DECKFORM®
ZINC-COATED
STRUCTURAL STEEL
TECHNICAL BULLETIN TB-29
Rev 1, September 2002
This issue supersedes all previous issues
INTRODUCTION Extensive testing of full-scale composite slabs
For over 30 years concrete slab design has has been performed and as a result it has been
utilised various proprietary profiled steel possible to gain a sound understanding of their
sheeting systems that act as both formwork physical behaviour. This information, coupled
and tensile reinforcement. BHP Steel Limited with wide ranging corrosion studies of metallic
has now introduced DECKFORM® zinc-coated coated products, enables BHP Steel to
structural steel, a specifically designed steel confidently recommend DECKFORM® steel for
product for use in structural formwork a wide range of applications.
applications. The Z350 zinc coating of the DECKFORM® steel is suitable for domestic
standard DECKFORM® steel product provides applications such as home units and town
an improved level of corrosion performance, houses, as well as commercial construction in
whilst the availability of an optional Z450 zinc steel-framed and concrete-framed buildings.
coating means that there is now also a product The use of DECKFORM® steel makes the
for severe environment applications. provision of concrete car parks particularly
cost effective.
BACKGROUND
Profiled, structural steel sheeting has been Although the top surface of DECKFORM® steel
used since the mid 1960s and today, structural is generally encased in concrete, the reverse
members consisting of steel and concrete (usually unpainted) side is left exposed to the
acting compositely, are commonplace. The environment. This exposure must be taken
compressive strength of concrete and the into account when specifying a DECKFORM®
tensile strength of steel form a well understood steel product.
system that is highly efficient, versatile and It is a known fact that the corrosion rate of a
robust. galvanised steel product is proportional to the
When DECKFORM® steel is used in composite coating mass of zinc applied to the steel
slab construction, the sheeting is placed on top substrate.
of steel beams. A protective barrier (for Therefore, severe environments require a
example by prepainting the beam) must be product with a higher zinc coating mass
used to insulate the sheeting from the beam to eg. DECKFORM® steel Z450. Additional post
avoid setting up a corrosion couple which will painting may be necessary in very severe
promote attack of the zinc coating (see figure 1.) environments.
In the case of composite decking, steel studs
These very severe environments can include
are then placed on top of the sheeting and
coastal regions within 1 km of breaking surf
welded through the sheeting, to the underlying
and locations close to heavy industry. Before
beam, using a proprietary stud-welding gun.
specifying a coating mass, your nearest BHP
APPLICATIONS Steel Sales Office should be contacted for
Since 1986 BHP Steel has been intensively specific advice.
researching the behaviour of composite slabs.
Figure 1: DECKFORM® steel fixed prior to concrete pour.
DECKFORM® STUD Uniform
steel Weld
“Flash”
Paint Barrier
e.g 25µms
zinc phosphate
Structural Steel Beam
MAINTENANCE STUD WELDING DECKFORM® STEEL.
Structural steel decking is often used in The steel beams are often painted with, for
projects where the expected design life of the example, 25-50µms zinc phosphate containing
structure is regarded as very long term. While paints. The thickness of both zinc and paint,
internal structural steel decking needs little and the type of paint affect the current, time
maintenance, external applications are and plunge settings of the welding gun.
exposed to long term unwashed conditions 1. Studs should be dry and clean.
and the affects of a changing environment. In
some cases additional corrosion protection 2. The surface of the beam should be dry
measures may be required to be undertaken and clean.
by the client to meet this circumstance and this 3. The DECKFORM® steel should lie on the
can occur, either at the time of construction or top surface of the beam without any gap.
at some later time dependent upon ongoing 4. Adjust the gun to suit the length of the stud.
maintenance inspection. Ultimately, this
typically involves the application of a suitable 5. Adjust the weld parameters on the
coating system to the external surface of the generator. The length of lead has an effect.
DECKFORM® steel, which ensures that the 6. Inspect the flash around the base of the stud
exposed material meets the design life of the after welding. Generally, a good weld is one
structure. The underside of DECKFORM® steel that has a uniform flash around the whole
is generally protected from rain but still circumference of the base of the stud (see
exposed to the elements. Figure 2.) If there is any doubt, test the
weld and replace the stud if necessary.
This situation falls under the category of an (Remember that a “current shunting” effect
“Unwashed Area” and requires special attention. can be generated due to studs being placed
An “Unwashed Area” is an area that can come too close together. Weld quality can also be
into contact with dust and other airborne affected by positioning studs too close to
contaminants and is not regularly washed by beam edges).
rain. This allows a build up of contaminants
against the metallic coating that, in turn, ON-SITE TESTING
becomes moist with condensed water vapour 1. Weld two studs.
from night air. This situation is ideal to 2. Allow the studs to cool to ambient
produce rapid corrosion of the metallic temperature.
coating. 3. Test the two studs by manually bending the
To avoid this situation a regular cleaning studs over to approximately 60 degrees
regime should be employed. This cleaning from vertical using a pipe over the welded
regime, if conducted every 6 months, can be stud. If the weld does not break, it is
as simple as hosing the underside of the deemed to pass. If failure occurs in the weld
DECKFORM® steel sheets and allowing them of either stud, adjust the generator then
to dry thoroughly. weld and test two more studs. Two
consecutive tests must pass before
Figure 2: Example of 360º Flash.
production welding. (Subsequent studs
should be tested on a regular basis. eg. every
100 studs or when weld set up changes.)
REFERENCES
Australian Standard AS 1554.2—1993 steel
welding Part 2: Stud welding (Steel studs
to steel)
ACKNOWLEDGMENT
BHP Steel Limited, Technical Services
acknowledges the assistance of BHP Lysaght,
Research and Development in writing this
Technical Bulletin.
The information and advice contained in this Bulletin is of a general nature only, and has not been prepared with
your specific needs in mind. You should always obtain specialist advice to ensure that the materials, approach and
techniques referred to in this Bulletin meet your specific requirements.
BHP Steel makes no warranty as to the accuracy, completeness or reliability of any estimates, opinions or other
information contained in this Bulletin, and to the maximum extent permitted by law, BHP Steel disclaims all liability
and responsibility for any loss or damage, direct or indirect, which may be suffered by any person acting in reliance
on anything contained in or omitted from this document.
DECKFORM® is a registered trade mark of BHP Steel Limited.
“BHP” is a trade mark of BHP Billiton Limited under licence by BHP Steel Limited,
an unrelated corporation.
Please ensure you have the current Technical Bulletin
BHP Steel
Copyright© 2002 BHP Steel Limited
BHP Steel Limited ABN 16 000 011 058
BHP Steel (AIS) Pty Ltd ABN 19 000 019 625
AUSTRALIA
SYDNEY Telephone: (02) 9795 6700
OVERSEAS
BHP Steel – MALAYSIA Sdn Bhd Telephone: (603) 350 8333
MELBOURNE Telephone: (03) 9586 2222 BHP Steel – THAILAND Ltd Telephone: (66 38) 685 710
BRISBANE Telephone: (07) 3845 9300
PT BHP Steel – INDONESIA Telephone: (62 21) 570 7564
ADELAIDE Telephone: (08) 8243 7333
PERTH Telephone: (08) 9330 0666 BHP Steel – SOUTHERN AFRICA Pty Ltd Telephone: (27 21) 419 2682
Produced by Artimprint (02) 9958 2622
