Table of Contents

Table of Figures

Overview

The ENDUROFLOOR™ system has been developed as an add-on intermediate floor system to be manufactured from an ENDURO® rollformer using standard ENDUROFRAME® components. It shall be able to be manufactured from both a 75 and 90mm section. A 75mm system shall be able to be made from gauges between 0.55 – 1.2mm thick, and the 90mm system shall be able to be manufactured from 0.55 to 1.2mm thick steel. Where possible, options shall remain open so the floor system can be manufactured on a Smartruss rollformer. Due to potentially being manufactured on Smartruss rollformers – and to increase the strength of the trusses – it will be used in its strong axis.

The ENDUROFLOOR™ system is designed to be used as part of the ENDUROFRAME® system but could also potentially be used as a standalone floor system to rest on wall frames, providing the loads are conforming with ENDUROFRAME® building system. Due to the variable and generally high corrosivity found in subfloor environments, TRUECORE® steel is not recommended for this application.

Scope of Manual

• This manual has been prepared for the construction of steel framed floors within the following parameters:

• Only ENDUROFLOOR™ components made from TRUECORE^® steel and made with the ENDURO^® rollformer can be used.

• Standard floor truss spacings are at 600mm or 450mm (max) centres dependent on floor truss design limitations. Other spacings may require additional engineering.

• Suitable for particle board sheeting and 75mm autoclaved lightweight concrete panels

Product performance

The ENDUROFLOOR™ system has been designed in accordance with relevant Australian Standards and the requirements of the Building Code of Australia. 

The floor framing system will perform in accordance with ENDUROFLOOR™ design documentation if installed in accordance with the recommendations and details set down in this manual and related references. This manual contains vital information. Please read it carefully. 

For more information and technical support, contact: www.enduroframe.com

Refer to www.truecore.com.au for locations where ENDUROFRAME^® can be warranted. 

General notes to be read before you use this manual.

1. This Manual has been prepared for a range of floor framing designs using ENDUROFLOOR™ building components manufactured from TRUECORE® steel supplied by BlueScope Steel, its licensed manufacturers or dealers.

2. The ENDUROFRAME® Building System has been designed as a complete framing system.

3. All erection and connection details must be made in accordance with the relevant standard connection drawing details contained in this Manual or its supplements, or drawings output from the ENDUROCADD® software.

4. Before commencement of any fabrication or construction develop a safety management plan to cover key risks. Key risks include, but are not limited to:-

   1. Working at heights

   2. Electrical safety

   3. Cuts and scratches

5. Consider and install the appropriate level of safety equipment to manage identified risks. Safety equipment that may be required includes:-

   1. Personal protective equipment including safety glasses, gloves, hearing protection (when using power tools) and sunscreen;

   2. Appropriate fall protection equipment including guard rails, scaffolds, ladders, elevated platforms, safety mesh, and fall restraint harnesses

   3. A temporary earth should be established during the construction of steel frames and, upon completion, the steel house frames must be permanently earthed in accordance with the requirements of local electricity authorities.

6. You should check with your local workplace health and safety authority to see what safety measures you need to put in place prior to and during construction. It is the responsibility of the installer/erector to ensure all local safe work practices are adhered to and the safety of the whole site is maintained at all times.

7. For wiring in steel wall frames, nylon grommets shall be installed to run electrical cables through.

8. Where insufficient detail is included in this manual for your project, seek specialist advice.

9. Before you commence construction:

   1. You should check with your local government authority to see if any form of prior permission or approval is required;

   2. If you want to build or construct any attached structure, you should seek advice from a suitably qualified engineer to verify the capacity of your existing structure to withstand any additional load arising from the attached structure. You should also check with your local government authority to determine any specific requirements for the attachment to existing structures;

   3. You should check with your local workplace health and safety authority to see what safety measures you need to put in place prior to and during construction. It is the responsibility of the installer/erector to ensure all local safe work practices are adhered to and the safety of the whole site is maintained at all times.

10. To ensure maximum lifespan of your house frame, consult your nearest ENDUROFRAME^® fabricator for information regarding maintenance, handling, storage and any other technical assistance you may require.

Important disclaimer about this construction manual

Date of Issue 

This Manual was issued on April, 2016. BlueScope Steel may make changes to this Manual in its sole discretion. You should check you are using the current version of the Manual before you start construction. Refer to www.enduroframe.com to check for the latest version.

Conditions of Use

If you use this Manual, you acknowledge and agree that your use is subject to the terms and conditions in this Manual. BlueScope Steel, its agents, officers, employees, subcontractors or consultants make no representations, either expressed or implied, as to the suitability of the information and data in this Manual for your particular purposes. It's your responsibility to ensure the design you use is appropriate for your needs, the products you have purchased, your site and structural limitations and your building and construction capabilities. It is recommended that you obtain qualified expert advice.

Use of Genuine Materials 
Structures in this Manual should only be built or constructed using ENDUROFLOOR™ made from TRUECORE^® steel and made with the ENDURO^® rollformer or recommended third party products. Except as otherwise provided in these terms, any warranties only apply to you (if at all) if you use the genuine BlueScope Steel or recommended third party products and method of construction. 

Check Delivery 
It is important that you check all materials delivered to site against your invoice before you use them in your building or construction to ensure all components have arrived, are of the appropriate quality and are ready for installation.

Precautions

Ensure that all barriers, scaffolding, and fall protection used in order to comply with safe work practices are installed so as not to damage or overload floor components.

Limitation of Liability

By using this Manual, you accept the risks and responsibility for all losses, damages, costs and other consequences resulting directly or indirectly from using this Manual. Except to the extent to which liability may not lawfully be excluded or limited, BlueScope Steel will not be under or incur any liability to any person for any direct or indirect loss or damage (including, without limitation, consequential loss or damage such as loss of profit or anticipated profit, loss of use, damage to goodwill and loss due to delay) however caused (including, without limitation, breach of contract, negligence, breach of statute and/or in equity), which may be suffered or incurred in connection with this Manual.

All rights reserved. No part of this brochure may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, recording or otherwise, without written permission of BlueScope Steel Limited. ABN 16 000 011 058

References

The following documents have been used in the development of this system:

• NASH Standard – Residential and Low-Rise Steel Framing Part 1: Design Criteria (2005)

• NASH Handbook – Design of residential & Low-rise Steel Framing (2009)

• NASH Technical Note 2 – Six Star Energy Efficiency Measures for Houses (March 2011)

• National Construction Code (Building Code of Australia - 2010), Australian Building Codes Board

• AS/NZS 1170.0: 2002 - Structural Design Actions - Part 0:General principles
  
  

• AS/NZS 1170.1: 2002 - Structural Design Actions - Part 1: Permanent, imposed and other actions principles

• AS/NZS 1170.2: 2011 - Structural Design Actions - Part 2: Wind actions

• AS4055:2012 - Wind loads for Housing

• AS/NZS 4600:2005 - Cold-formed steel structures

• AS 1684.2-2010 - Residential timber-framed construction – Non-cyclonic areas

• ABCB Protocol for Structural Software Draft Version 2011

• Minister's Specification SA A2.2 'Structural Engineering Software'

• NASH  standard Residential and Low rise steel framing Part 1: Design Criteria 2005

• AS1860.2-2006 Particle Board Installation

Design

Components used in the ENDUROFLOOR™ system are specified by an ENDUROCADD® software Trained Software User referencing loads and span tables contained in the ENDUROFLOOR™ Design Manual. Any floors designed outside the scope of this Design Manual must be checked and signed off by a suitably qualified engineer. Any supporting beams, and connections required in the floor structure are to be specified by others.

Required on-site Tools and Equipment

When installing an ENDUROFLOOR™ Floor Framing System, the following tools and safety equipment may be required.

Power Tools

• screw gun

Tool Accessories

• 8mm (5/16”) hexagon socket

• extension bar (length up to 150mm)

• suitable metal cutting blades

• 8mm (5/16”) spanner or socket and handle

• No.2 and No.3 Phillips head driver bits (length up to 100mm)

Hand Tools

• double action tin snips (left, right and straight cut)

• spirit level

• chalk line

• step ladder

• vice grips

• measuring tape

Essential Safety Equipment

• eye protection (safety goggles)

• High visibility personal protective clothing 

• hearing protection (when using power tools)

• protective gloves

• earth leakage circuit breaker for electrical equipment

• fall protection harness

• barriers, scaffolding, elevated work platforms, and any other equipment required to ensure worker safety

Material specification

ENDUROFLOOR™ sections are roll-formed from TRUECORE^® steel complying with AS1397:2011. The standard ENDUROFLOOR™ sections are shown in the graphic below. In the grade shown, the number prefixed with G indicates minimum yield stress in MPa; and the number prefixed with AZ or AM indicates minimum coating mass in g/m2.

• 0.55mm BMT, TRUECORE® G550 AM150 steel

• 0.75mm BMT, TRUECORE® G550 AM150 steel

• 1.00mm BMT, TRUECORE® G550 AM150 steel

• 1.20mm BMT, TRUECORE® G500 AM150 steel

Open

Open

ENDUROFRAME® sections

Components

A full list of components can be seen at this link - https://enduroframe.atlassian.net/wiki/x/L4Ms.

Rollformed Sections

U section definition	Part Code	t	D	B1	B2	Feed width mm	Usage
		mm	mm	mm	mm
Open	U754475G550	0.75	78.5	43	45	163	Dwarf plate
	U754410G550	1.00	78.5	43	45	163	Dwarf plate
	U904475G550	0.75	93.5	43	45	178	Dwarf plate
	U904410G550	1.00	93.5	43	45	178	Dwarf plate
	U904412G550	1.20	93.5	43	45	178	Dwarf plate

Lintels

Picture	Size	Application	Part No.
Open	200 x 35 x 1.5	Single lintel used to resist roll-over of floor trusses at ends.

Fasteners

The use of the correct fasteners in the quantities shown in the truss fabrication drawings are essential to ensure the design capacity of the trusses are achieved.

Brackets

Picture	Description	Application	Supplier	Part No.
Open	CPAH Hold down bracket 1.9 mm B.M.T. Zincform G450 Z275	Hold down bracket to connect joists to masonry walls	Pryda	CPAH
Purlin cleats	Purlin cleats 100AC - 90x70EA 150AC - 140x70EA 200AAC - 190x70EA 250AAC - 240x70EA	Connecting purlins to purlins	Lysaght
Open	General purpose brackets	Connecting purlins to purlins	Lysaght
Open	ENDURO angle 45 x 45 x 1mm	Trimmer Ceiling trim
Open	Enduro Floor Truss Bracket 35 x 35 x 1mm	Connection and support of floor trusses to bearers/beams
Open	SFS stiffening plate	Insert an oversized service penetration in a 300mm floor truss in its vertical axis. Length = 600mm Can also be used on a 350mm deep floor truss in its vertical axis. Length = 350mm.	SFS

Bracing & Blocking

Picture	Description	Application	Supplier	Part No.
Open	Speedbrace Z275 ZincForm® Steel G300	Rollover resistance brace	Pryda	SDB
	Strap bracing 25 x 1.0, G250 25 x 1.2, G250 32 x 1.0, G250 32 x 1.2, G250 51 x 1.2, G550 70 x 1.0, G250	Rollover resistance brace Diaphragm bracing	Lysaght

Beams & Bearers

Sections to be permitted for use in-plane, below floor truss or for cantilever applications.

Section Definition	Section Type	Part No.	t	D	B	L	Kg/m	Supplier
			mm	mm	mm	mm
Open