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SDI MANUALOF CONSTRUCTIONWITHSTEEL DECK
SDI MANUALOF CONSTRUCTION
WITHSTEEL DECK
MOC22006
22SECOND EDITION
TABLE OF CONTENTS Page I. PRODUCTDESCRIPTIONS.......................................... 4 1 General–AllDeckProducts................................... 4 2 CompositeFloorDeck.......................................... 4 3 RoofDeck........................................................ 5 4 CellularDeck..................................................... 5 5 FormDeck........................................................ 6 II. APPROVEDERECTIONDRAWINGS................................12 III. PACKAGING..........................................................12 IV. LOADING&SHIPPING...............................................14 V. RECEIVING,UNLOADING,STORAGE&PROTECTION............ 15 1 DeckProtectionExample...................................... 16 2 DeckOrderingCheckList...................................... 17 VI. ERECTIONOFDECK&JOBSITESAFETY.........................18 1 Alertness......................................................... 19 2 Lifting............................................................. 20 3 Fastening&Installing...........................................26 4 Housekeeping................................................... 34VII. DECKDAMAGE&PENETRATIONS.................................35 1 RoofDeck.........................................................35 2 PenetrationExample............................................36 3 DetailsforOpeningExample..................................37 4 SumpPans....................................................... 38 5 FloorDeck........................................................40 6 CantileversExample............................................ 41VIII. PLACINGCONCRETE................................................42 IX. SPECIALCONSIDERATIONSFORDIAPHRAGMS................. 45 1 ConstructionLoadTable........................................45 2 DeckLoadingDiagrams........................................46 3 References........................................................47
SDI NOTICE
TheSteelDeckInstitutemakesnorepresentationorwarrantyrespectinganyinformationcontainedinthismanual,including,butnotlimitedto,theaccuracy,completeness,orsuitabilityofsuchinformationforanyparticularpurposeoruse.TheSteelDeckInstituteexpresslydisclaimsanyandallwarranties,expressedorimplied.Bymakingthisinformationavailable,theSteelDeckInstituteisnotrenderingprofessionalservices,andassumesnodutyorresponsibilitywithrespecttoanypersonmakinguseofthisinformation.Inaddition,neithertheSteelDeckInstitutenoranyofitsMembersorAssociateMembersshallbeliableforanyclaim,demand,injury,loss,expense,costorliabilityofanykindwhatsoeverwhichinanywayarisesoutoforisconnectedwiththeuseoftheinformationcontainedinthispublication,whetherornotsuchclaim,demand,loss,expense,orliabilityresultsdirectlyorindirectlyfromanyactionoromissionoftheSteelDeckInstituteoranyofitsMembersorAssociateMembers.Anypartyusingtheinformationcontainedinthismanualassumesallliabilityarisingfromsuchuse.
©Copyright2006SteelDeckInstitute
2 3
PURPOSE Thismanualisintendedtobeanaideandgeneralguideforthesafeandpropererectionofsteeldeck.Theobjectivesaresafety,whichisalwaysparamount,andprovidingagoodqualityjob.Thismanualisnotintendedtodefinespecificdutiesorresponsibilitiesofanyoftheparticipantsinvolvedindoingtheworknorisitintendedtoreplacenecessarycontractdocuments.Eachparticipantthedesignprofessional,thedeckmanufacturer,thegeneralcontractor,thedeckerector,theowner,andeachindividualworkershouldbeawareoftheirindividualresponsibilities,asdefinedinthecontractdocuments,sothatthejobenvironmentwillbeassafeaspossibleandalsotoproduceagoodjob. Whiletheinformationpresentedinthismanualhasbeenpreparedinaccordancewithgenerallyrecognizedengineeringprinciplesandacceptedconstructionpractice,itisrecommendedthatitbereviewedbythedesignprofessionalandthebuilderforitsapplicabilityforanyspecificjob.
ACKNOWLEDGEMENT ThispublicationisarevisionoftheoriginaldocumentreflectingchangesinconstructionpracticesandrevisionstoOSHA1926SubpartR.Sincethisisarevisionoftheoriginalmanualwiththemajorityofitbeingreprinted,theSDIwouldstillliketorecognizethoseinvolvedwiththisoriginalmanual.EspeciallyProfessorLarryD.LuttrellofWestVirginiaUniversity(ResearchAdvisortotheSDI)forhisreviewandcomments;Mrs.CherylJanuszforeditingthetext;Mr.MerleNordykeforhisexcellentcartoons;Mr.JohnMcMahonoftheInstituteoftheIronworkingIndustryforhisadvice;andthemembersoftheSteelErectorsAssociationofAmerica(SEAA)fortheirmanyhelpfulsuggestions.
TheSDIErectionCommittee
SDI MANUALOF CONSTRUCTION
WITHSTEEL DECK
2 3
1. General - All Deck Products
Steeldeckismadebycoldformingstructuralgradesheetsteelintoarepeatingpatternofparallelribs.Thestrengthandstiffnessofthepanelsarearesultoftheshapeoftheribsandthemate-rialpropertiesofthesteel.Decklengthscanbevariedtosuitjobconditionsbut,becauseofshippingconsiderations,areusuallylessthan40’.Standarddeckwidthvarieswiththeproductusedbutfullsheetsareusually12”,18”,24”,30”or36”.Deckistypicallyfurnishedinastandardwidthwiththeendssquarecut.Anycuttingforwidth,suchasatopeningsorforangularfit,isdoneatthejobsite. Deckistypicallyattachedtothebuildingframewitharcpuddlewelds,selfdrillingscrewsorpowderorpneumaticallydrivenpins.Sheettosheetfasteningisdonewithscrews,buttonpunching(crimping),orwelds.
2. Composite Floor Deck
Afterinstallationandadequatefastening,floordeckservesseveralpurposes.It(a)actsasaworkingplatform(b)stabilizestheframe(c)servesasconcreteformfortheslaband(d)reinforcestheslabtocarrythedesignloadsappliedduringthelifeofthebuild-ing.Compositedecksaredistinguishedbythepresenceofshearconnectordevicesaspartofthedeck.Thesedevicesaredesignedtomechanicallylocktheconcreteanddecktogethersothattheconcreteandthedeckworktogethertocarrysubsequentfloorloads.Theshearconnectordevicescanberolledinembossments,lugs,holesorwiresweldedtothepanels.Thedeckprofileconfigu-rationcanalsobeusedtointerlockconcreteandsteel. Compositedeckfinishesareeithergalvanized(zinccoated)orphosphatized/painted.Phosphatized/painteddeckhasabare(phosphatized)topsurfacewhichisthesidetobeincontactwiththeconcrete.Thisbaretopsurfacecanbeexpectedtodeveloprustbeforeconcreteisplaced.Thebottomsideofthedeckhasaprimercoatofpaint.(SeethenextsectiononRoofDeckforadescriptionofprimerpaint.)Galvanizeddeckhasazinccoatingonbothsides. Compositefloordeckisnormallyinstalledsothepanelendsdonotoverlaponthesupportingbeams.Shearlugsorprofileshapeoftenpreventatightmetal-to-metalfitifpanelendsoverlap.Theairgapcausedbyoverlappingpreventsproperfusionwiththestructuralsteelwhensheetendlapsareshearstudwelded. Adequateendbearingofthedeckmustbeobtainedasshownontheerectiondrawings.Ifbearingisactuallylessthanshown,furtherinvestigationisrequired.
Steel DeckInstitute
I. PRODUCT DESCRIPTIONS
4 5
3. Roof Deck
Roofdeckisnotdesignedtoactcompositelywithothermateri-als.Roofdeckactsaloneintransferringhorizontalandverticalloadsintothebuildingframe.Roofdeckribopeningsareusuallynarrowerthanfloordeckribopenings.Thisprovidesadequatesup-portofrigidthermalinsulationboard. Roofdeckistypicallyinstalledtoendlapapproximately2”oversupports.However,itcanbebutted(orlappedmorethan2”)tosolvefieldfitproblems.Sincedesignprofessionalsfrequentlyusetheinstalleddecksystemaspartofthehorizontalbracingsystem(thedeckasadiaphragm),anyfasteningsubstitutionorchangeshouldbeapprovedbythedesignprofessional.Continuousperim-etersupportofthedeckisnecessarytolimitedgedeflectioninthefinishedroofandmayberequiredfordiaphragmsheartransfer. Standardroofdeckfinishesaregalvanizedorprimedpainted.Thestandardfactoryappliedpaintforroofdeckisaprimerpaintandisnotintendedtoweatherforextendedtimeperiods.Fieldpainting,touchupofabrasionsanddeteriorationoftheprimercoatorotherprotectivefinishesaretheresponsibilityofthebuyer.Itisrecommended,however,thatanyfieldpaintbeappliedoverasmalltestareaoftheprimeddeckandtestedforcompatibilityandadhesionpriortoproceedingwithfieldpainting.Specialpaint,orpainttobeappliedovergalvanizing,isavailableonspecialorderbutmustbeadequatelydescribedtothemanufacturerbeforebidding.
4. Cellular Deck
Cellulardeckismadebyattachingabottomsteelsheettoaroofdeckorcompositefloordeckpanel.Cellulardeckcanbeusedinthesamemannerasfloordeck.Electrical,telephoneandcom-puterwiresareeasilyrunthroughthechasecreatedbetweenthedeckpanelandthebottomsheet. Whenusedasapartoftheelectricaldistributionsystem,thecellulardeckmustbeinstalledsothattheribslineupandcreateasmoothcelltransitionatabuttingends.Thejointthatoccursatbuttingcellendsmustbetapedorotherwiseprotectedtopreventconcretefromenteringthecell.Cellinteriorsmustbefreeofweld-ingburrsorothersharpintrusionstopreventdamagetowires. Whenusedasroofdeck,thebottomflatplateisusuallyleftexposedtoview.Caremustbemaintainedduringerectiontokeepgoodalignmentandpreventdamage.
Steel DeckInstitute
I. PRODUCT DESCRIPTIONS
4 5
Cellulardeckissometimesusedwiththeflatplateonthetopsidetoprovideaflatwalkingsurface.Installationofdeckforthispurposerequiresspecialmethodsforattachmenttotheframebecausetheflatplatenowonthetopcanpreventdirectaccesstothedeckmaterialthatisbearingonthestructuralsteel.Itmaybeadvisabletotreattheflattopsurfacetopreventslipping. Cellulardeckisalwaysfurnishedgalvanizedorpaintedovergalvanized.
5. Form Deck
Formdeckcanbeanyfloororroofdeckproductusedasaconcreteform.Connectionstotheframearebythesamemethodsusedtoattachfloorandroofdeck.Weldingwashersarerecom-mendedwhenweldingmetalthicknessislessthan0.0280inches. Formdeckisfurnishedgalvanized,primepaintedoruncoated.Galvanizeddeckmustbeusedforthoseroofdecksystemswhereformdeckisusedtocarryalightweightinsulatingconcretefill. Inapatented,dryinstalledroofdeckassembly,formdeckisuti-lizedastheprimaryloadcarryingelement.Thisassemblyfunctionsasastructuralroofdeckdiaphragm.Theassemblymayincludedryinstalledthermalinsulationplacedaboveeitherprimepainted,fieldpaintedgalvanizedorgalvanizedandpaintedsteelsections.
Steel DeckInstitute
PRODUCT DESCRIPTIONS
6 7
Steel DeckInstitute
PRODUCT DESCRIPTIONS
6 7
DECK PROFILES
Figure 1ALL DIMENSIONS ARE NOMINAL
3”X12”
2”X12”
1-1/2”X12”
2”X6”
1-1/2”X6”
3”X8”(DR)
1-1/2”X6”(WR)
1-1/2”X6”(IR)
1-1/2”X6”(NR)
9/16”XVARIES
15/16”XVARIES
1-5/16”XVARIES
TYPICAL COMPOSITE FLOOR DECK PROFILES
TYPICAL ROOF DECK PROFILES
TYPICAL FORM DECK PROFILES
Steel DeckInstitute
DECK PROFILES
8 9
Figure 1AAll dimensions are nominal.
36”O
R24
”CO
VER
AG
E
12”
24-1
/2”C
OV
ERA
GE
36”O
R30
”CO
VER
AG
E
6”
24”C
OV
ERA
GE
8”
61 /8”
1½
”X1
2”2”
X1
2”3”
X1
2”Co
mp
osite
2”X
6”
Com
pos
ite
1½
”X6
”Co
mp
osite
3”X
8”
Com
pos
ite
.03” to .06”
.0
3” to .06”
.03” to .06”
.03” to .06”
2p
sfto 4p
sf
2p
sfto 4p
sf
2p
sfto 4p
sf
2p
sfto 4p
sf
Emb
ossm
entp
atte
rns
will
var
yfr
omm
anuf
actu
rert
om
anuf
actu
rer.
Side
lap
sar
efla
tadj
usta
ble
orb
utto
np
unch
able
.
Emb
ossm
entp
atte
rns
will
var
yfr
omm
anuf
actu
rert
om
anuf
actu
rer.
Side
lap
sar
efla
tadj
usta
ble
orb
utto
np
unch
able
.
Emb
ossm
entp
atte
rns
will
var
yfr
omm
anuf
actu
rert
om
anuf
actu
rer.
Side
lap
sar
efla
tadj
usta
ble
orb
utto
np
unch
able
.Thi
sp
rofil
eis
not
gen
eral
lys
uita
ble
foru
sew
iths
hear
stu
ds.
Steel DeckInstitute
DECK PROFILES
8 9
Figure 1BAll dimensions are nominal.
36”O
R30
”CO
VER
AG
E
36”O
R30
”CO
VER
AG
E
36”O
R30
”CO
VER
AG
E
6”
24”C
OV
ERA
GE
8”6”
1½
”X
6”
Wid
eRi
b(W
R)
1½
”X
6”
Inte
rmed
iate
Rib
(IR)
1½
”X
6”
Nar
row
Rib
(NR)
3”X
8”
Dee
pR
ib(D
R)
.03” to .06”
.0
3” to .06”
.03” to .06”
.03” to .06”
2p
sfto 4p
sf
2p
sfto 4p
sf
2p
sfto 4p
sf
2p
sfto 4p
sf
May
be
refe
rred
toa
s“B”
dec
k.Si
dela
ps
may
be
flata
djus
tab
leo
rb
utto
np
unch
able
.Aco
ustic
al
deck
will
hav
ep
erfo
rate
dw
ebs.
May
be
refe
rred
toa
s“F”
dec
k.
May
be
refe
rred
toa
s“A”
dec
k.
May
be
refe
rred
toa
s“N
”dec
k.Si
dela
ps
may
be
flata
djus
tab
leo
rb
utto
np
unch
able
.Aco
ustic
al
de
ckw
illh
ave
per
fora
ted
web
s.
6”
1 /2”
MIN
.
13 /4”
MIN
.
13 /4”
NO
M.
3 /8”
MIN
.
1”N
OM
.
11 /2”
MIN
.
21 /2”
NO
M.
23 /4”
NO
M.
Steel DeckInstitute
DECK PROFILES
10 11
Figure 1CAll dimensions are nominal.
24”O
R36
”CO
VER
AG
E
12”
6”
24”C
OV
ERA
GE
8”
3”X
12”
Com
pos
ite
Cellu
lar
2”X
12”
Com
pos
iteCe
llula
r
1½
”X
6”
Com
pos
ite
Cellu
lar
3”X
8”
Com
pos
ite
Cellu
lar
.03” to .06”
.0
3” to .06”
.03” to .06”
.03” to .06”
4p
sfto 7p
sf
4p
sfto 7p
sf
4p
sfto 7p
sf
4p
sfto 7p
sf
Bott
omp
late
may
be
per
fora
ted
fora
cous
tical
.
Bott
omp
late
may
be
per
fora
ted
fora
cous
tical
.
May
als
ob
eus
eda
sa
roof
dec
k.Bo
ttom
pla
tem
ayb
ep
erfo
rate
dfo
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ustic
al.
May
als
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eus
eda
sa
roof
dec
k.Bo
ttom
pla
tem
ayb
ep
erfo
rate
dfo
raco
ustic
al.
24”O
R36
”CO
VER
AG
E
12”
24”O
R36
”CO
VER
AG
E
Steel DeckInstitute
DECK PROFILES
10 11
Figure 1DAll dimensions are nominal.
24”T
O3
6”C
OV
ERA
GE
9/16
”X
Var
ies
Form
Dec
k
15/1
6”X
Var
ies
Form
Dec
k
1-5/
16”
XV
arie
sFo
rmD
eck
1-1/
2”o
r2”
XV
arie
sFo
rmD
eck
.014
”to .030
”
.017
”to .040
”
.017
”to .047
”
.023
”to .047
”
0.8
psf
to1.
5p
sf
1.0
psf
to2.
0p
sf
1.0
psf
to2.
8p
sf
1.4
psf
to2.
8p
sf
Stan
dard
form
dec
k.U
sed
as
cent
erin
g.
Hea
vyd
uty
form
dec
k.U
sed
asc
ente
ring
Extr
ahe
avy
duty
form
dec
k.U
sed
asc
ente
ring.
Sup
erd
uty
form
dec
k.U
sed
asc
ente
ring.
24”T
O3
6”C
OV
ERA
GE
24”T
O3
6”C
OV
ERA
GE
24”T
O3
2”C
OV
ERA
GE
Not
e: A
ll pr
ofile
s m
ay b
e us
ed a
s ro
of d
eck
(for
a p
aten
ted
asse
mbl
y)
Onlythoseinstallationdrawingsthathavebeenstamped“APPROVEDFORCONSTRUCTION”i.e.“FIELDUSE”shouldbeusedfordeckerection. Priortobeginningdeckerection,theerectorshouldreviewtheplansforoveralljobsiteorientation.Onprojectswithmultipledeckprofilesandgages,individualareasshouldbeidentifiedforeachtypeofdeck. AllGeneralNotesshouldbereviewedforspecialinstructions.Drawingsectionsinparticularneedtobestudiedforinstallationdetails.Thedrawingsandbundletagsneedtobeexaminedforproperbundleplacement. The engineer of record has approved the attachment method and pattern. Therefore, all fastening to the structure and sheet side laps should be carefully followed as shown on the “APPROVED FOR CONSTRUCTION” drawings.
Deckisbandedintobundlesthatcanweighseveralthousandpoundsbutthedeckbundleweightwillbelimitedtoamaximum4000poundsfordecktobeappliedtojoists.Deckbundleweightsformaterialtobeappliedoverstructuralsteelframesorotherfram-ingsystemswillbeasrequiredtosuitjobconditions,andtomeetsafehoisting,spreadingandinstallationprocedures.Ifheavierorlighterbundlesarerequiredbecauseofjobconditions,thisinfor-mationmustbeconveyedtothedecksupplierwellbeforeproduc-tionisscheduled.Thedecksupplier,theerectorandthepurchasershouldallbeinagreementaboutthebundlesizesandweightsthataretobedeliveredtothejob. Tags(seeFigure2)onthebundlesmayprovidesomeorallofthefollowinginformation:
1. weightofbundle 2. deckmanufacturer’scontractnumber 3. customernameandjobname 4. productdescriptiongage(thickness),productname, andfinish 5. numberofpieces,lengths 6. area(onjob)thatistoreceivethebundle 7. bundlenumber 8. anyspecialnoticesorstorageinstructions
Specialtags,suchasthoserequiredbyUnderwritersLabora-toriesorFactoryMutual,areappliedtothebundleandnottotheindividualsheets. Any special markings or other information (as well as special pack-aging) must be agreed upon prior to fabrication. Previouslyagreeduponcolorcodingisoftenveryhelpfulforgageidentificationonamultigageproject.Colorcodingmayalsobeagreeduponforotherquickidentificationpurposes.
Steel DeckInstitute
II. APPROVED ERECTION DRAWINGS
12 13
III. PACKAGING
Steel DeckInstitute
II. APPROVED ERECTION DRAWINGS
12 13
EXAMPLE OF BUNDLE TAGFigure 2
STEEL DECKFABRICATOR
CONTRACT NO.
CUSTOMER NAMEPROJECT NAME
PROJECT ADDRESS
DECK TYPE, GAGE, FINISH
NOTES:
NUMBER LENGTH OF PIECES FT. IN. INCHES MARK
20 27 10.00 334.00 20 25 11.00 311.00 5 25 7.00 307.00 45
BUNDLENO XOFX TRUCK:XXCONTROLNO. XXXX-XXX-XXXXXBOM.BUNDLENO. XX
Bundletagsshowthejobarea(derrick)wherethebundlebelongs.Thedeckmanufacturerwillsequencedeckbundlingsothatdeckwillbedeliveredinaproper(orpreviouslyagreedupon)orderandbeunloadedandhoistedinlogicalsequences.Erectioninformationshouldbemadeavailabletothedeckmanufacturerassoonaspossibleafterplacingtheordersothatsequencingcanbedoneduringpreparationofapprovaldrawings. Alljobconditionsthatwillaffectshipping(i.e.weightrestric-tions,staging,specialstrapping,blocking,tarping)shouldbedeter-minedwellinadvanceoffabricationsothatappropriatestepscanbetakenbytheshipper. Thedeckmanufacturerwillloadtrucksusingstandardproce-dures.Theseproceduresmayconsiderthefollowing:
1. Strappingwillbesecured,preventingblowofforloosening ofsheetsduringtransit. 2. Deckbundlesmaybeplacedagainstthetrailerortruck bulkheadtopreventforwardmovementincaseofa suddenstop.Notethatloaddistributionmaydictate anotherarrangement. 3. Deckbundlesareseparatedwithdunnage(horizontallyand vertically)ofatleast1½“(moreifagreedupon)sothat liftingslingscanbeinsertedforunloading. 4. Deckwillbeloadedwiththelongestbundlesonthebedof thetrucktoensurethattheloadwillbebalanced. 5. Toensuresafeandlevelloads,everyotherbundlemaybe turnedonthetruck.Inallcasesthebundlearrangementon thetrailerwillbemadewithanefforttoprovidethe greateststabilityoftheloadandtoachievethe allowableweight.
Duringtransportation,shockandvibrationtendstocompressbundles,whichcanresultinslackeningofthetrailerloadbindersnormallyusedinthetransportofdeck.Thismaycauseadangeroussituation;overtighteningofthetiedownsinanticipationofsettlingwilldamagetheproduct.Periodicadjustmentsandretighteningarenecessary.Eachadjustmentshouldalsoensurethatthetarpsarerepositionedtokeeptheloaddrytopreventmoisturefromaffectingthefinish. Unlesspartialshipmentsorlessthantruckload(LTL)shipmentsareagreedupon,fulltruckloadshipmentsarestandard.Truckloadswillbedeterminedbyweightandvolume.IfLTLshipmentsareused,thedeckmanufacturercannotberesponsibleforanydamagecausedbyrehandlingorloadtransferbetweentruckingcompanies.
Steel DeckInstitute
IV. LOADING AND SHIPPING
14 15
Receiving
Theremustbeproperaccesstothestructureforthedeckdelivery.Theaccessmustbeadequatetosupporttheliftingequip-mentandthedeliverytrucks.Liftingequipmentmustbecapableofsafelyliftingthedeckbundlesandhavesufficientreachtoproperlyplacethebundlesonthestructure.
Unloading
Materialshouldbecheckedasitisreceived.Bundlesshouldbecounted.Thebillofladingshouldbecheckedtoverifytrailercontents.Smallpackagesaresometimescarriedinsidethetractor.Checktoseeifallitemsarepresent.Anymaterialdamagesorshort-agesshouldbenotedonthebillofladingpriortosigningforthematerialandthesuppliershouldbeimmediatelynotified.
Steel DeckInstitute
IV. LOADING AND SHIPPING
14 15
V. RECEIVING, UNLOADING STORAGE AND PROTECTION
“KEEP LOAD IN SIGHT UNTIL SAFELY LANDED”
Storage and Protection
Ifgroundstorageisneeded,thedeckbundlesshouldbestoredofftheground,withoneendelevatedtoprovidedrainage.Bundlesshouldbeprotectedagainstcondensationwithaventilatedwaterproofcovering.Bundlesshouldbestackedsothatthereisnodangeroftipping,sliding,rolling,shiftingormaterialdamage. Bundlesshouldbecheckedfortightnesssowindcannotloosensheetsorworkthebundlesapart.Tightnessshouldbeperiodicallycheckedandadditionalsecurementshouldbeusedasneeded.Bundlesshouldneverbehoistedbythestrappingandshouldalwaysbeplacedtagsideup.ItisthepositionoftheSteelDeckInstitutethat;DECKBUNDLESMUSTALWAYSBEPLACEDONTHEFRAMENEARAMAINSUPPORTINGBEAMATACOLUMNORWALL.INNOCASE,SHOULDTHEBUNDLESBEPLACEDONUNBOLTEDFRAMESORUNATTACHEDORUNBRIDGEDJOISTS.Thestructuralframemustbeproperlybracedtoreceivethebundles. OSHAFederalRegisterSubpartR1926.757doesallowsomeflexibilityastohowandwhen,duringthestructure’serectionpro-cess,landingbundlesofdeckispermitted.ThisOSHAregulationmustbeexaminedbyanyoneengagedinthisactivity,suchthatallcriteriaisunderstoodandmet.
Steel DeckInstitute
RECEIVING, UNLOADINGSTORAGE AND PROTECTION
16 17
Recommendation for Protecting DeckBundles at Job Site
Important:Leaveendopenforventilation.
Properlysecuretarptopreventblow-off.
Waterproofcovering.Suchasplasticoratarp
Placeafewpiecesofblockingonbundletocreateoverhangtosupporttarp.
Elevate“thick”endofbundletohelpshedordrainanymoisturepenetration.
Important:Leaveendopenforventilation.
I. DeckProfile WideRib(WR)-B IntermediateRib(IR)-FNarrowRib(NR)A 3”DeepRib(3DR)-NOther
II. DeckType(thickness)–Gageandinches. 22(0.0295”) 20(0.0358”) 18(0.0474”) 16(0.0598”) CellularBottomPlate 20(0.0358”) 18(0.0474”) 16(0.0598”) Other-Specifydecimalthickness
III. DeckFinish PrimePaintedManufacturer’sStandard G60Galvanized G90Galvanized PrimePaint(manufacturer’sstandard)overG60 GalvanizingUncoated Other-SpecifyinSeparateDocument
IV. IsFireRatingRequired? Yes-GiveAppropriateU.L.DesignNumberandHours RequiredorF.M.Number
V. SheetLengthLimits NoneorSpecify
VI. BundleWeightRestrictions Nottoexceed_________lbs. NoRestrictions
VII.RequiredSpaceBetweenBundlesforHoistingDevices Standard1½”. Other-Specify
VIII.SpecialTaggingonBundles U.L.Labels F.M.Labels Other-Specify
Anyspecialsequencing,timingorotherrestrictionsmustbeprovidedtothedecksupplier.Thedecksuppliermustbeprovidedacompleteandaccurateaddressforshipping.
Steel DeckInstitute
RECEIVING, UNLOADINGSTORAGE AND PROTECTION
16 17
DECK ORDERINGCHECK LIST
Steel DeckInstitute
VI. ERECTION OF DECK AND JOB SITE SAFETY
18 19
Serious injury or death can result from failure to familiarize and comply with all applicable safety requirements of federal, state and local regulations and these safety guidelines before erecting steel deck. OSHAFederalRegisterSubpartR1926issuedJanuary18,2002providesspecificerectionguidelinesfortypicalconditions.How-ever,whereemployerselect,duetoconditionsspecifictothesite,todevelopalternatemeansandmethodsthatprovideemployeeprotection,asitespecificerectionplanshallbedevelopedbyaqualifiedperson.OSHAprovidesguidelinesforestablishingasitespecificerectionplaninAppendixAoftheOSHAFederalRegis-terSubpartR1926.Thedeckmanufacturerisnotresponsibleforpreparingthe“sitespecific”erectionplan.However,deckerectiondrawingsmaybehelpfultothosepreparingtheplan. Deckerectorscreatetheirownworkingplatform.Forthemostparttheseplatformswillnothaveprotectededgesorprotectedopenings.Erectorsmustalsoworkontheopensteelframeanduseladdersorscaffoldingtoaccessthework. Coil ordering practices and manufacturing processes have been established and are being followed so that as shipped deck products will be free of visible liquid lubricants and dry residues will be minimized. The purpose of establishing these practices and processes is to reduce the slipping hazard of the walking surfaces of decking products. For more information on this issue, please refer to the “Steel Coalition Lubricant Task Group Report” dated May 14, 2002. This report is available on the SDI web site.
Alertness
Mostdeckinstallationsaredoneonanelevatedstructureandthedangeroffallingisalwayspresent.Fallsmayoccuratanytimeandatanylocation.Alertnessisessential.Laddersshouldbesecurelytiedtothestructuralframeorthescaffolding.Stairs,ifavailable,shouldberigidlyattachedtothebuildingframe. Accessareasshouldbespeciallypatrolledtokeepthemfreeofequipment,material,anddebris. Deckedgesaresharp.Workersshouldtakeprecautionstopro-tectthemselvesfromsharpedgesorprojectingcorners. Itisveryimportantthatthestructurebereadytoreceivethedeck.Beforedeckbundlesareplacedontheframe,theframeplumbnessandconnectionsshouldbechecked.Verifythattempo-rarybracingisinplacetokeeptheframeinaplumbconditionuntilthedeckisplacedandsecured.
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“ SHARP EDGES ARE A CONSTANT THREAT”
Lifting
Steeljoistsmustbesecurelyattachedattheirbearingendsandhavetheirbridgingcompletelyattached.Verifythestructure’scapacitytocarrythedeckbundles. Thebundlesmustberiggedforliftingsothatshiftingandex-cessivetippingwillnotoccurandsotheliftingdevicewillnotdam-agethedeck(seeFigure3).Allliftingequipmentmustbeadequateforthejob.Thehoistingoperationmustbeproperlydirectedandmanned.Taglinesattachedtothebundles(nottothebands)willhelpworkerscontrolandpositiontheload.Nevermovebundlesbypullingonthestrapping.(SeeSectionVonUnloading).Ifpos-sible,spreaddeckbundlesoutalongthebuildingcolumnlinestocreateseveralsmallstacksratherthanstackingallthebundlesinonearea.Workersshouldbeinstructedtokeeptheloadinsightuntilitissafelyplacedonthestructure.Bundlesshouldbelandedsothattheendsofthebundlesrestonabearingsurfaceratherthanhavingoneorbothendscantilevered.Thebundlesshouldbepositionedforconvenientspreadingofsheetsandorientedsoindividualdecksheetswillnotneedtobeturned.Bundlesofdeckwhichhavebeenunbandedmustbesecuredtopreventindividualsheetsfrombeingblownoffthestructure.
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EXAMPLE OF ONE LIFTING METHODFigure 3
Cranehookwithspring-loadedsafetypin
Liftingcables
Chokerhitch
Bundlestrapsappliedatfactoryaretoremainonbundleuntilplacedforerectionandsheetsarereadytobespread.Checkfortightness.Bundle straps are not to be used to move or lift deck bundles.
Safe Working Platform
Tomaketheworkingplatformsafeandpreventdeckdam-age,thedeckunitsshouldbeattachedtotheframeandsidelapsconnectedassoonaspossible.Ifdecksheetsaretemporarilyusedtoaccessbundles,theymustbeendbearing(notcantilevered)andmustbesecurelyattachedtotheframetopreventslipoff.Aworkingareashouldbeatleast12feetwide.Itisrecommendedthataworkingareabeestablishedaroundoralongeachbundlesothatthebundlecansafelybeaccessed.Theplatformcanthenbeextendedinanyconvenientdirection.Specificjobrequirementsneedtobeconsideredtodeterminedeckerectionstartingpointsanderectionprogression.Astheplatformisextendeditwillbenecessaryforatleastoneworkertoworkfromthestructuralframe.OSHAstandardsrequirethatemployersprovidefallprotectionduringdeckerectionoperationsandallOSHAguidelinesforsafetywhileerectingdeckmustbefollowed.RefertoOSHARegulation29CFRSection1926.759(c)(2003)whichstatesthatunderspecialcircumstancesaControlledDeckZone(CDZ)maybeestablishedwhichpermitsflexibilitytothemethodsofpersonalfallprotection.
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“ PLACE HEAVY LOADS OVER MAIN SUPPORTS”
Placing Deck
Asthedecksheetsareplaced,oneedgeofdeckwillalwaysbe“open”orleading.Thisleadingedgeshouldonlybeapproachedinordertoplacethenextsheet.Workersshouldalsomaintainasafedistance(6feetifpossible)fromtheendofthedeckunit.Whenaligningtheedge(side)lap,theworkershouldkneel.Kneelinglow-ershiscenterofgravityanddecreasesthechanceoffalling.RefertoOSHARegulation29CFRSection1926.759(a)(1)(2003)whichstatesthatunderspecialcircumstancesaControlledDeckZone(CDZ)maybeestablishedwhichpermitsflexibilitytothemethodsofdeckinstallation. Roofandfloorholesandopeningsshallbedeckedover,unlessthesizeoftheholeorspecialdesigncircumstancespreventitfrombeingdeckedover.Itistheresponsibilityofthedesignprofession-altodefinewhetheraholeisrequiredtobedeckedover.Wherelargesizeholesorotherconditionsthatdonotallowanopeningtobedeckedover,employeesshallbeprotectedinaccordancewithOSHARegulation29CFRSection1926.760(a)(1)(2003).
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Other Trades
Othertradesshouldbekeptofftheworkingplatformandtheareaimmediatelybelowtheworkingplatformduringthedeckerectionprocess.Caremustbetakenwhencuttingbundlestrapstopreventstrapsordunnagefromdroppingontopersonnelorequipment.Workersshouldbeinstructedonallaspectsofdecksafetybeforeanydeckisinstalled.SuchinstructionisavailabletomembersonrequestfromtheIronWorkersInternationalAssocia-tion(AFL-CIO)bycontactingalocaluniontrainingcoordinator.Non-unionsourcesmayalsobeavailable. Floordeckshouldbeselectedsothatitprovidesatleastfiftypoundspersquarefootcapacityasaworkingplatform.Iftempo-raryshoringisrequiredtoattainfiftypoundspersquarefoot,thentheshoringmustbesecurelyinplacebeforethefloordeckerectionbegins.Thefifty-poundpersquarefootloadingdoesnotconsiderconcreteweight.SeeFigure16forrecommendedloadingofthedeckasaconcreteform. Roofdeckisnotgenerallyrequiredtocarryasmuchfoottrafficasfloordeck,butatleastthirtypoundspersquarefootshouldbemadeavailablebyroofdeck.Iftheroofdeckbeinguseddoesnotprovideaplatformcapacityof30psf,thenitshouldbeplankedorsupportedduringerection.Areassubjecttotrafficormaterialstag-ingshouldbeplanked.Themaximumrecommendedspansforroofdecks(seeFigure15)shouldalsobeusedasaguide. Asteeldecksurfaceisinherentlyslipperywhenwet.Cautionisrequiredbyanyoneonthedeckwhenthisconditionexists.
Figures 15 & 16 are on pages 46 & 47 respectively
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1. Makesurethatriggingisadjustedtokeephoistedloads
wellbalanced.
2. Donotstandunderloadsbeinghoisted.
3. Keeploadsinview.
4. Useproperhandsignalstocraneoperators.
5. Checkerectiondrawingstolanddeckinproperpositionand
orientationtoavoidturningdeck.
6. Makesurebundlesaresecureandstablebeforecuttingbands.
7. Payparticularattentiontosinglespanbundles.
a. Donotusesinglespanbundlesasaworkingplatform,
especiallytocutbands.
b. Sheetscouldshiftduetohandling.Ensurebottomsheet
extendspastthesupportatbothends,otherwise
placewherefullsupportcanbeobtained.
8. Whencuttingbandsonbundlesusebothhandsandstandwell
back-bandsareundertension.Eyeprotectionisrecommended.
9. Payspecialattentiontoshortunitsorsinglespanunits—
makesuredeckisfirmlysecuredbeforeusingitasa
workingplatform.
10.Makesurecutoutsandopeningsareadequatelysupported
andguarded.
11.Usechalklinestolocatesupportingsteel-measureaccurately.
12.Bealertforsharpedges.
13.Wetdeckisinherentlyslippery-watchyourfooting.
14.Keepalitterfreeworkplace.
15.Weareyeprotectionwhennearwelding.
16.Wheninstallinggalvanizeddeckonsunnydays,sunglasses
andsunburnprotectionareadvisable.
17.Stayalert.
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SAFETY NOTES
Fastening and Installing Deck
Deckisinstalledinaccordancewiththe“ApprovedforConstruc-tion”drawings.Thedeckmustbeinstalledbyqualifiedandexpe-riencedworkers.Thebeginningpointshouldbecarefullyselectedforproperdeckorientationandedgeofrooforfloorslablocation. Maintainingriborflutealignmentacrossthestructureisveryimportant.Asnapchalklineshouldbeusedatreasonableintervalstoassureproperalignmentofdeckpanels.Panelcoverwidthsmustbemaintainedtoachievelongstraightrunsofdeck. Roofdeckisoftenleftexposedonthebottom.Ribalignmentmustbeparalleltothegirdersatallgirderlinestopreventun-sightlyconditions. Floordeckflutesshould,ifpossible,maintainalignmenttoachievecontinuousconcreteribsacrossabuttingsheetends,mini-mizingconcreteleakage.Flutesthatdonotaligncancreateclosureproblemsthatmayinterrupttheslabdesign.Properalignmentcanonlybeachievedbyproperadjustmentofeachdeckpanelasitisplaced.Coverwidtherrorsaccumulatedacrossthebaycannotbecorrectedwiththelastsheetsintherun. On-siteexperiencehasdemonstratedthatthefrequencyofsnappingachalklinedeterminestheaccuracyofribandflutealignment.Thisminoreffortatthetimeofdeckplacementelimi-natestheneedforfieldcorrections. Fordecktoperformitsdesignfunctionsandserveasaworkingplatform,itmustbeadequatelyandproperlyattached.Oftenthedeckisusedaspartofthehorizontalbracingsystemandthefas-teningmethodandpatternhavebeenselectedtoprovideacertainstrengthandstiffnessintheplaneofthedeck.NO SUBSTITUTION of fastener type or pattern should be made without the approval of the designer. Deckfasteningtothestructuralframecanbeaccomplishedwithwelds,selfdrillingscrews,airdriven,orpowderdrivenfasten-ers.Aminimumof1½”ofendbearingshouldbeprovidedfordeck.Ifthereislessthan1½”ofbearing,additionalfasteningshouldbeprovidedandthedeckendloadcapacityshouldbechecked.Fordeckthatisintendedtoendlap(roofdeck),theendlaplocationshouldbeadjustedsothecenterofthelappedportionoccursoverthesupportor,whensupportedbybarjoists,overatopchordmember. Onlyqualifiedoperatorsmayusepowderactuatedtools;airactuatedtoolsmustbeusedbytrainedoperatorsfamiliarwithallsafetyprocedures.
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SIDE LAP CONNECTIONSFigure 6
Example of Overlapping
BUTTONPUNCH
WELDAFTERCLINCHING
SCREWORWELD
SCREWORWELD
SCREWSMAYBEPLACEDATANANGLEIFMALELEGISSHORT
Attaching
Specialelectricscrewgunsareusedtodriveself-drillingscrewstoattachdecktothestructuralframe.Thesescrewgunsareequippedwithaclutchanddepthlimitingnosepiecetopreventovertorquing.Screwsaretypically#12’sor1/4inchdiameterwithaspecialdrillpointselectedaccordingtothetotalthicknessofmetal(deckplusframe)beingjoined. Airdriventoolsareoperatedatapre-setpressurelevelconsis-tentwiththefasteningrequirementsofthedeckattachment.Airissuppliedbyacompressorequippedwitharegulatorthatpreventsover-drivingorunder-drivingthefastener.Thefastenershaveaflatheadatthedriveendandaballisticpointatthepenetratingend.Avarietyofsizesareavailabletomeetthepenetrationrequirementsofthesteelsubstrate.
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Powder Actuated Self Tapping/Drilling
Welding
Weldingmustbedonebyaqualifiedwelderduringproperweatherconditions.Qualityweldingoflightgagedeckrequiresexperienceandtheselectionofproperamperageandelectrodes.AweldqualitycontroltestprocedureisshowninFigure7.Allweld-ingshouldbedoneinaccordancewiththeStructuralWeldingCode,AWSD1.1orD1.3.Weldwashersarenotrecommendedfordeckthicknessesof0.028inchesthick(minimum22gage)andgreater.Weldwashersarerecommendedformetalthicknesseslessthan0.028inches.Properweldingrequiresgoodmetaltometalcontact;therefore,lappingcompositedeckunitswithshearlugsisnotrec-ommended.Forthesamereason,builtinhangertabs(infloordeck)thatbearonstructuralsteelshouldbeflattenedorremoved.
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Air Driven/Pneumatic
Shear Studs
Shearstuds,weldedinplacewithspecialequipment(inac-cordancewithAWSD1.1)canserveasweldingtoholdthedecktotheframe.Thesestudsareusuallyinstalledafterthedeckhasbeenspreadtoactasaworkingplatform.Therefore,itisnecessarythattheplatformbeadequatelyattachedtothestructurebeforethestudsareinstalled. Shearstudscanbeweldedthroughthedoublemetalthick-nessofcellulardeck.Note:Ifthedeckisheavierthan16gagethestudmanufacturershouldbeconsultedforinstallationprocedures.Shearstuds,likeallotherfasteners,mustbeinstalledinaccordancewiththedesigndrawings. Sincemostconstructionworkisdoneinopenair,ventilationforweldingisusuallyadequate.However,forclosedinareas,ventila-tionmustbeprovided.Adequateventilationisextremelyimportantwhenweldinggalvanizeddeck.Allworkersinvolvedintheweldingoperationmustweareyeprotectiontoavoidweldflash.
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WELD QUALITY CONTROL TEST PROCEDUREFigure 7
Apreliminarycheckforweldingmachinesettingsandoperatorqualificationscanbemadethroughasimplefieldtestbyplacingapairofweldsinadjacentvalleysatoneendofapanel.Theoppositeendofthepanelcanthenberotated,whichplacestheweldsinshear.Separationleavingnoapparentexternalweldperimeterdistresses,butoccurringatthesheet-to-structureplane;mayindi-cateinsufficientweldingtimeandpoorfusionwiththesubstrate.Failurearoundtheexternalweldperimeter,showingdistresswithinthepanelbutwiththeweldstillattachedtothesubstrate,wouldindicateahigherqualityweld.
PUDDLEWELDS
STEELDECK(TESTSAMPLE)
STRUCTURALANGLEORCHANNELUSEDASSUPPORTANDWELDINGBASE
USEC-CLAMPOROTHERRIGIDATTACHMENTTOCOLUMN
STEELCOLUMNOROTHERSTRUCTURALLYSTABLEMEMBER
*“IN-PLANE”FORCE
“*”NOTE: MAYUSEWOODBLOCKINGTO STABILIZE“FREE-END”
Weldingshouldnotbedonenearanytypeofcombustiblematerial.Cuttingandweldingsparkscancauseconstructionfires.Conditionsataconstructionsitearesubjecttorapidchange.Weld-ingmaybesafeinagivenareaandthen,becausecombustiblesareintroduced,theareaissuddenlynotsafe.TheGeneralContractor(jobsupervisor)shouldpreventothertradesfromstoringcombustiblesnearorunderareaswhereweldingistobedone.Constantalertnessinandbelowthegeneralareaismandatory.
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“DO NOT WELD NEAR COMBUSTIBLES”
Side Lap Connections
Sheettosheetconnectionsmayberequiredatthesidelapsofdeck.Thesearefrequentlyreferredtoasstitchconnections.Selfdrillingscrews,weldsorbuttonpunchesaretheusualstitchcon-nections.Stitchscrewsareusuallyselfdrillingtype;#8’sthrough1/4inchdiametercanbeusedbutscrewssmallerthan#10diameterarenotrecommended.Theinstallermustbesurethattheunderly-ingsheetisdrawntightlyagainstthetopsheet.Again,aswhenscrewsareusedastheframeattachment,thespecialscrewdrivinggunsareusedtopreventovertorquing. Manualbuttonpunchingofsidelapsrequiresaspecialcrimpingtool.Buttonpunchingrequirestheworkertoadjusthisweightsothetopofthedeckstayslevelacrossthejoint.Sincethequalityofthebuttonpunchattachmentdependsonthestrengthandcareofthetooloperator,itisimportantthataconsistentmethodbedeveloped.Automaticpowerdrivencrimpingdevicesarerarelyseenondeckjobsbutshouldnotberuledoutasafasteningmethod. Goodmetaltometalcontactisnecessaryforgoodsidelapwelds.Burnholesaretheruleratherthantheexceptionandaninspectorshouldnotbesurprisedtoseetheminthedeck.Thewelddevelopsitsstrengthbyholdingaroundtheperimeter.Agoodweldwillhave75%ormoreofitsperimeterworking.Onocca-sion,sidelapweldswillbespecifiedfordeckthathasthebuttonpunchablesidelaparrangement(seeFigure8forcommentsonthissubject;seeFigures8and9forweldingthesedeckunitstotheframe).Weldingsidelapsisnotrecommendedfordeckstype22(0.028inchminimum)orlighter.Weldwashersshouldneverbeusedatsidelapsbetweensupports.Justaswhenweldingtotheframe,adequateventilationmustbeavailableandweldingnearcombustiblesprohibited.
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SIDE LAP WELDS BETWEEN SUPPORTSFigure 8A
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SIDE LAP WELDS AT SUPPORTSFigure 8B
FRAME CONNECTION LAYOUTSConnections may be arc puddle welds, screws, powder-actuated or pneumatically driven fasteners.Figure 9
Housekeeping
Bundlingstraps,wooddunnage,anddeckcutoffsshouldbecollectedandremovedfromtheworkingplatformdailysoasnottocreateasafetyhazardunderfoot.Loosetoolsshouldnotbeleftlyingabout.Studweldingferrulesshouldbebrokenoffofthestuds.Alldebrismustberemovedfromfloordeckbeforeconcreteispoured. Allpartiesconcernedwiththeconstructionprocessshouldcooperatetoproperlystorecombustiblematerialandremovetrashthatcanbeafirehazard. Absolutelynoloosedecksheetsshouldbeleftattheendoftheworkingday.Anypartiallyusedbundlesmustbetightlysecuredtopreventblowoff.
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“ CLEANING IS EASIER THAN RECUPERATING”
Damagetodeckandpurposefulpenetrationshavemuchincommon:theirlocationandseverityareseldomknownbeforehand.Usuallythedesignprofessionalknowsthegeneralareawhereaventstackmaycuttheroof,orapproximatelywhereatelephoneconduitmaypiercetheslab;buthemaynotknowhowbigtheholewillbe.Thislackofinformationmakesitdifficulttoadvisehowholesshouldbereinforced,ifatall,orhowdamageddeckshouldberepaired.Guidespecificationsreflectthislackofspecificknowledge.TheSDISpecificationstates,“Openingsnotshownontheerectiondiagrams,suchasthoserequiredforstacks,conduits,plumbing,vents,etc.,shallbecut(andreinforced,ifnecessary)bythetradesrequiringtheopenings.”Thedesignprofessionalshouldbeconsultedforreinforcingrequirements,butfrequently,unlessdetailsareshownontheplans,nodeckreinforcingisprovidedandthedesignprofessionalisnotconsulted. Deckdamagepresentssimilarproblems.Broadstatementssuchas,“Alldamageddeckmustbereplaced,”canbemade.Thedesignprofessionalmustthenmakethedecisionastowhatconstitutesdamageddeckwhileconsideringhowreplacementmaydelaythejob.Howmuchdamagecanbetolerateddependsonarchitec-turalandstructuralconsiderations.Iftheundersideofthedeckisexposedtopublicview,verylittlevisibledamagemaybeallowed.Inmostcases,however,thedeckwillbehiddenbyaceilingorductsandutilitiesandtheusualconcernisaboutstructuralperformance.
Roof Deck
Formost1½”roofdecksthelossofoneribpersheet,eitherbydentingorpenetration,canbetolerated.Noreinforcingisgenerallyrequiredforanopeningof6”aslongasnotmorethantwowebsareremoved.Inmostcasesthecapacityofthedeckisgreaterthanrequiredforroofloads.Onesixinchdiameterholepersheetinaspanshouldnotadverselyaffectthediaphragmstrengthandadentcanbelargerthan6”andstillcarrythehorizontalload.Cover-ingadentoran8”maximumholewitha0.045”plateandextendingtheplatetoadjacentribscouldeliminateworriesaboutinsulationboardspanningthedentandabouta“softspot”intheroof.Forholesordentsgreaterthanarib(8”to13”),itisadvisabletousea0.057”minimumplate.Exceptionstothisrecommendationare: 1. theholemaybelocatedinsuchaplacethatthedeckcan safelycantileverfromeachadjacentsupport; 2. agroupofholesmaybesoclosetogetherthatastructural frameisrequired.
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VII. DECK DAMAGE AND PENETRATIONS
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SUGGESTED SCHEDULE:
OneRibRemoved(6”Diameter) NoReinforcingOr 0.045”Plate(Min.)8”Diameter 0.045”Plate(Min.)8”to13”Diameter 0.057”Plate(Min.)Over13” FrameOpening* (DesignByProjectEngineer)*Checkcantileverabilityofdeck
EXAMPLE OF 6” PENETRATION
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EXAMPLE OF DETAILS FOR OPENINGS
DETAILS FOR OPENINGS TO 24”PERPENDICULAR TO DECK
Note:Forholes6”Øorlessnoreinforcingorminimum0.045”platerequired,dependingonlocation.
DETAILS FOR OPENINGS TO 12”PERPENDICULAR TO DECK
Sump Pans
Aspecialcaseofroofpenetrationisthesumppan.Whenproper-lyattached,thesumppanwillcarrytheloadofthedeckitreplaces.Italsoactsasasmallheadertotransferloadsintoadjacentuncutsheets.Approximateperfoot(ofwidth)sectionpropertiesofastandard(0.075”)sumppanare:I=0.36in4;Sp=0.20in3.ApproximatesumppananalysismethodsareshowninFigure11;areinforcingtechniqueisshowninFigure12.
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M=50(22.5/12)2(12)+100(22.5)=3,305in.lb.2
TypicaldeckSn=0.184in.3/ftofwidth(20gageWR)
fb=3,305=18,000psi <20,000psiO.K.0.184 <26,000psiO.K.(temp.manload)
20GA.WRDECK DESIGN: LL = 40psf TL= 50psf
SUMP LOCATED AT CENTER OF SPAN
SUMP PAN ANALYSIS:
SUMPPANCALCULATION(Approximate)Figure11
Burnholesindecksidelaps,causedbyweldedsidelapattach-ments,arespacedfarenoughapartnottocauseproblems.Burnholesnearintermediatesupportsareunlikelytocausemuchlossofstrengthunlessatotalareagreaterthana6”diameterholeisremoved.Theseburnholesareusuallycausedbytheweldersearchingfortheunseenstructuralmember;thereforetheuseofchalklinesisrecommended. Distributedsmalldents,suchasthosecausedbyfoottraffic,willnotcauseastructuralproblem;butifthedentingcoversalargepercentageofthejob,theinsulationboardwillbebetterattachedwithmechanicalfastenersratherthanbyadhesives.Thedesignprofessionalmustapproveanychangeinfastening. Vigilanceshouldbemaintainedtodetectandcorrectany“soft”spotsinroofsthatcouldcauseinsulationboardstocrackunderfootloading.
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SUMP REINFORCING AT END OF DECKFigure 12
Put1-1/2”deepreinforcingchannelsineachribateachsideofopening(flushwithtopofdeck).Channelsspanbetweenjoists.Attachflangesofsumppantochannels.
Floor Deck Beforeconcreteispoured,thecontractorshouldinspectthedecktofindanyareasthatmaybedamagedorcrushedwhichmayrequireshoringfortheconcretepour.Areasthatbuckleduringthepourareusuallycausedbypreviousdamage,overspanningthedeck,orallowingconcretetopileup.Buckledareasdonotad-verselyaffecttheliveloadcapacity.TestsatWestVirginiaUniversity,byDr.LarryLuttrell,showednolossinliveloadcapacitywhenthedeckwaspurposelybuckled. Sincefloordeckdamageorpenetrationcanaffectthedeck’scapacitytocarryconcrete,anyfloordeckdamageorpenetrationmustbeevaluatedpriortopouringconcrete.Floordeck,likeroofdeck,canbeexaminedasacantilever.HowevertheSDIdoesnotpublishacantilevertableforfloordeckbecauseofthegreatprofilevariationsavailable.AmethodforcalculatingallowablecantileverspansisshowninFigure13.Apreferredformingmethodistoblockoutconcretefromwhereapenetrationwilloccur;and,aftertheconcretesufficientlycures,burnthedeckaway.Thedesignprofes-sionaldeterminestheneedforadditionalbarsormesharoundtheblockout. Itistheresponsibilityofthedesignprofessionaltodesignateholes/openingstobedeckedoverincompliancewithOSHARegu-lation29CFRSection1926.754(e)(2)(2003).Whenahole/openingisnotshownanddimensionedonthestructuraldesigndrawings,noprovisionsforconcreteretainagewillbeprovided.Whenaframedhole/openingisshownanddimensionedonthestructuraldesigndrawingsinfloordeck,pourstop(screed)anglewillbeprovidedfromthetopofthedecktothetopofslabonly.Cellclosureswillbeprovidedinthestrongdimensioninstandard10’-0”lengthstobefieldsized,cutandinstalledasshowninFigure14.Donotfieldcutdeckatholes/openingsuntilconcretehasreached75%ofitsdesignstrength(minimumofseven(7)daysinmostcases). Thedeckshouldbeinspectedforadequateattachmentatsupportsandatsidelaps.Sidelapsmustbetightlyconnectedtopreventopeningduringconcretepouring. Concreteprovidesanalkalineenvironmentthatdiscouragescorrosion.Sincemostapplicationsofcompositedeckareindryinteriorareas,fieldpaintingofburned,cutorabradedareasisnotusuallyrequired.Anytouchuprequirementsmustbeprovidedinthejobspecificationssincethedesignprofessionalestablishesthedeckfinishrequiredfortheenvironment.
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MAXIMUM FLOOR DECK CANTILEVERSFigure 13
NOTES:1) Allowablebendingstressof20ksiwithloadingofconcrete+deck+20psf, orconcrete+deck+150lb.concentratedload,whicheverisworse.
2) Allowabledeflectionoffreeedge(basedonfixedendcantilever)of1/120of cantileverspanunderloadingofconcrete+deck.
3) Bearingwidthof3-1/2”assumedwebcripplingcheck-concrete+deck+20 psfovercantileverandadjacentspan.Ifwidthislessthan3-1/2”checkwith thedeckmanufacturer.
STANDARD ACCESSORIES AT DECKED OVER OPENINGSFigure 14
Cellclosure(FIELDCUTTOCONTOUROFDECK,
ORUSEALTERNATEMEANSTODAMCONCRETE)
TYPICAL DETAIL @ ANGLE FRAMEDOPENING
(DECKINSTRONGDIRECTION)
Pourstop
Deck-fieldcutafterconcretepour(NOTBYDECKMANUFACTURER)
Pourstop
Pourstop
Pourstop
Deck-fieldcutafterconcretepour(NOTBYDECKMANUFACTURER)
TYPICAL DETAIL @ ANGLE FRAMEDOPENING
(DECKINWEAKDIRECTION)
42 43
Afterthefloordeck(orformdeck)hasbeenproperlyinstalled,itactsasaworkingplatformformanytrades.Thedeckshouldhavebeenselectedtoprovideatleastfiftypoundspersquarefootcapacityasaworkingplatform.Ifthecontractoranticipatesloadsontheplatformthatwillexceed50psf,heshouldtakeappropriatestepstoensurethedeckwillcarrytheload. Beforeconcreteispoured,thecontractorshouldmakesurethatthedeckisproperlyandcompletelyfastenedinaccordancewithap-proveddeckerectiondrawingsandthedeckhasadequatebearingonallsupports.Damagedareasmustberepairedoraccepted.Allferrulesshouldhavebeenbrokenoffthestuds.Alldirtanddebrismustberemoved.Allreinforcement,wiresorrods,shouldbesecure-lyinplace.Theconcretecontractorshouldreviewthedeckshoringrequirementsandmakesurethatshoresaresecurelyinplace. Concreteshouldbepouredfromalowleveltoavoidimpact-ingthedeck.Itshouldbeplaceduniformlyoverthesupportingstructureandspreadtowardsthecenterofthedeckspan.Concreteshouldbeplacedinadirectionsothattheweightisfirstappliedtothetopsheetatthesidelap,reducingthepossibilityofthesideopeningduringthepour.Workersshouldnotcongregatearoundtheconcreteplacementzone.Ifbuggiesareusedtoplacetheconcrete,runwaysshouldbeplankedandthebuggiesshouldonlyoperateontheplanking.Theplanksshouldbestiffenoughtotransferthebuggyloadswithoutdamagingthedeck.Deckdamagecausedbyrollbarsorcarelessplacementmustbeavoided. ForcalculatingdeckstressesanddeflectionsduringconcretingtheSDIloadingscheduleasshowninFigure16isrecommended.Thismethodofanalysishasbeeninuseformanyyearsandhasprovidedgoodresults.Becausepouringroomcanberestricted,specialconsiderationisrequiredforsinglespanconditions.Forexample,asinglespanconditioncommonlyoccursbetweenelevatorshafts,anditislikelythatconcreteplacementwillbelesscontrolled.A50%factoristhenaddedtotheconcreteweightandadeckgageselectedisbasedonthisloading.Asanalternative,shor-ingmaybespecified.Althoughdeckconnectionsareimportantforallspanconditions,theyareextremelyimportantforsinglespans.Connectionsshouldbethoroughlychecked. Asconcreteisplaced,theentireframeaswellasthedeckwilldeflect.Concretequantitiesshouldbecalculatedwithalldeflec-tionstakenintoaccount.Theweightofconcretefinishingequip-mentwillalsoaffectthecapacityofthedeckasaworkingplatform.Forexample,heavyequipmentsuitableforusetofinishslabsongradewillgenerallynotbesuitabletofinishelevatedconcreteslabssupportedbysteeldeck.
VIII. PLACING CONCRETE
Steel DeckInstitute
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PLACING CONCRETE
Whenthedeckhasbeendesignedtoactasasheardiaphragm,itshouldbenotedontherecorddrawings.Thenoteshouldcau-tionthatthedeckpanelsactasbracingforthebuildingandthatremovinganyofthepanelsisprohibitedunlessseparatebracingisdesignedandprovided.Deckfastenersusedaroundframedopen-ingsshouldbethesameas,andtheirspacingequaltoorcloserthan,thefastenersusedtoattachthedecktotheframe. Ifthedeckistoactasadiaphragmduringconstruction,itmustberealizedthatthediaphragmisnoteffectiveuntilalldeckunitsareinplaceandfullyconnected.Therefore,ifdeckerectionisinter-ruptedbeforecompletion,temporarybracingmayberequired.
Steel DeckInstitute
IX. SPECIAL CONSIDERATIONS FOR DIAPHRAGMS
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Figure 15
Recommended Maximum Spans for Construction and Maintenance Loads Standard 1 ½” and 3” Roof Deck
Narrow NR22 1 3’-10”1’-0”
RibDeck NR22 2ormore 4’-9” NR20 1 4’-10”
1’-2” NR20 2ormore 5’-11” NR18 1 5’-11”
1’-7” NR18 2ormore 6’-11”Intermediate IR22 1 4’-6”
1’-2”
RibDeck IR22 2ormore 5’-6” IR20 1 5’-3”
1’-5” IR20 2ormore 6’-3” IR18 1 6’-2”
1’-10” IR18 2ormore 7’-4”Wide WR22 1 5’-6”
1’-11”RibDeck WR22 2ormore 6’-6“ WR20 1 6’-3”
2’-4” WR20 2ormore 7’-5” WR18 1 7’-6”
2’-10” WR18 2ormore 8’-10”Deep 3DR22 1 11’-0”
3’-6”RibDeck 3DR22 2ormore 13’-0” 3DR20 1 12’-6”
4’-0” 3DR20 2ormore 14’-8” 3DR18 1 15’-0”
4’-10” 3DR18 2ormore 17’-8”
Maximum Span Span RecommendedSpans Type Condition Ft.-In. RoofDeckCantilever
CONSTRUCTION LOAD TABLE
DECK LOADING DIAGRAMS
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Bending Moments — Deflections — Support ReactionsFigure 16
concentratedmanorequipmentload(150lbs./ft.ofwidthunfactored)
P
uniformconcreteload
/ clearspan uniformconstructionload(20psf,unfactored)
IIIIIIIIIIIIIIIIIIIIIII
1. Design Manual for Composite Decks, Form Decks and Roof Decks, PublicationNo.30,SteelDeckInstitute,FoxRiverGrove,Illinois.2. Luttrell,L.D.andEllifritt,D.S.,“TheStrengthandStiffnessofSteel DeckSubjecttoIn-PlaneLoading’,’ReportNo.2011,Department ofCivilEngineering,WestVirginiaUniversity,1970.3. Steel Deck Institute Diaphragm Design Manual, DDM03.Third Edition,September,2004,SteelDeckInstitute, FoxRiverGrove,Illinois.4. “PreventingDamagetoBuildingsUnderConstruction”,1988 FactoryMutualApprovedProductNews,FactoryMutual Research,Norwood,Massachusetts.5. “FallProtectionforDeckInstallation”,ConstructionSafety AssociationofOntario,Toronto,Ontario,Canada.6. “StandardforSteelRoofDeck”,CanadianSheetSteelBuilding Institute,Willowdale,Ontario,Canada.7. Heagler,R.B.,Luttrell,L.D.,“HowtoFastenSteelDeck-Update andReview”,ModernSteelConstructionNumber1,1988, AmericanInstituteofSteelConstruction,Chicago,Illinois.8. 29CFRPart1926SafetyStandardforSteelErection,FinalRule, OSHA/U.S.Dept.ofLabor2001,Washington,D.C.9. “HandlingandErectionofSteelJoistsandJoistGirders”, TechnicalDigestNo.9-March,2006,SteelJoistInstitute, MyrtleBeach,SouthCarolina.10.Cold Formed Steel Design Manual,2002Edition,AmericanIron andSteelInstitute,Washington,D.C.11.Manual of Steel Construction,ThirteenthEdition,American InstituteofSteelConstruction,Inc.,Chicago,Illinois.12.Yu,W.W.,Cold Formed Steel Design,2000,JohnWileyandSons, NewYork,NewYork.13.Fire Resistance Directory,2006,UnderwritersLaboratories,Inc., Northbrook,Illinois.14.2006 Approval Guide,FactoryMutualSystem,Norwood, Massachusetts15.“LossPreventionData1-28”,2005,FactoryMutualSystem, Norwood,Massachusetts.16.NFPA.51B,StandardforFirePreventioninuseofCuttingand WeldingProcesses,NationalFireAssociation,Quincy, Massachusetts.17.Heagler,R.B.,“MetalDeckandConcreteQuantities”,SteelDeck Institute,FoxRiverGrove,Illinois.18.Structural Welding Code—Steel,ANSI/AWSD1.1-2006,American WeldingSociety,Miami,Florida.19.Structural Welding Code—Sheet Steel,ANSI/AWSD1.3-98, AmericanWeldingSociety,Miami,Florida.
Steel DeckInstitute
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REFERENCES
Publication No. MOC2
STEEL DECK INSTITUTEP.O. Box 25Fox River Grove, IL 60021-0025TEL: 847-458-4647FAX: 847-458-4648WEB SITE: http://www.sdi.org