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Consolis Technical Guide: & Product Manual
Consolis Technical Guide: & Product Manual
CONSOLIS IN BRIEF
Consolis is the largest manufacturer of prefabricated concrete elements in Europe.
The company has more than 50 factories and operates in 11 countries: Finland, Sweden, Norway, Germany, the
Netherlands, Estonia, Russia, Latvia, Lithuania, the Czech Republic and Poland.
Consolis produces a wide range of prefabricated concrete products such as floors, structures and walls.
These products are used in the construction of buildings. Consolis also makes products for infrastructure, such as
railway sleepers and structures for bridges and tunnels. In addition Consolis provides services ranging from
planning to erection of its products.
Through its market leadership and international presence, Consolis offers customers the benefits of:
◗ the latest solutions and technology transfer within the Group
◗ unique benchmarking possibilities
◗ pan-European purchasing power
◗ extensive design and engineering resources
◗ production capacity sufficient to deal with the largest projects.
Consolis works actively with environmental issues associated with construction. By prefabrication Consolis
can reduce environmental burden both during the construction period and the total building life cycle.
In 2003 Consolis had net sales of EUR 620 million and employed 5,000 employees at the year end.
Consolis was formed in December 1997 following the merger of Partek Precast Concrete and the Swedish
company Strängbetong. Consolis’ major shareholders are the Swedish private equity fund Industri Kapital, KONE
and various Finnish insurance companies. Management also has a shareholding in Consolis.
Elematic
Consolis Headquarters / Consolis Technology
Parma
Strängbetong E-Betoonelement
Spenncon
Parastek
Consolis Latvija
Betonika
DW Beton
Spanbeton
VBI
Consolis Polska
1.2 Quality guarantee 5.4 L-beams & inverted T-beams 8.9 Acotec walls
13 Addresses
5 Beams 8 Residential buildings
5.1 General
8.1 Architectural freedom
5.1.1 Types
8.2 Structural systems
5.1.2 Supports
8.3 Sound insulation
5.1.3 Inserts
8.4 Bathroom floors
5.1.4 Lifting and temporary
8.5 Foundation units
storage
8.6 Stairs
5.1.5 Production tolerances
1. GENERAL
General
General
ious purposes is not a new method. On the contrary, it has ◗ Continuing erection in Winter time until -20°C
been used since the beginning of the twentieth century. ◗ Quality surveillance system
Prefabrication technology has continually been refined and
developed since then. Compared with traditional construc-
It offers the customer the performance to fulfill all
tion methods or other building materials, prefabrication, as
requirements
a construction method, and concrete, as a material, have a
number of positive features.
◗ Opportunities for good architecture
Most buildings are suitable for construction in precast member size, etc. Irregular ground layouts are, on many
concrete. Buildings with an orthogonal plan are, of course, occasions, equally suitable for precasting. Modern precast
ideal for precasting because they exhibit a degree of concrete buildings can be designed safely and econo-
regularity and repetition in their structural grid, spans, mically with a variety of plans and with considerable varia-
tion in treatment of the elevations to heights up to twenty
floors and more. With the introduction of high strength
concrete, already currently used in Consolis' business
units, the sizes of load bearing columns can be reduced
to less than half of the section needed in conventional
concrete structures.
The calculation of the performance curves given in this ◗ FIP Commission on Prefabrication, "FIP
Technical Guide are based on the following European Recommendations Precast Prestressed Hollow Core
Standards and Technical Guidelines: Floors", Thomas Telford Ltd, London 1988.
◗ FIP Commission on Prefabrication, "Planning and design
◗ CEN European Committee for Standardization, handbook on precast building structures", - SETO Ltd,
EN 1992-1-1 “Eurocode 2: Design of concrete structures - London 1994.
Part 1: General rules and rules for buildings”. ◗ fib Commission on Prefabrication, Guide to good practice
◗ CEN European Committee for Standardization, "Special design recommendations for precast prestressed
EN 1992-1-2 "Eurocode 2: Design of concrete structures hollow core floors", fib bulletin 6.
- Part 1.2 General rules - Structural fire design”.
◗ CEN European Committee for Standardization, CEN/TC
229 “Precast concrete product standards”.
General
Precast building structures in reinforced and prestressed minutes is obtained by increasing the concrete cover on
concrete normally assume a fire resistance of 60 to 120 the reinforcement. The above fire ratings are based on the
minutes and more. For industrial buildings, the normal requirements set forth in Eurocode 2, Part 1-2 "Structural
required fire resistance of 30 to 60 minutes is met by all fire resistance" and confirmed by a large number of fire
types of precast components without any special measure. tests on precast concrete units in fire laboratories all over
For other types of buildings, a fire resistance of 90 to 120 Europe.
1.8 NOTATIONS
a support length
b total width cross section
bw web width
d camber
h height cross-section
l partial length
u warping
qk characteristic variable loading
C strength class of concrete (expressed as Hall for prefabrication of hollow core slabs
Normally, the skeleton of a single-storey industrial building building is normally stabilized by the cantilever action of
is composed of a series of basic portal frames. Each frame the columns. The horizontal load action on the gable walls
comprises two columns with moment-fixed connections at can be distributed to all columns by the diaphragm action
the foundations and a pin-joined roof beam. The latter can of the roof. The distance between the portal frames is gov-
be with either a sloped pane or a straight profile. The erned by the span of the roof and the façade construction.
Skeletal structural systems are very suitable for buildings The roof can be made with prestressed hollow core ele-
which need a high degree of flexibility, because of the ments or with light TT-units or steel sheet deck. The dis-
possibility of using large spans and to achieve open spaces tance between the portal frames is governed by the span
without internal walls. This is very important in industrial of the roof and façade construction - normally between 6
buildings, shopping halls, parking structures and sporting and 9 m for hollow core roof slabs and from 9 to 12 m for
facilities, and also in large office buildings. light TT-roof units. When steel sheet deck is used, the dis-
tance between the portal frames can be larger - up to 12
m and even 16 m- because of the lighter weight of the
roof. Secondary beams are generally needed to support
the steel sheet deck.
B
2.1.3 Horizontal stability
Projecting reinforcement
Roof
beam
Horizontal stiffness
Horizontal forces parallel to the beams are distributed
Façade
directly through the beams of the same row, whereas
forces in the transverse direction are transferred through
the in-plane action of the roof. For buildings with high
slender columns, the horizontal stiffness of the structure
can be secured by diagonal bracing between the columns
of the external bays with the help of steel rods, angles or
concrete beams.
Column
Expansion joints
Socle The design and detailing of frame structures takes into
account the dimensional dilatations due to temperature
changes, shrinkage and creep. Expansion joints are chosen
in conjunction with the length and the cross-section of the
columns. Generally, the distance between expansion joints
Pocket is not larger than 60 m. They are realized either by using
foundation
double columns or special bearing pads.
2.2 MULTI-STOREY BUILDINGS
Frame and skeletal structures
The
structural frame
is commonly composed
of rectangular columns of one or
more storeys height (up to four storeys).
The beams are normally rectangular, L-shaped or inverted
T-beams. They are single span or cantilever beams, simply
supported and pin-connected to the columns. Hollow core floor slabs
are by far the most common type of floor slabs in this type of structure.
2.2.1 Stability
For buildings up to 3 or 4 storeys, horizontal stability may staircases, elevator shafts and shear walls. In this way,
be provided by the cantilever action of the columns. They connection details and the design and construction of
are normally continuous for the full height of the structure. foundations are greatly simplified. Central cores can be
However, for multi-storey skeleton stuctures, braced sys- cast in-situ or precast.
tems are the most effective solution, irrespective of the
number of storeys. The horizontal stiffness is provided by
Example of precast central core Building with central core and hidden beam-column connections
2.2.2 Diaphragm action
Modulation is an important economic factor in the design precast floor units is modulated on 1200 and 2400 mm.
and construction of precast buildings, both for the struc- When planning a building it is advisable to modulate
tural parts and the finishing. The use of modular planning dimensions to suit the element widths. In a simple struc-
is not a limitation on the freedom of planning as it is only a ture, all the floor elements should preferably span in the
tool to achieve systematic work and economy and to sim- same direction, simplifying the layout and, in the case of
plify connections and detailing. prestressed elements, limiting the number of camber
clashes within a bay.
Precast concrete floors are extremely versatile and can
accommodate almost any arrangement of support walls When exact modulation is not possible, it may be necessary
or beams. There are, however, certain guidelines on the to produce a special unit cast to a smaller width or cut to
proportioning of a building in plan which can be usefully the desired width from a standard module. Changes in
employed to simplify the construction. The width of the floor level across a building can also be readily accommo-
dated, for example by split-level bearings on a single
beam or the use of twinned
beams at different levels.
When a building tapers in
plan, the precast units are
produced with non-square
ends. The angle should not
be more than 45°. At the
apex of a tapered floor area,
it may be appropriate to
cover this area with in-situ
concrete when the span falls
below 2 m.
3.1 CHARACTERISTICS
3.1.1 Rectangular columns
h b Weight
Profile
mm mm kN/m
300/300 300 300 2.20
300/400 300 400 2.94
400/400 400 400 3.92
400/500 400 500 4.90 h
500/500 500 500 6.12
500/600 500 600 7.35
600/600 600 600 8.82
300 b 300
Columns
b
300 400 500
h
h
h 300 105 kN 145 kN 185 kN
400 145 kN 205 kN 260 kN
500 140 kN 265 kN 335 kN
bb 300
300
Hidden corbels
The BSF system consists of a hidden steel insert in the
beam-to-column connection, enabling a beam support
without underlying corbel. A sliding plate fits into a rectan-
gular slot in the beam. A notch at the end of the plate fits
over a lip at the bottom of a steel box cast into the col-
umn. The system can be used for both rectangular and
round columns. The types of corbels and corresponding
bearing capacities are given in the table.
Minimum beam
Plate type Allowable
dimensions mm
height/ load in kN
thickness Height Width
150/20 200 200 400
200/20 300 200 500
200/30 450 300 500
200/40 600 400 600
200/50 700 400 700
250/50 950 400 900
BSF application
3.3 PERFORMANCE CURVES
The following figures give the performance curves of columns and Ø3M to Ø6M for round columns. The indicated values for
under axial loading combined with bending moments. The Nd and Md are design values at ultimate limit state, which
calculations are made for modulated cross-sections, from means that the permanent and variable actions are multi-
2
3Mx3M (300x300mm ) to 6Mx6M for rectangular columns plied by the appropriate safety margins.
15000
Columns
14000
13000
12000
11000
10000 600x600
8000 600x500
Nd (kN)
7000
6000 500x500
5000 500x400
4000
400x400
3000
400x300
2000
300x300
1000
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Md (kNm)
Performance curves for rectangular columns
11000
10000
9000
8000 Ø 600
7000
Nd (kN)
6000
5000 Ø 500
4000
Ø 400
3000
2000
Ø 300
1000
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
Md (kNm)
Performance curves for round columns
3.4 CONNECTIONS
Precast columns are fixed to the foundations with pockets,
projecting reinforcing bars or holding down bolts. The first
solution is mainly used for foundations on good soil; the
second and third in the case of foundation piles. Corner pockets with
anchor bars welded
Grout filling or alternative polyurethane filling to plate
Columns
Doweled connection
with bolting
Column splicing
with baseplate
and bolts
Corner pock-
Injection with
ets with an-
shrinkage free
chor bars
grout
welded
Joint fill
to plate
with grout Projecting
or concrete reinforcement
in grouted tube
Leveling shims
s
3.5 TOLERANCES
1)
1. Length (L): ± 10mm or L/1000
2 Cross-section (b, h, d): ± 10mm
1)
3 Curvature (a): ± 10 mm or L / 750
4 Orthogonality cross-section (p): ± 5mm lk
transversal: ± 10mm a L b
depth: ± 5mm
10 Position holes, voids: ± 20 mm
d
1)
Whichever is the larger
tl l
k
tt
tl
3.6 BETEMI COLUMNS
3.6.1 System
Columns
surface textures by using coloured concrete and different
types of aggregates. In the latter case, only the final coat
has to be of this more expensive material. Grey concrete
can be used in the inner part.
Load-bearing or decorative columns are the main applica-
tions. The columns are generally one storey high. Their
maximum height is 4 m and the maximum diameter 1.2 m.
Also conical shapes can be produced.
3.6.2 Applications
Cast in-situ
concrete
Load-bearing columns
3.6.3 Connections
Characteristics
a b c h Max.
column
mm mm mm mm
section
700 700 150 550 300/300
800 700 150 700 300/400
800 800 150 700 400/400
1000 900 200 850 400/500
1000 1000 200 850 500/500
1100 1000 200 1000 500/600
1100 1100 200 1000 600/600
Infill grout
In situ or precast
footing
5.1.1 Types
Beams
RF-beams: rectangular floor beams for
composite action with floor slabs
The cross-section of the beams is standardized. The inserts for connections and other specific purposes - for
prestressing force and the beam length is adapted to each example, for fixings, openings, etc.
specific project. The units are provided with details and
5.1.2 Supports
The maximum allowable stress on neoprene pads in the The pads should be placed at some distance from the
serviceability limit state is normally: support edge as load transfer at the edge may result in
◗ For non-reinforced elastomeric pads: σ = 6 N/mm
2
damage. The pad should allow for beam deflection so that
◗ For reinforced elastomeric pads: σ = 12 N/mm
2
direct contact between the beam and the support edge is
avoided.
5.1.3 Inserts
Inserts are details embedded in a precast unit for the ◗ Steel plates, profiles and steel angles
purpose of fixings, connections to other components, etc. ◗ Rolled channel
Beams
◗ Projecting bars The possible location and load capacity of inserts depends
◗ Anchor rails on several parameters and will be dealt with on request by
◗ Threaded dowels or bolts Consolis.
Lifting points are chosen to minimize deflections. The lift- Temporary bracing of slender roof beams may be neces-
ing angle for the slings should not be less than 60° without sary until the secondary beams or roof slabs are erected
spreader beam and 30° with spreader beam. Intermediate and fixed.
storage should preferably be on the normal support points.
o b1 b2
longitudinal: ± 15 mm u
transversal: ± 10 mm h2
depth: ± 5 mm h1
b
10 Position holes, voids (t): ± 20 mm
1)
whichever is the larger
5.2 PURLINS
Purlins are used as secondary beams for roof structures stressed concrete. The fire resistance is normally 60
with light roof cladding. The distance between the portal minutes. The standard cross-section is shown in the figure
frames is maximum 12 to 16 m. The units are in pre- below.
276
400
l 152
Purlins
bridge the distance between the portal frames. The latter
can be at larger distances, up to 12 and even 16 m. In this
way large open halls can be constructed in an economical
way.
20
18
16
Allowable loading in kN/m
14
12
4 12,5
10
2 12,5
6
2
Purlins
7,0 7,5 8,0 8,5 9,0 9,5 10,0 10,5 11,0 11,5 12,0
Span l in m
The allowable loading is the sum of the weight of the roof cladding and the variable load (snow and life load), excluding the
self-weight of the purlin.
5.2.2 Connections
The elements are connected to the supporting beam with For light roof structures where diaphragm action can not be
protruding bars and cast in-situ concrete. achieved by the roof structure itself, the distribution of hori-
zontal forces on the gable walls, over the external and inter-
nal columns, can be secured by diagonal bracing between
the beams of the external bays, with the help of steel rods
or angles.
Roofing
Steel deck Insulation
l b
L
Rectangular beams
Standard profiles and weight per m length
Compression flange
Composite floor beams
R-beams may be designed composite with the floor to
enhance the flexural and shear capacity, fire resistance
and stiffness. The main advantage of a composite beam
structure is that it permits less structural depth for a given
load-bearing capacity.The breadth of the compression
flange can be increased to the maximum permitted value,
as in monolithic construction. For composite action with
hollow core floors, the collaborating section is through the
unfilled hollow core. This comprises only the top and bot-
tom flanges of the slab. Detailed information about the
load-bearing capacity is available from the technical
department.
5.3.1 Performance curves R-beams
160
150
140
130
Allowable loading in kN/m
130
110
100
10
90 80
90 00
0/ /5
70 0/ 40 00
80 0/ 40 0
60 40 0
70 0/ 0
40
0
50
60
0/
40
50
0
40
40 0/
30
0
30
20
Rectangular beams
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Span l in m
The allowable loading is the sum of the permanent and of the self-weight and the permanent and imposed loading
variable loads acting on the beam, excluding the self- of the floor, without partial safety margins, and without
weight of the unit. For example, the allowable loading of a the self-weight of the beam.
beam supporting a floor, should be calculated as the sum
5.3.2 Connections
nut
washer
slot
threaded bar
neoprene pad
5.4 L-BEAMS & INVERTED T-BEAMS
L-beams and inverted T-beams are typical floor beams be- Standard Consolis’ cross-sections are shown in the table
cause of the reduced overall structural depth. The beams below. The boot width is governed by the adequate floor
are in prestressed or reinforced concrete. slab bearing distance.
400
200 500 200
200
130
110
100
70
0*
90
/5
60
00
0*
60
80
/9
/
0*
50
50
00
/4
0/
0*
70
00
90
50
/5
/8
0
0*
00
00
/4
60
/90 0
00
0
/8
50 40
0
0*
/3
40 00
/7
00
30
L-beams & inverted T-beams
20
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Span l in m
5.4.2 Beam width
The width of L-beams and inverted T-beams may be con- In this case, the floor modulation becomes independent of
fined within the width of the column or may project for- the column spacing and is thus simplified. When beams
ward to the column. The latter solution allows the floor are not wider than the column width, it will be necessary
units to remain plain edged. to form notches in the floor units
T12 / T16
T16
L-beams & inverted T-beams
5.5 SI-BEAMS
SI-beams with variable height are particularly suited for According to Eurocodes, the SI-beam types have a fire re-
roofs with large column free spans - for example, in indus- sistance up to 120 minutes. Standard cross-sections are
trial halls. The I-shaped cross section is typical for pre- show in the table below.
stressed beams. The slope of the top face is 1:16.
slope 1/16
f
e
h
bw
d
c
l b
L
5.5.1 Characteristics
SI-Beams
Profile h b c d e f bw Lmin Lmax
SI 900/500 900 500 150 190 95 150 120 6000 12000
SI 1050/500 1050 500 150 190 95 150 120 6000 12000
SI 1200/500 1200 500 150 190 95 150 120 8000 16000
SI 1350/500 1350 500 150 190 95 150 120 10000 20000
SI 1500/500 1500 500 150 190 95 150 120 12000 25000
SI 1650/500 1650 500 150 190 95 150 120 14000 28000
SI 1800/500 1800 500 150 190 95 150 120 15000 30000
SI 1950/500 1950 500 150 190 95 150 120 16000 32000
5.5.2 Connections
neoprene pad
5.5.3 Performance curves SI-beams
160
150
140
130
Allowable loading in kN/m
SI 550
120
SI 24 50
27
SI 22 0
2 00
00
SI 21
110
SI
SI 180
100
0
SI
19
50
90 SI
16
SI
0
50
15
80
SI
00
13
SI
50
70
12
00
SI
60
10
50
50
SI
90
0
40
30
SI-Beams
20
8 10 12 14 16 18 20 22 24 26 28 30 32 34
Span l in m
The allowable loading is the sum of the permanent and variable loads acting on the beam, excluding the self-weight of the
unit.
kN
400
SI 2700
SI 2550
350
SI 2400
SI 2250
300 SI 2100
SI 1950
250 SI 1800
SI 1650
200 SI 1500
SI 1350
150
SI 1200
SI 1050
100 SI 900
50
0
8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Beam length L in m
5.6 I-BEAMS
I-beams are used for flat and sloped roof structures and for are in prestressed concrete and the fire resistance is,
floor beams with heavy loading and large spans. The beams according to Eurocodes, up to 120 minutes.
f
e
h
bw
d
c
l b
L
I-Beams
5.6.1 Characteristics
Profile h b c d e f bw
I 900/500 900 500 150 190 95 150 120
I 1200/500 1200 500 150 190 95 150 120
I 1500/500 1500 500 150 190 95 150 120
I 1800/500 1800 500 150 190 95 150 120
5.6.2 Connections
neoprene pad
5.6.3 Performance curves I-beams
160
150
140
130
Allowable loading in kN/m
120
110
100
I1
I9
I
80
15
I
90
00
12
0
00
00
80
70
60
50
40
30
I-Beams
20
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Span l in m
The allowable loading is the sum of the permanent and variable loads acting on the beam, excluding the self-weight of the
unit.
kN
400
350
300
250 00
I 18
00
I 15
200 I 120
0
I 900
150
100
50
0
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Beam length L in m
6. HOLLOW CORE SLABS
Prestressed hollow core slabs are the most widely used depth and capacity, smooth underside and structural
type of precast flooring. This success is due to the highly efficiency.
efficient design and production methods, choice of unit
200
The nominal width of the units is 1200 mm, inclusive of 125,5 189
the longitudinal joint. The various cross sections are given
alongside. The edges of the slabs are profiled to ensure an
adequate transfer of horizontal and vertical shear between
adjacent units. The standard profiles have a fire resistance
265
of 60 to 120 minutes. The latter is obtained by raising the
level of the tendons.
152 220
The hollow core slabs are manufactured on long-line beds.
The units may be manufactured with a thermal insulation
layer on the under side - for example, for floors at ground
level.
320
185,5 275
1196
1196 mm 4 mm 1196 mm
The nominal width of the units is 1200 mm, inclusive of adjacent units. The standard profiles have a fire resistance
the longitudinal joint. The various cross sections are given of 60 to 120 minutes. The latter is obtained by raising the
alongside. The edges of the slabs are profiled to ensure an level of the tendons.
adequate transfer of horizontal and vertical shear between
The hollow core slabs are manufactured on long-line beds. The slabs are cut to length using a circular saw. A square
The units may be manufactured with a thermal insulation end is standard but skew or cranked ends, which are
layer on the under side - for example, for floors at ground necessary in a non-rectangular framing plan, may be
level. specified. Longitudinal cutting is possible for match plates.
250
150
100
100
98,5
98,5
180
300
100
98,5
186 225
200
100
400
98,5
186 225
1196
Hollow core slabs
1196 mm 4 mm 1196 mm
6.2 CHARACTERISTICS
Weight
Profile h b (joints filled) Joint filling
2
(mm) (mm) kN/m l/m2 (*)
HC-200 200 1196 2,60 7,0
HC-265 265 1196 3,80 10,0
HC-320 320 1196 4,10 12,0
HC-400 400 1196 4,65 17,0
Weight
Profile h b (joints filled) Joint filling
2
(mm) (mm) kN/m l/m2 (*)
HC-150 150 1196 2,57 4,7
HC-185 180 1196 3,87 5,9
HC-200 200 1196 3,18 6,8
HC-250 250 1196 3,85 8,9
HC-300 300 1196 4,55 10,4
HC-400 400 1196 5,24 14,7
16
13
Allowable loading in kN/m
12
11
HC
10
CE
CE
CE
E
20
26
32
40
9
5
0
0
8
7
6
5
4
3
2
1
4 5 6 7 8 9 10 11 12 13 14 15 16 17
Span l in m
Slipformed hollow core slabs
16
15
14
13
2
12
Allowable loading in kN/m
11
10
HC
HC
HC
HC
HC
H
CS
S1
S
S1
9
20
25
30
40
80
50
0
0
0
0
8
7
6
5
4
3
2
1
4 5 6 7 8 9 10 11 12 13 14 15 16 17
Span l in m
Hollow core slabs
Hollow core floors are normally used without structural be indicated. The thickness should be at least 40 mm,
topping. However, in the case of seismic action, frequent concrete quality C 30.
changes of load or important point loads, a topping may
6.5 PRECAMBER
Prestressed concrete units are subjected to precamber, of non-loaded elements after 1 month of storage. Possible
depending on the magnitude and centroid of the pre- tolerances are given in clause 6.11. The design should
stressing force, modulus of rigidity of the cross section and take account of the precamber in determining the thick-
length of the unit. The graph below gives an indication of ness of the topping and screeds and the final levels after
the minimum and maximum expected average deflection finishing - for example, for door thresholds, etc.
mm
40
30
20
10
0
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Span l in m
L2 + L3 x 20 kN/m ≥ 70 kN L3
2
A
A
B B L2
L1
L1 x 20 kN/m ≥ 70 kN
2
C
C
≥ 70 kN L1
x 20 kN/m ≥ 70 kN
2
L2 + L3 x 20 kN/m ≥ 70 kN
2
≥ 20 kN/m
6.7 CONCENTRATED LOADING
Floors composed of prestressed hollow core elements transmitted through the profiled longitudinal joints. The
behave almost as monolithic floors for transverse transversal distribution should be calculated according to
distribution of line or point loads. The loads are the prescriptions of Eurocode 2 and CEN Product Standard.
6.8 OPENINGS
Holes in hollow core floors are made as indicated in the width of the void. Holes are normally made in the fresh
figure. The dimensions are limited to the values given in concrete during the production process. The edges of the
the table. Small holes may be formed at the center of the openings are rough. The possible dimensions for openings
longitudinal voids. The maximum size is limited to the are given in the table.
Larger voids which are wider than the width of the precast
units are 'trimmed' using transverse supports such as steel
angles or concrete beams. The steel angles can be supplied
by Consolis on request.
6.9 CONNECTIONS
6.9.1 Bearing length
The nominal bearing length of simply supported hollow
core floor units is given in the table. Neoprene strips
ensure a uniform bearing.
Support length a
Supporting Slab Nominal Minimum
material thickness length effective a
length
Concrete or ≤ 265 mm 70 mm 50 mm
steel ≥ 300 mm 100 mm 80 mm
Brick ≤ 265 mm 100 mm 80 mm
masonry ≤ 300 mm 120 mm 100 mm
In-situ concrete
tie beam
6.9.2 Support connections
Topping
Tie bar floor diaphragm Tie steel in joint
1)
Whichever is the larger
2) t
Deviated from the calculated deflection
(including precamber and calculated t t
p a
deflection under loading circumstances)
3)
Valid for slabs h ≤ 300 mm y
b
6.12 HANDLING AND TRANSPORT
Handling, loading and storage arrangements on delivery
should be such that the hollow core slabs are not subjected
to forces and stresses which have not been catered for in
the design. The units should have semi-soft (e.g. wood)
bearers placed at the slab ends. Where they are stacked
one above the other, the bearers should align over each
other.
≤1m
General
clamps hanging on a steel spreader beam. The use of
a sling alone is strictly forbidden.
Joint infill and concrete screeds are used to compact the concrete. The screed may be
The longitudinal joints between the floor units should be power floated or rough tampered in the usual manner, de-
filled using concrete grade C25 to C30, containing an 8 mm pending on the type of floor finish. The topping screed
maximum size aggregate. The floor units should be should contain a shrinkage reinforcement mesh.
moistened prior to placement of in-situ
concrete. The joints should be filled
carefully since they fulfill a structural
function both in the transversal load
distribution and the horizontal floor
diaphragm action.
Fixings
There are several ways of fixing hanging loads to the hol- the voids, anchors placed into the longitudinal joints, etc.
low core floor - for example, special sockets drilled into Consolis will supply detailed information on request.
7. DOUBLE-T SLABS
Double-T floor units in prestressed concrete have a ribbed
cross-section and a smooth under face. The units are
mainly used for greater spans and imposed loading. The
units are manufactured with two standard widths: 2400
and 3000 mm. The standard cross-sections are given in
the tables. The ends of the units can be notched to reduce
the overall structural depth.
A structural topping can be used to ensure both vertical
shear transfer between adjacent units and horizontal di-
aphragm action in the floor plate. The standard double-T
units have a minimum fire resistance of 60 to 120 minutes.
Anchor rails can be cast into the soffits of the webs.
General
h
b0
TT- slabs
b2 b1 b2
Profile h b b1 b2 b0 Weight
2
mm mm mm mm mm kg/m
Fire resistance 60 min.
TT 2400-500/120 500 2390 1068 661 120 261
TT 2400-800/120 800 2390 1143 623 120 360
Fire resistance 90 min.
TT 2400-500/150 500 2390 1084 671 150 287
TT 2400-800/150 800 2390 1159 615 150 405
Fire resistance 120 min.
TT 2400-500/200 500 2390 1100 645 200 332
TT 2400 -800/200 800 2390 1175 607 200 481
7.3 CHARACTERISTICS TT-3000
Profile h b b1 b2 b0 Weight
2
mm mm mm mm mm kg/m
Fire resistance 60 min.
TT 3000-500/120 500 2990 1368 811 120 232
TT 3000-800/120 800 2990 1443 773 120 313
Fire resistance 90 min.
TT 3000-500/150 500 2990 1384 821 150 254
TT 3000-800/150 800 2990 1459 765 150 349
Fire resistance 120 min.
TT 3000-500/200 500 2990 1400 795 200 290
TT 3000-800/200 800 2990 1475 757 200 409
TT- slabs
30
28
26
24
22
TT 2400-500 TT 2400-800
20
18
16
14
12
10
8
6
4
2
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Span l in m
General
7.5 PERFORMANCE CURVES TT-3000
40
TT- slabs
38
36
34
32
2
Allowable loading in kN/m
30
28
26
24
22
20
18 TT 3000-800
16
14
12 TT 3000-500
10
8
6
4
2
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Span l in m
7.6 CONNECTIONS
7.6.1 Support connections
Connections between TT floors and supporting beams are topping or by bars welded to plates fully anchored in the
made through lapping reinforcement in the structural units.
Welded connection
l /b TT-2400 TT-3000 b
Center 1000/630 1000/930
Edge 1000/320 1000/460
Corner 1000/320 1000/460
General
t1
5. Flange angle (p): ± 10 mm t3
6. Slanting end (v): ± 15 mm t4
2) 1)
7. Camber before erection (∆d) : ± 30 mm or L/1000 a
8. Steel inserts, holes, and voids (t): L
- top surface: length- and cross wise: ± 20 mm p
- webs: longitudinal and vertical: ± 30 mm b
- depth of steel parts: ± 10 mm
h
tw
TT- slabs
1)
Whichever is the larger
2)
Deviated from the calculated deflection (including precamber and b0
calculated deflection under loading circumstances)
The units are provided with four cast-in lifting hooks, each
over the line of the webs. The slings or chains should be
long enough to enable an inclination to the slab of not less
than 60°.
8. RESIDENTIAL BUILDINGS
Residential buildings constitute an important activity within
the Consolis Group. A construction system has been devel-
oped for single family houses, low rise and high-rise apart-
ment buildings. The total structure includes complete outer
walls, inner walls, hollowcore flooring, stairway towers and
stairs, roof and balconies.
General buildings
Residential
Lay-out of apartment building with load bearing façades and
internal load-bearing cross-walls
General buildings
Residential
8.6 STAIRS
Precast concrete stairs are very interesting products for combined flight and landings. In the latter solution there
domestic and other buildings, because of the quality of may be differential levels at floors and half-landings,
finishing and the cost efficiency. Various types of precast necessitating a finishing screed or other solution.
stairs are available at Consolis, going from individual steps
to straight or helicoidal monobloc units. The second category comprises monobloc staircases. They
can be used either in the stairwells or individually between
The first category comprises straight stair units. They are the different storeys.
made out of both individual precast flights and landings or
Cantilevering balconies with intermediate thermal insulation Terraces supported on Betemi columns
8.8.1 Characteristics
General buildings
Leca concrete), a very safe environmentally friendly mate-
rial without health hazards. Acotec wall elements are hol-
low cored and produced to room height, max. 3.30 m.
The thickness varies between 68 mm and 140 mm. The
elements are 600 mm or 300 mm wide. For severe cir-
Residential
cumstances, as in seismic areas, the elements can be
produced with extra reinforcement.
8.9.1 Installation
8.9.2 Applications
The Acotec walls resist moisture very well, have good fire insulation is needed, for example apartments, hotels,
resistance and durability. A single wall structure has an schools, etc. Their high fire resistance makes Acotec walls
airborne sound insulation capacity of over 40 dB. very suitable for garages, parking buildings, etc.
Acotec walls have a wide range of applications. In the first Acotec walls can also be produced with coloured concrete
place they are used for bathrooms, kitchens, shower for applications such as fences and boundary walls.
rooms, and other areas with a high degree of moisture.
Another field of application is for rooms where good sound
9. BASHALLEN
9.1 SYSTEM DESCRIPTION
General
the units. The webs of the ribbed roof slabs are supported
in recesses in the load-bearing façades.
Bashallen
Welded connection
between façade and roof units
Welded connection
Pinned connection
with foundation
Corner solution
10. FAÇADES
Consolis specializes in the production of façade elements in not always need to have the appearance of concrete.
architectural concrete. There are two concepts: sandwich
panels and cladding units. The units are generally one Buildings clad in precast architectural cladding can give the
storey high and the normal standard widths are 2.40 m, impression of being constructed in brickwork, polished
3.00 m and 3.60 m. marble or granite. Alternatively, if the architect wishes to
maintain the appearance of concrete, the elements can be
The term "architectural concrete" refers to precast units produced in a vast range of self finishes - an array of pro-
which are intended to contribute to the architectural effect files and textures which bring out the natural beauty of the
of the façade through finish, shape, colour, texture and aggregates from which the elements are made. As a matter
quality of fabrication. Precast concrete offers an extremely of course, such finishing requires a high level of technology
wide range of visual appearances. Although the basic and workmanship, available at, and steadily further devel-
structural material is concrete, the finished elements do oped by Consolis.
General
cornices, pediments, etc.
Skilful and economical manufacture gives
all of the quality associated with natural
materials at a fraction of the cost.
Façades
Window opening
80
490 15 990 10
n x 1000
Consolis has more than fifty years experience in precast
bridge construction. Several systems have been developed Precast solid deck bridge system with inverted T-beams placed
side by side
of which the most important are solid slab bridges, girder
bridges with cast in-situ deck and complete precast box
girder bridges.
11.1.1 Systems
only for collision resistance
Solid slab bridges are constructed with precast units and a Girder bridge with inverted T-beams placed side by side and in-situ
deck slab
cast in-situ topping, acting together as a composite struc-
ture. They are used for decks of bridges, viaducts, culverts,
tunnel decks, etc.
For small spans up to about 8.00 to 13.00 m, solid precast
slabs can be used. They are modulated on 1200 mm width,
and the thickness varies from 150 to 350 mm. The slabs
are positioned side by side and a structural topping vary-
ing from 150 to 200 mm is cast on site. Girder bridge with I beams and in-situ deck
Precast bridges are well suited for projects where the real-
ization of classical scaffolding supported on the ground is
prohibitively expensive and where the speed of construction
is mandatory: watercourses, railways, roads and motor-
ways in use, in order to limit traffic restrictions.
Precast viaduct with box beams
General
by its overall aspect, in other words, by the first image
perceived by an observer situated at a distance. Also de-
tails such as the architecture of piers and abutments, the
aspect of the surface, shape, colour and proportions of the
edges are important
Infrastructural projects
continuity, and the combination of prestressing and post
tensioning. Box beam bridges exhibit a slenderness ratio
down to 30, which is comparable to classical slab bridges.
The bridge can also be executed with special edge profiles type 1 type 2
In comparison with other precast elements, concrete Consolis produces annually more than 2 million railway
sleepers are a highly sophisticated product. Concrete sleepers in Finland, Norway, the Netherlands, Germany
sleepers are produced to the highest standards due to the and the Baltics. The product range includes sleepers for
stringent demands of rail owners. The Consolis Group is a slab track systems, standard sleepers, switch sleepers,
pioneer in concrete sleeper production with more than 40 sleepers for urban railways and under ground systems, rail
years experience, having developed production and quality grids and crane runway sleepers. The monobloc sleepers
assurance systems which have defined the standard for are prestressed. The units are provided with rail fixing
certification in the majority of European anchors.
countries.
Existing quality and production aspects go along with a
steady development of new sleepers or sleeper systems.
Infrastructural projects
General
11.3.3 Railway platforms
Infrastructural projects
Modern railway platforms are constructed with large plat- The units are 3.00 m wide and the length is variable. The
form slabs in precast reinforced concrete. The principal top surface is sandblasted and slightly sloped for the
exigences are a slipp-free surface, dimensional accuracy evacuation of rain water. Longitudinal grooves are provided
and high durability. near the edge to conduct visually handicaped people.
There is also a wide rabbet with safety mark.
12. SPECIAL PRODUCTS
The Consolis Group manufactures special products and
develops techniques and know-how in the domain of water
treatment and specific structures for agriculture. In addi-
tion to this, exclusive products and projects are regularly
realised for specific applications such as monuments and
other one-off projects. They are merely the fruit of imagi-
nation and creativity in the collaboration between archi-
tects and our technical staff.
e1 / e2
Companies of the Consolis Group have been active in this
e3
specialised field for decades and have developed a range
of products incorporating all the available technical know-
how in the sewage treatment sector.
d1 d2 d3
Waste-water purification
The systems developed by Consolis optimise waste-water
purification by using different processes, such as:
General
placed in a horizontal plane along the circumference of the Therefore the capacity of the tank is between 150 and
3
tank. They may pass through ducts within the wall elements, 6000 m . On most farms the average capacity is approxi-
each crossing the vertical joints. mately one thousand cubic meter.
Special products
www.consolis.com
Columns
Pocket foundations
Beams
Hollowcore slabs
Double-T slabs
Residential buildings
Bashallen
Façades
Infrastructural projects