Have you ever heard the term metal deck or steel deck and wondered what it actually means?
You may have a set of plans for working on a steel deck that you need to learn more about. We cover all its basics in this article. At Ista Banaye Rasekh Company , we have been providing steel deck implementation for 10 years. Our goal is to answer all our customers’ questions, from simple to complex; So, let’s start with the definition of a steel deck roof .
In this article we cover the following:
- What is a steel deck roof?
- Additions to the steel deck
- Steel deck applications
- Types of steel decks
- How to build and implement a steel deck
What is a steel deck roof?
One of the types of roofs in metal structures is the metal deck roof . This type of roof was used for the first time in 1820 by Henry Palmer by assembling galvanized sheets as in-situ formwork.
Steel deck is a corrugated metal sheet used as a structural roof deck or composite floor deck. This deck is supported by steel beams and joists. The purpose of steel deck implementation is to provide a single layer of roof insulation or to provide a connection with concrete in order to create a steel deck composite roof .
The system of these roofs consists of four main components : formed steel deck sheet, studs, reinforcement mesh and concrete. The distinguishing feature of steel deck roofs over other types of roofs is its lightness, quick implementation and economic efficiency.
The steel deck has a high strength-to-weight ratio, which reduces material handling and installation costs. It is an ideal product for the construction of multi-storey buildings. This is a great platform for a concrete ceiling or floor.
Other names of steel deck: metal deck, pan deck and Q deck Q
There are several names for a steel deck , but they all mean the same thing; So if you hear these terms you know what they mean.
What is a metal deck?
Metal deck is just one name of steel deck . In some places it is called steel deck and in another place it is known as metal deck. There is an alternative definition that does not mean steel installation. There is a different product called STEELDECK that can be used as a portable device or an economical portable work platform system.
What is a Q deck?
Q deck is the original metal deck invented by HH REBERTSON in 1960. This composite decking was called Q LOCK FLOOR and was available in 2 and 3 inch depths. This type of decking is not available today when people ask for it, usually as a general term for steel decking .
What is a pan deck?
The pan deck is a cast-in-place metal model that was used from the 40s to the 60s of the 19th century. When people are looking for this type of deck, they mean steel deck.
Steel deck applications
Steel deck has two main uses: structural roof steel deck and multi-story steel deck. It works great for both applications because it has a high strength-to-weight ratio that is both inexpensive and easy to install.
Metal roof deck
The metal roof deck is a corrugated metal sheet used for roofing applications. These decks are installed on steel joists or beams and provide a durable platform for installing roofing materials, insulation, roof waterproofing and lightweight concrete. Decks are bolted to steel by welding, mechanical fasteners, or sheet metal wrapping.
A roof deck is a flat surface without any bumps and is not designed to have construction concrete poured on it. If you want to build concrete and a composite floor deck system, you will need a steel deck .
Uses of metal roof deck
- It provides the roof system of the building.
- The mezzanines, which are the middle floors in the building, are covered with plywood.
- Steel canopies on top of the building that provide shade and protection.
- Garbage inlet and roofs
Floor steel deck (floors)
Metal floor deck is a corrugated metal sheet that is used for floor applications. These decks are mounted on steel beams or girders and support wet concrete.
There are ridges in the vertical blades of the deck that are connected to the concrete slab. When concrete is cured, it becomes a composite floor deck that increases the strength of the floor without adding weight.
Uses of steel deck floors
- A work platform during the construction of multi-story buildings
- To stabilize the building frame
- A model for fine in-situ concrete
- Composite floor deck system that supports building design loads.
- Mezzanines are the middle floors in a building and are covered by concrete.
Types and sections of steel roof deck
The two most common types of steel roof deck cross sections that are readily available are B and N decks. There are also two other types of metal roof deck sections: A-type and F-type. These two types are less common in construction projects and are not readily available.
Deck B
This is the most common type of steel roof deck . Its main use is to provide a roof construction system. This deck is used for spans less than 10 feet. This item is available in light grade 22 and heavy grade 16. Deck B is 1.5 inches deep and 36 inches wide.
Deck B
N deck
This type of metal roof deck is used when you have a span greater than 10 feet. N type of roof platform is available in 22 degree lightness and 16 degree heaviness. It is 3 inches deep and 24 inches wide .
HSN3 deck
This is the newest type of metal roof deck . This deck is very similar to the N-type deck; But there are two important differences. HSN3 has a width of 32 inches, which takes less time to install. The blades are also more angled, which makes it easier to cut sheets from bundles.
Just like the N deck, this deck is also used when you have an opening larger than 10 feet. Type hsn3 roof deck is available in 22 degree lightness and 16 degree heaviness. This type is 3 inches deep and 32 inches wide .
Deck A
Type A deck is an older type of metal roof deck . This plate is 1.5 inches deep and 36 inches wide. The space between the blades is only 1 inch, which is why it is known as a narrow blade. In contrast, the space between the blades on deck type B is 2.5 inches. The narrow space between the blades makes the A-type deck a weak plate. This type of plate is mainly used in repair or retrofitting, when you are trying to connect an existing metal deck to an older building.
Deck F
Type F deck is 1.5″ deep, 36″ wide. This is a mid blade metal roof deck . Blade spacing is 1.875 inches, which is narrower than the B model; But it is wider than deck A. This deck has more power than the A deck, however, the B deck is a stronger board. Type F decking is often used for renovation work, where existing decking is used for old buildings.
Types and sections of steel deck
There are three sections of these types of decks that are readily available. At depths of 1.5-2-3 inches. The main difference between the three is the resistance of the plates. Deeper plates will have more resistance. For example, a 3-inch type will be stronger than a 1.5-inch type.
Format B-36
The b-36 formwork can accommodate concrete formwork thicknesses up to 3.5″ in depth and 7.5″ in height. This deck is used in short span conditions. This floor deck is available in light grade 22 and heavy grade 16. The b-36 mold is 1.5 inches deep and 36 inches wide.
W2-36 format
The w2-36 mold can accommodate slab thicknesses up to 4″ in depth and up to 8″ in height. This mold is stronger than B-36 mold but not as strong as w3-36. This template is available in lightness grade 22 and heavy grade 16. The w2-36 is 2″ deep and 36″ wide.
W3-36 format
The w3-36 formwork can accommodate concrete slab thicknesses up to 5 inches in depth and up to 9 inches in height. This mold is the strongest metal floor deck mold . This mold is available in lightness grade 22 and weight grade 16. w3-36 has a depth of 3 inches and a width of 36 inches
the system of these roofs consists of four main components : formed steel deck sheet , studs, reinforcement mesh and concrete. The distinguishing feature of steel deck roofs over other types of roofs is its lightness, quick implementation and economic efficiency.
How is the implementation of the steel deck roof?
The process of implementing these roofs starts from forming the galvanized sheets by forming machines – Roll Forming – in a trapezoidal shape. The presence of standard congresses on the surface of the deck sheet has led to a better engagement of concrete and galvanized sheets of the deck sheet, which leads to the composite performance of concrete and deck sheets. The existence of continuous longitudinal grooves in the sheet also prevents the local buckling of the sheet during concreting.
In addition to bearing the weight of concrete as an in-situ form, these sheets play the structural role of a rigid roof in transferring gravity and lateral loads to the metal structure system. The thickness of the deck sheet varies from 0.7 to 1.2 mm depending on the use and the way the roof is loaded, but usually the thickness of the galvanized sheet used in the deck sheet is 0.8 mm. The common steps of the deck sheet are 65 and 75 mm.
Studs are produced from alloy steel with low carbon percentage and during cold forging process. Cold forging production increases the density, uniforms the internal layers of steel and increases its tensile strength and yield strength. The correct implementation of studs is very important in transferring the shear loads of the roof to the metal bearing structure system.
Today, studs are made by a special electric arc welding machine with the abbreviated name of Stud Welder. The studs have various diameters and heights, which change according to the shear force of the design, the step height of the deck sheet, and the thickness of the concrete.
The minimum diameter of the stud is 19 mm and its minimum height from the step above the sheet is about 40 mm. The presence of dry ceramic during welding causes the concentration of the molten pool at the end of the stud and prevents the weld from splashing around.
The presence of protrusions on the deck sheet and the concrete conflict with it means that the deck sheet plates can withstand the tensile forces of the roof and there is no need for tensile bars in the roof; Therefore, in most cases, only the heat rebar network and concrete shrinkage are implemented in the roof of the steel deck .
If the design of the roof requires a tensile reinforcement network, the standards related to tensile bars should also be observed. In addition to the upper reinforcement network, the fire rebar is also implemented in accordance with the fire fighting regulations in the lower steps of the deck sheet. Fire rebar or fire retardant based on BS and SDI standards will delay the destruction of the roof caused by large fires.
Before concreting, the surfaces of these roofs must be free of any extra objects and the ceramics at the end of the studs must be broken and collected from the roof. The minimum grade of concrete used in the roof is C20, and the best concrete slump of the steel deck roof is 12, which should be provided by adding a lubricant – and not by adding water.
The minimum height of concrete from the upper step of the deck sheet is 50 mm, and the concrete cover on the studs should not be less than 13 mm.
Clip of concreting the roof of the steel deck of Parsa Fartak Dadeh viera factory
Steel deck roof price
Considering its long history in the field of designing and implementing steel deck roofs, Ista Banaye Rasekh Company declares its full readiness to cooperate with all dear organizations, institutions and employers across the country. You can ask for the supply of all the materials of these roofs including formed sheets, studs, rebar and concrete with the best quality and the most suitable price from this collection.
Nowadays, due to the importance of the speed of project implementation, the construction of steel deck roofs (metal deck) is the priority choice among employers.
Advantages of steel deck roof implementation
1- Very suitable speed of steel deck roof implementation compared to other roofs.
2- Absence of piles and holders under the ceiling, which causes parallel work in the execution process.
3- The effect of reducing the weight of the metal structure (increasing the distance of the secondary beams).
4- The integration of the roof and the structure of the building.
5- Other benefits
Construction steps of steel deck roofs:
- Preparation of steel deck sheet (metal deck or metal deck)
- Deck sheet forming and flushing
- Spreading and fixing the sheet on the structure with nails and automatic screws
- Stud welding with stud welder
- Rebar in the form of a mesh network or reinforcement
- Closing the flashing and moldings around the ceiling
- Placement of openings and location of facilities
- Preparing the roof for pouring concrete
- Concreting the roof using a hand trowel or butterfly trowel
The comprehensive standard for the implementation of steel deck roofs for industrial uses was compiled in 1939 by the Steel Roof Institute – SDI, but the comprehensive use of this type of roof in the construction industry since the late 1980s as a new and economical system was noticed by reputable construction companies in the world. .
In recent years, managers of Ista Benaye Rasekh Company have designed and implemented a large number of projects using the steel deck roof method, such as: export development project, Niavaran residential project, Melika residential project, Celtis commercial project, Golberg project and other projects.
In the first half of 2018, Ista Banaye Rasekh Construction Company was able to finish the construction of the steel deck roof of Pardis Technology Park with an area of 11,000 square meters within 60 days.