RESEARCH 1

ON
BT 115

Cast-in-Place and Pre-cast Concrete System

Prepared By:
Husana, Thessaly Aubrey S.
A18-24948

Schedule:
MWF 1: 30 – 3: 30

Submitted To:
Ar. Christopher P. Mirasol

Manuel S Enverga University Foundation

S.Y. 2021 – 2022
1. Flat Slab
Flat slabs are also known as beamless slabs, it is type of slab in which the floor slab
is supported directly on columns without the action of beams or girders.
Thin flat slabs ranging from 5 to 9 m are the preferred solution for building in-situ
concrete frame buildings.
Flat slabs are typically used on parking decks, commercial buildings, hotels or places
where beam projections are not desired.

Types Of flat slab:

Typical flat slab

This slab is also called beam slab construction, so beams are sometimes
avoided in warehouses, offices, public halls and slabs are supported directly by
columns. These types of constructions are also aesthetically appealing.
These slabs which are supported by straight columns are called flat slabs.

Flat Slab without drop and with column head:

The column head is sometimes widened to reduce perforation shear in the slab. The
widest parts are called column heads.
The column heads can be provided with any angle from an architectural point of view
but for design the concrete in the portion at 45° on either side of vertical only is
considered as effective for the design.
Flat slab with drop panel and without column head:
The moments in the slab are higher near the column, so the slab is thickened
near the column by providing drops. Sometimes the drops are called the capital of
the pillar.

Advantages of Flat Slab:

• This reduces the overall height of the structure.

• Flat slabs are capable of lifting concentrated loads.
• They require less formwork.
• Since the reinforcement of flat slabs can be easily expanded, it is easy
to place.
• They also have better quality control.
• Sprinklers, utilities and other piping are easy to install due to the
absence of beams.
• This gives better appearance and better diffusion of light.
• Better fire resistant than other floor systems.
• They can be constructed rapidly.

Disadvantages of Flat Slab:

• In the flat plate system, construction of large spans is not possible.

• The use of a drop panel can interfere with large mechanical ducting.
• They are not suitable for masonry walls (brittle supports).
• The thickness of the flat plate slab is greater than that of the typical
RCC two-way slab.

Uses of Flat Slab:

Flat slabs are mostly used in large industrial structures, parking garages,
ramps, warehouses, tall buildings and hotels.
They are used where the beam is not required.
They are also used where the structures requires less formwork.
Also provide better diffusion of light to the plain roof surface.
2. Flat Plate
A flat plate floor system is a reinforced concrete frame system with a uniform
thickness that is supported directly over the columns or the load-bearing walls. The
flat plate floor system is a common floor construction type employed in the
construction of the building.

Fig.1.Flat Plate Floor System

Features of Flat Plate Floor System

The important features of the flat plate floor system are enlisted below:

• One of the important features of a flat plate floor system is the thickness of the floor. It
is constructed with uniform thickness with a flat soffit.
• The soffit constructed for a flat plate system requires simple formwork which hence
makes the construction easier.
• The flat plate floor system is the best choice for serving the purpose of a horizontal
floor over a suspended ceiling.
• The flat plate floor is constructed with an economical span that takes up medium loads
and avoids the chances of long-term deflection.
• A flat plate floor system depending upon the load and deflection criteria can be either
pre-cambered or prestressed.

Construction Details of Flat Plate Floor System

A flat plate floor can be constructed with an economical span of 6 to 8m for
ordinary reinforced flat plate floor. For prestressed construction, the economical span
can be increased to 8 to 12m.
In general, if D is the depth of the slab, then Span ‘L’ for a Simply Supported
Reinforced Concrete Flat Plate System = D x 28
Span ‘L’ for an End Span Continuous Reinforced Concrete Flat Plate System = D x 30
Span ‘L’ for an Internal Continuous spanned Reinforced Concrete Flat Plate System
= D x 32
If the flat plate system is prestressed, the span L can change to D x 30, Dx 37 and D
x 40 respectively.
Advantages of a Flat Plate Floor System
The basic advantages of a flat plate floor system are:
• A flat plate floor system does not demand any beam.
• The use of zero beams helps to have underfloor spaces and more service
areas.
• The flat plate floor system requires simple formwork. This system is suitable
for a direct fix or sprayed ceiling.
• The structural depth of a flat plate floor is minimum.
• Reduced depth of slab helps to increase the floor-to-floor height of the
building.

Disadvantages of Flat Plate Floor System

The basic disadvantages of a flat plate floor system are:
• The lateral load capacity of a flat plate floor system is limited compared to a
moment frame.
• The spans employed are medium length
• Special reinforcement for shear must be provided at the columns or larger
columns must be constructed.
• Long-term deflection is an expected factor that requires full life control.
• A flat plate floor system is not a good choice for supporting partitions that are
too brittle. For example Masonry Walls.
• A flat plate floor system is not a good choice to take up heavy loads.
3. Waffle Slab
Waffle slab or ribbed slab is a structural component which is plain on its top and
contains grid like system on its bottom surface. The top of ribbed slab is normally thin
and the bottom grid lines are generally ribs which are laid perpendicular to each other
with equal depth. Waffle slab has two directional reinforcement.
All the ribs are directed from column heads or beams. The depth of ribs maintained
is as same as depth of column head or beam. Because of the ribs and double
reinforcement, it is more stable and recommended for larger span slabs or
foundations.

Characteristics of Waffle Slabs

• Waffle slabs are generally suitable for flat areas.

• Volume of concrete used is very less compared to others.
• The reinforcement in the waffle slab is provided in the form of mesh or
individual bars.
• Separate excavation for beams is not required in case of waffle slab.
• The bottom surface of slab is looks like waffle which is obtained by using
cardboard panels or pods etc.
• The thickness of waffle slab recommended is 85 to 100 mm while the
overall depth of slab is limited to 300 to 600 mm.
• The width of beams or ribs provided in waffle slab are generally 110 to 200
mm.
• Spacing of ribs recommended is 600 to 1500 mm.
 • Reinforced waffle slabs can be constructed for the span up to 16 meters
while beyond that length prefabricated waffle slab is preferable.
• Waffle slab is good against shrinkage and it is lower than stiffened rafts and
footing slabs.
• Waffle slab requires only 70% of concrete and 80 % of steel from the
concrete and steel used for stiffened raft.

Waffle Slab Construction Procedure

The construction of waffle slabs can be done by three ways as follows.

• In-situ
• Precast
• Prefabricated
In-situ waffle slabs are constructed by pouring concrete in the site or field with proper
arrangements. In case of precast waffle slab, slab panels are casted somewhere and
they are joined together with proper reinforcement and concrete is filled.
The third case, prefabricated waffle slab is costliest than the other two methods. In this
case, reinforcement is provided in the slab panels while casting with some tension.
Hence, they do not need internal reinforcement in the site.
To construct a waffle slab in-situ conditions, formwork should be necessary to support
the slab. But some special tools are required for the form work in case of waffle slab.

Formwork tools required in the construction of waffle slab are:

• Waffle pods
• Horizontal supports
• Vertical supports
• Wall connectors
• Cube junctions
• Hole plates
• Clits
• Steel bars

Horizontal support and vertical supports are arranged first and they are fixed in
position by the connectors. At the edges wall connectors are used to provide
connection between wall and slab. The horizontal beam supports are connected by
small beam connectors which form square like shape in which pods are going to be
placed.

The pods are generally made of plastic and they are available in different sizes and
different shapes. Size selection of pod depend upon the requirement and span length.
For longer span large number of pods are required. Same size should be used for one
complete slab.
Similarly beam connectors and cube junctions are also available in different sizes
based on the suitability of pod sizes.

Cube junctions are used to fix the corners of pods with the frame work. After fixing the
formwork, reinforcement is placed in the two directions of the slab and then concrete
is poured in the gaps which are called as ribs after hardening.

Thin concrete slab is provided on the top and after its hardening pods and frameworks
are removed from the bottom. Thus, the waffle like shape appears at the bottom
surface.

Waffle Slab Details

• The construction of a waffle slab is generally suitable for flat areas.

 • The Volume of concrete which is used in the waffle slab is less as
compared to other types of slabs.
• Waffle slabs have good shrinkage resistance.
• Waffle slab required very less amount of steel and concrete as
compared to other types of slabs.
• Waffle slabs are the Structural component which is plain from the
top and has a grid-like pattern at the bottom side.
• Waffle slabs can be used for both constructions of the floor slab as
well as ceiling slabs.
• A flat slab cannot be constructed for a longer span and also get
cracked.
• Waffle slabs are the special type of slab which is mainly constructed
for the longer span and has a crack and sagging resistance.

Waffle Slab Advantages

The Advantages of the waffle slab are as follows

• Load bearing the capacity of waffle slab is higher than other types of the slab.
• Waffle slabs have good structural stability.
• The construction of a waffle slab is very speedy and fast.
• Waffle slab can be used for larger span with less number of columns.
• Waffle slab can bear a larger amount of load as compared to the conventional
slabs.
• Waffle slabs are lightweight as compared to other types of slabs because of the
less dead load of the slab.
 • Waffle Slab has high vibration Control capacity.
• Waffle Slabs are attractive and have good Aesthetical appearance when
exposed.
• All the services like lighting, plumbing, electrical and air conditioning are easily
provided in the waffle slab without any difficulty.

Waffle Slab Disadvantages

The disadvantages of a waffle slab are as follows

• The Formwork which is required for the construction of the waffle slab is very
costly.
• The Construction of the waffle slab required skilled workmanship.
• Waffle slab Construction cannot suitable to bear high wind loads.
• The floor height in the waffle slab is high as compared to the conventional slab
due to which the number of floors in the structures is get reduced.
• The waffle slabs cannot be constructed on the slope areas.
• The Maintenance of waffle slabs is expensive and difficult.
4. Lift Slab

Lift slab construction is a method of constructing concrete buildings by casting

the floor or roof slab on top of the previous slab and then raising the slab up with
hydraulic jacks, so being cheaper and faster as it does not need forms & shores as it
is needed for cast-in-place slabs. Lift-slab construction can be more economic than
conventional construction when the building is vertically uniform, such as for hotels,
apartment buildings, and dormitories, and where the slab designs are repetitive.

Construction Sequence
• The Slabs are lifted by jacks, operating on the top of each column, which lift a
pair of steel rods attached to each lifting collar in the slab being raised.
• A central control synchronizes the process for a uniform lift from all directions.
• Lifting collars are cast into each slab around each column.
• The first-floor slab is cast inside edge formwork on top of the ground floor slab
and when it is mature it is in turn coated or covered with the separating medium
and next floor slab in cast on top of it.
• The casting of the other slabs continues until all the floors and roof have been
cast one on the other on the ground.
 ADVANTAGES
• Lift-slab construction method becomes more advantageous in buildings with
similar floor plans throughout the height of the building and where flush slab
may be desired.
• This method eliminates the need for redundant formwork as only shuttering
required on the edges, therefore casting concrete slabs is the simplest stage in
whole constriction process of lift-slab method.
• Lift-slab method may be employed with ribbed slabs not only flat slabs with
some compromise of the ease of casting.
• Another advantage is reduced handling and hoisting of materials and supplies
that can simply be placed on top of the slabs and lifted with them
LIMITATIONS
Major limitations This method not to be use for multistorey building, only use for 15-
16 storey building. No large span slab are constructed in this type of construction.
5. Ribbed Floor Slab
Ribbed or waffle slab is a slab system which consists of series of parallel
reinforced concrete T beams framing into reinforced concrete girders. The slab is the
flange of the beam and the extended part is the web. The extended part is known as
ribs. The spacing between the ribs should be in general 20-30 inch. The ribs are
tapered in cross-section in its lower part.

Types of Ribbed and Waffle slabs

There are two types of ribbed slab system:
• One-way ribbed slab system
• Two-way ribbed slab System (Waffle system)

One-way Ribbed Slab System

A one-way joist floor slab consists of a series of small, reinforced concrete T beams
that are connected with girders that in turn carried by the building column. T beams
are known as joists which are formed by setting steel pan at a constant spacing.
Concrete is cast between those spacing to make those ribs and, in this way,, the
slab also cast and the slab becomes the flange of T beam.
Two-way Ribbed Slab System (Waffle System)
The system was designed to decrease the weight of traditional full-concrete slabs.
The dome-shaped forms create a matrix of voids surrounded by orthogonal ribbing,
producing a two-way configuration very suitable for large-spanning slabs. Voids
between all the domes reduce the dead load as the width of that portion of the slab
is less than a flat slab. This type of slab is known as waffle slabs because they look
like waffles with rows of beams running underneath them. Waffle slab shows a
ceiling which is suitable to install all the electrical appliances and can give a better
outlook thus increasing the aesthetic factor.

Advantages of Ribbed and Waffle Slabs

• In this type of slab, the tension stress is eliminated in the tension side of the
slab. The strength of concrete in tension is very small and so elimination of
much of the tension concrete is done by the use of pan forms.
• Economical where the live loads are fairly small such as apartment houses,
hotels.
• Long slab spans can be constructed through ribbed and waffle Slabs. In
many cases, long spans are desirable in the building. Ribbed or waffle slabs
are an easy solution for this purpose.
• Provide architectural advantages. All the Electrical appliances can be
installed easily in the gap of the ribs which can be architecturally aesthetic.
• Slab thickness of ribbed or waffle slabs is less than other slab systems.
Therefore the weight of slab is reduced. This saving of weight can change
in structural characteristic.
 • Lighter and stiffer slab than an equivalent flat slab.
• Reducing the extent of foundations by reducing the ultimate load.
• They provide a very good form where slab vibration is a viable issue.

Disadvantages of Ribbed and Waffle Slabs

• Not suitable where the live loads are huge as heavy manufacturing
buildings, warehouses.
• The thickness of the slab is controlled as the requirement of fire resistance.
• Formwork cost is high.
• Sometimes difficult to install the electric equipment.
6. Span stress Floor System

Steel floor systems also means less labor and cost. For example, the simplest
solution of a downstand solid web I-section beam as opposed to a truss means;
fewer structural elements, less fabrication, fewer surfaces to be fire protected and
less time to design.
A construction method which utilizes span-stress prestressed T-joist that can
be used with filler blocks or collapsible steel forms or plywood forms.
FLOOR STIFFNESS
Stiffness is needed to ensure that a floor behaves correctly from a dynamic
point of view, thereby assuring user comfort. This is a complex subject, as the real
issue is how the floor responds (in terms of acceleration) and that is a function of a
number of variables including stiffness and the mass that is mobilized. The traditional
approach, which is recognized as being crude, for designing a floor to respond
acceptably is to check its natural frequency and compare that with a limiting value
(which is a function of the floor mass). The required behavior depends on the
function for a building/room. Some uses are less tolerant to floor movements (e.g.,
an operating theatre). Some uses (e.g., a gymnasium within an office) are more
likely to cause problems and warrant particular attention.

7. Slipform Method
SLIP FORM METHOD
Slip forming, continuous poured, continuously formed, or slipform construction
is a construction method in which concrete is poured into a continuously moving
form. Slip forming is used for tall structures (such as bridges, towers, buildings, and
dams), as well as horizontal structures, such as roadways.
Slipforming enables continuous, non-interrupted. Cast-in-place “flawless” (i.e., no
joints) concrete structures which have superior performance characteristics to
piecewise construction using discrete form elements.
Slip form construction, or continuously formed construction, is a construction method
in which concrete is poured into a continuously moving form. • Basically, this method
involves the continuous placing of concrete in a shallow mould having the same plan
as the building to be constructed. This rigid mould, or "slip-form" as it is called, forms
the working deck which is jacked slowly upwards at a controlled rate until the required
elevation is reached.
Method of vertically extruding a reinforced concrete section and is suitable for
construction of core walls in high-rise structures – lift shafts, stair shafts, towers.
•The formwork rises continuously, at a rate of about 300 mm per hour, supporting
itself on the core and not relying on support or access from other parts of the building
or permanent works. •Allows for the continuous pouring of concrete into walls of a
structure and only stops when the full required height of the structure has been
reached. •The height of the formwork is designed in such a way that while the top of
the formwork is being filled by concrete the lowest layer of concrete poured earlier
has already gained an initial set. When the formwork is moved upwards the concrete
that is then exposed remains firm.
PROCEDURE
• Assembly can only start once the foundations are in place and the wall starter
is in correct alignment.
• Slip form shuttering is aligned with the help of yokes. •Horizontal crossbeams
connect these yokes.
• Hydraulic jacks are attached to these crossbeams for simultaneous upward
movement.
• Height of the slip form ranges from 1.1 to 1.5 meters.
• Yokes and crossbeams also used to support the working platform.
• Structure should be rigid and shape maintained at all times.
• Make sure there is no lag or else it prevents the structure from free upward
movement
• It is also possible to reduce wall thicknesses as the construction gains height
and arrangements have to be made in the slip form structure that will enable
such reduction at regular intervals.

TYPES OF SLIP-FORM CONSTRUCTION

VERTICAL SLIP-FORM
In vertical slip forming, the concrete form may be surrounded by a platform on which
workers stand, placing steel reinforcing rods into the concrete and ensuring a smooth pour.
Together, the concrete form and working platform are raised by means of hydraulic jacks.
Generally, the slip-form rises at a rate which permits the concrete to harden by the time it
emerges from the bottom of the form.

HORIZONTAL SLIP-FORM

In horizontal slip forming for pavement and traffic separation walls, concrete is cast,
vibrated, worked, and settled in place while the form itself slowly moves ahead. This method
was initially devised and utilized in Interstate Highway construction initiated during the 1950s.

HORIZONTAL SLIP FORM:

• Slip form methods of construction can also be adapted to horizontal structures and are
used for paving, canals, and tunneling.
• The technique is more in use for structures that have continuous walls like silos ,
chimneys, and piers for very tall bridges.
• It has also been successfully used for construction of buildings, although this requires
the manner of leaving inserts for openings like doors and windows to be decided well
in advance, as well as also any necessary inserts to support floor slabs after the walls
are constructed.
TAPERED SLIP-FORMING
Slip-forming is also used in the construction of conical chimneys, cooling towers, piers
and other tall concrete structures involving constant or changing thicknesses in walls,
diameters and/or shapes. A form is used with sections which overlap so that one gradually
slides over the other. This is commonly done in chimney construction but it is not satisfactory
for architectural concrete because the lap shows. While the tapered slip-forming process is
similar to that used on the standard slip-forming, it requires greater attention, contractor
experience and expertise ensures the success of such projects.

ADVANTAGES:
• A major cost of concrete structure construction is the required formwork
to retain the concrete till it can be safely de-shuttered and be able to
support itself and other imposed loads.
• The formwork needs to be continually removed to newer locations and
then re- erected.
• Continuous use of manpower and lifting equipment like cranes. • In the
case of slip form building, the formwork is erected only once and remains
intact until the entire structure is completed.
• Great reduction in the cost of formwork as well as time saving for re-
erection.
• Cost effective
• The reduction in the movement of formwork and workers also leads to
far more safe working conditions that also make it a major advantage.

PRECAUTIONS
Concrete is continuously protected against loss of moisture and rapid temperature
changes for 7 days
• Unhardened concrete is protected from rain and flowing water
• Prevent plastic shrinkage • Plastic cracks are filled by injection of epoxy resin.

APPLICATIONS OF SLIP-FORM CONSTRUCTION

Slip-form construction is used for tall structures, such as towers, buildings, and dams,
as well as horizontal structures, such as roadway barriers. It enables continuous, non-
interrupted, cast-in-place joint-less concrete structures which have superior
performance characteristics over construction methods using discrete form elements.
Slip forming relies on the quick setting properties of concrete, and requires a balance
between quick- setting capacity and workability. Capital Gate Tower, Abu Dhabi King
Abdul-Aziz Airport Inn Canal, Germany

SUSTAINABILITY FEATURES:
• The formwork system is easy to clean and reuse with little formwork
waste generated compared to traditional formwork.
• Climbing formwork systems offer simplicity, safety and cost
effectiveness for certain high-rise building structures.
• The repetitive nature of the work, combined with the engineered nature
of the formwork, allows fine tuning of the construction operations, which
in turn leads to minimal concrete wastage.
• Many repeated uses of formwork are possible before maintenance or
replacement is needed, the number of uses depending on the quality of
the surface finish of concrete specified.
 REFERENCES:
https://constructionor.com/flat-slab/
https://civiljungle.com/waffle-slab/
https://theconstructor.org/building/flat-plate-floor-system-features-advantages/36113/
https://civiljungle.com/waffle-slab/
https://www.slideshare.net/tivarrose/lift-form-slab-construction
https://civiltoday.com/structural-engineering/227-ribbed-waffle-slabs
https://prezi.com/kaxxnyr4dbmq/span-stress-floor-system/
https://www.slideshare.net/rahulbhardwaj9650184/slipform
THECONSTRUCTOR.ORG
WWW.CONCRETECENTRE.COM
fac.ksu.edu.sa/sites/default/files/7-_slip-form_construction.pdf