MATERIAL DATA SHEET

Composite steel deck (e.g., Bondek, Comflor) (0.60mm, 0.75mm, 0.90mm, 1.00mm, 1.20mm BMT)

Metal Composite Panel
composite › Panelised › Metal Composite Panel
compositepanelisedstructural-steelformworkconcrete-slabbondekcomflorpermanent-formworkfire-ratedAS2327-compliant
ATLAS CODE
COM-PNL-MET-002
Composite steel deck (e.g., Bondek, Comflor) (0.60mm, 0.75mm, 0.90mm, 1.00mm, 1.20mm BMT)
Category composite
Material Family Panelised
Regulatory Status Non-combustible
Density
7850 kg/m³
Carbon (A1-A5)
16.5 kgCO₂e
Fire Class
Non-combustible
Lifespan
50+ years yrs
Description

Composite steel decking is a profiled steel sheet used as permanent formwork and tensile reinforcement for composite concrete slabs. LYSAGHT BONDEK is a common Australian profile with 590 mm cover width and 54 mm profile height, manufactured in 0.60-1.00 mm BMT high-tensile steel.

Primary Sectors
[Commercial][Residential][Industrial][Healthcare][Hospitality][Transport & Infrastructure]
Typical Uses
  • Multi-storey commercial buildings
  • Residential apartment construction
  • Office buildings and towers
  • Car park structures
  • Industrial facilities
  • Educational institutions
  • Healthcare facilities
  • Retail complexes
  • Hotel and hospitality projects
  • Infrastructure projects
  • Mezzanine floors
  • Bridge deck applications
Recycled Content 30
Renewable Content 0
Recyclability 100
Embodied Carbon 16.5 kgCO₂e
Embodied Energy 35 MJ/kg
EPD Available Yes
Advantages
Eliminates need for temporary formwork strippingProvides permanent tensile reinforcementReduces construction time significantlyCreates safe working platform during constructionExcellent spanning capabilities reducing propping requirementsComposite action saves concrete and reinforcement costsFire resistance up to 240 minutes with appropriate topping100% recyclable at end of lifeSuitable for all Australian climate zonesCompatible with various frame types (steel, concrete, masonry)Allows service integration in rib cavitiesReduces overall structural depth
Cautions
Requires skilled installation for optimal performanceInitial cost higher than conventional formworkAcoustic performance primarily dependent on concrete toppingThermal bridging through steel profileLimited availability of some thicknesses (0.90mm special order)1.20mm BMT not available for deck sheetsRequires appropriate edge protection during constructionCorrosion protection needed in marine environmentsDeflection control critical during concrete pourWeather-dependent installation conditions
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TECHNICAL DATA: PERFORMANCE PROPERTIES COM-PNL-MET-002
Density (Dry) 7850 kg/m³
Specific Gravity 7.85
Porosity 0 %
Water Absorption 0 %
Hardness 150
Surface Roughness 1.5 μm
UV Resistance Excellent
Chemical Resistance Good
pH Tolerance 7-13
Tensile Strength 550 MPa
Flexural Strength 450 MPa
Shear Strength 320 MPa
Elastic Modulus 200000 GPa
Yield Strength 550 MPa
Impact Resistance High J/m
Bearing Capacity 100 kN/m²
Poisson's Ratio 0.3
Creep Resistance Excellent
Abrasion Resistance Good
Thermal Conductivity 50 W/mK
Thermal Resistance 0.001 m²K/W
Specific Heat Capacity 450 J/kgK
Thermal Expansion 11.7 μm/m·K
Melting Point 1510 °C
Sound Transmission Class (STC) 50
Noise Reduction Coeff. (NRC) 0.05
Optical
Light Transmittance 0 %
Light Reflectance (LRV) 65 %
Solar Reflectance (SRI) 35

Composite steel decking was developed in the 1950s in the United States as an evolution of corrugated steel formwork. The technology was introduced to Australia in the 1960s, with Lysaght launching Bondek in the 1970s, becoming the dominant Australian brand. The system revolutionised multi-storey construction by eliminating formwork stripping and reducing construction time. Modern developments include enhanced profiles for improved composite action, higher steel grades (G550), and advanced coating systems. Australian innovations include adaptations for cyclonic regions and bushfire-prone areas. The system has become the standard for commercial construction, with AS/NZS 2327:2017 providing comprehensive design guidelines specifically developed for Australian and New Zealand conditions.

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SAFETY, ECOLOGY & INSTALLATION COM-PNL-MET-002
Flame Spread Index 0
Smoke Developed Index 0
Combustibility Class Non-combustible
Fire Resistance Rating 60-240 minutes hours
Heat Release Rate 0 kW/m²
Toxicity of Combustion None
Embodied Carbon (A1-A3) 16.5 kgCO₂e/kg
Embodied Energy 35 MJ/kg
Water Footprint 45 L/kg
EPD Available Yes
Recycled Content 30%
Renewable Content 0%
LEED Points 2
Circular Economy Score 85 /100
VOC Emissions 0 g/L
Skill Level Skilled trade
Crew Size 3
Installation Time 300-400 m²/day hr/m²
Temperature Range -10 to 50°C °C
Humidity Range 0-100% %
Required Tools
Self-drilling screw gunsSpot welding equipment (optional)Powder-actuated tools (optional)Angle grinders for cuttingSafety mesh/fall protectionLifting equipment for sheets
Certifications Required
White Card (construction induction)Working at Heights certificationEWP licence (if applicable)
Weather Limitations
High wind restrictions (>32 km/h)No installation during electrical stormsWet conditions affect safety
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COMMERCIAL, LOGISTICS & REGULATORY COM-PNL-MET-002
Material Cost $45-75/m²
Installation Cost $25-40/m²
Annual Maintenance $0/m²
Lifecycle Cost (50yr) $70-115/m²
Market Availability Readily available
Lead Time 2-4 weeks weeks
Design Life 50+ years years
Warranty Period Project specific years
Maintenance Interval None required months
Service Temp Range -40 to 200°C °C
Freeze/Thaw Resistance Excellent
Dimensional Stability Excellent
Certifications Held
AS/NZS ISO 9001 (quality management)CodeMark certification availableEPD available (Environmental Product Declaration)ResponsibleSteel certification (Port Kembla)Safe Work Australia complianceZero VOC emissions
Fire Code Compliance
AS 1530.4 fire resistance testsBCA Specification C1.1Fire resistance levels 60/90/120/180/240
Standards Compliance
NCC/BCA Volume OneNCC/BCA Volume Two (Class 1 & 10)Deemed-to-Satisfy provisionsASTM C1577 (composite deck standard)ASTM E119 (fire tests)ISO 14040 (LCA principles)ISO 12944 (corrosion protection)EN 1994-1-1:2005 (Eurocode 4)

DISCLAIMER: This specification document is generated from the CLAD Materials Atlas Database. Information is for general guidance only and does not constitute professional engineering advice. Values are typical and may vary by batch, manufacturer, and production run. Verify suitability for specific project applications independently.

ID: COM-PNL-MET-002 Schema: v3.0
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