CONCRETE TECHNOLOGY L.L.C | i SS Pn _p at Q HOLLOW CORE SLAB PRECAST PRESTRESSED CONCRETE FLOOR & ROOF SYSTEM + QUALITY + STRENGTH ++ SPEED ++ COST SAVINGINTRODUCTION Conerete Technology LLC (in short CONCRETEC) is one of the UAE’s leading manufacturers of precast and pre-stressed concrete products since 1997. CONCRETEC has developed a reputation for excel: lence in the provision of cost efficient structural precast system, As industry leaders, Conerete ‘Technology has served and assisted an array of presti- gious clients in achieving quality outcomes which are both economical and reliable and as part of our total solution, we offer a full package, including design, manufacturing, testing, supply and installation services. By adopting the best practices in the industry, we provide our clients with a wide range of high quality precast prestressed products and solutions side by side with the best customer service and technical support. Hollowcore slab is one of the products which Conerete ‘Technology is specialized in its design, production and installation. Hollowcore slabs are used for a variety of applications in low and high-rise commercial, residen- ial and industrial buildings. Hollowcore slabs are primarily used as floor or roof/deck systems, wall panels, sound barriers, spandra members and bridge deck units.www.coneretee.ae DESIGN A Hollow Core Slab is a precast prestressed conerete member with continuous v weight , Cost and for electrical & mechanical run, hence provide provide an efficient structural system. Is provided to reduce Tollow coreslab is a simply supported slab and can be designed in accordance with international stan dard, namely, ACI, BSI, ete. Conerete'Technology shall prepare and submit shop drawings for approval of the general arrangement of the slabs, adequacy and dimensions , prior to manufacture. Shop drawings detailing each unit.east-in inserts and its strand configuration shall be submitted to the Client for approval. The design of the structure to support the Hollow core slabs shall he the responsibility of the project struc- tural engineer of the Client unless designed by Conerete“Technology. ADVANTAGES 1. Hollowcore slab provide economical and efficient floor and roof system for various reasons; i, Holloweore slabs weigh up to 50% less than the conventional cast-in-situ slab of the same size, resulting in considerable savings in construction costs. ii, Concrete industrial production lines are providing just in-time manufacturing resulting in less-on-site congestion and reduced financing costs. iii, Hollowcore slabs help achieving a shorter and faster construction durations in all weather conditions resulting in more construction cost savings. 2, Hollowcore slab provides the efficiency of a prestressed member for load capacity, span range and deflection control. 3. Top surface of Hollow core slab can be prepared for installation of up to2 inches, 4. The underside (bottom) surface of the Hollowcore slab is smooth, which can be d hence used as finished ceiling. 5, Hollowcore slab can be used as diaphragms to transfer internal loads, 6, Holloweore slab reduces sound transmission and vibrations, 7. Holloweore slab provides excellent fire resistance and depending on the strand cover, it ean endure up to (4) hours, 8. The voids of the Hollowcore slab can be used as runs for electrical and / or mechanical servi floor covering on concrete topping ectly painted andworvccomeretec-ae PRODUCTS RANGE CONCRETEC provides Hollow core slabs of different thict ses as illustrated below: 1200 foe, raz rar 142 142 142 142149 102 2 | 2 | 42 | 2 | 142 | 2 | 102 | 102 (H.C.150mm THK.) 8 1043 | [i715] [ims] [rm] | 4s zs {Ls [I [isin IY Las (#4.0.265mm THK) (HiC.320mm THK) all et at ete (H.c.400mm THK) (H.C.500mm THK) LOAD-SPAN CHARTS AND TABLES > The attached Load-Span Charts and Tables are provided for a guidance for slab slosig range aud load capacity for various thicknesses of slabs with various combination of PC Strands in accordance with BS 8110,MnE"6 GON 9 mUE"g SON AOD OLS ONISA GALVINDIVD TAY SAND nugsi~ SH. 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HLLVINDIVS TRAV SIAN mico- SDH WU g630NP—e— ‘wus 0 wus 21 SONZHUEG SONZ uueB ONT (eeu nas ww ge IN 0981 fF wu gab ‘SCIONS ww o02t ww go, woo 080 AUN 28S UND LOE voag yo easy uorsuaUiC - ‘pes6 ajas2u09‘aa sZt “SON LT Wl SET “SON ET—jp— WAG'ET SON TT—e— WUS CT SON OT—e— WuS'eT SON @—w— uM G°ZT SON Se) ve oo. | ere rs | 39 we | as cere oe a or a COO O18 DNISA CALVINDVD TAY SAAN "ustugg¢- SOH. (aaa) eas ° ww ge BU) O98T 5 SAIOAy wu 002 ww 008 wy0e0 a uojsuewia 069 2pe8 aj220009- 8 WIN O79 1yBiam ges paquion - & awn o09 WB gs 820014 - sx 8 "SaULWadOud BVI 3 3 ow F se a Te ae“wvineconcretec.ae MANUFACTURING Hollow core slabs are manufactured in a closed environment using the highest levels of technology that ensure a high quality prod- uct, Using world renewed PCE production lines and exteud~ ers and employing a team of highly qualified staff, CON- CRETEC is considered nost reputed pi Hollow core slabs are pre-stressed elements production a long bed by using extruders and mechanically compacted. ‘The Hollow core slabs are produced in standard width of 1200 mm: service openings widths can be accommodated. ‘The top surface shall be finished as east by the machine or intentionally - roughened to achieve the specified bond characteristics of the topping to other finish applied after erection of the slabs. MATERIALS Hollowcore slab is same as any other structural precast member and is a composite member of conerete and reinforcing steel. 1. Concrete is made up of the following ingredients: > Ordinary Portland Cement (OPC) complying with BS EN 197-1 or ASTM C150. > Aggregates complying with BS 882 or ASTM C > Mixing Water complying with BS EN 1008 or ASTM € 1602. >» Concrete Admixtures complying with BS EN 934-2 or ASTM C494, Cement Supplementary Materials (CSM) such as silicafume or GGBS can be used in the production of concrete for the manufacture of Hollowcore slab if required 2. Prestressing Strands for reinforcement shall comply with BS 5986 or ASTM A 416 / AMIOM. TOLERANCES CONGRETEC Holloweore slabs are supplied in of the highest level of quality and within the tolerance limits set forth in Fig. 1.8.1 of PCL MNL-126. ‘The table helow shows some dimensional tolerances for produced precast Holloweore slabs Length +t/- 12.7 mm (+/- % in) Width +/+ 6.35 mm (+> Depth +1- 6.35 mm (+1- Blockout location +/- 50.8 mm (+/- Sweep 41-95 mm (+/- wi Variation from specified plan and squareness or skew+/- 13 mm (+/-% in) Center of Gravity (CG) of strand group 41-6 mm (+/-% in) Location of strand perpendicular to plane of panel +/- 13 mm (+/- % in) Location of strand parallel to plane of panel 4/19 mm (+/-% in) Location smooth: +/- 6mm 3m(+/- % im inl0 ft)[meer con ee me Ofmam Ba SET SON 6—o— UAE ET SON @—a— BREET SO Uw ww SET SOK So] AWN SOE Bien gejs yseoaig - g S3UMd0¥d BV18 2 2 (wu sxopuanap gy) se ‘UN Bam ajo sexe (asb)PeO Up coos UNUPEH- req) uedg-peoy oz)GE"ET GON ST—e— REET SCH ET —w— a S°ET SON TT maT SON Emp BREET SCH L—e— um SET SOK ES] SOION » ‘wu paz ‘ww 00+ au y1020 080. AUN He? UNI SH? 21g - ‘SpI0N JOON 4215 o ype eu - ess dag - wogaag 40 Bary ~ ‘vojsueWiG - 2pes8 ajouog - {Olam gets peRUoT - uBio oes ise0a1g - ‘SBULYIdOUd BYTS (cau uy suoxsuouunp yy) Ga eve | ay [oes | eve [oor [iver cer | ore | wee | SHEET B08 FF ve ew | tes | seve | ceor | zevet eeret | woroz | zee | wus *eT SON ET, wr sez | soe | ee7s | 6o°6 | byTT eerst | czvet | eee (wa S*zT SON TT, set | sore | core | aoe | aos so'st seer | cere | ww'eT SON 6 wer sre en ate Toor geet rest meer sox ee wo | see | ewer | wa eeT sows a> >a oe |e aan as : of 5 ai VINOD AAW SAAIND 00H SH st ZUIND Ur YBIoN ges Jo $890%0 UF (ssb]pe9|UBsep SOMES ume neq unds-peoy OOF we TI wt we oeHANDLING, LIFTING & DELIVERY Holloweore slab units shal be lifted and supported during manufet erection operatic ing, stockpiling, transporting and is only at the lifting or supporting points, or both, as specified by the company. Pull width Followcore slabs shall be hoisted by u clamp with spreader be ig specially dk cal lifting of slab, Hollowcore Slabs shall be stored off ground by placing them on plywood runner, ete. ‘The slabs should be stored in such a way that identification marks are discernible, The stacked Holloweore slabs shall be separated by patterns across full width of each slab, ‘The upper: used as storage area for shorter members or heavy equipment, b of the stacked tier should not be Hollow coreslab are handled in the lat horizontal position. Slabs are not turned on edge or end. unless approved by design engineer, While iting i with cut-outs near the end, sling belts of adequate capacity properly tightened around the slabs, are used for lifting process. w slabs (ied Tess Car, 1200 snun) aan slabs Hollow ¢ slabs are transported from the factory to the cured to the trailer, using latching chains (and belts if required). Loading is governed by trailer capacity and slab geometryINSTALLATION Bearing surfaces for the support of the Hollow core slabs shall be true and level. Temporary shor- ig and bracing shall also be provided as necessary to ensure the stability of the structure during erection, Installation and handling processes of the slabs shall be in accodance with CONCRETEC procedures and based on PCI MNL 126. ERECTION TOLERANCES ‘The erection tolerances for Holloweore slabs shall be within limits set forth in Fig. 1.8.2 of PCI MNL-126, ‘The table below shows some dimensional tolerances for erection of Holloweore slabs. (+/-lin) } Plan location from building grid datum 41-25 } Plan location from centerline of steel ‘HY 25 mm (+/-Lin) > Top elevation from nominal top elevation at member ends * Covered with topping +/- 19 mm (+/- % in) * Untopped floor +f- 6mm (+/-% in) * Untopped Roof +f- 19 mm (+/- % in) > Maximum jog in alignment of matching edges +125 (4/1 (Both topped and untopped construction) > Joint Width * 0 to 12 m (0 t0 10 ft) mombor le +113 mm (4F © 12.5 to 18m (41 to 60 ft) member length +/-19 mm (+/- % * 18. 5 mm ( +/- 1 (61 ft) plus m ber length, + > Bearing length +/-19 mm (+/- % in)worw.coneretec-ae ATTACHMENTS Attachments to the Hollow core slab shall be in accordance with the approved details, and shall not im I methods of fixing hanging loads to the hollow core slabs: for example. special socket drilled into the voids at the bottom of the slab or anchors placed into the longitudinal joint of the top of the slab which ean he used for fixing hanging loads to the slabs. Penetrations and chases to the Follow core slabs shall | ce the strength of the slabs. There are se accordance with details agreed by structural engi STRUCTURAL TOPPING Hollow core slabs can be used with or without structural topping: however if structural topping will not be used, special reinforcement detail will be needed to achieve diaphragm action .CONCRETEC ean design both systems. .Topping conerete shall have minimum characteristic strength @28 d 40MPa or as required by the structural design and it shall be reinforced with wire mesh as shown on the design drawings. If topping concrete is used to grout the keyways, the maximum aggregate size shall be 10mm, Maximum thickness of topping should be 50mm. The client shall provide a well-compacted in-situ structural concrete top- How core slabs as detailed in the drawings. Reinfore shall be in ae- ping to the F cordance with structural details. The slab surface shall be elean and free of loose material (saturated surface-dry) immediately prior to placing the topping. Fin ishing and curing of the topping should ensure that plastie shrinkage cracks are controlled to acceptable levels. The hollow core slab and the topping will act as a composite slab and eonse- quently the moment capacity of the hollow core slabs can be enhanced. and surface- DIAPHRAGM ACTION The diaphragm action of hollow core slab is achieved through a good joint design to transfer horizontal forces to the main structural system. The peripheral reinforcement plays a determinate role not only to cope with the risile forces of Uae diaphragm action but also wo prevent the relative horizontal displacement of the hollow core units so that longitudinal joints can take up shear forces.HOLLOW CORE TYPICAL PENETRATION DETAILS selma lang pents peed indetewy pr nein sl crebols typical ext ote The Hollow Core flooring system allows for significant flexibility in terms of penetrations and block-outs. Penetrations for plum| along with larger voids auch au stair openings and light wells. There are a number of different ‘s that these can be achieved. Examples of these are shown on the above drawing and can be described as follows: ng, electrical and be catered for 1. Core Holes: Core holes are the most common type of penetration and are easily achieved by simply drilling the required hole on site to suit the building requirements. Provided the holes are not greater than 120mm diameter (for 200 and 265 mm thick slabs) and 165mm diameter (for 320, 400, and 500 mm thick slabs) they ean be easily catered for by simply drilling through core. In broad terms up to 65% of the slab section has the allowance to be cored through without any significant structural effects. Where the penetration is greater than that inated above or if the hole cuts through the web and strand , CONCRETEC Structural ‘signer should be contacte to review the slab. uut-Outs: Larger penetrations, such as those required for mechanical services can be easily catered for as shown on the above drawing. These larger cut-outs are nominated during the design process to allow the design to take into account the local strand and web reduction, Thi cut-outs are generally pre-cut in the factory prior to installation. If future demands or site modi fications require these larger penetrations to be introduced, they can be catered for in most cases with minor onsite slab modi ‘Trimmer Beams: Large ops vices can be catered for by the use of trimmer beams. Where these large penctrations are required full width headers or trimmer beams are used to transfer the load to the adjacent planks. These planks are designed to support the additional load without the need for support- ing columns. ‘The slab manufacturer should be consulted during the preliminary stages of the project so that ad be provided on the n 1 prac! penetrations ngs to allow for stair voids, light wells or larger mecha ist cost effect sal des ign to accommodate theDUCT WORK ‘The voids in the Hollow core slab ean be utilized for distribution ducts for HVAC (Heating, Venti- lation, and Air Conditioning) and/or Exhaust Systems. Connections can be made thrugh several means (as illustrated in the drawing below). Field installed devices generally offer the most economical way and ensure placement in the exact locatio \s where the connection devices will be required. Light Soaps: for ceiling and dct work Only wih | L_ Tog Bl Bottom thickness only for vertical loads Suspended ceiling below hollow core sb Pipes hung from hollow-core slab system) Suspended ceiling below hollow-core slab BEARING LENGTH ‘support Precast member Hollow core (a) Each member a dimensions selected so that, after considering tolerances the distance from the edge of the support to the end of the o precast member in the direction of the span is at least supporting system shall have design Unarmored LN/180*,but not less than2in For Solid or Hollow core eal slabs - (b) Bearing pads at unarmored edges shalll be set back a mini: Bearing length mum of 1/2 in from the face of the support.or at least the pyr tee cee chamfer dimension at chamfered edges. (c) the above mentioned values are based on the America standard. Other international standards can be used if required * LN: Clear Hollow core Span Bearing lenght on support (LN 180> 2inALLOWANCE FOR CAMBER Hollow core floor slabs are cambered because of the upward bending induced by prestressi camber should be allowed for in det the joints at_ abutting wall ‘tu topping sereed u he slabs into am and provides a level working surface. est point of the slab. ing, the slabs an door op: and the like. A cast: ic floor. takes out differen- tial levels between unit ‘oceurs at the h FIR RESISTANCE Hollow « For fire ri 4.12 or any International code requirements. NOISE REDUCTION AND THERMAL RESISTANCE highest standards for non-flammability and fire resistance reference is made to BS 8110-1:1997 s ing of prestre: tio Noise reduction and thermal resistance properties for HOLLOW Ct below: For detail noise reduction factor, reference is made to BS8 IRE SLABS are according to the table 1987. HES 150+60 HS 200+60 HS 265+60 HS 320+60 HCS 400+60 HCS 500+60 INSPECTION AND ACCEPTANCE 1/ inspector shall verify the conformance of the product to the ery to the siteALAIN - HATTA ROAD Concrete Technology L.L.C Industrial Arae 2, abel All. P. O.Box 31950 Telephone No. 497148001777 Fax No ‘CONCRETE TECHNOLOGY Industral Ara 86 Al Jazerah -Al Hama as Al Khaimah, UAE ‘Tol: +971-7-2468019 Fax: ¥971-7-2448971