Beams and Composite Decking System(CDS)

ArcelorMittal is the world’s leading steel production company with a range of materials and products including steel profiles, jumbo steel beams, lightweight high-strength steel columns and many other unique products and materials for high-end applications with an annual output of about 100 million metric tonnes. In Pakistan, Cellpor in association with ArcelorMittal, provides and installs steel beams and composite decking systems (CDS) which have become the industry standard for high-rise buildings. Low weight and high strength metal ensures that whilst maintaining structural integrity, buildings are erected in a time-efficient manner. This latest technology has been introduced by Cellpor in Pakistan’s construction industry for the first time in the tallest building (62-story) Bahria Icon Tower.

Cellpor has successfully completed two mega projects with latest CDS technology, namely sixty-two story Bahria Icon Tower as well as the two thirty-five story towers at Dolmen City. These steel structure and composite decking system solutions have been proven to be efficient, reliable and a hassle-free solution for clients and engineers alike.

Method of Installation

Conventionally, reinforced cement concrete (RCC) is used to construct buildings. This not only is time consuming but is also material and cost-intensive. Cellpor uses innovative CDS technology to erect floor slabs at 1/3rd the usual time taken. In a floor area of 1100m2 (11,800 ft2), Cellpor can deliver up to 5 floors per month.

Steel beams are installed between the RCC core wall and peripheral columns and tie beams, after which decking sheets are installed and stud-welded on to the beams. Once the decking sheets are installed, 5mm wire mesh is placed and concrete is poured directly on to the decking sheet and is levelled using mechanical trawling. One of the specialities of using CDS technology is that the ribs in the design eradicate the need for reinforcement bars, with a simple anti-crack mesh required. The thickness of the concrete can vary depending on the design, but ideally a standard thickness of 120-130mm is maintained.

The CDS panels are quick to lay, provide a safe working platform for workers and contribute up to a 100kg/m2 saving of concrete as well as a 6kg/m2 saving in reinforcements compared to conventional RCC structures.

Composite floors offer a highly effective balance between high-tension and high-compressive strength requirements. Steel is an excellent material to work in high-tension environments whereas concrete possesses excellent compressive strength. CDS technology merges the best properties of both materials whilst also decreasing the overall dead load of the structure.