FLOORING SYSTEMSOmnia and Cobiax

Hanson Building Products

Omnia

System overview 4

Benefits 5

Construction details 6-7

Bearing details 8

Temporary support 9

Cobiaxdeck

System overview 10

Benefits 11

Design and construction 12-13

Nationwide service 14

The Omnia system from Hanson BuildingProducts is a pre-cast floor panel thatprovides the direct equivalent of an in-situslab but provides the facility to combine pre-cast and in-situ concrete.

Cobiaxdeck is a development that combinesthe advantages of Omnia wideslab flooringwith Cobiax void forming technology tocreate a long-spanning, biaxial deck systemwithout beams.

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FLOORING SYSTEMSOmnia and Cobiax

All Omnia products incorporate the

triangular Omnia lattice girder that is

attached to a lower layer of

reinforcement before wet concrete

is poured to create the Omnia panel.

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The system displaces non-working

deadload through the incorporation of

hollow spheres between the upper and

lower layers of reinforcement.

Cobiaxdeck

Omnia

The Omnia flooring system is equallysuitable for steel and concrete framedstructures and masonry buildings

SYSTEM OVERVIEWOmniaThe Omnia system provides major benefits over alternativeswhen used as fully participating permanent formwork.

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The basic Omnia product is theOmnidec panel which incorporatesthe distinctive triangular Omnialattice girder.

The Omnia girder is attached to anindividually designed lower layer ofreinforcement and wet concrete is thenpoured to create the Omnidec panel.

The triangular lattice girder providesthe panel with its stiffness during thetemporary condition and ensures abond between the pre-cast and in-situ concrete.

It also serves to provide support forthe upper mesh reinforcement(supplied by the contractor) and isused as the anchor point when liftingpanels into position on site.

Each Omnidec panel is designedand manufactured to order, eachwith its own specific shape andstructural capacity.

Unlike pre-stressed concrete flooringsystems, Omnidec panels are wet-cast into pre-formed shapes that buttjoint together on site.

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Omnia benefitsStructural strengthsCan be designed to withstand most loading conditions

Can be designed to cope with rigorous exposure conditions

Can be designed to protect against fire for long periods

Each panel is designed to suit its specific location

Progressive collapse conditions economically provided

Fast installation Large panels mean less lifts

Panels are lifted into place without the need for slings

Large areas of floor can be erected in a short space of time

Design flexibilityIrregular and complex shapes manufactured to suit contract requirements

Service holes and cut-outs accurately formed during manufacture

Smooth flat soffit can take direct decoration and top surface can be power-floated reducing depth of overall floor zone

Exposed soffit can be used to provide ‘thermal-mass’

Single or two-way spanning design possible

Competitively pricedSystem costs compare favourably with those of traditional formwork

Decorated soffit can be left exposed, negating suspended ceilings

In-situ topping can be power-floated negating extra finishing screed

Quality serviceFactory-manufactured to consistent quality standards

Complies with all relevant standards

Where Omniacan be usedThe Omnia system is suitable for use onsteel and concrete framed structures aswell as masonry structures

Commercial and IndustrialHotels, factories, warehouses and retail structures

Public buildingsHospitals, schools, fire and policestations, prisons.

ResidentialLow and high rise apartment blocks,student accommodation blocks, hostels etc

Car ParksSingle level or multi-storey complete with ramps

CONSTRUCTION DETAILSOmnia

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DimensionsEach Omnia panel is designed andmanufactured to suit its location. Sizes are, therefore, infinitely variable.

Panels are cast onto steel bedsaccurately set and split into individualpanel lengths.

The beds are 2.40m wide whichdetermines the maximum width ofpanel. However, every contract mayhave a proportion of non-standard widths.

ToleranceFor standard 2.40m wide panels, thewidth is controlled and the dimension is virtually exact.

For non-standard panel widths withformed edges and at the bearing ends,the panels are cast within thetolerances allowed, usually to ±10mm.

Panel depthsThe precast concrete panels can beprovided at 50, 60 and 75mm asrequired by the structure’s specific fireand exposure conditions.

ConstituentsThe Omnia lattice girders are cast intothe precast concrete panel at centresfrom 600mm down to 120mm toprovide stability in the temporary condition.

By increasing the amount, size andheight of the lattice girders, the panelscan be made to span great lengthswithout temporary propping.

Each panel is designed to cope with its specific loading condition and isreinforced with bars from 8 to 16mmplaced at 50 to 300mm centres.

With over 11 million permutations oflattice girder, steel reinforcement andconcrete available, it is possible tocope with the most onerous of loadingand exposure requirements.

Maximum SpansThe maximum span of any Omnia panel is a result of a number of factorsincluding the span/depth ratio,temporary condition requirements,preferred method of propping (if allowed).

Spans of up to 14m are possible,subject to satisfying deflection criteria,but the normal maximum panel length is approx. 11.0m. Hanson’s Omniadesign team can provide designs attender stage to determine the mostcost-effective span/depth ratio.

Appearance and shapeAll Omnia panels are cast to length onsteel moulds. Long edges are formedwith a chamfer to the underside sothat, when placed adjacent to eachother, the effect of a bird’s mouth jointcan be seen at regular intervals on thesoffit.

Holes for services etc. can be neatlycast into the panels during manufacture.

Special side forms are introduced atcasting stage enabling panels to beproduced to suit the shape of thebuilding and it is, therefore, possible tocater for structures with complex floorlayouts.

Ends of panels are formed with squareforms to provide a suitable surface atthe lines of bearing.

Soffit qualityThe steel moulds used for casting ensurea high quality finish suitable for directdecoration with paint or textured finish.

As no pre-stressing wires are used inthe manufacture of the Omnia panels,the soffit is also flat with no camber.

Omnidec

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The Omnicore variation

Accessories

Omniedge

All products in the Omnia system utilise the Omnia lattice girder, reinforcingsteel and dense concrete. Omnidec is the basis for the product range withvariations and accessories as shown below:-

A precast concrete panel reinforcedwith steel bars and incorporating theOmnia lattice girder to providestrength in the temporary condition(i.e. during erection). Reinforced in-situ concrete is placed over thepanel to create a solid concretehomogeneous slab.

Typically used for spans from 1.0m up to 6.50m, providing slab depths

from 135mm to 250mm, at whichpoint Omnicore should beconsidered to reduce overall deadweight on the structure.

However, on civil engineeringstructures, slab depths occasionallyexceed 750mm. Slabs can also becast using lightweight aggregate toreduce self-weight.

Similar to Omnidec except that inbetween the lattice girders, lengthsof polystyrene are cast into the topof the precast section to reduce theamount of in-situ required andtherefore the weight of thecompleted slab.

Typically used for spans of 6.00mand over, providing slab depths from250mm upwards.

Reductions of 20 - 45% in slabweight can be expected.

Omniedge is a galvanised steel edgeshutter cast into the edges of theprecast panels at the factory.

Generally it is used on masonrystructures and is a competitivemethod of providing an edge shutterto the completed slab.

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BEARING DETAILSOmnia

Bearing on steelwork

Bearing on in-situ concrete

Bearing on masonry

Omnia panels are suitable for use on concrete andsteel framed structures and on masonry buildings.

Panels require a nominal bearingof 55mm.

Panels bearing at differential levels mayrequire a compressible bitumenised stripto prevent point bearing and excessivegrout loss.

Shelf angles must be of such a length asto allow the end of the panel to pass thetop flange during placing, and be set at aheight that will allow continuity.

Support panels on the formwork and casta fully homogeneous slab. The OMNIA preferred option.

When supported on ‘half-cast’ beams,links must be so arranged to allow65mm nominal bearing.

Where less than 65mm bearing isavailable, a suitable temporary prop mustbe in place before placing the panel andleft in place until the in-situ portion hasreached working strength.

Panels are usually detailed to take the full bearing of the internal skin of masonry,allowing the use of ‘Omniedge’ edgeformwork (see page 7).

Two OMNIA panels can be supported on140mm wide load bearing blockworkwith a 20mm gap between.

Where less than 60mm bearing is availableeg. on 100mm walls, temporary props shouldbe in place prior to placing the panels.

TEMPORARY SUPPORTConstruction

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Unpropped

The greater the stiffness of the panel, the greater the distance it will span without propping.

The stiffness is as a result of the ‘Moment of Inertia’ created by the lattice girder.

The value of the ‘Moment of Inertia’ is aresult of a combination of lattice height,lattice top bar diameter and the number oflattice girders cast into the panels.

Spans up to 4.0m regardless of slab depthwill generally be designed to be erectedwithout props.

Depending on the depth of the slab, spansof over 6m can be designed to be erectedwithout propping and spans over 7m can be designed to be erected ‘post-propped’ (see below). Please check with Hanson formaximum spans using Omnicore, as theintroduction of the polystyrene limits the abilityof the panel to span with reduced propping.

No props are required, except for localised supports around openings etc.These will be identified on the Omnia layout drawings.

Post-propped

Panels are self-supporting, but will require one row of props placed mid-span prior to placing materials, particularly the in-situ concrete.

One row of propsplaced mid-span

Continuous head timber

Prop

ProppedProps are typically spaced at 2.50mcentres, although these centres can beextended to suit the contractorsrequirements.

Examples are spans in the 7m – 11m range.

OMNIA panels can also be designed to cope with the loads transferred from temporary props, therebyeliminating the need for ‘back-propping’ on lower floors.

Temporary props shall remain in position inaccordance with the requirements of therelevant code of practice, and whilst their

spacing will be shown on the Omnia panellayout drawings, the actual design of theprops will be responsibility of others.

Panel lowered onto supports

2.50m Max

Overall Maximum slab depth post-propped span

150mm 5.80m

175mm 6.80m

200mm 7.00m

225mm 7.20m

250mm 7.50m

Overall Maximum slab depth unpropped span

150mm 3.95m

175mm 4.40m

200mm 4.85m

225mm 5.40m

250mm 6.10m

SYSTEM OVERVIEWCobiaxdeck

Cobiaxdeck combines the establishedadvantages of the Omnia system withspherical void forming technology toenable the construction of light weight,biaxial floor slabs with column gridsranging from 6m up to 18m withoutbeams.

The resultant overall slab depth will bedetermined by the arrangement and spacingof the columns as well as the ultimate loading.

The combination of these technologiesallows the construction of buildings withwide open spaces, providing for greaterflexibility with internal design.

The absence of beams also means areduction in the overall floor zone which, in some instances, can allow space for the construction of an additional floor.

The use of void forming technologyreduces the volume of concrete in thefloor slab by displacing non-workingdeadload.

The reduced weight can impact on thedesign and reduce the cost of foundations and the system is ideal foruse where ground conditions are poor or piling is required.

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Cobiaxdeck benefitsBiaxial design

No need for support beams

Reduced structural zone

Resource effective

Fewer columnsWide open spaces

Greater design flexibility

Reduced costsFaster build

Reduced in-situ concrete

FoundationsLighter weight slabs means reduced costs for foundations

Ideal for poor ground conditions or piling

Thermal performanceDesign allows thermal mass to be exploited

Lower heating/cooling costs

Quality serviceFactory produced quality

Complies with all relevant standards

WhereCobiaxdeck can be usedSuitable for all types of buildings but isideal for larger scale projects including:

Shopping centresand supermarkets

Office complexes and high-rise commercial buildings

Schools and universities

Hospitals

Hotels

Apartment blocks

Industrial buildings

Multi-storey car parks

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DESIGN & CONSTRUCTIONCobiaxdeck

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StructuralprinciplesCobiaxdeck provides the potential forsavings on materials, floor depth, slabweight, foundations and build-time ifincorporated at the design stage of thecontract.

The Cobiax system of biaxial design inconjunction with the void formingsystem allows for a considerablereduction in the volume and weight ofthe slab without compromising thisability to maintain biaxial strength.

The Cobiaxdeck system provides a verycost-effective alternative to achieve therequired deflection criteria in long spanapplications.

Hollow spheres, manufactured fromrecycled polyethylene, are used as voidformers. They are held in place, relativeto the soffit and to each other, inlightweight steel cages.

Additional Space

Conventional construction Cobiaxdeck construction

Absence of beams in the Cobiaxdeckstructure offers the potential for anadditional floor (or floors).

Weight savings impact on floor slabs,vertical elements and foundationdesign, effectively reducing costs.

Less excavation

The utilisation of the spheres providesweight saving of between 20-30%compared to an equivalent solid concrete slab.

The extremely efficient biaxial design canalso enable savings to be made on theweight of reinforcement required for theultimate loads on the floor slab, as well asthe size of columns and foundationssaving up to 50% structural concrete.

CobiaxdeckoptionsThe Wet-Method is the name given to the system where the ball and cagematrices are fully bonded to thereinforced precast concrete at the factory.

The precast panels include 2 layers of reinforcement.

The panels are placed onto preparedfalsework, splice bars are threadedinto place and shear connectorslaced around the columns to pre-setshear ladders already cast into thepanels.

The top layers of reinforcement arethen placed across the whole of theassembly before concreting.

The Dry-Method is the name given tothe system where the precast panel issent to site for placing without the Balland Cage matrix attached. Only one layerof reinforcement is included in theprecast panel.

The 2nd layer of bottom steel and theshear connector bars are laid intoposition on top of the precast panel.

The Ball and Cage assemblies are sent to site separately and are placed inposition. The top steel is then placed andtied down to the lattice girder to prevent‘floating’.

The In Situ-Method is the name givento the system where the voided biaxialslab is created on traditional formworkwith no precast concrete involved.

DesignCobiaxdeck is a solutions driven systemand Hanson’s engineering team workwith the client throughout each project tomaximise the benefits and achieve anideal solution.

Hanson provide a full design serviceincluding all aspects of the biaxialconstruction, panel and loosereinforcement layout drawings for all 3 options.

Soffit qualityIf the Cobiaxdeck option includes aprecast Omnia element, this is cast onsmooth flat steel casting beds giving a first class soffit ready for directdecoration.

Thermal massThe thermal mass in a Cobiaxdeck slabcan significantly reduce the energyrequirement of the building once in use.This can be achieved passively, throughsolar gain and night cooling, or activelythrough the use of fluid circulation wherereduction figures of up to 66% of theenergy needed to heat and cool thebuilding have been achieved.

SustainabilityThe void forming technology and theabsence of beams in the structure,combined with the reduction in thenumber of support columns required,reduces the volume of the concrete usedin the building effectively reducing theCO2 omissions produced during themanufacturing process.

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Wet-Method

Dry-Method

In Situ-Method

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SERVICENationwide

A specialist design and

manufacturing facility for

Omnia systems is located at

Somercotes, Derbyshire.

Standards

All products are manufactured in

accordance with relevant British/

European/Trade Association Standards.

All Hanson Building Products sites are

quality assured to BS EN ISO9001:2000

We operate environmental

management systems at all our

production sites in accordance with

the methodology set out in the

BS EN ISO14001:2004.

All products are manufactured in

accordance with BES 6001 - the

Framework Standard for Responsible

Sourcing of Construction Products.

Other precast concrete products

Jetfloor

Beam and Block

Staircases

Hollowcore

Bridgedeck

Culverts

Bespoke solutions

For Omnia and Cobiax solutions please contact us at:

Hanson Building Products

Birchwood Way

Cotes Park Industrial Estate

Somercotes

Derbyshire

DE55 4NH

Tel: 08706 097094

Fax: 01773 603134

Email: precastuk@hanson.com

The Floors and Precast Division of Hanson Building Products operates from various plants located throughout the UK.

Hoveringham

Derby

Somercotes

Omnia production

Hanson Building Products Floors and precast locations

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Hanson Quarry Products

Crushed rock

Sand and gravel

Asphalt

Contracting

Ready-mixed concrete

Ready-mixed mortar

Screed

Civil engineering

Hanson Cement

Pulverised fuel ash (PFA)

Bulk cement

Ground granulated blastfurnace slag (GGBS)

Packed products

Hanson Building Products

Bricks

Blocks

Precast concrete products

Permeable paving (SUDS)

Chimneys and roofing

Cladding

Off-site solutions

Specialist brick and block laying

StructhermFastbuild Cladding Render

Our companies and productsHanson UK is split into three business lines – Hanson QuarryProducts, Hanson Cement and Hanson Building Products. We alsooffer a range of contracting services. For detailed information on allareas of Hanson and our products visit: www.hanson.com/uk

ENVIRONMENTALMANAGEMENT

UKASQUALITY

MANAGEMENT

UKAS

Floors and Precast Division

0870 6097094Hanson Building ProductsHanson House14 Castle HillMaidenheadSL6 4JJ

Website: www.hanson.com/uk

Hanson - A global business

Hanson is one of the world's largest suppliers of heavy buildingmaterials to the construction industry. We produce aggregates(crushed rock, sand and gravel), ready-mixed and precastconcrete, asphalt and cement-related materials and a range ofbuilding products including concrete pipes, concrete pavers, tiles and clay bricks

We are part of the HeidelbergCement Group, which employs70,000 people across five continents, has leading positions inconcrete and heavy building products and is the global leader in aggregates.

Hanson Building Products is the UK’s largest brick and aircreteblock producer. We also produce aggregate blocks, baggedaggregate and cement products, renders, pavers, pre cast floorsand stairs, SUD systems and prefabricated building systems.The division incorporates London Brick, Thermalite, Red Bank,Cradley, Formpave and Structherm.

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Hanson Building Products is committed to being a sustainablebusiness and contributing to sustainable development. We achieve this by continuous improvement of ourmanufacturing and extraction processes and by providingproducts which contribute to sustainable construction.

Made at factories certified to ISO 14001, our clay and concreteproducts have many features which assist our customers inconstructing attractive, sustainable buildings which enrich thebuilt environment and are ideal for zero carbon developments.These include: thermal mass, insulation, longevity, durability, lowmaintenance, flexibility, flood resistance and the ability to berecycled. We can advise on how best to use our products insustainable buildings and how they contribute to high ratingsunder the Code for Sustainable Homes and BREEAM.

Email: sustainabilityuk@hanson.bizWeb: www.hanson.com/uk/sustainability OM 02 | Dec 2010