Eastern Pretech EP PRECAST PRESTRESSED HOLLOW CORE SLABS TECHNICAL MANUALv NSL Eostern Pretech Eastern Pretech 2015 CONTENTS 1. TYPE TYPE TYPE TYPE TYPE TYPE TYPE TYPE NOTES REGARDING THIS TECHNICAL MANUAL: Technical and design changes reserved ‘The infomation in this Technical Manual s based on state-of the-art technology at the time of publication. We reserve the right to make ‘echnical and design changes at any time. Eastern Pretech shall not accept liability forthe accuracy ofthe information in this publication or for any printing errors. EP HOLLOW CORE SLABS - GENERAL INFORMATION GENERAL 1.1 STANDARD SECTIONS 1.2. MANUFACTURING 1.3. MATERIALS DESIGN 2.1 CONCRETE TOPPING 2.2 ADAPTABILITY TO SUPPORTING STRUCTURES OPENINGS IN HOLLOW CORE SLABS GUIDELINES FOR ECONOMICAL SLAB DESIGN TOLERANCES FOR MANUFACTURING FIRE RESISTANCE HANGERS, DRAINAGE HOLES MBE SERVICES SOUND INSULATION PRE-FINISHED CEILING EP HOLLOW CORE SLABS - TECHNICAL DATA SHEETS. Wv8-150 EV6-200 EV5-265 EV4-325 EV4-360 EV4-415 EV4-460 EV4-500 page NNO OHUHHYH eR RWW NN 10 "1 12 13 14 15 16 ¥ NSL Eastern PretechEP HoLLow core SLABS 1.GENERAL SELF JOINTED DerTH SECTION TYRE wEichT WEIGHT nm) knim’) (Ni) Prestressed precast hollow core slabs ate the most widely used precast flooring. It offers numerous benefits to QQQQQOOC wvasso 200 2.35 engineers and architects because i gives maximum = — strength with minimum weight versaiy in span / depth {YYYYYI ew20 205 205 ratio and speed of erection which lead to an economical floor constuction, ee aaa 1.1 STANDARD SECTIONS evs 378 405 The nominal width of hollow core slabs is 1.200mm, Cen inclusive of the longitudinal joint. The common standard | 7 cross sections are shown in the adjacent table and the =) aaae am = technical detalls / load-bearing capactties are given from mm page 9 to 16. Special hollow core slabs for specificusageeg. | heavy loads, 4-hours fire resistance, etc. are also available a5 EV4-415, 445, 4.80 and tore detailed information can be provided upon request from the marketing department of Eastern Pretech. r evisso S00 840 50640 re x 200mm 4 Typical longitudinal oint profile showing arrangement of a hollow care slabs. Standard EP precast hollow core slabs (Wote:standard width is 1,200mm) Hollow Core Slabs in stockyard, ¥ NSL Eastern Protech 0088! ie 1.2 MANUFACTURING + NSL astern Protech Hollow core slabs are manufactured on longline prestressing beds using state-of-the-art automated production process. Strength development of hollow core slabs can be accelerated by heat curing which provides shorter cycle time for speedy delivery. The finished hollow core slabs are then cut to the desired length using diamond-tipped automatic saw once the concrete has attained sufficient strength, Long-line prestressing beds. 1.3 MATERIALS Hollow core slabs are made from zero-slump concrete of C50 compressive strength. The prestressing tendons are indented 7 - wire low relaxation strands to BS 5896-1980 with a strength of 1860 N/mm2 Tendon sizes are normally of 9,6mm and 12.9mm in diameter. Extruder for production of hollow core slab .2.DESIGN ‘The design is_generally based on the following Standards and Technical Guide: * British Standard $8110: 1997 - Structural Use of Concrete + EN 13369 - Common rules for precast concrete products. + EN 1168 - Hollow Core Slabs = FIP Recommendations - Precast Prestressed Hollow Core Floors. 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 is omitted by longitudinal Voids, thus reducing the weight of slab. By applying prestressing force with tendons at bottom of slab will increase tensile capacity of the slab. This gives hollow core slab the distinct advantage for higher load ‘artying capacity and achieving long span capability. Floor consisting of jointed hollow core slabs provides a monolithic ‘slab 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 distributing vertical loads within the slab ‘field’ and provide a rigid diaphragm to transmit lateral loads to the stabilizing structure. 2.1 CONCRETE TOPPING Hollow core slab floor can be used without structural topping. . However itis recommended that a layer of concrete topping to be provided in order for easy leveling of floor, In addition, hairlines cracks can be minimized ‘on floors and this topping can also serve as a barrier feprevent water leakage through the joints of hollow core slabs. Generally, the thicknesses of topping is specified to be between 50mm to 85mm with C 30 concrete. 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 negative reinforcement. Stability tie reinforcement may also be provided wholly within the concrete topping. Hollow core slabs with topping hall be designed as composite structure hence increasing the load-bearing capacity of the slab. Specified topping thickness at support fd 045y) Force Strain and Force Distribution in Hollow Core Slab. i Noint groove; tobe filed with shear key grout (EmmKorequivalent) 196mm. 196mm. Profile longitudinal joint. Hollow core slab floor diaphragm action. Concrete topping with a layer of wire mesh and bars for hogging moment over beam support. = Nominal topping thickness (min 5Omnm) at mid span ‘Camber in hollow core slab floor. Camber (varies) 2.2 ADAPTABILITY TO SUPPORTING STRUCTURES, Hollow core slabs can be supported on virtually all types of structural material. lab can be supported by cast in situ or precast beams, steel beams or by precast load-bearing wallsand masonry walls Concrete beam (precast or castin situ). L 1 Steel beam. i 1 \ aT i eset] Load-bearing masonry wall. Load- bearing concrete wall. Pasi Easter Pretech 3. OPENINGS IN HOLLOW CORE SLABS Different sizes of openings can be made into hollow core slabs: 2. Very large opening 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. Steel spreader beam. Cast in situ concrete spreader beam. b. Medium size openings in hollow core slabs are usually made at the factory. The reduced cross section has to be designed to withstand the design loads. Small openings can be made at site by diamond tipped coring.4. GUIDELINES FOR ECONOMICAL SLAB DESIGN Standard hollow core slabs width is 1,200mm and the columns/walls centres should preferably be of modular coordinated dimension of 12M (where 1M = 100mm). Otherwise, floor slabs generally should be arranged in a way to minimize cast in situ strips and to maximize the Usage of full 1,200 mm wide slabs. However hollow core slabs can be cut to narrower widths (at a higher cost), should the need arises. Too big span / depth ratios, exceeding 35, should be avoided. The cost will be higher and the possibility of additional openings will be reduced thus restricting the flexibility for renovation. 5. TOLERANCES FOR MANUFACTURING = Item Fabrication tolerances (mm) Length (\) £15 or L/1000 Thickness (h) #5 0rh/50” Width (b) -full slab 6,40 =cut slab #20 Camber sideways +10 Slab end angular deviation +10 Camber before installation +60 L/1000”, max.+10 top surface deviation» £10 ‘Openings i -location 225 “cut in fresh concrete “0,450 -cutinhardened concrete -0,430 Use always the'bigger dimension 2 Deviation from a predetermined camber which included possible precamber and calculated defection >)Not valid for WV8 and Wve 6. FIRE RESISTANCE Standard hollow core slabs are designed for 2 hours fire rating except for slab type WV8-150 which is 1¥4 hours. Fire resistance shall be in accordance with the recommendations 0f BS 8110.Special slab can be produced up to afire rating of 4 hours, if required. Pasi Eastern Prevech 7. HANGERS Hangers can be fixed to the soffit of the slabs: Light duty fastening Usage: + Electrica conduits and ceiling Light duty services eg-signage, etc. RAMSET Ramplug HILTI hollow deck Nylon Masonry anchor HTWTWIN Anchors or or equivalent. equivalent. Light hangers using drill in anchor bot. Medium duty fastening Usage: + Air conditioned duct, fan-coil unit (ifapplicable) - Fire fighting main pipe i 150mm en - Electrical cable tray, nat ‘ollow trunking & conduit. HILTHKD'Sor anchor HKH ieee i valent. equivalent. orequvaient. 5mmdetc. ‘Medium capacity hangers using special anchors fixed into theslab Heavy duty fastening Usage: ~Heavy/large ‘equipments (subject toloading by respective nominated ‘sub-contractor for { Steel rod approval). St tel rod -Motors (e.g.for Concrete infill smoke spilled, etc) Heavy duty hangers are fixed through the slab and supported from the top of the slab 8. DRAINAGE HOLES Drainage holes that are provided at every void near the slab ends, will ensure no water is retained in the void during construction. These 10mm diameter holes may be patched back during finishing works. L300 Drainage holes in hollow core slabs. 9, M&E SERVICES ‘Concealed electrical conduit and telephone trunking can be laid on top of hollow core slabs before topping is cast which isillustrated in the photograph shown. Fixing of MBE services prior to concrete topping works. Psi caster PretechPasi astern Prevech 10. SOUND INSULATION Hollow core slabs used as structural floor units offer excellent sound insulation properties associated with concrete and the longitudinal voids give further dampening effect. This will contribute to less sound transmission between floors The airborne sound reduction index Rw forhollow core slabs, areas follows: Type Rw [dB] WV6 205 +75 topping 55 EV5265+75topping 57 £V4325+75 topping 59 Excellent sound insulation propeties associated with Hollow Core Slab. 11, PRE-FINISHED CEILING The soffit of hollow core slabs offers an aesthetically pleasing pre-finished celling. 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 for the ceiling, PRECAST HOLLOW CORE SLABS TECHNICAL DATA SHEETS Soffit of hollow core slabs as pre-finished ceiling.EP HOLLOW CORE SLAB TYPE WV8-150 Cross Section NSL Eastern Pretech poses dees] eee Loading Chart (Compote dean we 75mm conte tpn) + toad = posed ea + (urtacres,excuang woot sab & eeBea) * Detacson atrcoeg oping Span 250 180. 140. 120 * Loading Nim), Span im) Oe OOOO ——1200 © Technical Details ‘0 om deo = 180m anylarth fom 3.0m 801m naccrdance wih ozng ce 2. Conia srengh ors at28day2 = 500NIen ener engin topping st 28aye = 200 Ni 2. Fierce = 180 hem (maceoance 858110 er UBB, Malaya) 4 sapserwept = 200 HN? Sabjortatwepht = 235 ANE 5 Topi Picken frien ety ae wa ry cing te despre apetcaten est caroer and usage cf bung {6 Despre io 85 610,187, simpy suppones ls 2 Merter ‘erent Compote ut t= 2336408 mat S07Es08 it em 11987 Camber (mort ter manutactaing wiht taping &irpoced eas) 1 Based on heretcal cacalatn, bt ata carer may ier span mp (Weta: Dette ae intended for genera Information, spect projet deta nd dete may vary. Gantr Pretec (Mays) Sdn Bh wi sheet in proving deta information) 9 Pas. Easter Pretech EP HOLLOW CORE SLAB TYPE EV6-200 Cross Section 189 189: 189 189 189 OOOO Technical Details (Camgestedesan nth 73m eon opi) 200 “Loading = moot ond + Siparingnsed ae oad + Parente eat (tine, ecg wag ot 00 8 WEBNG) ton amb 0am Span setae > helo al 26-ys = 30.0 Ni "Detection star castgwo0m6 ‘™Deteaion tar casing ping «Spon 20 ajeeneeteee ie (inszosret0 85 810 or UBB Mayes) * 4 ssatwoiot = 245 Wn? Seep 25 nt “ 5. Top tae ri catatonia ar acrg \omopersopeaetons utconber ab sage bulora 7 Seton Poets z e: 8) om z : Camber i (rt ater rari wos 8 npn as) ; Smad on ose eso a camber er (ote: Dotals ar intended for ‘esist In providing etal ieEP Eastern Prevech HOLLOW CORE SLAB TYPE EV5-265 Cross Section Loading Chart, Technical Details (Connie cei wt 7am cent pg) *Loxdng= imposed ent» Suptingeed deed oad Parco ee Ta {tac og weg tas pon) ton oe om ny rth kom mo 1200 aeerdaes wh oan cave Span iactua engt = Detecon aor asta oping Concrete sengifetoping a 26 cays = 50.0 Nir “Detecsn afte cas pra «Span 280 ee - [iracorne 9B 810 or UBBL Malan} A, St et mst 228 aint Ss ted woe 35 in? 5 Topping hee orn balan ony an wil vary accrdrg 2 ‘ede spectestion out carter and voge 0 bing {6 Dasireste 858170, 1657, snl suppres Clase 2 Meo 2526:09 ant $5450 2 EE EI Camber (men sr manuacture whooping 8 rpore cs) ‘Based on moore catn, but sta camber may citer + tesa want) Ex soe 7 8 8 © nw sono) [Nice : tae ae Intended for gonaral information, specifi proc ais and dats may vary. Eset Pratech Malaysia) Sn Bh wll Siem roving deta intormeton) 7 Pasi EP HOLLOW CORE SLAB TYPE EV4-325 Cross Section 8 208 BF Yj Ly ip Z OOOOH ee ae = a (9 4200-————____| Loading Chart Technical Details (Compt gh encore 1, Tea nen cf V2 ht: + ison = poset + Speostd lt Parton ca ce iso om (trata eekaig vt aa ara) den = 35 sey eren tonsa 20min scr wen bdr ine ~ seo ant ts 2 corte onan ersep sinc = t00Nhe pease et aes ‘inet ang een st 8m = 300 Ne a pene sae es (inacrce 88010 Ul, 90 ane jaa A ooeetmegt = 378 Wet Somrecwae = a8? iad 5. Tp tier atin on ny ng (annrt opeatatn eatcant adage og 180 as euro 88 10,17, snr peed Cat 2 Member ais 7. sao Poti enews ongnte a | (= 258608 rent 46E+08 mm eS aso inno 100 i Camber ee (1 month afer manufacturing without topping & imposed loads) a0} {Pomet on neo ctdton, mt eislcabor ny tr 70 1» so te an “ ie 20 y 84 20 1 | ” oor 0 8 wo Hn 8 Soa ~seanim) (Not: Dba are intended for general infomation, specie projet details and are may vary. Eastem Pretch (Malaysia) Sen Bh wi Slatin proving deta information) 12HOLLOW CORE SLAB TYPE EV4-360 Cross Section Technical Details HOLLOW CORE SLAB TYPE EV4-415 Cross Section NSL eb Technical DetailsPus. Pasi aster Preech astern Protech EP EP HOLLOW CORE SLAB HOLLOW CORE SLAB TYPE EV4-460 TYPE EV4-500 Cross Section Cross Section pa ap TZ bY Se Loading Chart Technical Details (Comgonte ug wh C0 em concrete tee) Loading Chart (Compost deg wi 75 mm cancels topos) 1. Testa aransere of EV4 S00 8908 | + Loser = mosses ad + ipeosted ada Panton BH | {osana= noes ine ad Sipsnpone eae Pastore war) me (tare, eceig wee a & eno) | (tena eon wet tans br) ae ae sy ang tr 9. 8m inssrene ndig ve | seylrghtom® 0m 16min eat wm eng cane 7 Span is actual length of sib is Span is actual length of sab 2. Conzle ong sb at 28a = £00 on? | oe ter an ping «Span 250 Cunt tng rep 8 at = 200 Ne? “Detecon ter g on Sn 250 sa ee A ee Ps a nase 85 8110/0 UBB iy 2 (inacardnee ©8510 UBL tn) A Shbsetdon = 500 tt al A sabsateaggt = 508 tt 20 Siete 5] 3 Semjongwnont = 640? 0 5. Tepito cain onan ny acedng 2 Teng iw ri edn nad i ay cern ‘Gamngersapsteton out caer an iage are i to aroge’sopccanon s utcabran ge arg no {6 besa 856110, 007, spend Cie 2 Manta a {6 beepreds 85010157 spy supe les 2 Meer m0 a ¢ 7. sason Peres € 1. Secon Pepe ee Bare unt Composite unt 7* Bare unit Composite unt t= 7036.09 mt EHO. mt in t= 84SE+06 mnt 1.586+10 mt Brso we Tem 236? om is coe On 33120 an 3 t= 23580 mm 241.33 mm i] ty 25410 mm 26880 mm a Camber nae Camber 120 (7 month after manufacturing without topping & imposed loads) io i eee enn en nena # Btad on ert clon ail aba ny ar } i 2 Onset on eres caus, bt ac cabana er 10.0 o m 7 20 e” » e” = z En ’ bn “o 5 ye u i “ be : 5 20 7 2 Et ipesecctPaerccascretae- Chace aa ceca ee sn ~ Sane o jo ea. ~ span (Not: Dette are intra for general infomation, apc reject ett and dats may vary. astrn Pretec ali) Sn Bh wit (ta: Owe ar itnded or oneal nermaton, pect projet dete ad at may vary Eaten Preach Malay Sn Bh wi Satin roving cet intonation) Sst in proving deta iformaton} 15 16NSL Eastern Pretech Eastern Pretech (Malaysia) Sdn Bhd (184774-P) Head Office: 28 Jalan 7/108C, Taman Sungai Besi, 57100 Kuala Lumpur, Malaysia Tel: +603 7980 2728 Fax: +603 7980 5662 website: http:/iwww.epmsb.com.my Beranang Factory: Lot 2, Jalan Perusahaan 5, Kawasan Porindustrian Beranang, 43700 Beranang, Selangor Darul Ehsan, Malaysia, Tel: +603 8766 7941 Fax: +603 8766 0601 ‘Sungai Petani Factory: Plot 72, Bakar Arang Industrial Estate, (08000 Sungai Petani, Kedah Darul Aman, Malaysia. Tel: +604 420 0330 /3 Fax: +604 420 0332 Seelong Facto Lot 517, 518 & 546, Jalan Seelong, Mukim Senai, 81400 Daerah Kulai Jaya, Johor Darul Tak'zim, Malaysia Tel: +607 599 8063 Fax: +607 599 6069