T: 059 9721617

F: 059 9722316

E: sales@kilcarrigquarries.ie

Kilcarrig

Bagenalstown

Co. Carlow

KILCARRIG QUARRIES LTD.

c o n c r e t e f l o o r i n g

QUALITY & SAFETY CONTROL APPROVED

c o n t e n t s

1

Features - 2 - 3

Finish Floor Options - 4 - 5

Construction Details - 6

150mm Slab - 7

210mm Slab - 8

Cost Comparison & FAQ - 9

Advanced CAD Floorings - 10

Notes - 11 - 12

Kilcarrig Quarries is a long established company which has been supplying materials to the civil engineering and construction industries for the past 30 years. Our products are many and diverse in nature and includes crushed rock, drainage material, a complete selection of blocks, precast and concrete. In the year 2005 saw the expansion of our production facilities to include a purpose built installation for the production of Kilcarrig Concrete Flooring. These products are fast becoming the preferred option in new home construction.

FE

AT

UR

ES

2

Fire ResistanceA Safer HomeThe noncombustible nature ofconcrete makes it one of the best materials for containing fire.

Secure InvestmentA Durable HomeTimber shrinkage and creaking floors will be eliminated. Security, privacy and resistance to wear and tear will be increased.

Structural EfficiencyA Solid HomeA hollow core slab offers the ideal structural section by reducing the deadweight whilst providing themaximum structural efficiency within the slab depth.

Thermal EfficiencyA Warmer HomeUsing concrete slabs in your home provides a facility where by heat is absorbed during the day andreleased during the night.

Fast ConstructionA standard size house can usually be covered with Kilcarrig Precast flooring slabs in less than half a day. Floors can be grouted the same day and ready for use as a working platform the following day. This quick turn around enables greater turnover than with the traditional timber joist system at first floor level or fill and pour at ground floor level.

Underfloor Heating Made EasyConcrete floors such as those manufactured by Kilcarrig Precast are the preferable option when using an underfloor heating system. Underfloor heating manufacturers recom-mend that placing the heating pipes within a concrete screed offers “the highest thermal capacity” as against timber alternatives. Be cost effective when compared to traditional methods.

Easy InstallationKilcarrig Precast flooring slabs are narrower and therefore lighter than most other concrete flooring products. This enables the majority of Kilcarrig Precast slabs, supplied to both ground and first floor level, to be placed by our lorry mounted cranes.floor level or fill and pour at ground floor level.

Sound InsultationA Quieter HomeThe use of concrete floor slabs between levels has proven to cut noise transfer by over 50%. Using concrete floors instead of timber also eliminates creaking floor joists.

3

User Friendly No CamberThe design of Kilcarrig Precast floors (reinforced concrete rather than prestressed) means that they are level both above and below, hence greatly reducing the cost involved in finishing both ceilings and floors. In most domestic spans, a Kilcarrig Precast slab can carry the required load without the need for a structural screed. This gives the home builder a greater variety of options when choosing the finished floor surface.

Minimal Waiting Time Available Ex-StockKilcarrig Precast slabs are available ex-stock giving a faster response time. Lengths are available in 50mm increments from 1.0m to 6.5m. Approximately 20,000 square metres of Kilcarrig Precast concrete flooring are held in stock at all times.

Safe Working Platform ProvidedA grouted Kilcarrig Precast floor provides a safe working platform for following trades which simplifies health and safety management. The time and material required for scaffolding will be reduced.

Secure System Grout KeysKilcarrig Precast flooring units have a special shear key that enhances load transfer between units. This special grooved system, once filled with the appropriate concrete mix, enables the floor to act as one panel. As well as being a major influence in the reduction of cracks in ceilings, the grout key also provides a facility for easy fixing of suspended ceilings. The v-shaped key allows a moulded batten to be secured between adjacent slabs. This batten can then be used to carry counter battens below.

SavingsWith the rising cost and decreasing availability of new stone and quality fill, many people are using precast concrete floor slabs to form their ground floor. Savings of €1,000’s have been made, even in small houses, by opting for Kilcarrig Precast.

SimplicityIn situations where there is a considerable amount of block work below ground floor level it is often desirable to reduce the number of founda-tion walls which will reduce cost. Kilcarrig Precast floor slabs can be used to carry non load bearing block walls and hence facilitate a ‘spine wall’ system.

Flexibility of DesignOur floor units can accommodate openings for service pipes, electrical wiring etc.

FE

AT

UR

ES

FI

NI

SH

F

LO

OR

O

PT

IO

NS

4

Slab With Non Structural Screed

Slab With Timber Batten Finish

Rubber spacers are often placed between the battens and the slab to reduce the transfer of impact noise through the floor.

Insulation

35N10 grout in shear keys

Non Structural Screed

Heatingpipes located between battens

Floorboards / finished floor fixed to timber

Timber batten placed on floor

Electrical services fixed to battons

35N10 grout in shear keys

Special designed shear keyties slabs together into oneunit

Services for above and below locatedin screed

5

Slab With Structural Screed(used where higher loadings are required)

Structuralscreed.

Slabs coated with boarding before placing of structural screed

Concrete screed placed along with grouting of shear keys.

Services fixed to battens below slabs

Plasterboard finish below

Timber battens placed in shear key to receive fixings from below.

FI

NI

SH

F

LO

OR

O

PT

IO

NS

Requirements for a screed will be indicated on your customer drawing.

CO

NS

TR

UC

TI

ON

D

ET

AI

LS

6

Projects In ActionTypical Minimum Bearings:Steelwork - 75mmConcrete - 75mmBrickwork - 100mmBlockwork - 100mm

Note: These bearings may be reduced at the design stage if required or at the engineer’s discretion.

BattensDropped ceilings allow room for placing services underneath the slabs. Battens can be placed between slabs at the time of fitting to make counter battening easier.

CantileverSlabs can be cantilevered up to to 1.2m to accommodate stair openings.

Hanger BracketHanger brackets can be fabricated to support slabs around openings.

ServicesSlabs are commonly used at ground floor and service openings can be accommodated.

WallplatesWhere slabs are used in a dormer bungalow, the wall plate is usually fixed to the slab as indicated below.

7

Slab Properties

Loading RequirementsBS 6399 gives the required load carrying capacities for various applications. Some common applications are:

Housing - 1.5kn/m2

Garages - 2.5kn/m2

Industrial - 5.0kn/m2

Bar sizes increase at various stages.Heavier steel can be used to increase the load carrying capacity.

Note: Wall loads are in addition to the above.

Precautions: Do’s & Dont’sDo: • Read and adhere to all job specific customer information. • Use only specified mix when grouting / placing structural screed. • Allow one cubic metre of grout for every 100/m2

flooring.

Don’t: • Leave floor ungrouted. • Leave out any specified steel. • Load unpropped floors.

Span Load Table (Heavy Applications)

15

0M

M

SL

AB

Self weight of slabs is approximately 2.5k/nm2

1.0m3 of grout will cover approximately 100m2

600mm

563.8mm

150mm

Span Load Table (Housing Applications)

Kilcarrig 150mmClear Span (m)

Timber Batten

Non-Structural Screed

1.90

2.15

2.40

2.652.903.153.403.65

3.90

4.15

4.40

4.65

4.90

5.00

5.10

5.20

16.0

13.9

12.4

11.09.88.88.56.5

6.1

4.8

4.7

4.1

3.8

3.0

2.5

2

1.90

2.15

2.40

2.652.903.153.403.65

3.90

4.15

4.40

4.65

4.90

5.00

5.10

5.20

Finish Floor TypeDepth of Structural Screed (mm)

Kilcarrig 150mmClear Span (m)

50

75

100

4.0

10.2

10.5

10.8

4.5

9.9

10.3

10.5

5.0

8.5

9.0

9.2

5.5

5.9

8.4

9.0

6.0

3.1

6.0

8.0

6.5

1.2

2.9

5.1

21

0M

M

SL

AB

8

Slab Properties

Loading RequirementsBS 6399 gives the required load carrying capacities for various applications. Some common applications are:

Housing - 1.5kn/m2

Garages - 2.5kn/m2

Industrial - 5.0kn/m2

Bar sizes increase at various stages.Heavier steel can be used to increase the load carrying capacity.

Note: Wall loads are in addition to the above.

Self weight of slabs is approximately 2.9k/nm2

1.0m3 of grout will cover approximately 60m2

600mm

550mm

210mm

Span Load Table (Heavy Applications)Span Load Table (Housing Applications)

Kilcarrig 210mmClear Span (m)

Timber Batten

Non-Structural Screed

2.90

3.15

3.40

3.653.904.154.404.65

4.90

5.25

5.40

6.65

5.90

6.00

6.10

6.20

13.3

12.9

11.4

9.48.011.19.68.0

6.1

8.7

6.6

6.3

4.7

4.1

3.5

3

12.7

11.4

9.9

7.96.59.68.16.5

4.6

7.2

5.1

4.8

3.2

2.6

2

1.5

Finish Floor TypeDepth of Structural Screed (mm)

Kilcarrig 210mmClear Span (m)

50

75

100

5.5

8.4

7.0

7.0

6.0

7.8

7.3

7.2

6.5

5.9

7.3

7.3

9

Can walls be built off Kilcarrig Precast?Walls can be built off Kilcarrig Precast slabs in most cases. The type of wall construction depends largely on the span of the slabs. The Kilcarrig Precast design division will indicate on each customer drawing whether concrete block, lightweight block or studwork partitions are suitable.

Are deeper foundations required?Generally foundations are capable of carrying the additional load without changing the design. Piled foundations sometimes require additional design. Please inform your engineer/architect that you are planning to use slabs, as early as possible.

Is it necessary to build thicker walls?Wider walls are usually only required where two slabs meet on a wall. Our design division will highlight any requirement for wider walls when producing a slab layout drawing.

Are concrete floors more costly than timber joists?Precast concrete floors are slightly more expensive than timber joists, as can be seen from our cost comparison download, but the benefits far outweigh any additional cost. Kilcarrig Precast’s special design makes them the most cost effective precast option. Overall cost will vary depending on the finishing method used. Additional costs can be as little as 10%. It has been reported that up to one weeks labour per house can be saved by using Kilcarrig Precast Slabs, therefore increasing speed and reducing labour costs.

Are heavier lintels required?Normal 75mm prestressed lintels are sufficient for openings up to 900mm. Openings in slab bearing walls greater than 900mm require superior lintels. Your architect/engineer should however be consulted as this is only a guideline.

Is Kilcarrig Precast suitable for use on small sized houses?Kilcarrig Precast slabs have been used on various sites ranging from small semi detached houses to large apartment blocks.

When is Kilcarrig Precast used at ground floor level?Some building authorities recommend use of asuspended slab for structural reasons where depth of fill exceeds 600mm. Generally a suspended slab becomes the cheaper option where depths exceed 900mm. This however is dependent on availability of stone and labour.

CO

ST

CO

MP

AR

ISO

N &

FA

Q

Cost Comparison

Price Per m2 (€) Precast

Joists

Trimmers

Slab & Skim Ceiling

Insulate Between Joists

Apron Lining At Stairs

Standard Tongue & Groove Flooring

Cost Of Gleeson Kilcarrig Slab

Concrete To Fill Joints

75mm Screed Powerfloated

Bond & Skim Underside Of Slab

Timber Insert Between Slabs

Batten, Slab & Skim Underside Of

Slab

TOTAL

40.00

1.40

14.85

1.50

27.00

€84.75

Kilcarrig PrecastTimber

27.35

0.85

22.00

7.000.4523.00

€80.65

Lig

htn

ing

Prin

t & D

esig

n L

td. 0

59

91

42

21

2

T: 059 9721617 F: 059 9722316 E: sales@kilcarrigquarries.ie

Kilcarrig, Bagenalstown, Co. Carlow: : : :

All Precast concrete units are designed to the requirements of BS8110: 1997

c o n c r e t e f l o o r i n gKilcarrig Quarries are able to offer a variety of economical design solutions by combining their full range of precast products