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Estimating Concrete Volumes for Composite Decks

By Steven J. Peterson, PE, MBA
053000 Metal Decking and 053100 Steel Decking. Structural steel is part of Division 05Metals subdivisions 051000 Structural Metal Framing and 051200 Structural Steel Framing. Methods of Measurement Concrete for the deck is measured by the cubic yard (cubic meters). Feet may be converted to meters by multiplying the feet by 0.3048, and cubic yards may be converted to cubic meters by multiplying the cubic yards by 0.7646. Estimating Quantities The estimating of concrete for composite decks is similar to the estimating of slabs on grade with two exceptions. First, the thickness of the slab varies because the bottom of the slab is poured over an intentionally uneven surface (the metal deck). Second, because the structure supporting the slab deflects under the weight of the concrete, the slab at the center of the span will be thicker than the concrete near the supports unless measures are taken to avoid this. To account for the uneven surface equation: TAve = T + (W1 + W2)D/(2S) Eq. 1, where: T = Distance from Top of Slab to Top of Metal Deck W1 = Width of the Metal Deck Cell at the Bottom W2 = Width of the Metal Deck Cell at the Top D = Depth of the Metal Deck Cell S = Spacing of the Metal Deck Cells The amount of concrete needed to account for the deflection of the beam is a function of how much a structure deflects under the weight of the concrete as the concrete is being poured. The amount of deflection is dependent on the density of the concrete, the thickness of the slab, the dimensions of the metal deck, the distance between the supports, and the size of the beams supporting the metal deck. For a deflection that is limited to 1/360 of the span of the beam (a common limit placed on the deflection of a beam), the deflection typically adds 10 to 15 percent to the amount of concrete needed to pour the slab (JSE 2002). The deflection may be offset by cambering the steel beams, as shown in Figure 3, such that the weight of the concrete causes the beam to deflect to a point where the slab is the same thickness at the center of the span as it is near the supports. The calculation of quantity of concrete needed for a composite slab is shown in the following example: Example 1: A 10- foot by 5- foot by 3-inch thick slab is poured over the metal deck shown in Figure 4. The depth of the slab is measured from the top of the slab to the top of the metal deck. Determine the number of yards of Introduction Many buildings incorporate composite decks into their design. Composite decks consist of a concrete slab poured over metal decking supported by structural steel beams as shown in Figure 1. The concrete, metal deck, and structural steel all become part of the structure and work together to support the loads in a composite deck. When pouring the

concrete, the metal deck must be supported until the concrete has cured and achieved sufficient strength to support itself. As the concrete is placed, the weight of the concrete increases the load on the structural steel beams, which causes the beams to deflect. This deflection increases the amount of concrete needed for the slab. The purpose of this paper is to give the reader an understanding of how to estimate the quantity of concrete needed for a composite deck. CSI Divisions and Subdivisions Raised concrete decks are part of Division 03Concrete subdivisions 033000 Cast-in-place Concrete, 033100 Structural Concrete, and 035000 Cast Decks and Underlayment. Metal decking is part of Division 05Metals subdivisions
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of the metal deck, the average nominal thickness of the slab must be determined. For the metal deck shown in Figure 2, the average nominal thickness is determined by the following

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concrete needed to pour the slab. Allow 12 percent for deflection and 5 ting the cells as shown in Figure 5: The following formula needs to be entered into Cell B10 =B1*B2*((B3+(B5+B6)*B4/(2*B7))/ 12)/27*(1+B8)*(1+B9) The data for the slab is entered in Cells B1 through B9. The data shown in Figure 5 is from Example 1. Ratios and Analysis The amount of concrete needed for deflection may be compared between projects, provided they have similar design characteristics, namely: the density of the concrete, the thickness of the slab, the dimensions of the metal deck, the distance between the supports, and size of the beams supporting the metal deck. When these factors are different they may affect the amount of concrete needed to account for the deflection. Conclusion Composite decks consist of a concrete slab poured over metal decking supported by structural steel beams. When calculating the quantity of concrete, the estimator must take i n t o account the unevenness of the metal deck using Eq. 1 and the deflection of the supporting beams as the concrete is poured. Typically, deflection adds 10 to 15 percent to the amount of concrete needed for beams limited to a deflection of 1/360 of their span. The additional concrete needed to account for the deflection may be eliminated by proper cambering of the beams. Glossary Camber: A slightly convex curve placed in the top surface of a beam or girder. Deflection: The amount a beam or girder bends as a result of a load placed on the beam or girder. Loads: Forces placed upon structural members due to the weight of the structure, the occupants, wind, earthquake, and so forth. Span: The distance between supports for a beam or girder. References JSE (2002). Construction Considerations for Composite Steeland-Concrete Floor Systems, Journal of Structural Engineering, Vol. 128, No. 9, p. 1101.

percent for waste. The average nominal thickness is determined using Eq. 1 as follows: TAve = 3 in + (4-1/2 in + 2-1 /2 in)(1-1/2 in)/(2 x 6 in) = 3.875 in The volume of concrete is calculated as follows: V = (Length)(Width)(Thickness) V = (100 ft)(50 ft)(3.875 in)(1 ft/12 in)(1 yd3/27 ft3) = 59.8 yd3 Add 12% for deflection: V = 59.8 yd3(1 + 12/100) = 67.0 yd3

Add 5% for waste: V = 67.0 yd3(1 + 5/100) = 70.3 yd3 The volume of concrete for a composite slab may be set up in a spreadsheet by entering the data and format-

Steven Peterson is an associate professor in the Parson Construction Management Technology program at Weber State University. He teaches courses in estimating, scheduling, and construction finance. Prior to teaching at Weber State, Steve worked as a project manager and estimator in the construction industry. He received an MBA and a BS in engineering from the University of Utah. Steven is the author of Construction Accounting and Financial Management and is working on a book entitled Construction Estimating with Excel. He can be reached at (801) 6267556, or speterson9@weber.edu.

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ESTIMATING TODAY