• Where necessary the panels can be easily cut with a fine toothed saw to accommodate the most awkward lengths, spans, widths and services

• Each block measures 1200mm long and covers more than five times the area of a standard building block

• The EPS panels each weigh approximately 1.5kg and arrive on site in packs wrapped in fours, which can be carried comfortably by one person

• Chemically inert.

Structural floor screed

The T beams and EPS infill panels are topped off with a power floated C25/30 concrete structural screed finish by the main contractor. This screed is reinforced with A142 mesh or polypropylene fibres to your concrete supplier’s specification. The screed should have a minimum thickness of 60mm from the top of the beams.

Benefits

• Easy to handle, quick to install Blocks can be easily manhandled

• Simple all weather form of construction There is no need to worry about frost damage to floor

• Wall to wall EPS insulation with no concrete bridging blocks at floor ends

• Draught proof, rot proof and fire resisting The durability of solid concrete once the screed is applied, but as simple to lay as timber

• Eliminates backfill and site compaction Expensive backfill and compaction are not required. Subsequent ground heave problems are removed

• Good thermal insulation The Beamshield Plus blocks and concrete screed, easily achieve the insulation values required by building regulations and the code for sustainable homes.


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General notes

No prestressed unit is to be cut or drilled without submission to our technical department.

Shot-fired fixings are NOT PERMITTED in beams or blocks.


Differential cambers are likely to occur due to manufacturing/construction tolerances or where short and long units are adjacent or at change of direction of spans.

Either omitting blocks or trimming them with a fine-toothed saw readily accommodates services.

Off cuts of reasonable size can be reused so waste is minimised.

U Value Chart

Installation


2. Lay DPC and set out first beam in accordance with previously approved and issued layout drawings

3. Position remaining beams approximately in correct position

4. Ensure beams do not project into the cavity

5. Ensure that telescopic vents are correctly positioned to ventilate the void and the void is a minimum 150mm below the Beamshield Plus unit

6. Install polystyrene infill blocks. Blocks can be cut using a hand saw to suit service holes and run-out

7. Bed T-shaped concrete closure block along bearing walls

8. Install Beamshield Plus starter block as denoted on the layout drawing

9. Create screed rail/formwork using one of these options: a) 100mm x 50mm Soft wood b) Bedded split course blocks

or brick c) Proprietary edge profile (plastic

or steel angle)

10. Postion perimeter insulation strip to prevent cold bridging

11. Lay structural concrete screed.

U V

alue (W

/m2K

)

Perimeter/Area Ratio

SPECIFIED TOPPING MEMBRANE IF SPECIFIED

30mm PERIMETER STRIP GROUT INFILL BETWEEN BEAMS

30mm PERIMETER STRIP

GAS MEMBRANE TO LAP GAS MEMBRANE TO LAP UNDER CAVITY TRAY UNDER CAVITY TRAY

EXTERNAL GROUND LEVEL EXTERNAL GROUND LEVEL

DPC min 150 mm void

DPC

STARTER UNIT (MAX. 300mm SPAN)

HALF UNIT END PANELCUT FROM FULL UNIT ON SITE (MAX 300 mm SPAN)

FULL DOUBLE BEAM UNIT

STANDARD FULL BEAM UNIT


10 TETRiS floors

The TETRiS suspended insulation flooring system is designed for both domestic and commercial ground floor applications, excluding garages. The system comprises prestressed concrete beams in-filled with profiled closed-cell, high compressive strength extruded polystyrene panels, finished with a structural concrete topping.

Beams


TETRiS panels

TETRiS fully recyclable infill panels are used in place of standard building blocks and sit on top (75mm) and between the beams (15-85mm).

• The insulation value of TETRiS is more than three times better than even the most efficient lightweight thermal block and as a result, no further insulation is required in the floor structure

• TETRiS panels are very easy to handle and their design facilitates a very rapid installation

• Once installed, the TETRiS insulation panels produce a floating floor that completely isolates the warm structural slab from the cold concrete beams and any concrete floor blocks used. Around the external perimeter, thermal edge strips protect the

vertical edge of the structural slab from cold bridging, fully satisfying the requirements of the Robust Construction Details

• Where necessary the panels can be easily cut with a fine toothed saw to accommodate the most awkward lengths, spans, widths and services

• Each panel measures 2500mm long and covers up to sixteen times the area of a standard building block

• TETRiS panels are delivered to site on bearers in specific plot loads, helping to control cost. TETRiS panels can be easily carried around site and weigh less than 8.2kg.

Structural floor screed

The T beams and TETRiS panels can be finished with any of the following:

• 75mm thick RC30 to BS8500-2 with polymeric monofilament fibres at a dose of 900g/m3

• 75mm thick standard C35 concrete 10mm CEM1 slump class 3 to BS8500-1/2

• Proprietary self compacting concrete, containing admixtures to BE EN 934, mortar and grout.

General notes

No prestressed unit is to be cut or drilled without submission to our technical department. Shot-fired fixings are NOT PERMITTED in beams or blocks. Prestressed units have an inherent upward camber and due allowance should be made in any finishes to cater for this. Different cambers are likely to occur due to manufacturing/construction tolerances or where short and long units are adjacent or at change of direction of spans. Either omitting blocks or trimming them with a fine-toothed saw readily accommodates services. Off cuts of reasonable size can be reused so waste is minimised.

Benefits

• Easy to handle, quick to install Panels can be easily installed

• Simple all weather form of construction There is no need to worry about frost damage to slabs

• Underfloor heating easily integrated Heating systems can be fixed directly to the TETRiS panels prior to pouring the concrete finish


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• Eliminates the need to introduce wet Installation 6. Cut and install blocks and a flat trades later in the building process sheet to cut rows

1. Ensure bearings are level and Installing the finished structural floor

clear of debris 7. Construct retaining edge to before the house is built

perimeter of floor2. Lay DPC and set out first beam

• Good thermal insulation in accordance with previously 8. Pour concrete and level floor

The TETRiS system can easily approved and issued

achieve the insulation values required 9. If required powerfloat to a layout drawings

by Building Regulations. final finish 3. Bed split course and install blocks

• Helps achieve Code for Sustainable 10. Apply a layer of sand over theto perimeter

Homes level 3-6 floor to protect from other trades The TETRiS system has been 4. Break down the plot pallet and during the building process. awarded the highest green guide stack next to beamed area of floor rating available (A+) and will assist in

5. Install TETRiS infill panels in againing a high CSH level.

staggered pattern. Panels can be cut using a hand saw to suit service holes and run-out

Load span table

MHI1 MI04 125 625 2.01 4.54 4.26 4.03 3.83 3.46 2.97

MHR1 MR09 175 675 2.15 5.55 5.24 4.99 4.77 4.40 4.09

MHT1 MT10 175 675 2.01 6.90 6.54 6.24 5.96 5.49 5.11

Unit Beam type Design case Floor case width (mm) width (mm) self

weight (kN/m2)

Screed finish = 1.50 (kN/m2) Superimposed loadings in (kN/m2)

Clear spans in metres

1.5 2.0 2.5 3.0 4.0 5.0

Calculation of floor U-values

1. Calculate the floor exposed internal perimeter in metres 2. Calculate the floor internal area in metres squared 3. Calculate the perimeter/area ratio 4. Determine the U-value from the graph on page 9

Unheated spaces outside the insulated fabric, such as porches or attached garages, are excluded when determining perimeter and area (but the length of the wall between the heated building and the unheated space is included when determining the perimeter).

Thickness of insulation between the beams varies

depending on U-value required

1

150mm (min)

T - Panel

Fixed 150mm height above beams

Gap strip Edge strip2 3

Zero cold bridging

1. T-blocks: large insulation blocks (0.75 or 1.5m2) profiled to

suit specific prestressed concrete floor beams used, a

75mm section remains above the beams, with the balance

dropping between

2. Gap-strips: 75mm thick insulation blocks, used to make up

areas that T-blocks do not cover

3. Vertical edge strips: supplied to suit the thickness of

concrete finish (65 or 75mm), fixed around the floor’s

external perimeter to eliminate cold bridging.

TFIX: fixing pins used to secure the strips in position.


12 Acoustic separating floors - concrete Beam and block solutions for Part E

Awareness about noise transmission in the home is increasing. Noise is a modern paradox: we use more noise generating products than ever in the home yet we want increased levels of peace and quiet. A choice of beam and block acoustic flooring solutions are available.

Background

The 2004 changes to Part E of the Building Regulations, which cover resistance to the passage of sound, have attempted to address noise transmission by improving sound insulation for residential buildings.

Part E addresses key areas including separating walls, floors and stairs, internal walls and floors and reverberation in common areas and stipulates minimum performance criteria for airborne sound and impact sound insulation of separating floors. To achieve these standards, housebuilders can either:

1) use their own design and subject it to pre-completion sound testing, the onus being upon the builder to demonstrate that required levels of sound insulation are achieved as detailed in the performance table or

2) choose one of six approved separating floor ‘robust details’ solutions, which exceed the minimum standard in Part E by at least 5dB and therefore avoid pre-completion sound testing, and associated costs.

The minimum value for airborne sound insulation is as shown below:

Separating Floors

Separating floors are designed to limit or insulate against airborne sound, such as that from a television; impact sound, such as footsteps; and flanking sound - the indirect transfer of sound through the building fabric, usually through the walls separating dwellings. There are four principles to achieving the required sound insulation:

• Mass: The heavier the floor, the less sound is transmitted. Mass is designed into floors by using concrete or the addition of layers of dense material to timber

• Completion of the acoustic element: Air gaps and non-uniformity in the floor construction can reduce sound insulation performance. A high standard of installation is required to ensure airtightness and uniformity

• Flexibility: Flexible floors generally provide better sound insulation. Certain stiffness is required for structural reasons, and certain frequencies of sounds can be transmitted because of resonance

• Isolation: The physical separation of a floor reduces the transmission of sound through a structure. The installation of a floating floor, which incorporates resilient layers and uses soft or acoustic floor coverings, is the standard option for achieving separation.

Ceiling treatment in the room under the floor is just as important as the floor structure and floor covering.

Robust details - compliant separating floors

The ‘robust details’ scheme outlines the principal separating floor solutions for concrete flooring. There are 100 variations of ceiling and floor finishes within these headline solutions to satisfy Part E.

• Concrete floors: There are four robust detail concrete separating floor solutions, which are based on precast concrete beam and block or planks with a directly applied screed, floating screed or in situ concrete slab. A steel deck and in situ concrete composite floor option is also described.

Compliance with ‘robust details’ will negate the requirement for pre-completion site testing of new build separating structures for dwelling houses and flats. To use a ‘robust detail’ construction, an application must be registered with Robust Details Limited and a fee paid. Further details can be found at www.robustdetails.com.

Part E (PCT) requirements Robust details requirements

Airborne Bnt, w + Ctr >= 45 dB >=47dB

Impact Lnt,w >= 62 dB >= 60dB


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14 Acoustic separating floor - concrete E-FC-6 Part-E compliant

• Beam and block floor with precast or in situ edge beams

• Screed lid on Regupol E48 resilient layer system

• For use with dense aggregate block flanking walls only.

1

23

4

5

1. Screed: 65mm (min) cement:sand screed or 40mm (min) proprietary screed, nominal 80kg/m2 mass per unit area

2. DPM: 0.2mm (min) waterproof membrane

3. Resilient layer: 8mm Regupol E48, dimple side down, fully lapped up walls and Regupol tape for jointing

4. Structural floor: beam and block, min 100mm thick dense aggregate infill blocks, min 50mm concrete topping, min strength class C20, to floor blocks, min 300kg/m2

combined mass per unit area

5. Ceiling: Min 300mm from top of beam to ceiling board.

System installation

The use of this screed resilient layer system must incorporate the following:

1) 8mm Regupol E48 (resilient layer to be laid over entire floor area with 50mm overlaps)

2) All joints sealed with Regupol tape

3) 0.2mm (min) waterproof membrane

• Regupol E48 must be laid dimpled side down

• Regupol E48 must be turned up at walls and lapped under wall linings and skirting

• Lay a 0.2mm (min) waterproof membrane over the entire floor.

Do

• Butt floor blocks tightly together

• Cover floor blocks with min 50mm concrete topping

• Ensure that concrete does not enter the cavity and bridge the two leaves of supporting wall blockwork – it is acceptable to use proprietary cavity stops to provide a shutter

• Ensure precast or in situ edge beams are correctly installed

• Ensure in situ concrete downstand is at least 75mm wide

• Ensure Regupol E48 is laid dimple side down, covers entire floor area and has overlapped joints sealed with Regupol tape

• Ensure Regupol E48 resilient layer isolates screed from the perimeter walls, wall linings and skirtings

• Ensure depth from top of beams to ceiling is min 300mm

• Ensure 50mm mineral fibre quilt is installed over whole ceiling board areas.

1. Regupol tape

2. Min 50mm overlap

3. 0.2mm (min) waterproof membrane

4. Regupol E48 lapped under wall linings and skirtings. 1 2 3 4


15 Acoustic separating floor - concrete E-FC-7 Part-E compliant

• Beam and block floor with precast or in situ edge beams

• Using floating floor treatments

• For use with dense aggregate block flanking walls only.

1

2

3

Do

• Butt floor blocks tightly together

• Cover floor blocks with min 50mm concrete topping

• Ensure that concrete does not enter the cavity and bridge the two leaves of supporting wall blockwork – it is acceptable to use proprietary cavity stops to provide a shutter

• Ensure precast or in situ edge beams are correctly installed

1. Floating floor treatment • Ensure in situ concrete downstand is

2. Structural floor: Beam and block, at least 75mm wide min 100mm thick dense aggregate infill blocks, min 50mm concrete • Ensure levelling screed is applied

topping, min strength class C20, to before using FFT1 or FFT3 (resilient

floor blocks, min 300kg/m2 batten) floating floor treatments

combined mass per unit area • Ensure quilt is inserted within FFT2 (cradle/saddle) floating floor

beam to ceiling board. 3. Ceiling: Min 300mm from top of

treatment

• Ensure floating floor treatment is suitable and install in accordance with manufacturer’s instructions

• Install flanking strips around the perimeter of the flooring board to isolate floor from walls and skirtings

• Ensure depth from top of beams to ceiling is min 300mm

• Ensure 25mm mineral fibre quilt is installed over whole ceiling board areas.


16 Hollowcore floors

Hollowcore units can offer the designer and contractor a flexible and economic answer to flooring challenges, due to the spans and widths of units available.

From supply only to a complete structural floor our clients need only select those elements that meet their requirements.

When all the hollowcore units are in place and lined up, the joints between the units are to be grouted with either a 3:1 sand/cement mix or C30 concrete with 10mm aggregate.

Technical

Units are produced on a long line method and come in a range of depths from 100mm to 400mm as shown on the span load table.

The standard section is suitable for a ‘moderate’ exposure condition as defined in BS8110.

Finishes

Concrete surface finish to soffit is a Type A finish as described in BS8110 Part 1:1997. Clause 6.2.7.3.

Where a plaster finish is intended it may be necessary to use a bonding agent in accordance with the manufacturer’s instructions.

Suspended ceilings are the preferred choice when hollowcore units are used. The soffits are not suitable to be painted without finishes being applied.

Units may accumulate water within the cores due to exposure during the construction programme.

The general contractor should drill weep holes as necessary.

Installation


2. If applicable, lay DPC prior to placing first unit in accordance with previously approved and issued layout drawings

3. Position remaining units in sequence working away from the first

4. Bar up units tight to each other after chains have been removed

5. Ensure all unit ends are in line and do not project into the cavity or overhang steelwork

6. When all units are in place and lined up, the joints between are to be grouted with C30 concrete

7. All grouting must be completed before subsequent works continue.

100mm* 2.39 5 4.8 4.6 4.5 4 3.5 3

150mm ss 3.19 6.9 6.5 6.25 6 5.7 5.5 5

150mm 2.42 7.2 7 6.5 6.2 6 5.8 5.1

200mm 3.07 8.5 8.5 8.5 8 7.8 7.5 6.5

250mm 3.37 9 9 9 9 9 9 8

300mm 4.02 11 11 11 11 10.5 10 9

350mm 4.43 13 12.5 12 11.7 11.2 11 9.5

400mm 5.03 15 14.5 14.5 14 13.2 12 11.5

Unit depth Self weight (kN/m2)

Screed finish = 1.5 (kN/m2) Superimposed loadings in (kN/m2)

Clear spans in metres 1.5 2 2.5 3 4 5 7.5

Slab load/span table

* 100mm SOLID

slab is tabulated

with 75mm bonded

structural screed.

The flexibility of Hollowcore design

Hollowcore units are available in various options including solid ends, open cores, raking cuts, holes and notches.


17

General notes

No prestressed unit to be cut or drilled without submission to, and agreement with, our technical department.

Shot-fired fixings are NOT PERMITTED in hollowcore units.


Differential cambers are likely to occur due to manufacturing/construction tolerances or where short and long units are adjacent or at the change of direction of spans.

Unit cambers will be generally in accordance with the recommendations of BS8110 and are predicted to be approximately 1/300th of the span.

Some form of leveling screed by a general contractor is recommended for polystyrene and chipboard or ‘floating’ type floors to accommodate slight differences in camber and level between units. Typically prestressed floor units will provide a fire resistance of one hour, however, ratings in excess of this can be supplied if necessary.

Small holes up to 50mm diameter can be drilled on site. Larger holes can be formed during manufacture, dependent on design criteria.


18 Flooring accessories

Void Ventilators

Adequate sub floor ventilation is required under suspended floors to assist in reducing condensation and dry rot damage. Air vents and bricks should be installed approximately every 2m. (See Building Regulations 1991 Approved Document C 1992 edition.)

Installation

No special fixings are required. Installation is easily carried out as work proceeds. Adjust the height of the vent to suit courses and height of floor.

Colours: Black.

Air Bricks

High airflow allows suitability in many applications. Louvres promote unrestricted airflow and reduce the risk of blockage as well as keeping large insects out.

Installation

No special fixings are required.

Colours: Blue/Black, Terracotta, Buff.

Split Course

Split Course bricks have a minimum 7N/mm2 compressive strength. Designed to be bedded top and bottom, they are available in the following sizes:

150mm Floors: Sizes: 385mm long, 100mm/140mm wide, 40mm deep. Pack Sizes: 168No, 336No.

200mm / 225mm Floors: Sizes: 195mm long, 100mm wide, 95mm deep. Pack Sizes: 180No, 360No.


19

Trimmer Angles

Steel trimmer angles can be utilised to trim service voids or create openings through the floor. Where a void created by removing blocks from between the beams is insufficient, then a steel angle painted with one coat of protective paint can be used. Supplied to a maximum of 1.2m long.

Butt Plates

Galvanised steel units to overcome localised butt seating requirements, which cannot be accommodated on the wall.

Manufactured to suit either 100mm or 140mm wide walls.

Butt Plates are available in two sizes:

BC1 - 160mm long to suit individual beams.

BC3 - 480mm long to suit double or triple beams.

Ceiling Clips

Ceiling batten support clips are inserted from below the floor; at the time the timber battens are being fixed. This is to ensure their correct position.

The top of the clip has a galvanised steel plate bent at right angles to allow the clip to be knocked into place. This plate wedges between the shoulder of the beam and the block.

The legs are designed to allow for bending or twisting around the timber battens. The pre-drilled holes accommodate nails or screws for fixings. Counter battens or propriety ceiling systems can then be installed.


20 Stairs and landings

Precast stairs and landings are available to suit most combinations of architectural design. Straight flights or integral top and bottom landings are available offered with unit widths, riser and tread dimensions to suit. Precast components are designed and manufactured to suit the clients requirements before leaving the factory. Speed of installation reduces risk and cuts cost. Installation is rapid providing instant and safe access between floor levels.

Benefits

• Straight flights or integral top and bottom landings are available

• Width, riser and tread dimensions to suit

• Stepped landings.

Speed

Precast components are designed and manufactured to suit the building before leaving the factory. Speed of construction reduces risk and cuts costs. Installation is rapid providing instant safe access between floor levels.

Design

Structural design is in accordance with BS8110 Part 1: 1997. The Structural Use of Concrete and the client’s loading specification. Stair dimensions will be in accordance with the client’s specifications, which should usually comply with the requirements of the Building Regulations Approved Documents B, K & M. and are then submitted for approval prior to manufacture.

Finishes

Stairs and landings are manufactured in moulds which produce Type A finishes as described in clause 6.2.7.3 of BS8110 Part 1: 1997. The soffit is a high quality steel float finish in accordance with NSCS specification section 4.

The precast units will require some making good and the lifting points will need grouting in after installation.

Lifting points

Each precast stair and landing unit will have between two and four lifting points for off-loading and placing the units.

Please contact the sales office at the time of ordering to confirm the type of lifting clutches being used.

Fire resistance

Stairs and landings will achieve a fire resistance of one hour. Higher fire resistance ratings can be achieved where specified by the client.

Durability

Precast concrete is unaffected by climatic conditions and is suitable for external and internal use.

Balustrade fixings

It is recommended that the main contractor should drill fixings for balustrade on site. A minimum dimension of 50mm should be allowed between the edge of any pocket or fixing and the edge of the concrete.


21

Precast stairs and landings

Finishes to suit Return landing architect’s requirements

Support landing

Support landing

Tread and riser units

Tread and riser units can be used where large precast stairs and landings are not suitable.

Benefits

• Easy to handle and built into spine walls to suit progress of the building

• Variable width, rise and tread dimensions

• Can be used internally and externally with finishes applied to the units.

Speed

Installation is rapid providing safe access between floor levels. No crane or plant required for installation.

Dimensions

LENGTH max. 1400mm

GOING max. 300mm

RISE max. 220mm

All units are easily positioned on each other to obtain the required going dimension.


22 Other structural solutions in precast

Aggregate Industries provides a huge range of civil engineering and construction solutions in precast concrete. We can manufacture products to any project requirement. Please call us for further information.

Railway platform products Stadiums and terracing Beams, columns, walls, and roof slabs

Precast stairs, landings Sea defences Architectural dressings, walling and flooring and roof tiles

Product development

Charcon Flooring has a policy of continuous product

development and product information is subject to change

without notice. All products are manufactured to the

appropriate British, (BS) standard or harmonised European

standards, (BS EN) wherever possible. If no standard currently

exists then Charcon Flooring’s own standard is applied. All

products are supplied subject to Charcon Flooring’s Terms

and Conditions of Sale, a copy of which is available on request.

Use of information within literature

The designs shown in this literature are illustrative only, and all

dimensions are nominal. Every effort is made to ensure the

accuracy of all textual and pictorial content in this guide. No

charge is levied for this brochure or the advice therein, and

accordingly the company, its employees and authorised

agents can accept no liability whatsoever, either indirectly or

directly arising from the use of its products in connection with

any information or advice contained in this guide. It is the

responsibility of clients and installers to check that installations

achieve the appropriate standard. The relevant British or

European standard should be referenced at all times.


23 Aggregate Industries The complete service

Charcon Flooring is part of the Aggregate Industries group offering an extensive range of products and services to the construction industry.

Structural Solutions

Charcon Precast Solutions

Charcon Precast Solutions supplies and installs precast stairs, landings and bespoke solutions for all specifications.

South Tel: 01353 861 416 Email: [email protected]

Midlands Tel: 01226 779 092 Email: [email protected]

North Tel: 01642 612 724 Email: [email protected]

Other Aggregate Industries businesses

Bardon Concrete

Bardon Concrete (and London Concrete within the M25) offers a complete range of ready-mixed concretes and screeds, operating from over 50 sites. The Elite Minimix operation caters for smaller collect loads.

Bardon Concrete Tel: 01283 714 187 Email: [email protected]

London Concrete Tel: 0208 380 7300 Email: [email protected]

Charcon

Charcon flag paving, block paving and kerb products are available in both concrete and natural stone. Surface water drainage and SUDS are also part of a wide ranging product portfolio.

Tel: 01335 372 222 Email: [email protected]

Bradstone Structural Solutions

Supplier of walling, roofing and cast stone architectural dressings for commercial and domestic building projects throughout the UK.


Charcon Specialist Products

Supplier of civil engineering products including service protection ducting, covers, markers and posts as well as rail platform products, highway furniture and filter bed wall and tile units.


Bardon Aggregates

Bardon Aggregates supplies crushed rock, sand and gravel and fill materials. These can be delivered by road, rail or marine transport.


Bardon Asphalt

Bardon Asphalt is a leading supplier of a full range of coated materials with over 50 locations in the UK, serving major conurbations, including Express Asphalt sites for collect business.



Charcon Flooring South Rowan House, Sheldon Business Park Chippenham, Wiltshire SN14 0SQ

Tel: +44 (0)1249 463244 Fax: +44 (0)1249 467353 Email: [email protected]


Charcon Flooring North Stephenson Way, Barrington Industrial Estate Bedlington, Northumberland NE22 7DL

Tel: +44 (0)1670 531160 Fax: +44 (0)1670 531170 Email: [email protected]


Founding Member

© Aggregate Industries UK Limited. February 2010

Stairs Flooring Precast Concrete

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