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CONCRETE TECHNOLL.L.C.

Y OG

Hollow Core Slabs


PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM

Economical

Cost saving

Easy installation

Table of Contents
I II III IV V VI VII VIII IX X XI XII XIII XIV XV XIV Introduction Manufacturing Product Details Load Tables and Charts Structural Topping Diaphragm Action Opening Duct Work Bearing Length Connection Details Storage & Transportation Erection Lifting Hollow Core Slabs Fixing Noise and Reduction Thermal Resistance Production & Site Images 1 1 2 3 to 8 9 10 10 11 11 12 13 to 14 14 15 16 16 to 18 19 to 20

PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

L.L.C. CONCRETE TECHNOL Y OG

I. Introduction I. Introduction
Concrete Technology (concretec) is specialized in Design, Production and erection of Hollow Core Slabs. A Hollow Core slab is a precast pre-stressed concrete element having continuous voids provided to reduce self weight and to provide an efficient structural section Hollow core slabs are used for a variety of applications in low and high-rise commercial residential and industrial buildings. Primarily used for floor deck system, panels and bridge deck unit.

II. Manufacturing
Hollow core slabs are manufactured in a controlled environment to ensure a quality product. Using world renowned PCE production lines and extruders, and employing a team of highly qualified staff, Concretec is considered among the most reputed providers of Hollow Core slabs in the region. Hollow core slabs are pre-stressed members produced using extruders. The Hollow core slabs are produced in standard width of 1200 mm; service openings and special widths can be accommodated.

III Advantages

III. Advantages
1.) Hollow Core slabs provide an economical and efficient floor/roof system for various reasons: Hollow Core slabs weigh up to 50%less than traditional in-situ concrete slabs of the same size, resulting in considerable savings in construction costs The reduction in weight will results in a lighter structural framing leading to savings in Construction cost. Concretec industrial production lines are providing Just In-Time manufacturing resulting in less on- site congestion and reduce financing cost. Hollow Core slabs will help achieving a shorter and faster Construction durations in all weather conditions, which are in turn, are reflected as savings. Hollow Core slab bottom surface is smooth which means that paint can be applied directly to it and it is maintenance free. 2.)Hollow Core slabs provide the efficiency of prestressed member for load capacity ,span range and deflection control. 3.) Hollow Core slabs reduce sound transmission and vibrations. 4.) Hollow Core slabs meet the highest requirements for non-flammable and excellent fire rating. 5.) Concretec Hollow Core slab voids provide raceways for electrical, heating or other MEP service pipes. 6.)Hollow Core slabs are manufactured in a closed environment using the highest levels of technology to ensure a high quality product.

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

IV Products details
Hollow core slabs are produced in a standard width of 1200mm.Services openings and special width can be accommodated Concretec Hollow core production faculty covers all ranges and thickness of hollow core. Product Details and different Hollow Core sections Concretec product range is as follows: 150mm thick 320mm thick How to check your slab? A Hollow core slab is designed as a simply supported slab in accordance with British Standard BS110.The main structural issues to consider are span, load capacity, transverse distribution of vertical loads, diaphragm distribution of the horizontal actions as well as fire resistance and accidents which may affect the floor elements or the structural supports. The attached tables and load charts are for guidance only. The attached tables and charts are for slab design range and the load capacity for various thicknesses with various combinations of strands. Concretec structural design department are more than happy to advise, assist and design the required slabs as part of our services. 200mm thick 400mm thick 265mm thick 500mm thick

Hollow core slab 150 mm

Hollow core slab 320 mm

Hollow core slab 200 mm

Hollow core slab 400 mm

Hollow core slab 265 mm

Hollow core slab 500 mm

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PRECAST/ PRECAST/ PRESTRESSED PRESTRESSED FLOOR & ROOF SYSTEM FLOOR HOLLOW & ROOF CORE SYSTEM SLABS

HOLLOW CORE SLABS

CONCRETE TECHNOLL.L.C. Y OG

V. Load Charts and Tables


- For higher slab capacity Concretec provide Grade 60 and different Void profiles for higher capacities. - This curves is based on 1 hour fire rate and it may be change according to every project specifications.

HCS - 150 mm
CURVES ARE CALCULATED USING BS8110 CODE SLAB PROPERTIES: - Precast slab weight - Jointed slab weight - Concrete grade - Fire rate - Area of Section - Depth of slab - Nominal width of slab - No. of voids - Diameter of one void - Prestressing steel yielding stress - Reinforcement cover

2.04 KN/m2 2.16 KN/m 2 C50 REI60 0.102 m2 150 mm 1200 mm 8 VOIDS AS SHOWN 1630 N/mm2 35 mm

Maximum service design load (qsls) in excess of slab weight in KN/m2

SERVICE LOAD

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

HCS - 200 mm

CURVES ARE CALCULATED USING BS8110 CODE

SLAB PROPERTIES: - Precast slab weight - Jointed slab weight - Concrete grade - Fire rate - Area of Section - Depth of slab - Nominal width of slab - No. of voids - Diameter of one void - Prestressing steel yielding stress - Reinforcement cover

2.47 KN/m2 2.63 KN/m 2 C50 REI60 0.12 m2 200 mm 1200 mm 6 VOIDS 155 mm 1860 N/mm 32 mm

Maximum service design load (qsls) in excess of slab weight in KN/m2

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

SERVICE LOADS (KN/ M 2)

CONCRETE TECHNOLL.L.C. Y OG

HCS - 265 mm
CURVES ARE CALCULATED USING BS8110 CODE SLAB PROPERTIES: - Precast slab weight - Jointed slab weight - Concrete grade - Fire rate - Area of Section - Depth of slab - Nominal width of slab - No. of voids - Diameter of one void - Prestressing steel yielding stress - Reinforcement cover 3.61 KN/m2 3.82 KN/m 2 C50 REI60 0.176 m 2 265 mm 1200 mm 5 VOIDS 185 mm 1860 N/mm 35 mm

Maximum service design load (qsls) in excess of slab weight in KN/m2

SERVICE LOAD

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

HCS - 320 mm
CURVES ARE CALCULATED USING BS8110 CODE SLAB PROPERTIES: - Precast slab weight - Jointed slab weight - Concrete grade - Fire rate - Area of Section - Depth of slab - Nominal width of slab - No. of voids - Prestressing steel yielding stress - Reinforcement cover 3.65 KN/m2 3.87 KN/m2 C50 REI60 0.183 m 2 320 mm 1200 mm 4 VOIDS 1860 N/mm2 35 mm

Maximum service design load (qsls) in excess of slab weight in KN/m2

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

SERVICE LOADS (KN/ M 2)

CONCRETE TECHNOLL.L.C. Y OG

HCS - 400 mm
CURVES ARE CALCULATED USING BS8110 CODE SLAB PROPERTIES: - Precast slab weight - Jointed slab weight - Concrete grade - Fire rate - Area of Section - Depth of slab - Nominal width of slab - No. of voids - Prestressing steel yielding stress - Reinforcement cover 4.15 KN/m2 4.34 KN/m 2 C50 REI60 0.2074 m2 500 mm 1200 mm 4 VOIDS 1860 N/mm2 35 mm

Maximum service design load (qsls) in excess of slab weight in KN/m2

SERVICE LOADS (KN/ M 2)

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

HCS - 500 mm
CURVES ARE CALCULATED USING BS8110 CODE SLAB PROPERTIES: - Precast slab weight - Jointed slab weight - Concrete grade - Fire rate - Area of Section - Depth of slab - Nominal width of slab - No. of voids - Prestressing steel yielding stress - Reinforcement cover 6.00 KN/m2 6.40 KN/m 2 C50 REI60 0.304 m2 500 mm 1200 mm 4 VOIDS 1860 N/mm2 35 mm

Maximum service design load (qsls) in excess of slab weight in KN/m2

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

SERVICE LOADS (KN/ M 2)

CONCRETE TECHNOLL.L.C. Y OG

VI. Structural Topping


Hollow core slab are normally used without structural topping. However, in the case of seismic action, frequent changes of load or important point loads, topping may be indicated. The thickness should be at least 50 mm, concrete quality as per design. The hollow core slab and the topping will act as a composite slab and the moment capacity of the hollow core slabs can be enhanced. With shallow height electrical system, a comp. System can be provided in a reasonably this

FIGURE (5) - Showing Topping Mesh and Usage

VII. Diaphragm Action


The diaphragm action of hollow core slab is realized through a good joint design to transfer of horizontal forces to the main structure system. The peripheral reinforcement plays a determinate role not only to cope with the tensile forces of the diaphragm action but also to prevent the relative horizontal displacement of the hollow core units, so that the longitudinal joints can take up shear forces. The positioning and minimum proportioning ties, required by PCI codes, is shown in the figure below.

FIGURE (6) - Showing Diaphragm Action

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

VIII. Openings
Opening in hollow core slabs are made as indicated in the figure. The dimensions are limited to the values given in the table. The small holes may be formed at the center of the longitudinal voids. The maximum void size is limited to the width of the void. Holes are normally made in the fresh concrete during the production process. The edges of the opening are rough. The possible dimensions for openings are given in the table. L/B Corner Front Edges (1) (2) (3) HCS 150-265 600/ 400 600/ 400 1000/ 400 100/ 400 core minus 20 mm

Center (4) Square opening Round holes

Voids, which are wider than the width of the precast, are trimmed using transverse supports such as steel angles or concrete beams. The steel angles can be supplied in case of client request.
HOLLOCORE SLAB + TOPPING STEEL CHANNEL

OPENING AREA BOLTS & NUTS

FIGURE (5) - Showing Large Opening

APPLICABLE CUTOUT IN HOLLOWCORE SLAB

FIGURE (6) - Showing Allowable Cut Out In Hollow Core Slab

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

CONCRETE TECHNOLL.L.C. Y OG

IX. Duct Work


The spaces may be utilized with in hollow core slabs for distribution ducts for heating, air conditions or exhaust systems. Connection can be made by several means see figure field installed devices generally offers the best economy and ensure placement in the exact locations where the connection devices will be required.

PIPES HUNG FROM HOLLOW-CORE SLAB SYSTEM

SUSPENDED CEILING BELOW HOLLOW-CORE SLAB

X. Bearing Length
The nominal bearing length of simply supported hollow core slab is give in Supporting Material Slab Thickness Support length (a) Nominal Minimum Length Effect length 70mm 100mm 50mm 80mm

Concretec or steel Brick Masonry

150mm - 265mm 150mm - 265mm 150mm - 265mm

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

XI. Connection Details

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

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XII. Storage
When storing hollow core slabs the following requirements should be taken into consideration: Storage should only be permitted on solid ground forming a level footing. Slab stacks are recommended to be a maximum of 3.50 5.00 m high depending on the slab type. Only slabs of the same length and with no large recesses should be stacked together and directly on top of each other.

Wooden spacers should be used. All spacers should be stacked exactly on top of each other

-Wooden spacers should be used. All spacers should be stacked exactly on top of each other

Special care should be given to slab with large openings. They must be stored in separate piles with only some 2-3 slabs on top of each other. The overhanging length beyond spacers should be between 200mm-400mm in normal practice and a maximum of 1000mm, when top reinforcement is used. All damage caused to slab in the stockyard should be reported to the quality control staff.

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

XIII. Transportation
The hollow core slabs are hoisted with specially designed clamps hanging on a steel spreader beams. The use of railing alone is strictly forbidden. Hollow core slab are transported from our factory to the site on flat bed trailers. Full slabs are lifted using the specially designed lifting equipments (as shown).

XIV. Erection
The erection of hollow core slab should be done according to the instructions of concrete Technology design engineers usually concrete technology provides method statements of the principles of site erection. After erection the longitudinal joints between the hollow core slab should be filled with grout, the joint should be filled carefully since they fulfill a structural function both in the transversal load distribution and the horizontal floor diaphragm action. When a structural topping is to be used, it is advisable to fill the longitudinal joint, immediately prior to the casting of the topping.

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

CONCRETE TECHNOLL.L.C. Y OG

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

CONCRETE TECHNOLL.L.C. Y OG

Erection of the Hollow Core Slabs


In some cases, CONCRETEC'S customers i.e., the main contractor, erects the Hollow core slabs themselves. In this event, it is very important that the lifting and handling of the slabs is done correctly following the procedure described below. For erection purposes, CONCRETEC will provide the specially designed lifting equipment (to be returned immediately after completion of erection) for lifting and placing of the slab. CONCRETEC has no responsibility for the slabs during lifting, handling an erection, if erection is done by the contractor. CONCRETEC will only guarantee for the slabs after completion of grouting and tamping according to the specification in this manual. Slabs are lifted directly from the trailer and into position. Full slabs are lifted using the specially designed lifting equipment. When lifting with narrow slabs (width less than 1200mm) and slabs with cut-outs near the end, sling belts will be used (sling belts are not supplied by CONCRETEC).

XVI. Lifting of Hollow Core Slabs


When lifting with clamps always use the safety chains underneath the slab. The chain should not be released until the slab is about 100mm from the support. Work to be performed after erection: Immediately after erection and leveling, it is important to grout the joints and tamp between the Hollow core slabs and the cast in-situ support beam. For steel and pre-cast structures only the grouting is needed. For grouting, use dry mortar with aggregate size less than 10mm, and strength =25 Mpa. It is very important that the customer assures himself that the slabs are leveled to his satisfaction before grouting and tamping takes place, because as soon as grouting and tamping is completed, the leveling of the slabs can not be adjusted. If the customer, prior to grouting, finds that the slabs, are out of level, he is welcome to contact CONCRETEC for rectification as early as possible. The erection of hollow core slab should be done according to the instructions of Concrete Technology design engineers usual concrete technology provides. Method statements of the principles of site erection. After erection the longitudinal joints between the hollow core slab should be filled with grout, the joint should be filled carefully since they fulfill a structural function both in the transversal load distribution and the horizontal floor diaphragm action. When a structural topping is to be used, it is advisable to fill the longitudinal joint, immediately prior to the casting of the topping.

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

XIV. Fixing
There are several ways of fixing hanging loads to the hollow core slabs - for example, special sockets drilled into the voids, anchors placed into the longitudinal joint or the top of the slab.

Fire Resistance
Hollow core slab elements meet the very highest requirements for non-flammability and fire resistance. For fire railing of prestressed concrete elements, reference is made to BS8110 part 1 & 1997, section 4.12.3.13 or any International code requirements.

XV. Noise Reduction and Thermal Resistance


Noise reduction and thermal resistance properties for HOLLOW CORE SLABS are according to the table below: For detail noise reduction factor, reference is made to BS8233, 1987.

Slab Type HCS 150 HCS 200 HCS 265 HCS 320 HCS 400 HCS 500 HCS 150+60 HCS 200+60 HCS 265+60 HCS 320+60 HCS 400+60 HCS 500+60

R - Value (m K/W) 0.12 0.15 0.19 0.20 0.22 0.26 0.16 0.19 0.23 0.24 0.26 0.30

U-Value (W/m K) 8.33 6.67 5.26 5.00 4.55 3.85 6.25 5.26 4.35 4.16 3.85 3.33

Noise Reduction (dB) 50 53 56 58 60 63 53 56 59 61 63 65

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

CONCRETE TECHNOLL.L.C. Y OG

Cement:
Ordinary Portland cement complying with the requirement os BS EN 197 1:2000.

Micro Silica:
Densified or undensified micro silica grade 920D or 920 4D.

Coarse Aggregates:
Crushed local aggregates complying with BS 882.

Fine Aggregates:
All fine aggregates are local sand complying with BS 882.

Water:
Clean water with total dissolved solid contents not exceeding 700 p.p.m.

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

Admixtures:
Water reducing admixtures complying with ASTM C 494 Type A, D2F

Strength:
Characteristic cube strength can be f cu = 50N/ mm , 60N/mm or as per design requirements.
2

Control:
Concrete is made under strict laboratory control.

Reinforcement:
9.53mm or 12.70mm Prestressing strands complying with the following standards.
2

* ASTM A416/ A416M-2002 or BS 2 5986: 1980 Ultimate tensile strength: 1860 N/mm Modules of elasticity: 195 KN/ mm Relaxation for 70% initial

Finishes:
Hollowcore Slab elements have a light roughened top surface allowing for good bond to the floor finish or structural topping. The soffit is smooth, off steel mould finish, which requires only a minimum of preparation before painting.

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PRECAST/ PRESTRESSED FLOOR & ROOF SYSTEM HOLLOW CORE SLABS

CONCRETE TECHNOLL.L.C. Y OG

XIV. Production & Site Images

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L.L.C. CONCRETE TECHNOL Y OG

e-mail: info@concretec.ae website: www.concretec.ae

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