SCHOOL OF ARCHITECTURE, BUILDING AND DESIGN

BACHELOR OF QUANTITY SURVEYING (HONOURS)

CONSTRUCTION TECHNOLOGY III

BLD 60304

BUBBLE DECK & HOLLOW CORE

Precast Concrete Framing, Panel and Box System

GROUP MEMBERS NAME : CAROL TANG NGIE BING 032963

DAPHNE TAN LI WEN 0329055

FOO VAN JEAN 0330017

HENG YI CHENG 0327895

LECTURER : IR CHAI VOON CHIET

BLD 60304 CONSTRUCTION TECHNOLOGY III

Contents

1.0 BUBBLE DECK

1.1 Introduction ................................................................................................... 3
1.2 Types of Bubble Deck ................................................................................ 3-4
1.2.1 Type A Filigree Element (Pure in-situ)
1.2.2 Type B Prefabicated (Reinforcement module)
1.2.3 Type C Finished Plank
1.3 Bubble Deck Slab Manufacturing Process ............................................... 5-6
1.4 Advantages of Bubble Deck ......................................................................... 7
1.5 Disadvantages of Bubble Deck .................................................................... 7
1.6 Case Study - Eindhoven Airport ............................................................. 8-12

2.0 HOLLOW CORE SLAB

2.1 Introduction ................................................................................................. 13

2.2 Hollow Core Slab Manufacturing Process ........................................... 14-18
2.3 Advantages of Hollow Core Slab ............................................................... 19
2.4 Disadvantages of Hollow Core Slab .......................................................... 20
2.5 Case Study - Ikea @ Cheras .................................................................. 21-23

3.0 CONCLUSION ............................................................................................................ 23

4.0 REFERENCES .......................................................................................................... 24

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1.0 BUBBLE DECK

1.1 Introduction

The bubble deck technology is a biaxial hollow core slab invented by Professor Bruening in
Denmark. It is certified in the Netherlands, the U.K, Denmark & Germany and has been in
the market close to 20 years. The three main elements bubble deck is made of are
reinforcing steel mesh for lateral support and diagonal girder (Grade Fy60), recycled plastic
hollow sphere (high density polyethelyne) and concrete(Portland cement). It uses the
spheres to create voids

The main usage of bubble deck is to provide lighter design by incorporating the plastic
spheres to eliminate non-structural concrete from the neutral axis of a floor slab. It reduces
structural dead weight yet providing strength for long span. The curve profile withstand
loadings as the arch in roman architecture.

1.2 Types of Bubble Deck

Bubble deck comes in three forms- filigree elements, reinforcement modules, and finished
planks.

1.2.1 Type A Filigree Element (Pure in-situ)

This type of bubble deck is optimal for new construction projects where the designer can
determine the bubble positions and steel mesh layout. The installation process is as below:

1. Precast of 60mm thick concrete layer acts as formwork, part of the finished depth is
precast and brought to site without bubbles and reinforcement attached.
2. Laying the lower reinforcement.
3. The bubbles are then supported by temporary stands.
4. Placing of top reinforcement.
5. Casting & compacting of first concrete layer.
6. Casting of concrete topping.

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1.2.2 Type B Prefabicated (Reinforcement module)

A reinforcement module consists of a pre-assembled sandwich of steel mesh and plastic

spheres. These bubble lattice are brought to the site, laid on traditional formwork,
connected with additional reinforcement on top, followed by cast in-situ concrete. It is utilized
for tight construction areas since these modules can be stacked on top of one another for
storage.

1.2.3 Type C Finished Plank

All plastic spheres, reinforcement mesh and concrete are manufactured to its finished form
with final depth. These finished planks are then delivered to site. Unlike Type A and Type B,
it uses one-way spanning design that requires support beams or load bearing walls. This
option is best for shorter spans and limited construction schedules.

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1.3 Bubble Deck Slab Manufacturing Process

Pre-fabricated plastic Production of the bubble-lattice The diagonal griders keep the
bubbles made of by welding the top and bottom bubbles fixed between the top and
recycled plastic. reinforcement together bottom reinforcement

Vibration of the concrete The bubble-lattice is lowered Preparation of concrete for

into the concrete filigree-bottom at the assembly
line

Finishing of a filigree- Finished BubbleDeck BubbleDeck filigree-

element filigree-element element at stock

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Transportation of BubbleDeck Transport slabs in the air

Filigree-elements

on trucks

Placing top reinforcement Fitting the element

and ties between slabs.

Concreting & Vibrating Surface finishing

Completion of Bubble Deck Slab

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1.4 Advantages of Bubble Deck

Material and weight reduction Bubble deck uses 30-50% lesser concrete since
HDPE bubbles has replaced the non-effective concrete, hence decreasing dead
load. Reduced concrete material and weight also leads to less structural steel
needed for reinforcement. Several downstream components can be engineered
for lower loads and thus save additional material.
Structural properties Longer spans with fewer supporting points offers flexibility
in architectural design. Due to reduced dead weight of the slab and its two-way
spanning action, load-bearing walls and support beams become unnecessary.
Consequently, structural requirement for columns and foundation are minimized.
Construction and time saving Quicker curing time since less concrete is used.
As downstand beams, cross-bracing and intermediate supports are excluded, this
offers faster erection of walls and services. With simplified installation, savings on
material and transportation cost, overall cost is substantially reduced.
Environmentally green and sustainable - The HDPE bubbles can be recycled and
reused for other projects. Energy saving and lesser carbon emission can be
achieved by using lesser concrete.

1.5 Disadvantages of Bubble Deck

The size of the elements should be maximised to increase cost efficiency,

however this is limited by local transport restriction.
Not affordable to the initial costs for manufacturing and heavy machineries are
expensive.
The shear & punching shear resistance of the bubble deck floor is significantly
lesser than a solid deck since resistance is directly related to the depth of
concrete.

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1.6 CASE STUDY (EINDHOVEN AIRPORT)

Eindhoven Airport is located in Netherlands. The P1 car park which accommodates 800 cars
was under construction when it collapsed on 27th May this year.

F
Figure 1.6.1 Plan drawing of carpark near Eindhoven airport terminal.

Above plan drawing indicates the corner where it collapsed. The red lines are the joints of
the bubble deck filligree plates. The 15m(L) x 6m(W) floor is designed as floor spanning in
two direction: and point supported by the columns. No beams were used. The collapse
started at joint 3 at the top floor.

Figure 1.6.2 (Left) Simulation model of carpark when collapse begun.

Figure 1.6.3 (Right) Simulation model of end of complete collapse.

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The fourth floor started to crack over an area of 60 by15 metres and finally collapsed onto
the third floor. This caused a domino effect involving all floors. The complete collapse
happened in about three seconds.

1.6.1 Stress and bending moment

Cutting a cross section of floor slab, the shear stress changes from zero to maximum value
at the neutral axis. And shear strength of any concrete slab is dependent on the effective
mass of concrete. As a result, the inclusion of plastic bubbles makes the shear resistance of
a bubble deck slab to be reduced. According to a theoretical models conducted in MIT, the
shear strength of the voided slab was determined to be 60-80% of a solid slab with the same
depth.

With shear stresses, bending also occur. The slab tends to bend in the central area whereas
near the junction of slab and column we face shear due to the couple force (i) Downward
vertical force of the slab+live load, (ii) Upward vertical reaction of the column.

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push push

Coupling reinforcement
pull pull

wideplate

The report shows how the joint was made between the
Bubble Deck elements in width direction. In order to
couple the slabs, coupling reinforcement is used here.
These were 4 16mm bars per ball. The bars were
placed directly on the precast concrete filligran
elements.

The moment capacity of the floor at the joint is determined by:

Tensile strength of the coupling reinforcement
Anchorage of the bundled coupling reinforcement
Interface shear resistance between the filigran slab and the in-situ cast concrete.

1.6.2 Crack and failure between interface

Some experiments conducted in the laboratory on the joint, and concluded that:
Failure was ductile. The slab pulls apart upon failure of materials loaded in tension.
The bending capacity present of 125 kNm/m was only 1/3 of the bending moment acting in
joint 3.

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(Left figure). Comparison of resistance against

moment between coupled and uncoupled member.
As self-compacting concrete was used to produce
the precast filigran elements, concrete on the top
side was too smooth - there was no friction present
in the interface. Only with sufficient friction at
contact area, the internal forces can transmit from
one element to another. Thus the entire created
element will behave as a monolithic cast.
Otherwise, slippage between surfaces will weaken
the total bearing capacity such as in this case.

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1.6.3 Investigation outcome

Based on the investigation conducted by The Netherlands Organisation for Applied Scientific
Research (TNO) assigned by Eindhoven airport and engineering consultant assigned by
BAM the main contractor, the report attributes the failure to:

1. Incorrect design and detailing of the joint between the panels which provides
continuity of the tension reinforcement in precast slabs.
2. The investigations show that the shear strength of the interface between the precast
concrete floor slabs was insufficient to convey the traction.
3. The high ambient temperature on the day of the collapse was a contributing factor.
The floor curved upwards due to the top of the floor was heated. But through the
connection with the columns this bending upwards was hindered, such that it resulted
in additional moments in the floor. Due to the low bending capacity the floor failed,
and by progressive collapse the whole part of the car park came down.

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2.0 HOLLOW CORE SLAB

2.1 Introduction

Hollow core slabs are precast, pre-stressed concrete elements which generally have
between four to eight six longitudinal cores running through them with constant cross
section. It uses low-slump, high-strength concrete and reinforced with high-strength pre-
stressing strands. The slab sizes are typically 0.90m 1.25m wide, thickness varies from
150mm to 300mm thick. The common spans are 12m long and may reach up to 18m.

The primary objective of using precast hollow core slab includes the light weight feature due
to the hollows, longer spans due to prestressed, and lesser cost of steel as only tendons are
used. With these capabilities, it can be found in wide range of application including hospitals,
industrial and large commercial roof coverings, high rise residential buildings, underground
carparks or repetitive construction projects.

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2.2 Hollow Core Slab Manufacturing Process

7 Concrete dosing
to extruder

Cleaning and oiling the bed Concrete transportation

8
1 3

2 4 Lifting extruder on the bed

9 Draw openings
by plotter
5 Concrete mixing

Tensioning strands Extruding

Strand Pulling

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Cutting of slab
Making openings Covering of slabs

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10
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Curing of slabs Recovering of slabs

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Lifting of slab Drilling of

drainage holes

Transportation to storage

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15

17

Handling of slabs in storage Transportation to site

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A. Cleaning, oiling the bed and pulling of strands
Cleaning and oiling the bed
Strand Pulling
B. Tensioning of strands
C. Concrete Transportation
D. Extruding
Hollow core slab are made on casting bed. The
beds have to be cleaned and lubricated before
casting. The strand are pulled and pre-stressed
by special machine, BedMaster, which
simultaneously cleans the bed with a rotating
brush. Once the BedMaster returns to the active
end, it places the steel strands onto the casting
bed and it lubricates with form oil.
All of the strands in a casting bed are pre-
stressed simultaneously. A machine moves
crosswise up to the end of the hall so each
casting bed can be handled by the same
machine. Casting bed specific stressing
cylinders can be used as alternative stressing
method. After that, lifting extruder on the bed.
Concrete is distributed from the mixing plant by
an overhead transport system. A shuttle brings
the concrete batch automatically to appropriate
site in the plant and through feeding bucket
gantry the concrete mix into the extruder.
Concrete is dosing in the extruder. The key
component in the manufacturing process is a
high capacity of extruder. Its extruding the
slabs in a continuously process.
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E. Draw opening by plotter

All opening in slabs are marked by the plotter
and point where the slab is cut and
recesses.Slab data needed for plotting is loaded
in the plotter in advance.

F. Making opening and slab covering

Making opening and recesses can be easily
made while concrete is still green. The opening
can be made by hand or using machine. Once
completed, the cast slab line is covered with
tarpaulins to minimize evaporation.

G. Cutting of the slabs

After curing process, the tension of the strands
is relieved and slab is cut according to
measures markings. Cutting by a diamond-
tipped saw which goes along the same tracks
than the extruder.

H. Lifting of slabs and drilling of drainage holes

After cutting, the slabs are lifted from the

casting beds by using crane with clamps. The
slabs are transferred to an automatic drill that
makes the drainage holes on each end of the
slab.

I. Transportation to storage
The hollow slabs are set on the wagons that
pass the quality control, holes are fitted with
plugs and marked with project information.
Then, wagons proceed to the storage. The
hollow core slab is readily available transport to
site.
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2.3 Advantages of Hollow Core Slab

Quick & easy installation

- With only 3-4 workers, possible to install more than 500-600 m2 of floor per day.
Cost savings
- Only with large production volumes with uniform cross sections.
Lighter panels reduce the cost of transport and allowing easy handling both on-site
and in production plant.
High load capacity & rigidity
- Minimal deformation even with high slenderness ratios. The produced elements
have high load resistances due to a low water/cement ratio.
Efficient span/depth-ratio leading to reduced storey height
- Due to the slenderness and long span capacities, one more storey added within the
maximum building height.
Long spans without the need of temporary supports
- No need for supports during installation. Possible to load the floor immediately after
installation.
Reduced self-weight
- The longitudinal voids leads to approx. 50% saving in concrete and cuts the amount
of prestressing steel by 30%.
Prefinished ceilings
- Exposed hollow core soffits can be painted directly or spray coated to provide
attractive ceilings
Fire Resistance
- Floors can be produced with a high fire resistance up to 180 minutes or up to 4
hours.

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2.4 Disadvantages

2.4.1 Disadvantages of Precast

Handling and transporting - Delivery of precast elements to various points of a tall

building requires substantial care time.

Usually feasible only if cast yard is within reasonable distance from site.

Adequate design and detailing for a joint to be formed on site and also providing the
required strength.

Over a short span, solid precast slabs can be thinner. It is preferred where head
room is important on top of an elevator shaft or equipment vault.

2.4.2 Disadvantages of Prestressed Concrete

Higher initial cost due to the requirement of hardware ( prestressing jacks,

anchorages, bearing plates, more complicated formwork and higher labour cost).

Harder to fabricate and require closer supervision.

Special considerations are required in the design, construction and particularly in the
demolition process.

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2.5 Case Study (Ikea @ Cheras)

Ikea at Cheras, owned by Ikano Cochrane Sdn Bhd is considered 2nd largest Ikea after
Tebrau in Malaysia. The project with a total of 42,000 sq. meter built up area was completed
in 6 months. Eastern Pretech (Malaysia) Sdn Bhd has been supplying precast components
to Ikea. While McConnell Dowell (MCD), an international engineering and construction firm
based in Australia remained as the main contractor since the first outlet in Malaysia.

As a multinational company with outlets widely spread across various countries, high
efficiency is essential for building their massive retail outlets. The features of precast system
are able to fulfill the requirements of Ikeas core business which required repetition and large
volume production.

Besides, modular coordination is a concept for coordinating dimension and space for which
buildings and components are given with dimensions and positioned in basic units or
modules. Its an internationally accepted system to support global market. The principal
objective of implementing modular coordination is to improve productivity through the
reduction of wastages, installation process, to improve quality in the construction industry
and to encourage an open system. With Open System approach, building components could
combine in a variety of individual building projects while ensuring the architect freedom in
their designs.

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Ikea at Cheras is built up with 12m long spans and consists of up to 2.6tonnes/m2 design
loading. Hollow core slab is suitable for Ikea which 90% of its outlet is covered. These slabs
are designed for interior application as the water will enter into the cores of hollow core slab
and reduce the strength of slab. Thus, sealing the cores with grout.

One of the benefits of using hollow core slabs in Ikea is offering high resistance to interfloor
noise impact since there are always huge numbers of customer especially at the cafeteria
with seating capacity of 800 pax. . Airborne sound transmission at roof level is reduced as
well.

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Besides elimination of secondary beams, the other important benefit of hollow core slab is
ease of mounting of building systems. The longitudinal core holes in floor slabs can be used
as service ducts for concealed services such as electrical trays, water sprinkler and HVAC
systems. Breakouts can be drilled as required. As a result, access to services becomes
easier when maintenance is needed.

CONCLUSION

In order to encourage the adoption of IBS components in buildings, home buyers and
developers have to be aware of the long term benefits in terms of quality as well as energy
saving housing. Although the government exempted the 0.125% levy on buildings with at
least 50% IBS components, it may not be sufficient to offset the cost of utilising IBS
components which cost 15-20% more excluding the initial investment in plant and
machinery.

Besides, construction firms in a developing economy like Malaysia with access to cheap
migrant labour keep construction costs down by utilising greater labour inputs. Wet trades
are still predominant in the industry. Whereas worker wage rates are higher in developed
countries like Australia, construction firms will increase capital input and depend less on
labour. Clearly the choice of inputs for construction is market driven.

Semi-precast system would be the logical way forward for Malaysia at this stage of its
development. Once a clearer policy with regards to the reduction of these migrant workers is
outlined, coupled with the incentives and training support, the economics of the various
systems of construction may evolve leading to a different system being optimal.

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4.0 REFERENCE

1. Construction Technology for Tall Buildings. 4th Ed.(2012) Chew Yit Lin. World
Scientific.Singapore.

2. Bubble Deck. (n.d.). Retrieved from Advanced Structure Engineering:

http://www.bubbledeck-uk.com/design.html

3. Bubble deck. (2008). Retrieved from Bubble deck structure solution:

http://www.bubbledeck-uk.com/pdf/4-BDSiteManual-Bv6.pdf

4. Bubbledeck. (2017). Retrieved from BUBBLEDECK Biaxial Hollow Precast Slab

System: https://www.youtube.com/watch?v=vJLZPNe195Y

5. Elematic. (n.d.). Retrieved from hollow core slab production plant:

http://www.ceeind.com/public/data/companyCatalogue1233069526.pdf

6. Hollow Core Concrete PTY LTD. (n.d.). Retrieved from Concrete Hollow Core Floor
Slab: http://www.hollowcore.com.au/hollow_core_floor_slabs.php

7. Lafarge Precast Edmonton . (17 April, 2016). Retrieved from Concrete Hollowcore
Production Process Alberta Canada: https://www.youtube.com/watch?v=h6hzY-
gZ4k8

8. New way in concrete construction. (n.d.). Retrieved from

http://www.bubbledeck.com/download/bubbledeck_presentation.pdf

9. Nordimpianti. (n.d.). Retrieved from Hollow Core Slab:

http://www.nordimpianti.com/brochures/eng/pdf_mr/3.1_ENG_Hollow_Core_Slabs.pdf

10. Treehugger. (2017). Retrieved from Bubble Deck Technology Uses Less Concrete by
Filing The Slab With Beach Balls: https://www.treehugger.com/green-
architecture/bubble-deck-technology-uses-less-concrete-filing-slab-beach-balls.html

11. Ultra Span. (n.d.). Retrieved from The advantages of Hollow Core:
http://www.ultraspan.ca/the-advantages-of-hollowcore/

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