Filigree construction

Filigree construction
The Filigree method is a process for construction of concrete decks that successfully
integrates “factory precast” and field-construction technologies. This is accomplished by
constructing such decks from two interconnected concrete placements, one made in a factory,
and the other done in the field.
The Filigree Wideslab Method of Construction is based on the concept of using left-in-place
precast concrete forms which become an integral part of the concrete frame. Inservice, structures
utilizing Filigree Wideslabs perform the same as poured-in-place concrete structures. This concept of
construction is identified by ACI 318-95 as Composite Concrete Flexural Construction
The Filigree method is a process for construction of concrete decks that successfully integrates
“factory precast” and field-construction technologies.
This is accomplished by constructing such decks from two interconnected concrete placements,
 one made in a factory,and other in the field.
The Filigree Wide slab method has a 40 year success record as an efficient and economic
construction process that results in safe and lasting structures.
Filigree construction and design is in full compliance with the former BOCA and current ACI and
ICC building codes.

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 The method was developed during the late 1960s by Harry H. Wise as a more efficient and
economic construction process than conventional cast-in-place technologies
The process begins by manufacturing thin precast concrete panels, typically 2.25" thick, with the
deck's bottom reinforcement included. The panels are then shipped to a job site and erected on
temporary shoring. Subsequently, the deck's top reinforcing steel is placed on top of the precast
panels at the site, and concrete is poured over the entire assembly to achieve the final thickness
of the deck.
This process effectively accelerates the construction of structures by eliminating the need for
costly and time-consuming field forming, and the placing of bottom
reinforcement. Polystyrene blocks are often incorporated into the panels during their
manufacture in order to create voids, reducing both the quantity and cost of concrete added in the
field, and the overall weight of the structure, which further reduces the costs of columns and
foundations.
The soffits of the panels have a smooth uniform finish as a result of casting them in polished
steel molds.
This reduces the labor cost and time typically required to grind and patch the soffits of cast-in-
place concrete decks to achieve an acceptable aesthetic finish.
The method of deck construction can be applied anywhere conventionally poured-in-place
concrete is specified, such as
 flat plate,
 beam and
 slab, and
 wall-bearing structures.

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filigree is a 2 ¾” x 3” thick precast concrete form, reinforced with lightweight truss, prestressed
strand and bottom steel
. - these elements are combined in the field with the balance of top reinforcement and secondaray
concrete topping.
- this method of construction results in a composite slab in which both layers act together as a
monolithic unit.
- filigree is engineered for elevated floor and roof decks in low, medium and high-rise building.
- filigree can be used in wall bearing, column and beam, tilt-up and flat plate construction.

ADVANTAGES OF FILIGREE CONSTRUCTION

Filigree is Economical:
Efficient use of the Filigree method reduces cost of concrete structures.

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Filigree Reduces Labor:
The prefabrication technology in Filigree reduces the need for field skilled and unskilled trades.
Although all trades are represented, fewer are needed for each task with a reduction in payroll
needs and enhanced cash flow.
Filigree Saves Time:
Filigree structures go up fast. High production rates of up to 50,000 sqft. per 5 day week can be
achieved.
Filigree Eliminates Field Forming and Reduces Shoring Requirements.
Filigree is Easy to Use:
All Work is done in a traditional manner, familiar to all trades.
Filigree Reduces the Volatility and Uncertainty of Construction Cost:
Filigree method of construction is less dependent on field labor and field labor productivity. It
will substantially reduce the overall labor/material cost ratio.
Filigree Quality is Superior:
The final product is a combination of the most desirable properties inherent to poured in place
and precast, pre-stressed construction, In addition, Filigree Wideslabs® are cast in polished steel
molds, and will greatly enhance the appearance of any concrete structure.
Filigree Resists Sound Transmission:
Certified reports confirm that Filigree can meet the strictest requirements of sound resistance for
residential and institutional use.
Filigree Structures are Fire-Rated:
The system has fire resistance ratings up to 4 hours established through a full scale fire resistance
test at the Underwriter Laboratories.
Filigree is Environmentally Friendly:
Many trees are saved by the elimination of wood and plywood framing.
Filigree design complies with current ACI and IBC Building Codes.
The Filigree Composite Concrete Deck System has been Fire Tested and Rated by
Underwriters Laboratories (UL):
The Filigree Wideslab System fire resistance testing confirmed it’s capability to sustain an over-
four hour fire test, maintaining it’s full integrity and load capability, without any signs of
delamination.
Cost-Saving, Timely, and Light
filigree is the only prestressed building system used in such a diverse range of concrete and steel building
applications
 the filligree system is extremely versatile, satisfying many of the demanding architectural and
structural requirements without compromising the conceptual design.
 voided filigree slabs lower shell cost by reducing the concrete pour by as much as 65%, consequently
reducing foundation requirements
 . combining both prestressed and bottom steel in the filigree slab reduces top steel reinforcement by
as much as 50% over conventionally poured decks.

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 tie-beams, bond-beam or u-blocks are not required with the filigree system.
 with a 95% reduction of field formwork and the use of recycled content during manufacturing, the
filigree system is an environmentally conscious building system, promoting green building.
 manufacturing and jobsite waste are minimal and can be eliminated during construction.
 the dense, smooth factory produced surface provides a ceilling ready for finishing. joints maybe
finished with a low-cost non-shrink joint compound if desired. a variety of ceiling finishes can be
applied directly to the filigree slab.
Design features for Filigree Wide slabs include the use of high tension steel for the bottom
reinforcing assembly of the finished deck, and the application of factory-installed polystyrene
foam voids.High tension steel in the form of 3/8 -inch- (9.5 mm) diame-ter, seven wire strand is
substituted for mild reinforcing steel in accordance with the ACI Code criteria for strain
compatibility prepossessed concrete formula 18-3.
 Steel shall be 270 Ksi or 250 Ksi complying with ASTM A416.“Voids,” hollow areas
within the concrete slab, are con-strutted from 1 lb/ft 3 or less density polystyrene foam.
 These voids are factory installed and shall only be locate din areas of the structural
elements where concrete can be eliminated without substantial reduction of performance
as determined by the registered design professional response-bel for the design of the structural
element.Filigree Wide slabs are semi-finished precast concrete panels designed to be used
as a left-in-place concrete form.
 They are made approximately 21/4 -inches- (57.2 mm)thick by up to 8 feet (2.44 m) wide and
up to 70 feet (21.3m) long.
 These panels are reinforced with longitudinally placed shallow steel joists.
 The joists have their bottom chords cast into the panels and the remainder protrudes
above the top face.
 Wide slabs are reinforced with mild steel or prestressed.
 Minimum concrete cover for principle reinforcing is 3\4 -inch (19 mm) for rebar and
15/16 -inch (23.8mm) for strand.
 The minimum 28-day strength of concrete used in Filigree Wideslabs is 4,000 psi (27.6
MPa).Steel bar joists, which are referred to as Filigree trusses,are primarily used as mechanical anchors
to enhance design shear transfer through the contact faces of the two concrete placements.
 These joists consist of two resistant-welded bottom chord wires, one top chord wire and a laced web
wire.The smallest wire used is 6 mm in diameter.
 The two bottom wires anchor the web within the Filigree Wideslaband contribute to the bottom
reinforcing of the deck; the top chord anchors the web wire to the poured-in-place portionof the deck; the
web wire penetrates contact face approx-mately every 5 inches (127 mm) on center.
 The joists varyin height from 21/2 inches (63.5 mm) to 71/2 inches (190.5mm).
 Spacing of joists is governed by the structural or fire-resistance requirements of the finished decks
Filigree construction is used for one-way as well as two-way decks and flat plates. The decks are
reinforced withmild steel or prestressed cables and designed as continu-ous or simply supported
spans. Wideslabs customarilyprovide the positive moment assembly for the entire deck.The
minimum depth of a solid deck is 4 inches (101.6 mm)and a voided deck is 5 inches (127 mm)

How Filigree Wideslab Works for Philly

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 Filigree, fabricated by Mid-States Filigree, is a per-fabricated thin prestressed concrete slab used
in conjunction with field cast concrete for a finished concrete slab. The method gained popularity
in the 1980s when many Atlantic City casino towers were looking for a way to build cost
efficiently and quickly.
The Filigree system saves on form work because the factory-made precast shell is the project’s
formwork. These precast shells are made using a smooth metal formed system in eight-foot wide
planks. The system incorporates styrofoam voids that are set in the shell. This helps lighten the
slab in its final form. The smooth surface is a major benefit to the Filigree system and the joints
can either be exposed or covered up- depending on the needs of the project. Overall, the precast
shells reduce forming requirements thus potentially saving labor in the field, which is key for the
Philadelphia construction market.
The Harman Group also utilized the J Filigree system for the St. Barnabas Medical Center in
Livingston, New Jersey. The 240,000-square foot west wing addition to the Cooperman Family
Pavilion added an outpatient surgery suite, private inpatient bed units, an expansion to the
current NICU unit, a new central administration area, a public atrium, and associated campus
upgrades. The new west wing of the hospital was constructed with a thin concrete filigree and
drop beam structural system, which allowed for a slim structural depth. This is a departure from
traditional methods used in hospital construction, which often call for a more traditional
structural system like composite steel and slab on metal deck. The Filigree method was chosen in
order to match the existing hospital floor elevations with a thin structural system yet maintaining
a long span between columns.
St. Barnabas Medical Center also added a four-level, open, precast parking structure with 400
spaces as part of the project.
As the building boom continues in Philadelphia and the surrounding area, The Filigree method
continues to be selected for a light, thin, cost effective structural system.

SYSTEM QUALITY
- our engineering and drafting staff use the latest autocad technology, combined with quality
control oversight to ensure superior product quality, maintaining strict construction tolerances.
- the deck itself is more uniform and of higher quality because a large portion of it is produced
under controlled conditions by crews working in an offsite facility away from the interference of
other trades.
- there is no differential camber between the filigree units as there is in other systems,
eliminating the need for floating and grinding between precast units. the final product is a
combination of the most desirable properties inherent to poured-in-place and precast
construction. - the design provides a stronger structure because the decks, wall cells, columns
and beam are poured together producing a monolithic structure. - fabrication in casting beds
greatly enhances the appearance of the finished concrete slabs reducing the amount of finish
work required in the field. - erection of filigree will comply with standards and best practices for
precast concrete installation. resources and capabilities - engineering & design – engineering,
drafting and cad division provide value engineering recommendations to maximize filigree’s cost
saving benefits. - manufacturing – 4 acres manufacturing facility which is geographically

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positioned to serve the florida market. production rates up to 1000 square foot per day. -
instalation – trucking and installation divisions are dejdicated to meet scheduling demands by
controlling logistics. typical installation rates of 10,000 – 12,000 square feet per day. residential
applications commercial applications condominums / apartments parking garages townhomes
office buildings single family homes institutional muiti-family units hospitality mixed-used retail
/ warehouse / storage

Filigree Slabs
Filigree Slabs are prestressed concrete elements that have a constant cross section. They are
manufactured using high tensile strength prestressed strands or single wire which are
embedded within the element.

The production of these elements is achieved using our Slip former or Wet Casting machines
that cast an element continuously on a long production bed without the need of any form
works.

Filigree Slabs are used as covering elements in residential and social construction. A floor is
usually made of lattice slabs with hollow blocks (concrete or clay) or polystyrene in-fills. The
in-fill blocks can be mounted in 2 steps.

The in-fills keep the weight of the floor to a minimum and are then covered with in-situ
concrete to form the ribs and the floor slab.

As well as the prestressed wire reinforcement the ribbed slabs have steel mesh embedded in the
lower part to further increase the element strength. To ensure adequate fire resistance the slab
can be manufactured with a different thickness of the lower part to give a greater concrete
covering of the steel reinforcement.

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FILIGREE CONTRUCTION IN CONTEMPORARY HIGH-RISE
BUILDINGS

Looking through the skyscrapers evolution -from the use of load bearing beams and columns
combined with perimetrical load bearing walls, to the replacement of the load bearing structure
with a central core (containing all vertical systems of elevators and stairs) and to the use of
building envelope as a superstructure, able to contrast wind and earthquakes actions- is it
possible to understand the relationship between architectural and structural form.
The first “skyscrapers” had the shape of Renaissance palace, just a little higher than those
ones. When the iron (or reinforced concrete) load bearing structure was also used for the first
time on façades, by eliminating the load bearing masonry, the relationship between
architectural and structural form began to be more legible, even if it was often camouflaged by
using decorative elements made of, e.g. terracotta. This use of iron or reinforced concrete
filigree construction contributed to define the aesthetic of the first high-rise buildings even if
their shape was still strictly related to a prism. But now, instead of the Renaissance palace, the
architects took inspiration from the bell towers of the historical European cities, such as the San

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Marco's bell tower in Venice (MetLife Tower, New York, by N. Le Brun, 1909). Moreover the
articulation of the inner space became more flexible and useful for the exploitation of the floors.
When the use of reinforced concrete structure was replaced by the use of a reinforced
concrete core, able to support overhanging floors or beams connected to suspended columns on
façades, the shape of high-rise buildings became more complex and their height started growing
up. This last configuration, with a "double core", allowed to have much more resistant schemes
that notably increased the buildings height by defining, simultaneously, their shape. Today, the
building envelope contributes to improve the resistance to wind and earthquake actions;
computer fluid dynamics analysis allow to understand its behavior under these actions and to
better design the building shape.
The use of filigree slab offers great advantages in the construction of mezzanines, slabs or roofs
means. It allows to work with many design variants (arches, elements in wedge or of various
formats, hollows, integration of beams and brackets, etc.), and it has an extremely simple system.
Produced in precast plants, it is the lower part of the slab, and it allows a cheaper forge of the
slabs than the one built in traditional way.
The installation of the filigree slab is very fast, because no formwork is needed thanks to the fact
that the predalle acts as a lost formwork. Also, these elements are light, so no heavy lifting
systems are required, and they allow, also, to cover large surfaces at one time.
Reinforcements and metal meshes are reduced to a minimum quantity, and the result is a
monolithic, solid slab, more resistant than built and cast on site to equivalent steel sections, and
with a high resistance to fire and excellent behaviour against the noise.
Moldtech manufactures and supplies fixed tables with or without prestressing capacity to enable
prefabricators to deal with all types of projects based on slabs. In addition, as with the other
products we offer, our technical team is responsible for the necessary electrical pre-installation,
as well as for the installation of additional elements such as vibration and heating systems for a
better finish and an acceleration of the hardening of the concrete.
Also, we handle the transport and full installation of the machinery, and we offer our clients the
certification of the production processes, together with our support and technical monitoring,
which provide the maximum guarantees.
The tower superstructure of Burj Dubai is designed as an all reinforced concrete building
with high performance concrete from the foundation level to level 156, and is topped with a
structural steel braced frame from level 156 to the pinnacle…” (Abdelrazaq et al. 2008).
In this building, structure and architecture are strictly related to satisfy man's ancient desire
to reach to the sky (see the ziggurats in Mesopotamia, the Egyptian or Mayan pyramids, the
Chinese pagodas, the Moslem minarets and so on).

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 Fig. Burj Khali

FILIGREE SLABS — Half slabs

Filigree slab is an industrially pre-fabricated element which consists of a smooth concrete slab with
integrated lattice girders as reinforcement and cross reinforcement. The load-bearing longitudinal
reinforcement is installed in the slab element at the factory.

Once the elements have been laid on site, any additional reinforcement layers have been integrated and the
concrete has hardened on site, a monolithic floor system is created.

The Filigree slabs is a modern solution most often used in multi-family, office and public buildings, and is
also gaining considerable popularity in single-family construction. It is a variety of composite ceiling
(combining various materials which, when joined together, form one of the more durable parts of the
building).

The main feature of the filigree is the wide range of construction possibilities and large spans. This allows
innovative and modern projects to be shaped freely. The ceiling is quickly assembled using a crane. It can
be laid on the whole surface or on a selected part.

Maximum production width 3.3m and length 10.5m.

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The product features, as well as the rapid assembly of these large-area elements, eliminate costly
formwork elements and allow for a significant reduction in construction time, thus shortening the work on
site related to reinforcement assembly and formwork work.

The main advantages of using these elements are the economy of the system, aesthetic effect and
increased safety on the construction site.

These elements are designed and manufactured in accordance with the specific design requirements and
are particularly suitable for heavy duty ceilings. Planning and highly automated production takes place
according to strict quality criteria.

Since the production of floor elements is not linked to a modular system, it is possible to use many
different geometric and architectural forms and correspondingly different areas of application:

 Service buildings
 Residential buildings
 Hotel buildings
 Agricultural buildings
 Cellars and underground garages

Prestressed Filigree Slab vs Hollowcore

As far as precast/prestressed spanning elements go, hollowcore is the dominant product in the
building industry and has enjoyed significant market growth in North America since the 1970s.
Compared to other spanning systems hollowcore offers numerous benefits such as:

 Economical span/depth ratio

 Rapid speed of construction
 High quality manufactured production
 Superior thermal and acoustic properties

However, as designs have started to push the envelope as far as the use of hollowcore, the
product has evolved away from the commodity status of years past, in favor of a more
customized designs. Producers are spending large sums on labor to make cutouts, notches and to
install special inserts, core fills etc during production in the plant which can be tedious given the
nature of the production methods used.

However, there is another alternative that could offer a higher level of flexibility: the filigree
slab.

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Filigree slabs are also known as lattice girder slabs due to the special lattice girder reinforcement
which serves as support during handling and also as a composite tie between the topping and the
main slab.

 They are supplied to the site ‘un-topped’ but serve as an immediate working surface, just
like hollowcore.

 They can be prestressed or not, depending on the requirements, and can be supplied with
foam or block infills to create the voids in the slab. the main advantage of filigree slabs
is the fact that their structure is ‘open’ during construction to allow for the passage of
services, special connections and other integrated work which is best suited to the field.

Another major advantage is the weight of the system at the time of erection, as half slabs can be up to 40%
lighter than hollowcore at that point. Further, the widths of half slabs are flexible, and can be in width ranges
typically up to 8’ (2.4m) or even larger, similar to double tees. This means that more square feet can be placed
per ton lifted compared to hollowcore, and the number of visible joints in the soffit can be reduced compared
to standard 4’ wide hollowcore plank.

FURTHER ADVANTAGES ARE:

 Monolithic connections allow for two-way spanning

 Highly flexible shear capacity
 Strong seismic and diaphragm action
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  Very easy to create openings

Unlike hollowcore however, filigree slabs require support during erection and for a period after the
topping is cast to support against deflection as the moment of inertia of the system is low until composite
action is achieved; which can be viewed as a logistical and economical drawback of the system.

Technical information:
 workshop design of the ceiling as an element of the „inBetPref” system
 designing the shapes and dimensions of the ceiling tailored to customers’ needs
 welded mesh for overconcrete reinforcement cut according to the design
 thickness of the filigree slab from 5 cm to 7 cm
 weight of the prefabricated element from 125 to 150 kg / m 2 of the slab
 max. filigree slab dimensions 2.5 m x 12.0 m
 slab’s chamfering 83°/83° or 90°/90°
 deliveries up to 175 m2 on a transport trailer

REFERENCES

Abdelrazaq, A. Kyung Jun Kim, S. E. & Ho Kim, J. 2008. Brief on the construction planning of the Burj
Dubai project, Dubai, UAE. Tall and Green: Typology for a Sustainable Urban Future. CTBUH 8th
Walraven, J.C. 2009. “High Performance Fiber Reinforced Concrete: Progress in Knowledge and
Design Codes.” Materials and Structures/Materiaux et Constructions 42 (9): 1247–60.
Redaelli, D., Muttoni, A. 2007. “Tensile Behaviour of Reinforced Ultra-High Performance Fiber
Reinforced Concrete Elements.” Concrete Structures - Stimulators of Development, Proceedings
of the Fib Symposium Dubrovnik 2007, 267–74.
Zerbino, R., Tobes, J.M., et al., 2012. “On the Orientation of Fibres in Structural Members
Fabricated with Self Compacting Fibre Reinforced Concrete.” Cement and Concrete Composites
34 (2): 191–200.
Berger, H. 2007. From Pre-historic Stickdomes to State-of-the-art Gridshells. STRUCTURE
magazine:
https://www.wikipedia.org/

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