{"id":25355,"date":"2026-10-27T08:39:58","date_gmt":"2026-10-27T07:39:58","guid":{"rendered":"https:\/\/incoperfil.com\/?post_type=guia-tecnica&#038;p=25355"},"modified":"2026-11-10T09:45:11","modified_gmt":"2026-11-10T08:45:11","slug":"27-optimising-composite-metal-deck-flooring-sheet-thickness-slab-depth-and-temporary-propping","status":"publish","type":"guia-tecnica","link":"https:\/\/incoperfil.com\/en\/guia-tecnica\/27-optimising-composite-metal-deck-flooring-sheet-thickness-slab-depth-and-temporary-propping\/","title":{"rendered":"27. Optimising Composite Metal Deck Flooring: Sheet Thickness, Slab Depth and Temporary Propping"},"content":{"rendered":"<p>Selecting the thickness of a composite metal deck profile involves more than simply checking its load-bearing capacity during concrete pouring. The decking also contributes to the structural behaviour of the composite slab, and its thickness can influence the slab depth required to satisfy structural design checks.<\/p>\n<p>In certain projects, increasing the sheet thickness makes it possible to reduce the overall floor depth, decrease the dead load and eliminate temporary propping during construction. The following example shows how these variables can be combined to achieve a more efficient structural solution.<\/p>\n<h2>Influence of deck thickness on composite floor design<\/h2>\n<p>The thickness of the composite deck profile affects both structural stages of the system.<\/p>\n<p>During the <strong>formwork stage<\/strong>, thicker decking provides greater strength and stiffness against the loads generated by fresh concrete, reinforcement and construction activities. Its influence is particularly relevant when checking positive and negative bending resistance and assessing whether the floor can be installed without temporary propping.<\/p>\n<p>During the <strong>composite stage<\/strong>, sheet thickness also affects the load-bearing capacity of the section, both in terms of positive bending resistance and longitudinal shear forces between the steel and concrete.<\/p>\n<p>The latter check can be decisive when determining the slab depth. Longitudinal shear resistance depends on the characteristics of the profile, the design of its embossments and the resistance values established through testing of the steel\u2013concrete system.<\/p>\n<p>Therefore, the selection of sheet thickness must consider the checks required for both structural stages, rather than focusing solely on the decking&#8217;s resistance during concrete pouring.<\/p>\n<h2>Calculation assumptions for the example<\/h2>\n<p>The following composite metal deck floor is analysed:<\/p>\n<p>&nbsp;<\/p>\n<ul data-spread=\"false\">\n<li><strong><a href=\"https:\/\/incoperfil.com\/en\/profiles\/inco-100-3-composite\/\">INCO 100.3 Composite Deck<\/a><\/strong> profile.<\/li>\n<li>Four equal spans of 4.50 m.<\/li>\n<li>Continuous decking layout consisting of two spans per sheet (2+2) during the formwork stage.<\/li>\n<li>Additional permanent loads: 2.00 kN\/m\u00b2.<\/li>\n<li>Imposed load: 3.00 kN\/m\u00b2.<\/li>\n<li>Fire resistance: REI 30.<\/li>\n<li>Verification in accordance with Eurocodes 3 and 4.<\/li>\n<\/ul>\n<p>\nTwo configurations are compared, using sheet thicknesses of 0.75 and 1.20 mm. The corresponding slab depth is determined for each configuration, and the need for temporary propping is assessed.<\/p>\n<p>The objective is not to achieve a maximum span, but to examine how the choice of sheet thickness affects the resulting structural solution under identical project conditions.<\/p>\n<h2>Comparison of the calculated solutions<\/h2>\n<p>The calculation report provides the following results:<\/p>\n<table>\n<tbody>\n<tr>\n<th>Parameter<\/th>\n<th>Solution A<\/th>\n<th>Solution B<\/th>\n<\/tr>\n<tr>\n<td><strong>Profile<\/strong><\/td>\n<td>INCO 100.3 Composite Deck<\/td>\n<td>INCO 100.3 Composite Deck<\/td>\n<\/tr>\n<tr>\n<td><strong>Sheet thickness<\/strong><\/td>\n<td><strong>0.75 mm<\/strong><\/td>\n<td><strong>1.20 mm<\/strong><\/td>\n<\/tr>\n<tr>\n<td><strong>Span between supports<\/strong><\/td>\n<td>4.50 m<\/td>\n<td>4.50 m<\/td>\n<\/tr>\n<tr>\n<td><strong>Overall slab depth<\/strong><\/td>\n<td>210 mm<\/td>\n<td>160 mm<\/td>\n<\/tr>\n<tr>\n<td><strong>Concrete topping depth<\/strong><\/td>\n<td>110 mm<\/td>\n<td>60 mm<\/td>\n<\/tr>\n<tr>\n<td><strong>Top reinforcement<\/strong><\/td>\n<td>150\u00d7150\u00d78<\/td>\n<td>150\u00d7150\u00d78<\/td>\n<\/tr>\n<tr>\n<td><strong>Self-weight of floor<\/strong><\/td>\n<td>3.31 kN\/m\u00b2<\/td>\n<td>2.24 kN\/m\u00b2<\/td>\n<\/tr>\n<tr>\n<td><strong>Temporary propping<\/strong><\/td>\n<td>Required<\/td>\n<td>Not required<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>\nThe solution using 1.20 mm decking presents three significant differences compared with the 0.75 mm configuration:<\/p>\n<ul data-spread=\"false\">\n<li><strong>50 mm reduction in the overall floor depth.<\/strong><\/li>\n<li><strong>Approximately 32% reduction in the slab&#8217;s self-weight.<\/strong><\/li>\n<li><strong>Elimination of temporary propping during construction.<\/strong><\/li>\n<\/ul>\n<p>\nBoth alternatives satisfy the relevant structural design checks and maintain the same support arrangement, additional permanent loads, imposed load and top reinforcement.<\/p>\n<h2>Structural interpretation of the results<\/h2>\n<h3>1. Longitudinal shear resistance and slab depth reduction during the composite stage<\/h3>\n<p>In this example, longitudinal shear resistance is one of the determining checks during the composite stage.<\/p>\n<p>The system must transfer forces between the composite decking and the concrete through the profile geometry and its embossments. The available resistance is established on the basis of experimental results corresponding to the characteristics of the profile.<\/p>\n<p>In both configurations analysed, the longitudinal shear verification is close to its resistance limit. However, the 1.20 mm solution allows an overall slab depth of 160 mm, compared with 210 mm for the 0.75 mm solution.<\/p>\n<p>This difference demonstrates that the required slab depth does not depend exclusively on the bending capacity of the slab. The longitudinal shear resistance of the steel\u2013concrete system can also have a decisive influence on the final floor geometry.<\/p>\n<h3>2. Behaviour during the formwork stage<\/h3>\n<p>The choice of sheet thickness also changes the construction requirements.<\/p>\n<p>With 0.75 mm decking and an overall slab depth of 210 mm, the calculations require temporary propping to support the loads generated during concrete pouring.<\/p>\n<p>By contrast, the 1.20 mm solution with a slab depth of 160 mm can be installed without temporary props under the assumptions considered.<\/p>\n<p>This result is due to the combined effect of two factors: the greater load-bearing capacity of the decking and the reduction in loads resulting from the lower volume of fresh concrete.<\/p>\n<p>Therefore, the benefits of increasing sheet thickness should not be assessed solely in terms of improved mechanical properties of the profile, but also in terms of its impact on slab depth and construction procedures.<\/p>\n<h3>3. Reduction in the self-weight of the floor<\/h3>\n<p>Although 1.20 mm decking incorporates a greater quantity of steel, the 50 mm reduction in slab depth results in a lower volume of concrete.<\/p>\n<p>As a result, the calculated self-weight decreases from 3.31 to 2.24 kN\/m\u00b2.<\/p>\n<p>This reduction can be beneficial in terms of the loads transferred to the supporting structure and the project&#8217;s concrete consumption.<\/p>\n<p>However, a structurally lighter solution does not necessarily mean a lower overall cost. To assess its economic viability, the price of the decking, concrete, reinforcement, temporary propping and construction conditions must also be considered.<\/p>\n<h2>Scope of optimisation through sheet thickness<\/h2>\n<p>The results above correspond to a specific configuration and cannot be directly extrapolated to other spans or loading conditions.<\/p>\n<p>For example, maintaining a span of 4.50 m while increasing the imposed load to 5.00 kN\/m\u00b2 requires a slab depth of 200 mm with 1.20 mm decking, together with temporary propping in certain spans.<\/p>\n<p>Therefore, <strong>increasing sheet thickness does not, by itself, guarantee a specific reduction in slab depth or the elimination of temporary propping<\/strong>.<\/p>\n<p>The selection must be based on a comparison of complete configurations, verifying the structural behaviour of the decking during the formwork stage and the slab during the composite stage, as well as fire resistance requirements and construction conditions.<\/p>\n<h2>Conclusion<\/h2>\n<p>This example demonstrates that the selection of sheet thickness can have a decisive influence on the overall design of a composite metal deck floor.<\/p>\n<p>Under identical span and loading conditions, the configuration using 1.20 mm decking makes it possible to reduce the overall slab depth, decrease the self-weight and eliminate temporary propping compared with the calculated alternative using 0.75 mm decking.<\/p>\n<p>Longitudinal shear resistance during the composite stage is a particularly relevant factor in this comparison, together with the structural checks required for the decking during concrete pouring.<\/p>\n<p>Consequently, sheet thickness must be selected by considering <strong>load-bearing capacity during both structural stages, slab depth, concrete consumption and the need for temporary propping<\/strong>. Profile selection should not be based solely on nominal sheet thickness.<\/p>\n<h2>Composite metal deck floor calculation report<\/h2>\n<p>The results presented are technical and indicative in nature and correspond to the specified structural assumptions.<\/p>\n<p>The final design requires a project-specific calculation report verifying the Ultimate and Serviceability Limit States during both the formwork and composite stages, fire resistance and the actual construction conditions.<\/p>\n<p>Incoperfil&#8217;s Technical Department prepares calculation reports tailored to the characteristics of each project, in accordance with Eurocodes 3 and 4.<\/p>\n<blockquote><p><strong><a href=\"https:\/\/incoperfil.com\/en\/calculation-report\/composite-floor-deck-calculation\/\">Request a composite metal deck floor calculation report.<\/a><\/strong><\/p><\/blockquote>\n<h2>Related articles<\/h2>\n<ul data-spread=\"false\">\n<li><a href=\"https:\/\/incoperfil.com\/en\/guia-tecnica\/11-composite-deck-thickness\/\">Composite deck profile thickness<\/a>.<\/li>\n<li><a href=\"https:\/\/incoperfil.com\/en\/guia-tecnica\/19-composite-floor-without-propping\/\">Composite metal deck flooring without temporary propping<\/a>.<\/li>\n<li><a href=\"https:\/\/incoperfil.com\/en\/guia-tecnica\/28-selecting-a-composite-floor-deck-profile-governing-design-variables\/\">Choosing a composite metal deck profile<\/a>.<\/li>\n<li><a href=\"https:\/\/incoperfil.com\/en\/guia-tecnica\/26-optimising-support-spacing-with-inco-70-4\/\">Optimising the spacing between supports<\/a>.<\/li>\n<\/ul>\n<h2>Incoperfil Technical Manual<\/h2>\n<p>For a complete description of the system, design criteria, calculation principles, load-bearing capacity tables, construction details and installation procedures, consult the <a href=\"https:\/\/incoperfil.com\/en\/documentation\/\">Incoperfil Technical Manual for Composite Metal Deck Flooring<\/a>, available upon registration in the Documentation section of the website.<\/p>\n<div><\/p>\n<hr \/>\n<\/div>\n<p>Last updated: October 2026<\/p>\n<p>\u00a9 Incoperfil. All rights reserved.<\/p>\n<p>The technical content of this article forms part of the Technical Manual for Composite Metal Deck Flooring and the documentation registered by Incoperfil with ColorIURIS (Record No. 1-INCOPERFIL-12.2025).<\/p>\n","protected":false},"excerpt":{"rendered":"<p>The choice of composite metal deck sheet thickness can influence the overall slab depth, self-weight and the need for temporary propping. Using a calculation example based on the INCO 100.3 profile, two structural solutions are compared under the same span and loading conditions, analysing their behaviour during both the formwork stage and the composite stage.<\/p>\n","protected":false},"author":2,"featured_media":14115,"menu_order":28,"template":"","meta":{"_acf_changed":false},"categories":[1328],"tags":[],"class_list":["post-25355","guia-tecnica","type-guia-tecnica","status-publish","has-post-thumbnail","hentry","category-technical-guides-for-composite-flooring"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>27. 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