Concrete Structural Floor

Heavy weight concrete mezzanine floor

Drawing detailing the requirements for a successful completion

Piling


It is essential to understand the weight load on each of the columns in order to establish the requirement for a stable foundation.  In this case due to the weight of the equipment positioned onto this floor we had to support the columns by means of piling.  (see below)

Piling drilled and filled with concrete and rebar

Piling Schedule of quantities

Number of Piles:- 26 Pipe piles

Core Diameter:- 200mm diameter through existing surface bed

Size of pipe:- 165mm diameter Install at 150kN not exceeding 2m below floor   level

Pile includes:- Reinforcing 3Y10 in top 2m of pile 25Mpa concrete filled

Shaft Stress:- 7MPa

Safe working load: 150kN

 

 

Shear pins welded onto main beams

 

Structural floor components

Main Beams:-

356 x 171 x 67kg’s  I Beam  SABS 1431 grade S355JR

Shear pins:-

Shear connectors of 150 x 200 x 150 x 20mm shear connectors spaced at 200mm apart.  Welded to top flange on centre line

Main beams supporting the QC Decking

 

Columns:-

254 x 254 x 88kg’s H columns SABS 1431 grade S355JR

Hot dipped galvanised:

All columns on ground level to be hot dipped galvanised including base and capping plates

Base plate:

500 x 400 x 20mm base plates including gusset plates of 150mm x 10mm

Capping plate:

300 x 180 x 20mm capping plate welded to top of each column

 

Support structure for fridge panels (above concrete slab)

Main Beams:- 254 x 146 x 31kg’s I Beam SABS 1431 grade S355JR

Secondary beams:- 180 x 91 x 14.94kg’s IPE section

Columns:- 203 x 203 x 46kg’s x 254 x   88kg/m H columns SABS 1431   grade S355JR

Base plate: 300 x 300 x 12mm base plates

Capping plate:  300 x 300 x 12mm capping plate   welded to top of each column

Concrete pour accommodating services – drainage and electrical

Height:-

Finished floor level:-  4000mm

Clear Underside:-  3644mm

Carrying Capacity:-  2 000kg / Square meter

 

QC Decking (formwork)

QC Decking:-QC Decking 54 x 250 x 1.2mm thick (galvanised)

Quantities:-148 Sections of 3640mm long  –  222 Sections of 3395mm long

QC Flashing:-FD1 Kerb Flashing 24 x 3000mm lengths

300mm girth 75 x 200 x 25

System includes Pop rivet aluminium seal 4.8 x 14

72 x 1000mm deck strapping – 2600 Q deck clips

Concrete slab

Concrete:-Formwork and cladding

Reinforced rebar seated into QC decking

Prop floor @ 1400mm spacing between main beams

76 props required – 21 days

Prop floor on main beam – middle only 12 props required

Indufloor Floor completed with a polyurethane screeds for wipe clean and non-slip finish

ISO panelling installed onto mezzanine floor including – doorways – lift shafts – piping drainage

 

 

 

 

First Office Storage Concepts took on the challenge and successfully completed the immense task of designing

and installing a 2 ton per square meter Concrete Structural Mezzanine Floor.  324 Square meters of Structural

floor was erected in an existing facility while production continued.  Concrete was poured, finishing of

polyurethane screeds and installing Iso panelling including roofing were all done with great precision and

without interruption of business as usual.  Thanks to the team at First Office Storage Concepts and all the other

parties that participated to conclude this awesome project.

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