Hollow Core Concrete Pty Ltd

[Melvina Kryder]

Ahollow core slab, also known as a voided slab, hollow core plank or simply a concrete plank is a precast slab of prestressed concrete typically used in the construction of floors in multi-story apartment buildings. The slab has been especially popular in countries where the emphasis of home construction has been on precast concrete, including Northern Europe and former socialist countries of Eastern Europe. Precast concrete popularity is linked with low-seismic zones and more economical constructions because of fast building assembly, lower self weight (less material), etc.

Slabs in prestressed concrete are usually produced in lengths of up to 200 meters. The process involves extruding wet concrete along with the prestressed steel wire rope from a moving mold. The continuous slab is then cut to required lengths by a large diamond circular saw. Factory production provides the obvious advantages of reduced time, labor and training.

Another fabrication system produces hollow-core floor slabs in reinforced concrete (not prestressed). These are made on carousel production lines, directly to exact length, and as a stock product. However, the length is limited to about 7-8 meters. Especially in Belgium, this method is widely used in private housing.

To meet modern standards (both hollow-core and massive slab) of soundproofing the floor needs to be covered with a soft floor covering that is able to dampen the sound of footsteps or a floating floor screed should be installed. An alternative is to put a strip of rubber underneath the floor slabs.

Hollow-core slabs and wall elements without prestressed steel wire can be formed by extruders. The size of these elements will typically range in width from 600 to 2400 mm, in thickness from 150 to 500 mm, and can be delivered in lengths of up to 24 m.[1]

Not familiar with that kind of repair, but I would be concerned about ongoing corrosion of the existing reinforcement. If that could be prevented , then the idea of providing a steel structure below seems to be a reasonable approach. If the steel structure extends down to the ground, the foundation must be prevented from heaving due to expanding soil or frost.

It might be well for Ron to chime in here too as he has more experience being in Florida, but from what I have experienced, once rust starts in reinforcing steel, it is just a matter of time before the member fails, regardless of any corrective measure taken to control the rust.

would love to hear about an update. I have a similar problem with my 10 inch hollow core precast concrete with eight strand or 1 inch rebar I have material loss underneath and slightly above the rebar and one 6 inch section and the flanges came apart as you could see on the underside. I would love to know if this could be repaired and how?

The concrete hollow core slabs have between four and six longitudinal cores running through them, the primary purpose of the cores being to decrease the weight, and material within the floor, yet maintain maximal strength.

We have served an array of prestigious clients and assisted them in achieving quality outcomes which are both economic and reliable. The aim of our company is to provide cost effective structural designs and industry leading products which are of the highest standard.

With the assistance of our own specialist in-house design team, we provide clients and their project consultants with design and feasibility solutions which utilise Hollow Core's precast components. From the initial concept to the final design, this cooperative approach to construction reduces costs, improves quality and results in an efficient use of resources. By combining our renowned expertise with the use of precast products, Hollow Core deliver a total precast structural solution that meets specific construction needs.

State-of-the-art European technology is employed in the manufacture of Hollow Core's range of prestressed and precast concrete products. It has proven to be the most cost effective, safe and efficient method of construction. Our structural system offers distinct advantages in the construction of a wide variety of projects.

This Design Guide is intended to fill this knowledge gap by providing a detailed review of this subject and thereby promoting a greater awareness and understanding of how precast concrete buildings are constructed. It will concentrate on discussing the concepts of precast concrete buildings but will refer to referenced documents for the detailed design. It has been written particularly for those already familiar with this form of construction but do not have the detailed knowledge of the detailing required to plan and design a complete precast concrete building.

Boccella is a major manufacturer of high-quality PCI certified hollow core precast concrete slabs, proudly serving the Mid-Atlantic region since our founding in 1968. Our years of experience and highly engineered solutions allow for some of the most complete, ready to install plank solutions on the market. Our business is continually expanding across the eastern U.S. in New York, New Jersey, Pennsylvania, Maryland, Rhode Island, Delaware, Virginia, Vermont, New Hampshire, Connecticut, Massachusetts, and Maine.

With over 50 years of industry wide experience, our 60-acre production facility can meet the needs of any project, no matter the square footage. One plank or one thousand, we are your go-to source for hollow core precast concrete slabs.

In the past, safely tying off when working with precast concrete hasbeen challenging - until now. The Guardian Fall Protection"Hollow CorePrecast Concrete Anchor" allows for a single user to tie off safely witha reusable anchor. Toggle action makes the product quick and easy touse. Durable components hold up under harsh environments and meets 5,000pound load requirements. This product can be used in an 8 inchhollowcore or larger and as a range of 1.5 to 3.5 inches of concretethickness. The anchor is composed of aluminum and stainless steelcomponents and tested to meet ANSI Z359.1. The bolts in this productrequire a 1 inch impact drill bit to install and holes must be kept atleast 1 foot away from the edge or corner of the applied concretestructure.

Why use hollow core slabs? These pre-stressed floor slabs with either round or shaped voids are one of the most popular, efficient and long span floor construction components that exist today. Due to long spans, less load-bearing structures such as columns and inner walls are needed. This results in increased architectural and structural freedom and less raw materials used in a building. Continue reading to discover how to benefit from using precast hollow-core slabs.

One fascinating perspective to hollow core slabs is not often discussed. The slabs are made of two materials, the properties of which are taken almost to the extreme. Firstly, concrete: general wet cast concrete strength is C20 / 25, while hollow-core concrete strength is C40 / 50-C50 / 60. That is, more than twice as strong. Of course, special concrete with strength of 100-200 MPa, has been produced for specific purposes but now we are talking about basic construction.

However, hollow core slabs are not always used as horizontal structures. They can also be installed vertically as outer walls, dividing walls and noise barriers. This is enabled by the long spans and durable structure. Hence, they are especially beneficial for industrial buildings, where a high unified space is needed. On the other hand, the slabs are highly resistant to changing weather conditions and have efficient noise reduction, which makes them ideal noise barriers.

Not only do hollow core slabs enable construction of versatile buildings, they increase the usable floor area. How? The span of a hollow-core slab can be even up to 20 m without intermediate supports, which results in spacious rooms with less partition walls.

Think about it: if long-span hollow-core slabs are utilized for the floor of residential buildings, non-load-bearing partition walls can be placed inside of the flats. This gives freedom to the architects, because the floor layout can be easily modified. To enable this, the structure of the building should be designed so that the slabs are longer than the rooms or even apartments. Likewise, in commercial and public buildings, long-span hollow-core slabs enable less inner supporting structures, e.g. pillars, which can be rather annoying, for example, in parking halls. Thus, architects and structural designers have more freedom in designing well-functioning and visibly appealing spaces.

Moreover, the decreased need for load-bearing partition walls and columns results in lighter structures. Therefore, the weight of the whole building is reduced, which results in smaller and more affordable foundations. This is especially beneficial when designing and constructing buildings in seismic areas, because earthquake forces are proportional to the weight of the structure.

Hollow core slabs, or plank, are precast prestressed concrete components typically used as structural floor or roof deck systems in single and multi-story buildings. To reduce weight and provide a more efficient product, the planks are cast with continuous voids that run the length of the panel. Prestressing the slabs creates an exceptionally strong structural component that can be used to span areas up to 45 feet in length.

I was able to model a hollow core plank roof but in section the concrete hatch is total so it looks like the planks are solid grouted....which they're not. How can I limit the concrete hatch to the planks and leave out the voids?

Are you taking a longitudinal section? Are you sure the section marker cut plane is intersecting/bisecting the hole? Maybe it's cutting through the solid portion of the plank - or maybe you are just misreading what you are seeing. If the Projection and Cut Pattern of the Material are different, then maybe changing your view scale will help you differentiate the two Patterns in the View.

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