Bondek User Guide

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BONDEKUsers Guide

LYSAGHTBONDEKUsers GuideGeneral construction manual

construction and formwork tables.

Our newest release of supportingsoftware and the Design Manual forBONDEKincorporates LYSAGHTs latest

research and development work.Improved design and testingmethods have again pushed BONDEKto the forefront.

BONDEKoffers significant advantagesover other metal decking systemsavailable in Australia.

Anti-glare BONDEKBlue is nowavailable in Victoria only.

New formwork tables are optimisedfor steel frame construction.

Please consult formwork General

Notes when using in alternativetypes of construction and refer tothe Design Manual.

IntroductionBONDEKis a highly efficient, versatileand robust formwork, reinforcementand ceiling system for concrete slabsIt has been widely used since the1960s with success on many projectslarge and small. It is a profile steelsheeting widely accepted by thebuilding and construction industryto offer efficiency and speed ofconstruction.

Scope

This manual is to be used inconjuntion with the BONDEKDesignManual - and forms a practicalconstruction handbook, rather thana design manual.

Designs can be adopted fromthe BONDEKDesign Manual, inconjunction with a consultingstructural engineer.

Topics in this guide include


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Bonfill

Polystyrene foam stops concreteand air entering ends of ribs.

Stock length: 1200 mmRequired: 300 mm per sheet of Bondek

Bonstrip

Plastic trim to cover

gaps formed by ribs.Used when underside of

Bondek forms an exposed ceiling.Stock length: 3000 mm

Allows gyprock to be fixed to Bondek

Edgeform

A galvanised section that creates a permanent formwork atthe slab edgescut, mitred and screwed on site.

Stock slab depths: 100, 125, 150 mm (others to special order).Stock length: 6100 mm

Brackets from builders strapping

25 mm x 1.0 mm

Fixed with self drilling, hex. headTeks screws with drill point,

10-16 x 16Required: 40 per length of Edgeform

Bonwedge

Lightweight bracket for rodsto suspend ceilings or services

(other than fire sprinkler systems).Max. load: 100 kg

Ceiling suspension nut

Pressed metal threaded bracket

to suspend ceilings or services.Thread: M6

Max. load: 270 kg

End plug

Polyethylene end plug stops

conrete and air from enteringend of ribs.

Bon-nut

Heavy duty square nut tosuspend ceilings or services.

Glued to a paper strip it makes insertion easy.Threads: M8, M10 and M12

Loads: 390 to 670 kg depending on Bondek BMT

Figure 1Bondek accessories

BONDEKaccessories

Equal formwork spans

Slab span

BONDEK formwork

joints over permanent

supports only

Prop

Concrete slab

Two rows

of props

Slab span

One row of props

concre

f

Concrete slab

BONDEKProp

Equal formwork spans

Slab span

Figure 2Bondek single slab span

Figure 3BONDEKcontinuous slab spans(BONDEKmust be continuous at least forthe whole slab span).

LYSAGHTBONDEKdesignadvantages

Excellent spanning capacities forgreater strength and less deflection

Acts as permanent formwork withminimal propping and no strippingof formwork is required

Fast and easy to install (590mmwide) with less handling required

Works as composite slab saving onconcrete and reinforcement costs

Ribs at 200 mm centres creatinga safe working platform with slipresistant embossments

Durable galvanised coating

Installation of suspended servicesand ceilings without drilling into

the concrete slab Reliable interlocking mechanism

provides vertical lapping for fasterinstallation.


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BONDEKformwork span tablesSingle span

L/240 formwork deflection limit - visual quality important

0.6 BMT Bondek 0.75 BMT Bondek 1.0 BMT Bondek

Slab depth No of props per span No of props per span No of props per span

Dcs, mm 0 1 2 0 1 2 0 1 2100 1900 4000 4000 2100 4000 4000 2300 4000 4000

110 1850 4400 4400 2000 4400 4400 2200 4400 4400

120 1800 4450 4800 1950 4800 4800 2150 4800 4800

130 1700 4350 5200 1900 5200 5200 2100 5200 5200

140 1650 4250 5600 1850 5200 5600 2050 5600 5600

150 1600 4150 6000 1800 5100 6000 2000 5650 6000

160 1550 4050 5900 1750 4950 6400 1950 5550 6400

170 1550 4000 5700 1700 4850 6600 1900 5400 6800

180 1500 3900 5550 1650 4750 6400 1850 5300 7200

190 1450 3850 5450 1600 4650 6300 1850 5200 7050

200 1450 3800 5300 1550 4550 6150 1800 5100 6900

210 1400 3700 5200 1550 4450 6000 1450 5000 6750

220 1350 3650 5100 1500 4350 5900 1700 4900 6650

230 1350 3600 4950 1500 4300 5800 1700 4800 6550

240 1300 3550 4850 1450 4200 5650 1650 4700 6450

250 1300 3500 4800 1450 4150 5550 1600 4650 6350

Single span

L/130 formwork deflection limit - visual quality not important



Dcs, mm 0 1 2 0 1 2 0 1 2

100 2050 4000 4000 2500 4000 4000 2750 4000 4000

110 2000 4400 4400 2450 4400 4400 2650 4400 4400120 1950 4400 4800 2350 4800 4800 2600 4800 4800

130 1900 4300 5200 2300 5200 5200 2550 5200 5200

140 1850 4200 5600 2250 5100 5600 2500 5600 5600

150 1850 4100 6000 2200 5000 6000 2450 6000 6000

160 1800 4050 6050 2200 4900 6400 2400 6350 6400

170 1750 3950 5950 2150 4800 6800 2350 6200 6800

180 1750 3900 5850 2100 4750 7100 2300 6100 7200

190 1700 3800 5750 2050 4650 7000 2250 6000 7600

200 1700 3750 5650 2050 4550 6850 2250 5900 8000

210 1650 3700 5550 2000 4500 6750 2200 5800 8400

220 1650 3650 5450 2000 4400 6650 2150 5700 8450

230 1600 3600 5400 1950 4350 6550 2150 5600 8350

240 1600 3550 5300 1900 4300 6450 2100 5500 8200250 1550 3500 5250 1850 4200 6450 2100 5450 8100

Mounting of concrete = 300kg/m2overan area of 1.6 x 1.6m and zero over theremainder.

Stacking of material on BONDEK sheetsbefore placement of concrete only = 100kg/m2

5. Ratio of two adjacent slab span lengths doesnot exceed 1.2. (L

l/L

s) 1.2

6. Tables developed based on maximumBONDEKlength is 19500. (Check availability of locallengths.)

7. No loads from stacked materials are alloweduntil the concrete has set

8. The sheets shall not be spliced or jointed9. Ponding dead load - the additional concrete

due to ponding of the concrete from thesheeting deflection has been included.

10. Supports shall be effectively rigid and strongto support construction loads.

11. The sheeting shall not have cantileverportions.

General Notes1. These tables are primarily developed for

steel frame construction with BONDEKsheetssecurely fixed to all permanent and temporarysupports at every pan.

Suitable fixing methods should be used suchas spot welds, self drilling screws or drivenails.

The tables can be used for alternative typesof construction provided adequate fixing tosupports is used.

2. The tables shall be used for normal densityconcrete (2400kg/m3).

3. The lines of support shall extend across thefull width of the sheeting and have a minimumbearing 50mm at the ends of the sheets and100mm at intermediate supports over whichsheeting is continuous, including at props.

4. The tables are based on the followingmaximum construction loads:

Workmen and equipment = 100kg/m2

12. Wet concrete deflection of BONDEK= L/240or L/130, where L is the distance betweencentres of props or permanent supports.

13. Adopt 300mm form-ply on top of prop bearerto minimise prop marks where BONDEKis leftto be exposed.

14. The information contained in the publicationis intended for guidance only. This informationto be used only in conjunction with aconsulting structural engineer.

15. Further details can be sought from theBlueScope Lysaght publication Design &Construction Manual or consulting SteelDirect on 1800 641 417.


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BONDEKformwork span tablesTwo spans




Dcs, mm 0 1 2 0 1 2 0 1 2100 2350 4000 4000 2700 4000 4000 3000 4000 4000

110 2250 4400 4400 2650 4400 4400 2900 4400 4400

120 2200 4350 4800 2550 4800 4800 2850 4800 4800

130 2150 4200 5200 2500 4800 5200 2750 5200 5200

140 2100 4050 5600 2450 4650 5600 2700 5150 5600

150 2050 3950 5900 2350 4500 6000 2650 5000 6000

160 2000 3800 5750 2300 4400 6400 2550 4900 6400

170 1950 3700 5600 2250 4300 6450 2500 4800 6800

180 1900 3600 5450 2200 4150 6250 2450 4700 7050

190 1850 3500 5300 2150 4050 6100 2400 7600 6900

200 1800 3450 5150 2100 4000 6000 2350 4500 6750

210 1750 3350 5050 2050 3900 5850 2300 4400 6650

220 1750 3300 4950 2000 3800 5750 2250 4350 6500230 1700 3200 4850 1950 3750 5650 2200 4250 6400

240 1650 3150 4750 1950 3700 5550 2200 4200 6300

250 1650 3100 4650 1900 3600 5450 2150 4100 6200

Two spans

L/130 formwork deflection limit - visual quality not important



Dcs, mm 0 1 2 0 1 2 0 1 2

100 2300 4000 4000 2800 4000 4000 3550 4000 4000

110 2250 4400 4400 2750 4400 4400 3500 4400 4400

120 2200 4400 4800 2650 4800 4800 3400 4800 4800

130 2150 4300 5200 2600 5200 5200 3350 5200 5200

140 2100 4200 5600 2550 5100 5600 3250 5600 5600

150 2050 4100 6000 2500 5000 6000 3200 6000 6000

160 2000 4050 6050 2450 4900 6400 3150 6050 6400

170 1950 3950 5950 2400 4800 6800 3100 5950 6800

180 1950 3900 5850 2350 4750 7100 3050 5850 7200

190 1900 3800 5750 2300 4650 7000 3000 5750 7600

200 1850 3750 5650 2250 4550 6850 2950 5700 8000

210 1850 3700 5550 2250 4500 6750 2900 5600 8400

220 1800 3650 5450 2200 4400 6650 2850 5500 8300

230 1800 3600 5400 2150 4350 6550 2800 5450 8150

240 1750 3550 5300 2150 4300 6450 2750 5350 8000

250 1750 3500 5250 2100 4200 6350 2700 5250 7900


Stacking of material on BONDEKsheetsbefore placement of concrete only = 100kg/m2


l/L

s) 1.2




















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BONDEKformwork span tablesThree spans




Dcs, mm 0 1 2 0 1 2 0 1 2100 2300 4000 4000 2550 4000 4000 2850 4000 4000

110 2200 4400 4400 2500 4400 4400 2750 4400 4400

120 2100 4350 4800 2400 4800 4800 2650 4800 4800

130 2050 4200 5200 2350 4800 5200 2600 5200 5200

140 1950 4050 5600 2250 4650 5600 2500 5150 5600

150 1900 3950 5900 2200 4500 6000 2450 5000 6000

160 1850 3800 5750 2150 4400 6400 2400 4900 6400

170 1800 3700 5600 2100 4300 6450 2350 4800 6500

180 1750 3600 5450 2050 4150 6250 2300 4700 6500

190 1700 3500 5300 2000 4050 6100 2250 4600 6500

200 1650 3450 5150 1950 4000 6000 2200 4500 6500

210 1650 3350 5050 1900 3900 5850 2150 4400 6500

220 1600 3300 4950 1850 3800 5750 2100 4350 6500230 1550 3200 4850 1800 3750 5650 2050 4250 6400

240 1550 3150 4750 1800 3700 5550 2050 4200 6300

250 1500 3100 4650 1750 3600 5450 2000 4100 6200


Stacking of material on BONDEK sheetsbefore placement of concrete only = 100kg/m2


l/L

s) 1.2




















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BONDEKinstallation andconstruction

Step 1: Open BONDEKsheet bundles

Step 2: Place props if required

Step 3: Trim BONDEKsheets if required and place onsteel beams

Step 4: Fix BONDEKsheets to steel beams if required

Step 5: Fix steel edgeform

Step 6: Cut penetration

End

caps


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Step 7: Place reinforcement

Step 8: Place concrete

Bon Strip

Bon Wedge

Ceiling suspension nut

Bon Nut

Step 9: Allow slab to cure and remove props

Step 10: Install services andceilings with BONDEKaccessories


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For information, brochures

and your local distributor call

1800 641 417Please check the latest

information which isalways available atwww.lysaght.com

Copyright BlueScope Steel Limited6 June 2005

LYSAGHT and BONDEK are trademarks ofBlueScope Steel Limited A.B.N. 16 000 011 058

The LYSAGHT range of products is exclusivelymade by BlueScope Steel Limited trading as

BlueScope Lysaght.

LYSAGHTBONDEKUsers Guide

Certification of FormworkBlueScope Lysaght certifies that the informationcontained within this Specification complies withSection B of the building Code of Australia and withthe relevant Australian Standards.

This specification has been based on the exclusiveuse of BONDEKmanufactured by BlueScope Lysaght.

Bondek profileMaterial specification Yeild

Thickness Mass Strength Coverage

(mm) kg/m2 kg/m MPa m2/t 0.60 8.52 5.03 550 117.37 0.75 10.50 6.20 550 95.24 1.00 13.79 8.14 550 72.52

New Technical Developments include: Advanced Design for Fire Resistance

BONDEK2004 software gives new flexibility and ease of design

Increased unsupported spans ofBONDEK

sheeting Anti-glare BONDEKBlue (Victoria only)

54mm200mm

590mm

BONDEKprofiled steel sheeting isroll-formed from hot dipped, zinc-coated, hi-tensile steel strip, in basemetal thicknesses (BMT) of 0.60,0.75 and 1.0mm. The steel stripconforms to AS1397 grade G550,Z350. 0.9mm thickness is availablefor projects by Special Order. Excellent spanning capacities for greater strength and less

deflection

Acts as permanent formwork with minimal propping and nostripping of formwork is required

Fast and easy to install (590mm wide) with less handlingrequired

Works as composite slab saving on concrete andreinforcement costs

Ribs at 200 mm centres creating a safe working platform withslip resistant embossments

Design Advantages include:

Bondek User Guide

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