Precast concrete composite flooring is a high quality, economical concrete floor construction where long spans and/or high load bearing capacities are required.
Suspended concrete floors are constructed using prestressed planks supported by either masonry walls or a supporting steel frame structure. This plate floor is then topped with a structural concrete screed to provide a robust floor capable of resisting very high loading.
Concrete composite floors constructed in ACP’s wideslab plank system are suitable for ground floor to top floor.
Individual precast floor units are manufactured in the long line prestressed system minimizing costs and production time.
Openings for services, pipes and ducting can all be cast into the precast concrete flooring at manufacturing stage rather than cut out on site, ensuring better finish and less down time during construction.
The wet cast system also enables shear link reinforcement to be accurately placed during manufacture, cutting time on site.
The casting system also enables special width floor planks to be cast to size rather than cut down from stock as is typical of traditional hollowcore flooring systems.
Composite flooring is delivered to site ready to install using ACP’s specialist wideslab lifting system that’s not only safe but also fast and simple eliminating plank damage caused by choke hitch chains. Lifting inserts are cast into the units during production, these lifting points are then used to handle the planks within the factory and once again on site.
The wideslab floor lifting system also eliminates the need to “bar” individual floor beams into final position as is typical of hollowcore flooring lifted with chains or beam clamps.
Accurate first time placement means the floor plank is in its final position before the crane unhooks. ACP’s precast concrete wideslab floors are therefore ideally suited to inclusion in modern high U-value construction schemes where supporting walls are built from autoclaved aerated blocks such the Thomas Armstrong Airtec Block System incorporating the latest thin joint technology.
ACP concrete composite floors are specifically designed to comply with the new approved Document E, 2003 Edition – Resistance to the passage of sound. The dense concrete slab used in the ACP wideslab system has benefits in acoustic performance over hollowcore flooring.
• Dimished airborne sound paths
• Minimal joints restricts the possibility of sound penetrations
• Reduced sound vibration passage
Composite concrete floors also exhibits excellent and fire resistance properties. The dense nature of the product eliminates possible fire spread through hollow cores.
Precast concrete floor units have a special shear key detail on the long edge. This joint is designed to receive the insitu screed without additional shuttering to the soffit.
Suspended concrete floors constructed with ACP’s composite flooring can be designed to eliminate additional ceiling finishes in many cases. A smooth soffit finish to the precast floor is a benefit of the wet cast system and is suitable to receive a direct paint finish.
The precast concrete floor is suitable for underfloor heating systems providing a high thermal mass in addition to the benefits of a concrete floor solution
Composite floor units are also ideal for suspended flooring to subsequent levels, being quickly and safely installed to provide an instant safe platform for following trades.
Prestressed composite floor beams are manufactured as standard at 1200mm wide maximizing transport efficiency. Plate floor sections are generally 100mm thick although other sections are available depending on spans and loads. The high strength nature of the prestressed units can drastically reduce or eliminate the need to prop units during screed pour saving time and money.
Screed thickness and reinforcement can be designed to suit each span and load applications. For outline screed details please see the Safe Span Table in the design section.
ACP Concrete Wideslab floors are manufactured to comply with the requirements of the current Robust Details E-FC-1, E-FC-4 and E-FC-5
A full design and build package is available including all on site activities to deliver high quality composite floors.