Most often, in country houses, of course, wooden floors are arranged. But in cottages on 2-3 floors, this element of the building structure can also be poured from concrete. Such ceilings are able to withstand heavy loads and at the same time are reliable. However, the construction of such structures, in comparison with wooden, of course, is more expensive. In addition, the technology itself for arranging floors of this type is considered relatively complex. Concrete structures of this type can be poured, for example, according to a profiled sheet.
Specifications
Monolithic ceilings can be erected on corrugated flooring not only in private houses, but also, for example, in industrial buildings, garages, warehouses, etc. Such structures are quite heavy. But since in this case corrugated board is used as the formwork, less concrete is required for their pouring than for the installation of a conventional monolithic slab. Consequently, the weight at the floor is reduced. Accordingly, such a plate has less load on the supports.
The advantages of such structures, in comparison with conventional monolithic, also include:
lack of need for use of multi-row fittings;
the ability to install the floor in a short time;
no need to dismantle the formwork.
In industrial premises, a ceiling so flooded is usually not even additionally finished. It looks like a professional sheet and is quite aesthetically pleasing.
Design
Before proceeding with the construction of a monolithic flooring on corrugated board, of course, you should draw up a detailed drawing of it and make all the necessary calculations. Designing such structures is a very complicated and responsible matter. Errors in the calculation of monolithic ceilings can lead to higher prices, reduced service life, and in some cases even to collapse of the structure.
Therefore, the design of such plates is usually entrusted to specialists. The owner of a house can do the calculation of a monolithic flooring on a professional flooring independently only if he has a special education. You can also design such a slab using software developed for this purpose.
Floor requirements
In most cases, I-beams are used as beams for such plates. When designing a monolithic flooring according to corrugated board, the following factors are taken into account, among other things:
each sheet must rest on at least three beams - at the edges and in the center;
beams should be laid at a distance of 1.5-3 m from each other;
along the length of the sheets when assembling the formwork under the floor can be mounted end-to-end;
at the same time, they overlap at least 1 wave;
the layer of concrete mixture after pouring should rise above the waves of material by at least 5 cm;
the reinforcing cage for such a plate is supposed to be knitted from a rod of 12-8 mm.
The surface of the finished plate can stand vertically from the edge of the sheet waves and by 3 cm. However, pouring in this way is allowed only if it is subsequently supposed to fill the screed on it.
Concrete ceilings are equipped, including professional flooring, only in buildings with heavy walls. Supporting plates on metal sheets is allowed exclusively on brick or block walling. It is impossible to equip structures of this type in wooden structures.
The device of monolithic flooring according to corrugated board: installation technology
Corrugated metal sheets on I-beams are laid so that their waves are perpendicular to the last. Most often, roofing material marked N. is used to fill the ceilings. It is believed that a sheet with a not too high wave is best suited for the installation of such structures. It is advisable to use such a professional flooring for a monolithic overlap primarily because in this case it turns out to be the most durable.
Ribbed metal sheets are fixed on the I-beams when mounting formwork with reinforced self-tapping screws. When using such fasteners, there is no need to pre-drill holes in the flooring and beams. Screws are screwed with a drill at low speeds in increments of about 30 cm. The overlays of the profiled sheet are usually additionally fixed with rivets.
Attic passage
After the entire opening of the building is closed, the vertical walls of the formwork from the boards are installed along the edges of the future slab. The same elements are mounted where in the future it is supposed to make an exit to the attic. Specialists advise to cover the boards before assembly with plastic wrap. Subsequently, this will greatly facilitate their dismantling.
After removing the boards from the finished plate at the exit to the attic, the corrugated board is simply cut with metal scissors. The operation is very simple and can be completed in a few minutes.
Reinforcement
At the next stage, reinforcement is installed on the formwork made of corrugated board and boards. In parallel with the waves, when it is knitted, they usually have a thicker rod of 12 mm. Perpendicular elements are made of reinforcement 6-8 mm. If desired, for such an overlap, you can also purchase a ready-made reinforcing mesh. However, filling the slab will cost in this case, of course, a little more expensive.
Of course, after pouring a monolithic overlap along the corrugated board, the frame should be in its thickness. Therefore, the connected reinforcement is lifted above the sheet on special plastic clips. According to the regulations, the knitted mesh should be located above the bottom of the metal formwork at a height of at least 1.5 cm. This will allow pouring a sufficiently reliable and durable overlap.
And the reinforcing frame made independently and purchased during the arrangement of the plate on the profiled sheet is mounted according to the same technology. Do-it-yourself wire for knitting a mesh is supposed to be used strong, 1.2-1.4 mm thick.
Additional supports
After the reinforcing cage is connected and installed, they begin to actually fill the slab. Previously, if necessary, additional steel or wooden vertical supports are installed under the sheets between the beams. Such structures are used in the event that the distance between the I-beams during the design of a monolithic overlap on the corrugated board was chosen sufficiently large. After the plate has hardened, the additional supports are simply dismantled.
Plate Fill
The concrete mixture for the construction of monolithic floors on corrugated board with their own hands in the vast majority of cases use a ready-made purchase. The fact is that such structures should be poured in at one go. Parts of concrete are laid into the formwork mainly only during the installation of large floors, for example, production workshops.
Of course, it will be extremely difficult to immediately prepare a large amount of cement mortar and pour it onto the sheets yourself. Therefore, concrete is laid when monolithic floors are installed using corrugated board, usually using the following technology:
a concrete truck is ordered to the place of work;
feed the solution into the formwork from a steel hose;
as the mixture spreads, all formed defects are leveled manually.
Also, in the process of pouring concrete, it is advisable to pierce with a shovel from time to time. This will avoid the appearance of voids in the finished plate, reducing its strength.
The final stage
Monolithic ceilings on the corrugated board freeze for quite a long time, like any other concrete structures. Sufficient strength of the plate will be gained only 4 weeks after pouring. At this point, additional supports can be removed from under them and proceed, for example, to the erection of a roof.
While the stove will solidify, it must be properly maintained. The first two weeks, the overlap at least 1 time per day should be watered. Otherwise, surface cracks may form on the plate. And this in the future will necessarily lead to crumbling of the upper layer. For reliability, the wetted plate can also be covered with plastic wrap. It is especially important to carry out such a procedure in hot weather.
What you need to know
Fill interfloor ceilings is supposed only at positive temperatures. Otherwise, such a design will not work too strong. Sometimes concrete slabs are made on profiled sheets in the winter. However, in this case, a mixture of a special composition is used for pouring, which increases the cost of the work.
Monolithic flooring on corrugated board: manual filling guide
Concrete is supplied during the manufacture of slabs into the formwork, thus, in most cases, from the tank using a hose. However, there is technology and self-pouring of such structures. In this case, an additional sectional climbing formwork is installed above the profiled sheet.
Filling of each part of such a design in this case is supposed to be performed at a time. Sections should be located across the I-beams so that each individual slab rests on at least three beams.
The shutoff walls of such formwork are not statically attached to the main frame. After pouring each section, the board is simply rearranged at the same distance. The configuration of this formwork element is such that the adjacent ready-made slabs after pouring turn out to be coupled according to the tenon / groove locking principle.
Do you need a screed?
The technology of the monolithic flooring device according to the corrugated board is thus relatively simple. Compared to concrete structures, slabs cast on a metal ribbed sheet are usually thinner. Indeed, in this case, formwork gives them additional strength. However, when used for supplying a hose solution with special evenness, the surface of such overlappings, unfortunately, usually does not differ. After all, adjusting it to builders during pouring can be quite difficult.
Therefore, after hardening the slab over it, in most cases a concrete screed is also equipped. The mixture for such a leveling coating can be prepared independently. It is used for pouring screeds, usually concrete, mixed in the ratio of cement / sand as 1/3. The minimum allowable thickness of such a leveling coating is 3 cm.
Terms of Use
The service life of monolithic ceilings, including those poured on a profiled sheet, corresponds to the durability of the main load-bearing elements of the house. That is, in the future, such a design will never have to be changed. However, such overlappings can last so long, of course, only if they are used correctly.
The service life of structures of this type may be reduced due to:
In order that such a monolithic flooring over corrugated board does not subsequently have to be repaired or dismantled, communications - heating and water supply pipes - should be laid in the attic with the exact observance of all the required technologies. This is especially true for stoves that serve as floors or ceilings for bathrooms, steam rooms, etc. Any leaks over such ceilings should be repaired immediately.