PRODUCTS

HOLLOW-CORE
SLABS
2016 Edition
delivering
innovative
precast
solutions
 GENERAL
Precast hollow-core slabs are the most widely used
type of precast flooring. The system offers numerous
benefits to engineers and architects because it gives
maximum strength with minimum weight, versatility in
span / depth ratio, smooth soffit and speed of erection
which leads to an economical way to construct floors.

STANDARD
The nominal width of hollow-core slabs is
1,200mm, inclusive of the longitudinal joint.
The common standard cross sections are

SECTIONS
given in this brochure and more detailed
information can be provided upon request
from the sales department of Eastern Pretech.

1200 mm 1200 mm

Typical longitudinal joint profile for arrangement of adjacent hollow-core slabs

2 Eastern Pretech
MANUFACTURING
Hollow-core slabs are manufactured on long-line prestressing beds using a
state-of-the-art automated production process. Maturity of the concrete can
be accelerated by heat curing which provides shorter cycle time to provide
speedy delivery.

Cured hollow-core slabs are then cut to the desired length using a
diamond-tipped automatic saw once the concrete has attained
sufficient strength.

Delivering Innovative Precast Solutions 3

 MATERIALS
Hollow-core slabs are made from zero-slump concrete with C40/50
compressive strength. The prestressing tendons are 7-wire low
relaxation strands to BS 5896-2012 with a strength of 1860 N/mm2.
Tendon size is normally 9.6mm and 12.9mm in diameter.

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 PRODUCTION
Dimension
a) Length of member
- For straight cut ±15mm

TOLERANCE
- For angle cut ±25mm

b) Thickness (h) or Depth +10mm / -5mm or ±(h/30)mm(1)

c) Width
- Whole Slab ±5mm
- Narrowed Slab ±25mm
- Split Slab ±20mm

Openings and Blockouts

a) Size +50mm

b) Location ±50mm
Pre-Camber
a) Camber at erection ( ) Calculated (predicted) camber
±50% or ±10mm(1)
b) Difference between adjacent 2mm per metre length but not
panels (of the same length) greater than 15mm
at soffit
Strand Slippage
a) 9.6mm diameter strands 2.5mm

b) 12.9mm diameter strands 3.0mm

Strand Position ±10mm

Stressing (Difference between 5%

Actual and theoretical)
Note: (1) Whichever is greater

ANGLE
ENDED
Hollow-core slabs can be angle cut.

SLABS

Delivering Innovative Precast Solutions 5

 NARROW
SLABS
Standard hollow-core slab width
is 1,200mm and the columns/walls
centers should preferably be of modular
coordinated dimension of 12M (where 1 M
= 100mm). Otherwise, floor slabs generally
should be arranged in a way to minimise
cast-in-situ strips and to maximise
the usage of full 1,200mm wide slabs.
However hollow-core slabs can be cut to
narrower widths should the need arises.

All slabs can be produced with reduced

widths. The narrow slabs are produced
by cutting the standard width slabs after
extrusion. The location of the longitudinal
cut should correspond to the location of a
longitudinal void, at a distance of 50mm-
100mm. It is recommended that the cut
edge is placed over a wall or beam as the
cut edge will be straight without chamfer
as for full width slabs.

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 DESIGN
Hollow-core slabs can be regarded as the best section for a structural
flexural member.

The design of the cross-section allows the concrete to be used optimally both
in the compression and tension zones.

Theoretically, the concrete below the compression zone which is redundant The design is generally based on the
is omitted by longitudinal voids, thus reducing the weight of slab. By applying following Standards and
prestressing force with tendons at the bottom of slab, this will increase Technical Guide:
the tensile capacity of the slab. This gives hollow-core slabs the distinct
advantage for higher load carrying capacity and achieving long span capability. BS EN 1992-1-1 : 2004
SS EN 1992-1-1 : 2008
A floor consisting of jointed hollow-core slabs provides a monolithic slab Structural use of concrete
structure. In order to achieve this, the joint between adjacent hollow-core
slabs must be properly grouted. The jointed hollow-core slabs are capable of FIP Recommendations
distributing vertical loads within the slab ‘field’ and provide a rigid diaphragm Precast Prestressed Hollow-Core Floors
to transmit lateral loads to the stabilising structure.
PCI-Handbook

Concrete in compression

Strain Force Section

Delivering Innovative Precast Solutions 7

 DIAPHRAGM
ACTION
The diaphragm action of hollow-core floors is realised through
a good joint design. The peripheral reinforcement plays a
determinant role, not only to cope with the tensile forces of the
diaphragm action but also to prevent the horizontal displacement
of the hollow-core units, so that the longitudinal joints can take
up shear forces.

Steel bar Steel bar from Steel bar

in topping wall or beam in topping

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 CONCRETE
TOPPING
It is recommended that a layer of concrete
topping is provided in order for easy leveling
of the top of the slabs. In addition, hairline
cracks can be minimised on floors and this
topping can also serve as a barrier to prevent
water leakage through the joints of hollow-
core slabs, as well as embedment of
electrical conduits.

Generally, the thicknesses of topping shall be

specified to be between 50mm to 85mm with
C30 - C40 concrete.

Concrete topping with a layer of wire mesh and bars
for hogging moment over beam support
The structural topping is normally designed to
prevent crack at serviceability limit state and
should normally be reinforced with a layer of
wire mesh and top reinforcement. Stability tie
reinforcement may also be provided wholly
within the concrete topping.

Specified topping thickness at support Nominal topping thickness Hollow-core slabs with topping is designed as
a composite structure, hence increasing the
load-bearing capacity of the slab.

Camber (varies)

Camber in hollow-core slab floor

BEARING
LENGTH
Support length (a) The nominal bearing length of simply
Supporting Material Slab thickness Normal length Minimum effective length
supported hollow-core floor units is given in
the table. Slab is sitting on neoprene strip to
Concrete or 325 mm 100 mm 80 mm
ensure a uniform bearing.
steel 325 mm 150 mm 100 mm

Delivering Innovative Precast Solutions 9

 ADAPTABILITY
Hollow-core slabs can be supported on virtually all
types of structural members. Slabs can be supported
by cast-in-situ or precast beams, steel beams or by

TO SUPPORTING
precast load-bearing walls.

For erection on steel structures, precast beams

STRUCTURES
and walls, the slabs can be placed directly on the
support structure or on a bearing strip. On in-situ
concrete structures, the hollow-core slabs are placed
on neoprene strip for leveling purpose, to ensure
continuous support of the full slab width.

Support connections with reinforcement shown

In-situ concrete tie beam

Topping
Tie bar floor diaphragm
Tie steel in joint

In-situ concrete
Lifting loops or vertical
bar used for connections
with floor slabs

Tie bar longitudinal joint

Tie bar in transversal joint

Concrete beam (precast or cast-in-situ) Load-bearing block work wall

Steel beam Load-bearing concrete wall

10 Eastern Pretech
 CANTILEVER
Hollow-core slabs can be cantilevered by 1m to 2m
depending on the slab thickness. The cantilevered slabs can
be used for making balconies, bay windows, extensions and

SLABS
other decorative structures.

Shorter extensions may be realised on site using additional

reinforcement embedded in slab joints or in the
concrete topping.

OPENINGS IN
HOLLOW-CORE
SLABS
Different sizes of openings can be made into
hollow-core slabs.

Very large openings are where one or more slabs are

totally cut. The load from the slab(s) with no support will
be transferred to the adjacent slabs mainly through the
shear keys and through a ‘hidden” steel or cast-in-situ
concrete spreader beam.
Cast-in-situ concrete
Medium size openings in hollow-core slabs are usually spreader beam
made at the factory. The reduced cross section has to be
designed to withstand the design loads.

Small openings and recesses can be made at site

by diamond tipped coring. Holes may be circular or
rectangular, and up to three are normally permitted in the
same cross-section.

Holes are considered to be in the same cross-section if they

are less than 750mm apart in the longitudinal
slab direction.

When making openings, great care must be taken not

to damage the slab. It is particularly important that the
prestressing strands are not cut without the permission of
the design engineer.

Steel spreader beam

Delivering Innovative Precast Solutions 11

 SUSPENSIONS
Lightweight Suspensions Anchor Drill depth (mm) Maximum Suspension
Lightweight suspensions can be fixed by (kN)
drilling the fixing to the lower surface Spring bolt plug M4 Up to hollow-core 0.3
of the hollow-core slab. Here are some
Spring bolt M6 Up to hollow-core 1.0
examples of permissible suspension loads:
Expansion bolt M6 30 1.5
Expansion bolt M8 30 2.3
Expansion bolt M10 40 3.5

Heavy Suspensions Bolt size (mm) Maximum load (kN)

It is advisable to fix heavy suspensions
to slab interfaces or with a through-slab 6 5.5
suspension bolt. For G4.6 suspension
8 10
bolts, permissible loads are as follows:
10 15
12 20

12 Eastern Pretech
 EV4 Slab Flat Bar
anchored in slab 40

Flat Bar at 1200c/c Drop-in

3x38 anchor or
For Heavy Load equivalent
(depending on load Through-bolt for
to be supported) MS Channel Heavy Load
Other Hanging Method
with predrilled holes

Delivering Innovative Precast Solutions 13

 PRE-FINISHED
CEILING
The soffit of hollow-core slabs offers an aesthetically pleasing
prefinished ceiling. It is completely set at one plane level without
the necessity to introduce secondary beams. Omission of the
secondary beams will give the functional advantage of greater
overall headroom and better appearance of the ceiling.

Soffits of hollow-core slabs are smooth and ready to receive skim

coat. Joints in the soffit between precast hollow-core slabs can
be closed, if required for aesthetical reasons.

14 Eastern Pretech
 QUALITY
ASSURANCE
EP’s quality assurance and environmental control systems are
independently audited to comply with international standards.
Our ISO 9001, 14001 and 18001 are certified to international
best practices.

Compressive concrete strength is determined by standard

test cubes from the wet concrete and these are tested in
accordance with BS EN 12390-3:2009/
BS 1881:Pt 116:1983/ SS78: Part A16-1987.

The concrete strength is at least 70% of the design strength

before the tension in the prestressing strands is released.
After the slabs have been cross-cut, strand slippage must
remain within permissible limits. After production, all slabs
are checked visually for cracks, broken edges and strand
slippage before they are released for erection.

SS EN 206-1:2009
SS 544:Part 1 & 2:2009
SAC CT 06:2010
Cert. No:CIS/8032RMC Cert No: PD-2009-06

Delivering Innovative Precast Solutions 15

 HANDLING AND
TRANSPORT
When stacking units on the ground site, the ground should be firm
and the bearers horizontal, such that no differential settlement
may take place and cause spurious forces and stresses in the
components. During handling, provisions shall be taken to ensure
safe manipulation, for example safety chains under the slab.

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 ERECTION
The erection of the hollow-core floor slabs should be done
according to the instructions of the design engineer. We
will supply written statements of the principles of site
erection, methods of making structural joints and materials
specification on request.

Delivering Innovative Precast Solutions 17

 Technical
details
Composite Design With
75mm TOPPING & SDL 1.2KN/m2
24

23 380EV4

22
360EV4
21
360MV4
20

19 400MV4

18

17 415EV4

16
VARIABLE ACTION (kN/M2)

325EV4 400EV4
15
265EV5
14
215EV6
13

12

11

10

6
360MV4 400MV4
5
215EV6 265EV5 325EV4 360EV4 380EV4 400EV4
4 415EV4

4 5 6 7 8 9 10 11 12 13 14 15 16

SPAN (M)

Design Information for Hollow Core Slabs

Design Code : BS EN 1992-1-1 : 2004, SS EN 1992-1-1 : 2008

Design Method : Composite with 75mm thick concrete topping & SDL 1.2 KN/m2

Concrete Grade : HC Slab : fck = 40N/mm2 (Cylinder Strength), 50 N/mm2 (Cube Strength)
C40/50

Load : Only unfactored Uniformly Applied Permanent and Variable Actions

(self weight of slab and topping already taken into consideration)

Details are intended for general guidelines only. Point loads & wheel loading are not meant
for this loading chart. Specific project details and data may vary.

18 Eastern Pretech
 Composite Design With
75mm TOPPING & SDL 2.7KN/m2
24

23 380EV4

22

21
360EV4
20
360MV4
19

18
400MV4
17
325EV4
16
VARIABLE ACTION (kN/M2)

415EV4

15
400EV4
14

13 265EV5
215EV6
12

11

10

6 380EV4

5 265EV5 325EV4 400EV4 360MV4 400MV4

215EV6 360EV4
415EV4
4

4 5 6 7 8 9 10 11 12 13 14 15 16

SPAN (M)
Design Information for Hollow Core Slabs

Design Code : BS EN 1992-1-1 : 2004, SS EN 1992-1-1 : 2008

Design Method : Composite with 75mm thick concrete topping & SDL 2.7 KN/m2

Concrete Grade : HC Slab : fck = 40N/mm2 (Cylinder Strength), 50 N/mm2 (Cube Strength)
C40/50

Load : Only unfactored Uniformly Applied Permanent and Variable Actions

(self weight of slab and topping already taken into consideration)

Details are intended for general guidelines only. Point loads & wheel loading are not meant
for this loading chart. Specific project details and data may vary.

Delivering Innovative Precast Solutions 19

 Thickness
range
215EV6
215

Jointed weight: 2.90 kPa

1200

265EV5
265

Jointed weight: 3.50 kPa

1200

325EV4
325

Jointed weight: 4.05 kPa

1200

360EV4
360

Jointed weight: 4.25 kPa

1200

380EV4
380

Jointed weight: 4.75 kPa

1200

400EV4
400

Jointed weight: 5.25 kPa

1200

415EV4
415

Jointed weight: 4.80 kPa

1200

For longer span and heavier loading, special hollowcore will be designed separately
20 Eastern Pretech
460EV4
460

Jointed weight: 5.25 kPa

1200

500EV4
Jointed weight: 6.77 kPa
500

1200

360MV4
360

Jointed weight: 4.85 kPa

1200

380MV4
380

Jointed weight: 5.30 kPa

1200

400MV4
400

Jointed weight: 5.80 kPa

1200

420MV4
420

Jointed weight: 6.30 kPa

1200
Eastern Pretech Pte Ltd
15 Sungei Kadut Street 2,
Singapore 729234
Tel: (65) 6368 1366
Fax: (65) 6368 2256
www.easternpretech.com

Eastern Pretech (Malaysia) Sdn Bhd

28 Jalan 7/108C, Taman Sungai Besi
57100 Kuala Lumpur Malaysia
Tel: (60-3) 7980 2728, Fax: (60-3) 7980 5663
www.epmsb.com.my

Dubai Precast LLC

Post Box 61055, Jebel Ali,
Industrial Area No.3,
Dubai, UAE
Tel: (971) 4 8802671, Fax: (971) 4 8802159
www.dubaiprecast.ae

Parmarine Ltd
Murrontie 8, PO BOX 95
FIN - 30101 Forssa, Finland
Tel: (358) 377 77400, Fax: (358) 341 27395
www.parmarine.fi

Company Registration No. 198203232D

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