CORCON Design, Construction and Technical Information Manual
SIMPLE DESIGN CHART & SAMPLE CALCULATIONS
INDEX

DESIGN CONSIDERATIONS

SIMPLE DESIGN LOAD AND SPAN CHARTS FOR CORCON
P2

SAMPLE CALCULATION
P6
BEAM DESIGN
P15

REFERENCE FIGURES FOR DESIGN
P24
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CORCON Design, Construction and Technical Information Manual
DESIGN CONSIDERATIONS
CORCON is a hybrid moltiribbed slab +beam system using the best properties of a slab
coupled with all the advantages of the beam used to stiffen the slab in deflection.
CORCON is a flexible system that can be applied to any span and loading
configuration by the use of inserts which can be used to vary the depth of the CORCON
rib beams - from a nominal 50 m2 depression to 300 m2 deep for extra heavy loads and or
long Spam over 8 to 9m. Also by reducing the (c to c) centre to centre spacing from 1200
m2 and continuity the spam can be increased to 26m using post-tensioning.
Small spans - say 3m- use CORCON with "FLAT" insert mould (see the Figure below):
If require structural primary beams could always use upstand beams subject to
requirements. (see the Figure below):
This upstand systems allows continuous layting of CORCON ribs.
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CORCON Design, Construction and Technical Information Manual
SIMPLE DESIGN LOAD AND SPAN CHARTS FOR CORCON
Beams @ 1200 Centres
Single Span
Allowable superimposed live load (KPa)
Reqd Avg
Conc
C to C spans metres
Beam bar
Total
.
Depth size
depth
vol
d mm overla
mm 4.0 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 10.0 11.0 14.0
m3/
p
m2*
50 2Y12 0.12 184 3
75 2Y12 0.12 209 5 .5^
100 2Y12 0.12 234 5 1.5
150 2Y12 0.12 284
5 2.5 1
200 2Y12 0.12 334
4 4 2 1^
250 2Y16 0.13 384
5 5 3.5
300 2Y16 0,14 414
5 5
1.5 hour fire rating, stc 49, min cover 85mm,
f62 mesh top & 1/250 deflection
* based on 20m2 room
^ roof loads
** post tensioned
*** continuous post tensioned built in primary beam
2
4
0.3 3**
2 1^ 5** 3** 2***
Single Span
Avg Total
Allowable superimposed live load (KPa)
Beam Reqd
bar
Conc.
C to C spans metres
Depth
depth
vol
d mm size
mm 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5
overlap m3/m2*
50
2Y12
0.10
164 5 5 3
100 2Y12
0.10
214
5
150 2Y12
0.10
264
200 2Y12
0.11
314
250 2Y16
0.11
364
300 2Y16
0.12
414
0.5-hour fire rating, min cover 65mm,
f62 mesh top & 1/250 deflection
* based on 20m2 room
^ roof loads
1
4.5 2.5 .05
5 3.5 1.5
4 2
5
1
1
5
5
4
5
2
5
1.5 0.5
3.5 2 1
Continuous Span
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CORCON Design, Construction and Technical Information Manual
Beam
Depth
d mm
50
Allowable superimposed live load (KPa) and
Reqd
Avg
Total
deflection to span ratio.
bar
Conc.
depth
C to C spans metres
size
vol
mm
10. 10. 11.
overlap m3/m2*
5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5
0 5 0
2Y12
0.12*
2
184 1/2
70
75
2Y12
0.12*
209
100
2Y12
0.12*
234
150
2Y12
0.12*
284
200
2Y12
0.13*
334
250
2Y16
0.13*
384
300
2Y16
0.13*
2
1/2
75
2
1/3
00
2
1/2
75
434
2
1/2
75
2 2
1/3 1/3
50 00
2 2 2
1/3 1/3 1/2
50 00 50
1.5 hour fire rating, stc 49, min cover 85mm,
f62 mesh & y16 @ 1200mm top
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CORCON Design, Construction and Technical Information Manual
SELECTED SECTION PROPERTIES
B
d
D
b=
B=
D=
d=
Fck =
Fy =
Conc. Cover =
Rib Spacing =
110mm
155Mm
485mm
300mm
30N/mm2
460N/mm2
25mm
900mm
Cross sectional Area =
177954.57mm2
Moment of Inertia Ixx =
2468.22E6 mm4
Reinforcement at Mid-Span =
2 * T16 mm Dia.
Reinforcement at Supports =
3 T 12mm Dia.
Moment Capacity at Mid Span =
69.08KN-m
Section Capacity at Support =
81.03
Actual Deflection =
1.14mm
Shear Capacity =
0.86N/Sq.mm
Shear Reinforcement =
Please check CORCON test Results.
Concrete Volume per Sq.m of Plan Area =
0.15Cub.m
Reinforcement per Sq.m of Plan Area =
0.26Kg
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CORCON Design, Construction and Technical Information Manual
SAMPLE CALCULATION
PROJECT
JOB REF
The Sukhothai Bangkok
DECOIN PTY LTD
ACN 008 625 590
ABN 30 008 625 590
CALCULATION BY
Upul Perera
PART OF
STRUCTURE
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CHECKED
BY
CALC SHEET
PRINTED BY
Decoin Pty Ltd
DATE
09/02/2003
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CORCON Design, Construction and Technical Information Manual
MEMBER
REF
LOAD CALCULATIONS
OUT PUT
Loading (Guest Room Area)
(A) Rib Self weight
kN/m2
Screed + Finishes
kN/m2
Services
kN/m2
Ceilings
kN/m2
= 3.36
= 1.177
= 0.225
= 0.225
References to BS 8110
Partitions
=
kN/m2 - DL
Imposed Lead
kN/m2 - LL
3.434
8.421
1.962
n= 14.93 kN/m2
Udl for Ribs
(ult)
DL = 8.421 x 1.2 = 10.1 kN/m
LL = 1.962 x 1.2 = 2.4 kN/m
(B) Plant Room Area
Rib Self wt.
Screed
= 3.36
= 1.1772
0.225
=
4.7622
Services
kN/m2
- DL
Live Leads
kN/m2 - LL
= 7.35 8
N= 18.439 kN/m2 (ULT)
Udl for Ribs
(C )
Storage Room,
Rib self wt.
Screed
Services
kN/m2 - DL
Imposed Load
2
kN/m - LL
DL = 5.715 kN/m
LL = 8.829 kN/m
= 3.36 kN/m2
= 1.177
0.225
=
4.7622
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4.905
-
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CORCON Design, Construction and Technical Information Manual
UDL  for Ribs,
MEMBER
REF
DL = 5.715 kN/m
LL = 5.886 kN/m
Specimen Calculation
Y20
OUT PUT
Y20
125
Area=140561 mm2 = 0.14 m2
400
66
References to BS 8110
Loading for [live load of 300 kg/m2 Area]
Ribbed slab self wt = 0.14 x 24 = 3.36 kN/m2
Screed
= 1.18
Services
= 0.225
Ceilings
= 0.225
4.99 kN/m2 – DL
= 2.943 kN/m2 -
Live Load
LL
Design Ultimate Load
x 1.6
n = 4.99 x 1.4 + 2.943
= 11.69 kN/m2
Uniformly Distributed Load on a Rib
DL = 1.2 x 4.99 = 5.88 kN/m
LL = 1.2 x 2.943 = 3.53 kN/m (service load)
Three load combinations were considered. Please refer
Prokon print out sheets #01 to #03.
The rib beam is designed for max. sagging and hogging
moment for each span, considering BM and SF envelopes.
MEMBER
REF
CALCULATIONS
OUT PUT
A. Durability and Fire Resistance of Rib Slab
BS8110
Cl 3.3.4
Exposure conditions: It is assumed that these rib beams are
used in areas where the concrete surfaces are protected
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CORCON Design, Construction and Technical Information Manual
against weather or aggressive conditions.
Therefore treat as mild Exposure Conditions.
BS8110
Table 3.4
For Grade 30 Concrete (30 Mpa) the Nominal cover
requirement is as 25 mm, for Durability requirement,
Note: Above cover requirement is including links
BS 8110
Table 3.5
Nominal cover for Ribbed slab for : 01 hr. Fire Period = 20 mm
02 hr. Fire Period = 35 mm for continuous beams
45 mm for Simply Supported beams
use 35 mm cover for bottom bars
BS 8110
Fig. 3.2
Minimum member Dimensions regeared for Ribbed
beams, is 125 mm and Slab thickness of 95 mm for 1 hr
fire rating?
Same for 2-hr fire rating is 125 mm ribs & 125 mm slab
thickness.
MEMBER
REF
CALCULATIONS
OUT PUT
Design for bending.
MaxM + re moment in the span = 71.1 kNm.
BS 8110
Cl.3.4.4.4
Effective Depth (d) = 400 – (35+6+15) = 344 mm
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CORCON Design, Construction and Technical Information Manual
K=
M
71.1  10 6

=0.017 < k’ = 0.156
bd 2 f cu 1179  344 2 30
Hence Compression R/F is not required.
Z=d [0.5 +
k 

 0.25 
 ] < 0.95d
0.9 

0.017 

=344 x [0.5+  0.25 
]
0.9 

=344 x 0.98 >0.95d
 Z=0.95d=0.95x344=327mm
Depth to Neutral axis ‘x’ = (d-z)/0.45
=(344-327)/0.45
=37.8mm <100mm min. flange thickness
Hence, Neutral airs is within flange thickness.
BS 8110
Table 3.27
area of tension R/F,
M
71.1  106

As =
 555mm 2
0.87 fyz 0.87  450  327
As =555 mm2
100As min
bw h

=0.18 for
(As)min =
bw 95.5

 0.08  0.4
b 1179
0.18  95.5  400
 68.7 mm 2  555mm 2
100
Minimum Steel requirement is satisfactory.
MEMBER
REF
CALCULATIONS
OUT PUT
Maxm Support (at 1st intention Support) = -63 kNm
Effective depth to tension R/F;
d=400(25+6+25+20/2)=334mm
Effective depth to compression R/F;
d’=35+6+15=
56mm
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CORCON Design, Construction and Technical Information Manual
M/bd2 fcu =

63  10 6
= 0.285 > k’=0.156
66  334 2  30
Compression Steel is required.
Z=d [0.5 +
k' 

 0.25 
 ]
0.9 

= 334[0.5 +
0.156 

 0.25 
 ]
0.9 

= 334 x 0.776
= 259 mm
x= (d-z)/0.45 = (384-259) / 0.45 = 166.6 mm
Area of compression Reinforcements:
A's=(k-k') fcubd 2/0.87 fy(d-d')

0.285  0.15630  66  334 2
=
=261.8 mm2
0.87  450  334  56 
Area of tension R/F : As = k' fcu bd2 / 0.87fyz +A's
0.156  30  66  334 2
As =
+261.8 = 601.6 mm2
0.87  450  259
Compression steel
area at support
A's = 261.8 mm2
Tension steel area
at support
As = 601.6mm2
100 Asmin .
=0.26
bwh
0.26  95.5  400
Asmin. =
= 99.3 mm2 <601.6 mm2
100
minimum steel requirement is satisfactory.
minimum tension R/F
BS 8110
Table 327
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MEMBER
REF
CALCULATIONS
OUT PUT
Check for Shear
Maxm. shear force at 1st interior support = 60.6 kN,
Take Maxm shear force at ‘d’ away from face of the
support:
V=54.8 kN
Tension Steel provided 2 Y 20 (628 mm2 )
BS 8110
Table 3.9
100 As 100  628
=
=1.968
bd
95.5  334
mm2
54.8  10 3
=1.718 N/
95.5  334
Design concrete shear stress vc
1
Or from
equation:
v=
1
1
 100 As  3  400  4
 f 3
vc = 0.79 
 
 /γ m   cu 
 bvd   d 
 25 
1
 100  628  3
= 0.79 

 bvd 
1
1
 400 / 334  4  30  3

   
 1.25 
 25 
 1.046 
2
vc = 0.79  1.250  
  1.0625 = 0.878 N/ mm
 1.25 
Asv  b v sv (v-vc) / 0.87 fyv
BS 8110
Table 3.8
sv 
0.87 f yv Asv
bv v  vc 

0.87  250  28.3  2 
95.5  1.718  0.898
sv  153mm  provide R6-150 c/c
max shear link spacing 0.75d= 0.75 x 334 = 250 mm
BS 8110
cl.3.4.56
minimum link requirement Asv  0.4 bv sv / 0.87 fyv
Table 3.8
sv 
Provide Shear links
at 1st interior
support
R6-150 mm c/c.
0.87 f yv Asv
0.4bv
0.87  250  28.3  2 

= 322 mm
0.4  95.5
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CORCON Design, Construction and Technical Information Manual

provide nominal links @ R6 -225 c/c
Provide Nominal
links R6-225 mm
c/c.
MEMBER
REF
CALCULATIONS
OUT PUT
Check for Deflection, (250mm Rib -n = 11.69kN/m2
 bw   95.5 
  =
 = 0.081
 b   1179 
Ref. BS 8110
Table 3.10
basic span/Depth ratio = 16.76 (Value between simply
supported & continuous)
As
538
1
fs= 5  f y  req. 
= 5  450 
 1 = 240 N/
8
8
629
Asprov. b
mm2
M/bd 2 =
71.1  10 6
= 0.509
1179  344 2
Modification factor = 0.55 +
477  f s 
M 

120 0.9  2 
bd 

 2.0
M.F. = 0.55 +
477  240  1.95  2.0
1200.9  0.509
Allowable span = 16.76 x 1.95 x 344 mm
=11,242 mm > actual span 7,258 mm
Hence: Deflection is satisfactory.
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CORCON Design, Construction and Technical Information Manual
CHECK FOR DEFLECTION (BS8110)
DATA
Bending moment at mid span =
114 kNm (Ultimate)
Average web width
(b w) =
95.5 mm
Effective Flange width
(b) =
1179 mm
Effective depth at mid span (d) =
394 mm
Actual span of rib
=
7525 mm
Strength of reinforcement (fy)
=
450 N/mm
Area of steel required (Asreq.) =
778 mm
2
Area of steel provided (Aspro.) =
805 mm
2
Moment redisribution ratio
=
1
=
16.76
2
CALCULATIONS
Basic Span/Span Depth ratio
The design service stress (fs) =
Modification factor
=
Allowable Span
=
271.82 N/mm
2
1.67
11,046
1.673
mm
Deflection is Satisfactory
Table 3.10 of BS8110
See the BS 8110- Table 3.10
b w/b =
0.1
Rectangular
Support Conditions Sections
Flanged Beams with bw/b
<=0.3
Cantilever
7
5.6
Simply Supported
20
16
Continuous
26
20.8
Note: Linear Interpolation between values given above
can be used.
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BEAM DESIGN
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REFERENCE FIGURES FOR DESIGN
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