Hollow Core

Slab
1965_ALIPTHA SHETTY
 INDEX
● Introduction
● Application
● Advantages
● The efficiency of the hollow core slab production
● Common Connection Details

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Introduction
● Hollow core slabs are pre-stressed floor
products with either round or shaped voids,
depending on local requirements. They are one
of the most popular, efficient and long span
floor construction components that exist today.
● The cores can be used for cable services and
serve as ducts.
● They play a very crucial key role as they
reduced the weight of the slab thus maximizing
structural efficiency.
● The long-span ability is ideally suited for retail
outlets, offices or car parking decks. As per the
requirements of the structure, the units are fixed
with or without a structural screed.
● The slabs that arrive on the site already have a
smooth pre-finished eave.
● They can very useful specifically in parking
structures and open structures due to its
maintenance free.

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DIFFERENT CROSS SECTION TYPES
The nominal width of the units is 1200
mm. The various cross-sections are given
alongside. Their thickness is 120-500 mm
and casting width 1.2–2.4 m.

DIFFERENT TYPES OF CROSS

SECTIONS CAN BE PROVIDED AS
SHOWN

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Application

● Floors for both commercial buildings and homes. It can

also be used as a roof or a wall element, for example, in
storage buildings or as a fence element.
● Due to pre-stressing, the hollow core slab can span up
to 23 m, easily in the range of 5.0 to 10.0 m for typical
residential buildings.
● The number of vertical structural components, like
column-beam or structural walls, can be reduced
substantially using the pre-stressed hollow-core slabs.
● Their thickness is 120-500 mm and casting width 1.2–2.4
m.

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 Advantages
Less Weight
The hollow core slabs are lighter in weight compared to
the custom prestressed or cast in situ slabs. The load
transfer is reduced from slabs to beams and from
beams to columns, thereby lowering the construction
cost the Also, we have smaller dimension for
foundations.
Easily Adaptable
The application of hollow core slabs is not only used in
precast concrete structures as well as in masonry and
steel construction, irrespective of the type of
construction that is whether it is traditional or
prefabricated.
Large Spans
A span of 16 m can be bridged by hollow core slabs,
thereby considerably reducing the quantity of
intermediate supports required. As the length of the
slab is increased, the thickness of the slab increases;
also the slabs transfer the load in one direction.
Raw Material Saving
50 % of concrete and 50% of the armature can be
saved by incorporating the hollow core slabs as against
the conventional slabs.
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 Advantages
Ease of Production
1 m of traditional slabs and 2.5 m2 of hollow core slabs
can be yielded by consuming the same amount of
materials, manpower, and energy. In addition to this,
the production of hollow core slabs is completely
automated.
Hollow Utilization
Hollows can be can be effectively utilized for various
installation purposes.
Fire Resistance
Hollow core elements are made immune to fire by
providing two levels of fire resistance.
Sound insulation: With respect to sound insulation,
hollow core slabs are comparable even to the most
rigorous standards, and are suitable for all types of
building sectors – mainly for residential purposes.
Fast Production
About 500 m2 of hollow core slabs can be produced in
24 hours.
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 Advantages
High Quality
As the production is highly mechanized and executed in
strictly controlled conditions. These slabs are
manufactured with the help of gliders on 150 m tracks
by means of concrete extrusion method. Very
high-quality steel strands are used by giving 3 times
stronger than contemporary ribbed steel. The hollows
are created by pipes and concrete is mechanically
hardened around them. This system of manufacturing
enables strict control of production methods and
products.
Duration of Construction
The time taken for manufacturing and transportation
of hollow core precast elements is easy and quick.
Moreover due to light in weight and accurate
dimensions slabs can be assembled and erected on site
straight from the delivery vehicle, thereby cutting the
labor and the time of assembly. Precast elements can
be very effective if there are number experienced team
of erectors who can assemble up to 500 m2 of these
slabs in one day.
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PROCESS OF MANUFACTURE
1. Drawing, Design and Planning

2. Preparation of Casting Beds -Hollowcore slabs are cast onto steel pallets or beds that are typically upwards of 100m in length.

3. Prestressing - Prestressing involves the application of load into the high- strength, low-relaxation tendons prior to casting.

4. Concrete Batching and Distribution - The concrete mix required to manufacture hollow core slabs varies depending on the casting machine used.
Planetary or twin-shaft mixers are typically used. High quality materials are desirable, and may be supplemented with additive (admix) chemicals.

5. Casting- Once the concrete has been delivered to the casting machine, it begins to form the hollowcore slab.

6. Detailing- Hollowcore slabs often require additional detailing, such as openings, shelf-angles, narrow widths, and insertion of lifting pins. Some
factories may use an automated Plotter – which is linked to the design/planning software – to accurately mark out these details and record data
Vacuum suction machines/aspirators can be used to remove concrete and create openings. Wet cut saws are used to make longitudinal or ‘rip cuts’
in the fresh concrete.

7. Curing- Once cast, insulated covers are normally used to assist with curing of the slabs, and to retain moisture.

8. Detensioning
Once the appropriate strength has been reached, the concrete will have bonded effectively with the prestressed tendons.
They can then be detensioned, capturing the prestressing load within the slab

9. Storage- Slabs may be removed from the factory on bogeys, using forklift trucks, or side loaders. They are stacked on timber bearers in the
stockyard.

10. Delivery and Installation- They are loaded onto trailers and delivered to site, where they can be installed using lifting clamps with spreader
beams or chains
 MARKET
STUDY
Hollow Core
Concrete | Technical
Data Sheets
HC Brochure
(hollowcore.com.au)

img-425190124.pdf
(bca.gov.sg)
The Hollow Core flooring system allows for significant flexibility in terms
of penetrations and block-outs. Penetrations for plumbing, electrical
and mechanical services can be catered for along with larger voids such
as stair openings and light wells. There are a number of different ways
that these can be achieved.
1. Core Holes: Core holes are the most common type of penetration and
are easily achieved by simply drilling the required hole on site to suit
the building requirements. Provided the core holes are not greater than
120mmØ (for 205 and 220mm thick slabs) and 165mmØ (for 300 and
400mm thick slabs) they can be easily catered for by simply drilling
through core.
2. Cut-Outs: Larger penetrations, such as those required for mechanical
services can be easily catered for as shown in drawing. These larger
cut-outs are nominated during the design process to allow the design to
take into account the local strand and web reduction. These cut-outs are
generally pre-cut in the factory prior to installation. If future demands
or site modifications require these larger penetrations to be introduced,
they can be catered for in most cases with minor onsite slab
modification.
3. Trimmer Beams: Large openings to allow for stair voids, light wells or
larger mechanical services can be catered for by the use of trimmer
beams. Where these large penetrations are required full width headers
or trimmer beams are used to transfer the load to the to the adjacent
planks. These planks are designed to support the additional load
without the need for supporting columns. The slab manufacturer should
be consulted during the preliminary stages of the project so that advice
can be provided on the most cost effective and practical design to
accommodate the required penetrations.