Suspended Concrete Floor Systems
Suspended concrete floor systems, like Superfloor and Insuldeck, are innovative construction methods that offer several advantages over traditional concrete floors. Here’s a breakdown of their key features and benefits:
What are Suspended Concrete Floor Systems?
Elevated Structures: Unlike traditional concrete slabs poured directly on the ground, suspended concrete floors are elevated and supported by structural elements like beams or joists. This creates a void or space beneath the floor.
Components: These systems typically involve a combination of:
- Structural Supports: Beams, joists, or other structural members that carry the weight of the floor.
- Formwork: Temporary or permanent structures that hold the concrete in place until it cures.
- Reinforcement: Steel bars or mesh embedded in the concrete to increase its strength.
- Concrete Slab: The finished concrete floor surface.
Advantages of Suspended Concrete Floor Systems
Design Flexibility: They offer greater flexibility in design, allowing for longer spans and unique architectural features.
Space Optimization: The void beneath the floor can be used for various purposes, such as:
- Mechanical, electrical, and plumbing (MEP) systems
- Storage space
- Crawl spaces
Improved Insulation: Some systems, like Insuldeck, offer enhanced thermal insulation, leading to energy savings.
Acoustic Performance: They can provide better sound insulation compared to traditional concrete floors.
Durability and Longevity: Concrete floors are known for their strength and resistance to wear and tear.
Fire Resistance: Concrete is inherently fire-resistant, enhancing the safety of the building.
Applications
Suspended concrete floor systems are suitable for a variety of applications, including:
- Residential buildings
- Commercial buildings
- Industrial facilities
- Parking garages
- Mezzanines Considerations
Cost: Suspended concrete floor systems can be significantly cheaper and faster compared to traditional methods.
Complexity: Installation may require specialized knowledge and skills.
Overall, suspended concrete floor systems like Superfloor and Insuldeck offer a range of benefits in terms of design flexibility, space utilization, performance, and durability. They are a valuable option for construction projects seeking high-quality and efficient flooring solutions.
Super Floor is a leave in place formwork system that can be installed by almost anyone. The system combines a pre-cambered galvanized steel joist, formwork tray and support bars all made to measure to insure a high-quality finished floor with fast installation.
The Super Floor system is manufactured in Ohio from pre-galvanized high tensile steel. The joists are placed on the primary support then the Super Floor support bars securer the joists into the correct position. Finally, the tray/pan is laid across the support bars and the system is ready for wire mesh reinforcement to be placed and the concrete to be placed and finished. Generally Super Floor uses a 3.5”- 4” concrete topping but can easily be designed for thicker slabs if required.
The Super Floor USA composite floor system is suitable for use in all types of construction including ICF structures, Steel frame buildings, masonry buildings, poured in-situ or precast concrete. From single family detached housing to mid-rise multi-story residential and commercial buildings as well as parking garages. Super Floor is a complete proprietary system that provides contractors and developers with a piece of mind solution allowing them to continue works on site without interruption, increasing productivity and efficiencies.
Super Floor
INSUL-DECK is a fast, versatile joist construction system for concrete Floors, Roofs and Elevated Buildings. The stay-in-place insulated concrete forms (ICFs) are made of Expanded Polystyrene (EPS), an insulation material of choice for many decades. Integrated steel beams are molded into each Insul-Deck panel creating formwork for the support of concrete, reinforcement, and construction loads with minimal shoring.
The forms are lightweight so that two people can handle each panel. Insul-Deck also reduces the floors’ weight, producing a T-beam shape instead of a conventional flat slab. Ceiling finishes, such as drywall, can be attached directly to the Insul-Deck forms.
To speed up job-site installation, Insul-Deck concrete forms are made-to-order in whatever lengths & thicknesses required using a patented continuous molding process. The system is the result of years of research, design, and practical field experience.
(1) Molded-In Steel Beams (extended for illustration purposes) are continuous providing the strength for Self-Supporting Concrete Forms, which greatly reduces shoring and labor. They also serve as Attachment Points for Finishes every 12″. For example, drywall can be screwed directly to the exposed steel furring strips at the bottom of each panel.
(2 / 4) Utility Chases can be used to install a variety of electrical, plumbing, or ducting. It’s easy to enlarge those chases by simply cutting away some of the insulation (after the concrete is poured and cured).
(3) Tongue-and-Groove Interlocks form the bottom of the concrete T-beams, or joists. Rebar reinforces each joist with ¾” Double-Rebar-Chairs available from Insul-Deck. Steel mesh or rebar reinforces the floor slab. Engineering guidelines and detailed design documentation is available for a wide variety of project requirements.