HOLLOW

CORE
PLANKS
Design Manual 2023 Edition

This document contains

production guidelines for
Knife River Prestress product:
HOLLOW CORE PLANKS
 PRODUCT OVERVIEW
Table of Contents 1

2
LOAD TABLE

BENEFITS

3-4 TOLERANCES
Camber Design
Camber Accomodations

5-6 SUGGESTED SPECIFICATIONS

Materials & Fabrication
Work Included / Not Included

7-8 SECTIONS
KR 8” Section
KR 12” Section

9-11 HOLLOW CORE DETAILS

Hanger Guide
Penetration Guide
Suspending Guide

INSTALLATION
13 Steps 1-4

14 Steps 5-8

15 Steps 9-12

TYPICAL SECTIONS
Product
Overview
Product Overview 1

HOLLOW CORE
LOAD TABLE
Maximum Live Load (psf)

SPAN (FT) 8” COMPOSITE 8” NON-COMPOSITE 12” COMPOSITE 12” NON-COMPOSITE

18 370 270 460 385

20 325 245 400 310

22 285 220 355 295

24 255 195 315 265

26 230 175 285 235

28 205 160 250 200

30 190 145 230 195

32 160 130 210 185

34 140 110 195 165

36 115 100 175 150

38 90 80 160 140

40 70 65 150 130

42 50 50 135 120

44 30 40 125 110

46 35 115 105

48 25 105 95

50 95 90

NOTES: • Self weight of member is included in load table NOTE: For applications requiring close control of member
• Composite section requires a min. 2½“ topping = 32 psf camber and deflections between adjacent members and
• Strand pattens may vary other constructed elements, see additional discussion
• F’c = 7000 psi (at 28 days) on pgs. 3-4
• F’ci = 4000 psi (at release)
• Topping f’c = 3000 psi (at 28 days)
• Assuming full cross-section available

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Product Overview 2

BENEFITS

01 RAPID CONSTRUCTION
Reduced construction time results in significant
savings. An average of six to eight Hollow Core
planks can be set per hour.

02 ECONOMICAL CONSTRUCTION
Hollow Core is competitive with conventional
materials and methods. It alleviates the need to
combine multiple types of products to build a
floor or roof system.

03 MAINTENANCE FREE
Hollow Core is resistant to corrosion and deterioration.
It does not need to be painted, coated or covered to
protect it from interior or exterior elements.

04 EXCELLENT FIRE RESISTANCE

Untopped 8” Hollow Core plank has a fire
endurance of 11/2 hours. The addition of
toppings, undercoatings, fire resistive ceilings,
roof insulation, or core fill will increase the
heat transmission fire endurance.

05 LOW SOUND TRANSMISSION

The density and configuration of Hollow Core
combine to control both impact (foot steps) and
airborne (voice) transmissions. Reduced sound
transmission is further obtained by using proper
wall, floor, and ceiling finishes.

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Product Overview 3

TOLERANCES
For Hollow Core plank in
relation to camber

h= Variation from specified end squareness

or skew . . . . . . . . . . . . . . . . -/+ 1/2in

n= Applications requiring close control

of differential camber between adjacent
members of the same design should be
discussed in detail with the producer to
determine applicable tolerances

CAMBER DESIGN
Per PCI Manual for the Design of Hollow
Core Slabs and Walls (MNL-126-15E)

Camber is the upward deflection of a prestressed

concrete member and results from the
prestressing force being eccentric from the center
of gravity of the cross section.

Because both the prestressing force and the

eccentricity are established by the required design
loads and the span length, camber is a result of
the design rather than a design parameter.
Therefore, camber requirements should not
be specified.

Camber and deflections will change with time due

to creep, prestress loss, and other factors, the
sustained compression due to the prestressing will
cause camber growth.

Balancing this is the effect of creep on

deflections due to self-weight and other sustained
loads. It is this time-dependent movement, in
addition to instantaneous deflections, that must
be considered in the development of framing
schemes and detailing.

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Product Overview 4

TOLERANCES
(cont’d)

CAMBER ACCOMMODATIONS
Camber must be accommodated in several design
considerations, including but not limited to:

01 HOLLOW CORE SLABS THAT RUN PARALLEL TO

A STIFF VERTICAL ELEMENT (SUCH AS A WALL)

02 TOPPED HOLLOW CORE SLABS

03 HOLLOW CORE SLABS WITH PEAK

CAMBER LOCATION NEAR A DOOR SWING

04 FLOORS WITH MULTIPLE BAYS OF VARIED

LENGTH AND CHANGES IN SLAB DIRECTION

05 ROOFING DETAILS

In design scenarios where camber, camber growth, and

deflection will be a factor in relation to adjacent members,
the designer should take these items into consideration in
the project planning stages to control costs and minimize
issues at time of construction.

A typical approach to accomodating long-term camber

include adding the camber to the minimum required
topping thickness to determine floor to floor heights.

It is recommended that the designer consult with the

producer for estimations of expected camber as PCI
calculation procedures for determining long-term effects
will only allow for approximate estimates.

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Product Overview 5

SUGGESTED
SPECIFICATIONS

MATERIALS & FABRICATIONS CONSTRUCTION LOADS

Hollow Core planks shall be as manufactured by Knife Construction loads should never exceed 70% of
River Prestress. Materials used in the fabrication of the allowable superimposed loads. Stockpiling of
planks shall conform to the following: materials or use of manlifts, skidsteers, etc. on the
prestressed planks is prohibited unless approved
by Knife River Prestress.
01 All concrete material shall be clean and
properly graded. The resulting concrete NOTE: OSHA and other safety requirements must be
complied with when installing Hollow Core plank and
shall have minimum compressive strength other structural materials.
of 4000 psi at release of prestress force
and 7000 psi at 28 days. Test results shall
be made available upon prior request by
the architect showing concrete strengths
at 28 days.

02 Prestressing steel shall be uncoated,

7-wire, stress-relieved strand, conforming
to ASTM A416.

03 Portland cement shall conform to ASTM

C150, or blended cement conforming to
ASTM C595.

04 Concrete aggregates shall be in conformity

with ASTM C33.

05 No admixtures containing calcium chloride

shall be used.

06 Plank shall be the cross section shown

on the plans and prestressed to sustain
superimposed loads as indicated on the
drawings. In general, the design of all
planks shall conform to ACI 318,
except the top surface shall not be
intentionally roughened.

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Product Overview 6

SUGGESTED
SPECIFICATIONS
(cont’d)

WORK INCLUDED:

Furnishing and delivery of all precast planks. Engineering design and shop drawings.

Bearing pads, plank hangers, void dams and Openings larger than 6” in diameter as shown
dowels as specified on Knife River Prestress on structural drawings.
shop drawings as “SUPPLIED BY OP.”

WORK NOT INCLUDED:

Installation (quotes available upon request). Straps or threaded rods for hanging ceilings,
electrical and/or mechanical conduits, and other
Forming and shoring if required. suspended items.

Grouting of joints. Closure pours at locations where the plank does

not cover the entire floor area.
Topping reinforcing, topping pours and caulking
if required. Structural embeds cast into planks.

Openings 6” in diameter or less and openings

not shown on structural drawings.
 Product Overview 7

KNIFE RIVER 8” SECTION

SECTION 8” H.C. 8” COMPOSITE

AG (in2) 214 304

I (in2) 1676 3656

YB (in) 4 5.63

WT (psf) 99
60
@155 pcf

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

 Product Overview 8

KNIFE RIVER 12” SECTION

SECTION 12” H.C. 12” COMPOSITE

AG (in2) 299 389

I (in2) 5393 9345

YB (in) 6 7.73

WT (psf) 121
82
@155 pcf

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Product Overview 9

HOLLOW CORE
DETAILS

HANGER GUIDE: HOLLOWCORE HANGER

01 Hangers may be required for large

blockouts placed within the hollow
core span.

02 Hangers are used when blockouts

eliminate a full section width (4’-0”)
of the hollow core.

PLAN
03 Hangers can be placed near the end of
the span, or two hangers can be placed
within the span.

04 Consult with Knife River Prestress

engineers for more details and
load capacities.
SECTION
SECTION 1
1

SECTION 2
HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS
Product Overview 10

HOLLOW CORE
DETAILS
(cont’d)

PENETRATION GUIDE: PLAN

01 Blockouts larger than the voided

cells are cut at the plant to
accommodate penetrations.

02 Blockouts without the use of a hanger

should be a maximum width of 2’-0”
(cut out of a 4’-0” wide section).

03 Two planks with 2’-0” blockouts on each

edge can be placed side by side allowing
for an overall opening of 4’-0”.

04 The length of the blockout is variable.

For long blockouts it is best to keep
them near the ends of the span.

05 Blockouts 6” in diameter or less are cut

in the field. Field cut blockouts should
be through Knife River Prestress cells
only. The stem and strand area should
not be disturbed. Any field cut blockouts
should be verified with Knife River
Prestress engineers.

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Product Overview 11

HOLLOW CORE
DETAILS
(cont’d)

SUSPENDING GUIDE:

01 Straps or threaded rods can be used to

support suspended loads.

02 Straps fit into the hollow core joints as

often as required for the added load.

03 Threaded rods are drilled through the

voided cells with a flat plate on top of
the hollow core.

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Installation
Installation 13

01 Check Bearing Surfaces

Check to ensure that all bearing surfaces are straight and level. Make sure
that the actual building dimensions are the same as shown on the shop
drawings. Bearing pads supplied by Knife River should be used on concrete
bearing surfaces. Bearing pads are not required on flat steel bearing
surfaces or on non-bearing surfaces along the sides of the plank.

02 Install Planks
Install each plank in the same position as indicated on the shop drawing.
Lifting and handling should be done with strap slings capable of supporting
the plank weight plus appropriate safety margins. The lifting straps must be
placed at 2 feet or less from each plank end. Do not lift the plank near or at
the center or from any location other than 2 feet or less from each end.
Planks can be temporarily set on the ground but must be set on support
dunnage that is level and carefully placed within 2 feet or less from the end
of each plank. Do not support the plank near or at the center.

03 Set Planks in Position

The planks should be kept close together with tight joints. Standard width
planks are positioned at 4 feet on center. The preferred placing method is to
set the first three planks with just enough room between them to allow
removal of the lifting straps. Use a pry bar against the second plank to move
the first plank into the correct position. Follow the same procedure for the
second plank, prying against the third plank. Set the fourth plank and follow
the same procedure for the third plank. Continue this method until all planks
are set in their final location. The last plank may be temporarily set on a 2x4
along the outside edge and then moved into place with a pry bar (similar to
setting the other planks).

04 Load Beam Evenly

If a beam is the common support for two adjacent bays, load the beam
evenly on each side to avoid twisting the beam.

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Installation 14

05 Adjust Plank Elevations

Differential camber between planks may occur due to variables in the
casting process. If the bottom of the planks are exposed to view or the top
of the planks will not be covered with topping concrete, it may be desirable
to adjust plank elevations. There are numerous ways to level the plank but
it must be done prior to grouting the joints. Leveling methods may
include shimming, jacking and shoring, or installing a strong back assembly
on the top of the planks. Please contact Knife River Prestress for
leveling information.

06 Clean & Grout Joints

Key joints must be fully grouted prior to and separately from the topping
pour. The grout mix should consist of a 1:3 cement/sand ratio or a
prepackaged grout that will yield a minimum compressive strength of
3,000 psi. Plank joints should be clean and free from dust, dirt and oils
before placing the grout. When mixing grout, use only enough water to
enable placement of the material. Too much water will reduce grout
strength. Wet the joints prior to placing the grout. A square nose shovel
can be used to place the grout.

07 Proper Penetrations
Penetrations larger than the width of one voided cell should be cut by Knife
River during the manufacturing process. Holes smaller than the width of one
voided cell may be cut at the job site provided, the web or solid area of the
plank is not penetrated. Holes should be neatly cut or drilled. Using a
hammer to make an opening should be avoided. Knife River Prestress
should be consulted prior to cutting openings in the field that will penetrate
webs or sever prestressing strands. Please see the Penetration Guide in
this brochure (located on pg. 10).

08 Properly Using Openings

Large openings may be provided using steel hanger devices that bear on
full-length planks at either side of the opening. The full-length planks are
set first, leaving a slightly wider opening (than what is required on the
drawings) along the bearing ends, then the steel hangers are installed.
The short planks are then placed on the steel hangers and the nylon straps
are removed near the bearing ends, where the wider opening was left. Use
a pry bar to move planks into their final positions and close the open joints.
Knife River Prestress should be consulted before large openings are cut in
the field. Please see the Hanger Guide in this brochure (located on pg. 9).

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Installation 15

09 Ceiling Suspension
Wires, threaded rods or other mechanical devices can be used to
support suspended ceilings, electrical conduits, plumbing or mechanical
equipment. Power-actuated fasteners should be avoided. Care should
be used to drill only in the void area of a plank. Prestressing strand must
not be penetrated. Please see the Suspending Guide in this brochure
(located on pg. 11).

10 Place Topping Slabs

Cast-in-place concrete topping slabs are commonly used to provide a
finished floor surface. The top of the planks should be clean and free
of dirt, dust and oil before the topping concrete is placed. The plank surface
should be wetted just prior to pouring the topping. Reinforcement should be
chaired from the plank to position if within the topping slab.

11 Drain Water
Topping slab concrete should have a minimum compressive strength of
3,000 psi. Plank should be topped as soon as possible after the ends of the
plank are enclosed. Plank exposed to wet weather after the ends have been
enclosed may accumulate water in the voids. Water must be removed by
drilling small drain holes into the voids near the ends of the plank, prior to
finishing. Water that can seep into the cells that are enclosed may cause
freeze/thaw damage during freezing temperatures.

12 Grout & Cure Joints

Plank bottom surfaces that are exposed to view can be finished similarly
to drywall surfaces. Plank joints must be grouted and cured before
finishing work is done. Joints may be caulked or finished smooth using
drywall taping techniques. Surfaces should be clean and dry before
texturing or painting.

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Typical
Sections
Typical Sections 17

BACKER ROD
AND GROUT

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

Typical Sections 18

HOLLOW CORE PLANKS Design Manual KNIFE RIVER PRESTRESS

BUILDING THE
kniferiverprestress.com

NORTHWEST.

OREGON WASHINGTON

23505 Peoria Road 7721 N. Idaho Road

Harrisburg, OR 97446 Newman Lake, WA 99025
541-995-4100 509.536.3300