HOLLOW CORE SLAB

SEMINAR REPORT

Submitted in partial fulfillment of the requirements

for the award of the Diploma in Civil Engineering
under the Board of Technical Education Govt. of Kerala

Submitted by
JITHIN JOSE
SEMESTER V
Diploma in Civil Engineering

Guided by
Mr. ARUNKUMAR K K
HOD, CE Department

DEPARTMENT OF CIVIL ENGINEERING

SCMS COLLEGE OF POLYTECHNICS

VAIKKARA
 BONAFIDE CERTIFICATE

DEPARTMENT OF CIVIL ENGINEERING

SCMS COLLEGE OF POLYTECHNICS

VAIKKARA

CERTIFICATE

This is to certify that this seminar report entitled “HOLLOW CORE SLAB” is a bonafide
record of the work done by JITHIN JOSE, under our guidance towards partial fulfillment of
the requirements for the award of Diploma in Civil Engineering, under the Board of Technical
Education, Govt.of Kerala during the year 2024-25.

Mr. ARUNKUMAR K.K Mr. ARUNKUMAR K.K

Guide Head of Department
Department of Civil Engineering Department of Civil Engineering

Internal Examiner External Examiner

 ABSTRACT

A hollow core concrete slab is a voided slab having continuous number of hollow cores in the slabs
both concentric and eccentric to the axis of slabs. The present study aims to give the overview on the
behavior of hollow core concrete slabs under certain loading conditions.

Geometric nonlinear analyses are performed based on experimental tests. The steel-concrete
composite beams with hollow core slabs with concrete topping are simply supported and subjected to
two points loads symmetrically spaced.

Utilizations of favorable diurnal temperature difference and ground thermal source for air conditioning
are among these low energy technologies. Utilization of the hollow cores in the prefabricated slab for
ventilation and the mass of the hollow core slab for thermal storage is widely used in building systems
in Europe by exploiting the low energy source of the ambient air. These hollow core slabs aim at
enlarging the heat transfer surface between the slab mass and the air in the core, which permits
substantial heat flows even for relatively small temperature differences. This, in turn, allows the use
of low energy cooling or heating sources, such as the ground, outside air or recovered process heat.

Simplified thermal network models are simple and easy to be developed, the parameters of these
thermal network models were determined manually based on the geometry description of the slab
which may deteriorate the modeling accuracy. Simulation-based performance evaluations and in situ
measurements show that significant energy and operation cost could be saved, the peak cooling load
or heat load can also be reduced significantly when conventional air conditioning systems are used as
supplements.

Finally, this review shows that more works on the active slab are worthwhile for further promoting
these hollow core slabs to be used in low energy architecture for improving energy efficiency and
occupant thermal comfort wherever the climate is appropriate.

The resistance of steel-concrete composite beams with precast hollow core slabs may vary depending
on the transverse reinforcement rate and interaction degree. Ductile behavior was observed for all
situations, considering partial interaction.

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 ACKNOWLEDGEMENT

First of all, I would like to thank, the God Almighty for divine grace bestowed onme to complete
my seminar success fully on time.

I am grateful to Dr. Indu Nair, Director, SCMS College of Polytechnics Vaikkara,

Perumbavoor for providing the facilities for the completion of my task.

I express profound gratitude to Prof. Baby P.P, Principal, SCMS College of Polytechnics
Vaikkara, Perumbavoor for his support and motivation.

I am deeply indebted and gratefully acknowledge the constant support and valuable patronage
of my seminar guide Mr. Arunkumar K. K, Head of the Civil Engineering Department.

I thank all the faculty members of Department of Civil Engineering for all the help extended
to me and for motivating me. I, on this occasion, remember the valuable support and prayers
offered by my family members and friends which were indispensable for the success full
completion of this seminar.

JITHIN JOSE

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 TABLE OF CONTENTS

SL NO DESCRIPTION PAGE NO

1
ABSTRACT i.
2
ACKNOWLEDGEMENT ii.
3
TABLE OF CONTENTS iii.-iv
4
TABLE OF FIGURES v

CHAPTER 1
5 1-3
INTRODUCTION
1.1 INTRODUCTION
1.2 DEFINITION OF HOLLOW CORE SLABS
1.3 DEFORMATION
1.4 OBJECTIVE OF HOLLOW CORE SLABS
1.5 USES AND NEED OF HOLLOW CORE SLAB

CHAPTER 2
6 4-5
CHARACTERSTICS OF HCS
2.1 SYSTEMS
2.2 SHEAR COMPACTION
2.3 SPECIFIC CHARACTERISTICS OF HOLLOW CORE
SLABS
2.4 HISTORICAL DEVELOPMENTS OF HOLLOW CORE
SLABS

7 CHAPTER 3 6
PROCESS OF DESIGNING AND
IMPLEMENTATION IN HCS
3.1THE PROCESS OF DESIGNING AND
IMPLEMENTATION IN HOLLOW CORE SLABS
CHAPTER 4
8 EXPERIMENTAL WORK 7 - 10
4.1 GENERAL
4.2 MATERIAL AND THEIR CHARACTERISTICS
4.3 EXPERIMENTAL METHOD
4.4 MACHINES AND EQUIPMENTS
CHAPTER 5
9 EXPERIMENTAL RESULTS 11 - 12
5.1 COMPRESSION AND BENDING TEST
5.2 FAILURE MODES
5.3PROPOSED SHEAR STRENGTH FORMULA FOR
HOLLOW-CORE SLABS WITH STEEL FIBERS

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 CHAPTER 6
10 MANUFACTURE AND TRANSPORTATION 13 - 15
6.1MANUFACTURE, TRANSPORTATION AND
ERECTION PROCEDURE
CHAPTER 7 16
11 PRINCIPLES OF HOLLOW CORE SLABS
CHAPTER 8 17
12
ADVANTAGES AND DISADVANTAGES
8.1 ADVANTAGES OF HOLLOW CORE SLAB
8.2 DISADVANTAGES OF PRECAST PRESTRESSED
HOLLOW CORE SLAB
13 CONCLUSION
18
14 REFERENCE 19

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 TABLE OF FIGURES

FIG NO DESCRIPTION PAGE NO

1.1 Hollow Core Slab 1

1.2 Precast HCS 1

1.3 Hollow Core Slabs Models 2

1.4 Typical Precast Hollow Core Slab 3

2.1 Basic Core Unit and Application 5

2.2 Vacant Shapes to Form Hollow Core Slabs units 5

4.1 Geometry of PPHC Control slab 8

4.2 Typical plan for specimens S4G2L, and S4G4L 8

strengthened by four strips
4.3 Typical plan for specimens S2G4L, strengthened by 8
two strips
4.4 Typical plan for specimens S4ST2, and S4ST3 9
strengthened by four strips
4.5 Test setup and instrumentations 9

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CHAPTER 1
INTRODUCTION
1.1 Introduction
Precast, prestressed hollow-core slabs are usually used as part of a simple span system. However,
in a multi span floor slab system, designing for continuity over supports leads to increased span
capacity, improved structural integrity and savings in materials.

1.2 Definition of Hollow core slabs

The HCS are efficient. The hollow core slabs are made using dry casting or extrusion molding
systems where the concrete is required very low through a machine. The concrete is compressed
around the cores formed with role or pipes. The slab with continuous holes is being as heating/cooling
ducts and as channels for electrical wiring. Hollow core slabs minimize the transmission of sound and
vibrations between building floors and eliminate floor squeals.

The precast – prestressed HCS are usually used in covering structures with large spans, such as
hospitals, office buildings, schools, industrial buildings, shopping areas, etc.

Fig1.1: Hollow core slab

1.3 Deformation
The precast HCS has longitudinal voids extending the full slab length which makes the slab lighter
than a considerable solid slab of equal depth or strength. The lower weight is very important issue
because it reduced the costs of transportation and construction costs. Usual precast hollow core
concrete slabs are shown in Figure-1.2

Fig1.2: Precast HCS

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The precast concrete slab has the same voids with full length of the slab, commonly with a diameter
equal to the 0.67–0.75 thickness of the slab. This makes the slab lighter than a solid concrete slab with
the same thickness. The reduced weight is important, because it decreases the costs of transportation
and concrete costs. In addition, they are economical, sound insulation properties, have good fire
resistance, and are capable of long span distances with relatively small depths.

1.3.1. Properties of Hollow core slab members

Floors and roofs in concrete buildings are often made of prefabricated, hollow core members. These
systems are quick to set up and are cost competitive. This will reduce the depth of the structural
members to a minimum. The introduction of longitudinal cores reduces the dead load and results in
an effective structural system.

1.3.2. Hollow core slabs dimensions

All the test slabs are with 4000 mm span, 100 mm cantilever, 1200 mm width, and 200 mm thickness
and they were reinforced with nine strands with 9.3 mm diameter. Numerical models were employed
based on the FE method using ANSYS version 12.0 to investigate the behavior of the tested slabs up
to failure. Comparing the results of the numerical models with experimental test results was presented
and discussed as shown in Figure-1.3

Fig1.3: Hollow core slab models

1.4 Objective of Hollow Core Slabs:

Hollow core slabs derive their name from the voids or cores which run through the units. The cores
can function as service ducts and significantly reduce the self-weight of the slabs, maximizing
structural efficiency. The cores also have a benefit in sustainability terms in reducing the volume of
material used. Units are generally available in standard 1200mm widths and in depths from 110mm
to 400mm. There is total freedom in length of units, and splays and notches can readily be
accommodated.

Hollow core slabs have excellent span capabilities, achieving a capacity of 2.5 kN/m2 over a 16m
span. The long-span capability is ideal for offices, retail or car park developments. Units are installed
with or without a structural screed, depending on requirements. Slabs arrive on-site with a smooth pre-

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finished soffit. In car parks and other open structures, pre-finished soffits offer a maintenance-free
solution. Prestressed units will have an upward camber dependent upon the span, level of prestress,
etc. This will be reduced when screeds/toppings or other dead loads are applied.

1.4.1. Efficiency & Sustainability:

Prestressed concrete, and hollow core slabs in particular, offer exceptional structural efficiency. Long
spans and shallow units allow for low material usage, and better use of space within buildings. Hollow
core is extremely durable, retaining its structural capacity for a lifespan of 100 years or more.
Production of elements in a controlled factory environment reduces waste, noise and emissions.
Concrete has a large part to play in the heating and cooling of buildings, which consumes large
amounts of energy. Hollow core slabs contribute to the thermal mass of a building, and innovations
such as TermoDeck enable reductions in the energy used for air conditioning.

1.5 Uses and need of Hollow core slab

 A Hollow core slab or voided slab is a precast concrete slab usually used to build floors in
structural buildings.
 The hollow core slab was particularly popular in countries where the focus was on the
construction of prefabricated concrete houses.
 HCS also have usage as members, partition sections, and bridge deck elements.
 The hollow core slabs are made using dry casting or extrusion molding systems where the
concrete is required very low through a machine.
 The precast prestressed hollow core slab provides a solution to the current and future market
demand for the building industry.
 Hollow core slabs minimize the transmission of sound and vibrations between building
floors and eliminate floor squeals.

Fig1.4: Typical precast hollow core concrete slab

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CHAPTER 2
CHARACTERSTICS OF HCS

2.1 Systems
Based on the patent applications, we can distinguish 3 main systems of hollow core slab
manufacturing. For each category subcategories can be defined:
• Wet cast
• Permanent void formers
• Temporary void formers
• Slip forming
• Tamping
• Vibrating
• Extrusion
• Compaction by high frequency vibration

2.2 Shear compaction

In general, these manufacturing methods can be used for the production of reinforced slabs as well
as for the production of pre-stressed slabs. They are mostly in normal dense concrete, but there are
also examples of structural light weight concrete. In the early days, hollow core slabs were
manufactured either in a plant, or on site. Often individual moulds were used and sometimes even long
line beds, but in a discontinuous way. The compaction of the concrete was mostly carried out by
tamping the fresh concrete. Here also a patent study could bring more insight, but it is not the main
subject of the present article.

2.3 Specific characteristics of hollow core slabs

The most characteristic feature in the development of hollow core slabs was that they deviated
strongly from the at that time existing design principles of reinforced and prestressed concrete, by
which compression is taken up by concrete and tension by reinforcement. Indeed, in most cases, the
developed manufacturing technique was only possible under the following conditions:
• No vertical web reinforcement;
• No transversal reinforcement at the bottom side of the units;
• Only longitudinal reinforcing bars or prestressing tendons;
• No protruding reinforcement for connections, etc.
As a consequence, the tensile capacity of the concrete had to be taken into account in the design and
new techniques for connections had to be developed. This was new especially with regard to transfer
of forces at the support, shear capacity of the units, diaphragm action of the floors, transversal load
distribution among adjacent units, non-rigid supports, floor openings, fire resistance, etc.

2.4 Historical developments of Hollow core slabs

Today’s prestressed and reinforced hollow core floor slabs are the result of a long period of
development and testing. New variants of the hollow core slab are still finding their way to the market

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(see for example the transversely curved hollow core slabs for the tunnel vault on the Italian A4
autostrada at the entrance of the trade fair area in Milan). Even more than the hollow core slab itself,
the production methods are subject to permanent optimization.

2.4.1. Wet cast

The wet cast technique is using preformed cores (void formers) to realize the longitudinal voids.
They are positioned in the mould prior to the casting of the slab.

2.4.2. Wet cast with permanent void formers

Wilhelm Siegler (Germany, 1906) can probably claim the first application of longitudinal void
formers in concrete slabs. His system to realize cores was based on prefabricated short moulding tubes
in hardened mortar or another material, which were positioned on a scaffolding (Fig..2.1). The length
of the slabs was arbitrary. The tubes had lateral lugs at the bottom, serving as mould for the webs.
They were placed either continuously in the longitudinal direction, or with short inter-distances at
certain places to form transversal ribs. The longitudinal and transversal webs were reinforced in the
classical way.
During the following two decades several solutions to form longitudinal voids in flat floor slabs
were developed. An overview is presented in Fig 2.2

`
Fig2.1. Basic core unit and applications into a floor slab ;(1) short moulding tube, (2) lateral
lugs, (3) tubes positioned longitudinally in contact to each other, (4) tubes positioned at a
short distance to form transversal ribs

Fig2.2: Vacant shapes to form hollow core slab units

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CHAPTER 3
PROCESS OF DESIGNING AND IMPLEMENTATION IN HCS

3.1 The process of designing and implementation in Hollow core slabs:

The design method for a HC floor system would naturally contain the subsequent conditions :

 The Over-all organizational arrangement containing the supposed self-weight of the slab and
any important floor penetrations.
 All other permanent appointments containing partition loads and possibly changeable loads .
 All designs are placed on the floor containing live loads distributed uniformly and point loads.
 Customized floor support activities containing any special requests for plastic hinge areas.
 Displacements of support caused by earthquake and rotations.
 Vertical seismic loads.
 Floor diaphragm requests.
 Over any estimated elongations ensuing from inelastic behavior in supporting beams.
 Tolerance issues.
 Any other issues, such as minimum compressive strengths, propping restrictions fire resistance,
durability, etc.

A hollow Core Slab is a precast prestressed concrete member with continues voids provided to reduce
weight, Cost and for electrical and mechanical run, hence provide an efficient structural system.

Hollow core slab is a simply supported slab and can be designed in accordance with international
standard, namely. ACI, BSI, etc.

Concrete Technology shall prepare and submit shop drawings for approval of the general arrangement
of the slabs, adequacy and dimensions, prior to manufacture. Shop drawings detailing each unit cast –
in-inserts and its strand configuration shall be submitted to the client for approval. The design of the
structure to support the Hollow core slabs shall be the responsibility of the project structural engineer
of the Client unless designed by Concrete Technology.

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CHAPTER 4
EXPERIMENTAL WORK

4.1 General
This chapter includes the test program of the study and experimental methods performed in the present
project. The experimental program had been planned to investigate and produce precast concrete
systems.
Hollow Core Slabs are prestressed concrete elements that are cast with advanced extrusion
technique to be used as floor and roof deck system, partitions walls, as well as boundary wall panels.

The primary purpose of the cores/voids running through the slabs continuously is to decrease the
weight and materials within the floor, yet maintaining the maximal strength. These voids also offer
the possibility to be used as service ducts for concealed services such as plumbing and electrical works.
They can even be used as ducts for air conditioning. Building systems using hollow core slabs have
proven to be effective and efficient in residential buildings, schools, bridges, car parks, multi-story
buildings and multi-purpose centers.

Precast prestressed hollow core (PPHC) slabs are widely used in concrete or composite floor structures
in buildings. Because of their excellent structural performance at room temperature, advanced
manufacturing methods, and low-cost installation, PPHC slabs have an important market presence in
many countries. Prestressed reinforcement improves the serviceability performance of PPHC slabs
compared to plain slabs (those without voids), increasing the cracking moment as well as the load
bearing capacity. Span lengths of up to 16 m and high load levels can be achieved with PPHC slab
floor systems.

4.2 Material and their Characteristics

Several different materials have been adopted throughout the project. This section outlines the
physical and chemical properties of material used in the different concrete mixes adopted.

4.2.1. Concrete HCS

All the prestressed precast PPHC slabs were manufactured in the precast factory (Modern Concrete
for Precast and Prestressed Members) at Sadat city.

4.2.2. Concrete mixes with fibers in Hollow core slabs

As mentioned in Section 2, three types of fiber were incorporated in the concrete mixes to produce
fiber-reinforced concrete hollow-core slabs. Fig. 2 shows the three types of fiber used in this study
while their properties.
It is noteworthy that fresh concrete used in the extrusion method must be very dry (zero- or nearly-
zero-slump concrete). This requirement posed challenges in adding fibers into fresh concrete PCHC
slabs. The inclusion of fibers introduces new surface area to react with water into the fresh concrete
and the amount of water should be increased to obtain similar workability. However, to achieve a

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target compressive strength, water-to-cement ratio must remain unchanged.

4.3 Experimental Method

The following sections present the experimental procedures that were taken to manufacture and
produce the reference and concrete systems considered. This includes details of samples, mold
preparation, mixing, pouring, and compaction, leveling and curing of various concretes. The section
also includes high temperature heat treatment of samples and finally testing of both untreated and heat-
treated samples.

4.3.1. Bending test

The first series tested, called series was a bending test. From this test, the flexural tensile strength of
the concrete was determined from the segments, whose value was compared with the result obtained
from specimens.

4.3.2. Test specimens for hollow core slabs

Full-scale load test was conducted on nine precast prestressed hollow-core slabs obtained from a local
precast manufacturer factory (Modern Concrete for Precast and Prestressed Members) at Sadat city;
All specimens have a total length of 4100 mm and clear span of 4000 mm, a depth of 160 mm and a
width of 1200 mm. The first group contains two specimens CO1 and CO2. They are considered as
control specimens. Fig. 4.1 shows the cross section of the control specimen. The second group contains
three specimens strengthened using GFRP warps; S4G2L, S4G4L, and S2G4L. S4G2L is strengthened
by using four strips of 100 mm width; each strip consists of two layers as shown in Fig. 4.2 and S4G4L
is strengthened by using four strips of 100 mm width, each strip consists of four layers. S2G4L
strengthened by using four layers of GFRP wraps (two strips 200 mm width) as shown in Fig. 4.3. The
third group contains four specimens S4ST2, S4ST3, S2ST2, and S2ST3. S4ST2 strengthened by using
steel plates 2.0 mm thickness (four strips, each 100 mm width), as shown in Fig. 4.4

Fig 4.1: Geometry of PPHC control slab

Fig 4.2: Typical plan for specimens S4G2L,

And S4G4L Strengthened by four strips

Fig 4.3: Typical plan for specimen S2G4L

Strengthened by two strips

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Fig 4.4: Typical plan for specimensS4ST2,

And S4ST3 strengthened by four strips

4.3.3. Measuring Devices

Three mechanical dial gauges with accuracy 50mm and 25mm were installed to measure the
deflections at different points of the tested hollow core slab. One dial gauge was placed at midspan,
and two dial gauges were placed under line loads to measure deflection. The testing equipment and
the test setup are shown in Fig.4.5

Fig 4.5: Test setup and instrumentations

4.4 Machines and Equipments

The machines and equipment’s that are used for the production of Hollow core slabs are: -

I. Casting Machine Extruder

 The machine is capable to cast slabs of different thickness started from 15 to 40 cm.

 The width is Standard (120 cm) and the length is to be cut according to the span required.

 Compressive strength of the concrete is up to 90 Mpa. The core is hollow along the slab with void
percentage ratio up to 50%.

II. Prestressing Device

 Either all the strands of one bed are tensioned simultaneously, or else tensioning can be done
using a single wire stressing jack.
 It is a single wire hydraulic pre‐stressing pump. This method is reliable, secure, and safe. Single
wire stressing jack consists of a motor pump and stressing jack.
 Also, it is very fast, precise and accurate. Pre‐stressing capacity is up to 400 bars.

III. Standard Concrete Saw

 It has a fully hydraulically operated saw blade and travelling control. The cutting capacity is up
to 40 cm depth Easy and quick handling.

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IV. Bed Cleaner Machine
 It has a fully hydraulically operated control, powerful vacuum system for dry bed cleaning, easy
and quick handling. Computerized Mix Plan.
 The mix plant is controlled and operated by a computer system. It is supplied with water content
sensor to control the mix.

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CHAPTER 5
EXPERIMENTAL RESULTS

5.1 Compression and bending test

Precast/ prestressed concrete hollow core (PCHC) slabs have been the favorite products for wall or
floor systems since the 1970s.
Not with standing this, there are still some concerns regarding the web-shear capacity of PCHC slabs.
The reason for this lies in the fact that the extrusion method, which is the most popular method to
fabricate PCHC slabs, does not allow any stirrups or shear reinforcement to be placed in the slabs.
Therefore, the web-shear capacity of PCHC slabs solely relies on tensile strength of concrete webs
which usually consist of thin sections. With a reduction in cross section due to presence of longitudinal
hollow cores, relatively low tensile strength of concrete, and most importantly, the absence of stirrups,
PCHC slabs are naturally vulnerable to web-shear failure. This concern becomes more critical for the
so-called deep PCHC slabs, which have non-circular voids and with flat webs and depths exceeding
300 mm.
These slabs could fail in web-shear mode at loads smaller than those predicted by design codes such
as ACI

5.1.1. Objective of the test:

Knowing the strength of the hollow core slab with the changes of several factors

Variables
1- The area of the empty core
2- Reinforcement ratio
3- Empty core shape

Comparing the Tests results with a solid beam with the same dimensions (1.5*.45*.20*).

5.2 Failure modes

Three types of failure were observed:

Web-shear (WS);
A combination of web-shear and anchorage (WS & A);
A combination of flexural and shear (FS),

The so-called flexural-shear failure. In the first mode of failure, cracks initiated in concrete webs near
the support and immediately propagated towards the bearing and loading locations, resulting in a
sudden failure without warning with the formation of diagonal web-shear.

In the second mode of failure, web-shear failure was combined with anchorage failure and the web-

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shear cracks occurred almost concurrently with cracks along longitudinal strands. Loss of bond
between the concrete and the prestressing strands due to splitting resulted in longitudinal cracks at the
slab edge regions. In the last mode of failure, flexural cracks first occurred at the bottom of the slabs
and then propagated diagonally towards the applied-load location, forming shear cracks. The slabs
failed due to interaction between flexure and shear modes. All the specimens without steel fibers failed
in web-shear or a combination of web-shear and anchorage modes. However, when steel fibers were
included, in some instances, failure mode changed from web-shear to flexural-shear failure. This was
because when the tensile strength of concrete in the webs was considerably strengthened by steel
fibers, web-shear cracks could not emanate; instead, flexural cracks at the bottom of slabs occurred
first and then propagated vertically and diagonally towards the applied load location, resulting in
flexural-shear failure. For hole core slabs that failed in flexural-shear mode, shear strengths calculated
from the applied loads were not equal to their web shear strength; instead, they were just lower bounds
of the web-shear strength.

5.3 Proposed shear strength formula for hollow-core slabs with steel fibers
As the 2010 fib model code is overly conservative for shear-strength prediction of hollow core slabs,
a new formula was proposed considering the respective contributions of concrete in compression zone,
prestress, steel fibers, and arching action to shear resistance. The formula was then verified using a
database of 45 shear tests (6 slabs with steel fibers from this investigation and another 39 steel-fiber-
reinforced concrete hollow core slabs from the literature.

5.3.1 Proposed formula

It is commonly accepted that shear strength of reinforced concrete beams or slabs without stirrups is
provided by longitudinal reinforcement through dowel action (Vd), aggregate interlock (Va), and the
concrete in compression region (Vc). When steel fibers are added, their contributions (Vfib) must be
included.

Of the four components, the contribution of dowel action by longitudinal reinforcement is considered
trivial compared to contributions of the other three, especially in concrete slabs with very low
reinforcement ratios such as hollow-core slabs (typically, the ratio is within the range of 0.5–1.5%).
In addition, due to thin webs of PCHC slabs, it is believed that aggregate interlock only has very minor
effect on shear resistance.

Therefore, in this proposed equation, contributions of dowel action and aggregate interlock are
ignored. This assumption was also adopted in previous studies and will result in safe predictions. Thus,
the shear resistance of SFRC hollow-core slab.

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CHAPTER 6
MANUFACTURE AND TRANSPORTATION

6.1 Manufacture, Transportation and Erection Procedure

6.1.1 Manufacture/Production cycle

i. Cleaning and oiling of the bed

ii. Strand pulling and tensioning of strands
iii. Lifting the extruder on the bed
iv. Concrete mixing and transportation
v. Concrete dosing to extruder
vi. Extruding
vii. Making openings
viii. Covering and curing of slab
ix. Cutting of slab
x. Drilling of drainage holes
xi. Transportation to storage
xii. Handling of slabs in storage
xiii. Transportation to site

6.1.2 Transportation of Hollow Core Slabs to site

Transportation of precast elements should be planned according to the general erection sequence to
minimize unnecessary site storage and handling. Where possible it is desirable to transport the precast
elements in a manner which they can be lifted directly for erection or storage without much change in
orientation and sequence.

Hollow core slabs are manufactured in a closed environment using the highest
levels of technology that ensure high quality product. Using world renewed PCE production lines and
Extruders and employing a team of highly qualified staff, CONCRETEC is considered among the
most reputed providers of Hollow core slabs in the region.

Hollow core slabs are pre-stressed elements production a long bed by using
extruders and mechanically compacted. The Hollow core slabs are produced in standard width of 1200
mm; service openings widths can be accommodated. The top surface shall be finished as cast by the
machine or intentionally- roughened to achieve the specified bond characteristics of the topping to
other finish applied after erection of the slabs.

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6.1.3 Materials

 The hollow core slabs are produced with two basic concrete mixes:
 Low slump concrete
 Normal slump concrete
 For the low slump concretes, water content is limited to slightly more than that required for
cement hydration.
 Water- Cement ratios are typically about 0.3.

6.1.4 Storage and erection of Hollow Core Slabs

The storage area provided in the yard and job site should be adequate to permit easy access and
handling of the precast elements. Appropriate stacking method should be used to store the precast
concrete elements to prevent any undue stresses and damages. Horizontal precast concrete elements
can be stacked and supported separately using strips of woods or battens across the full width of the
designated bearing points. Precast walls and facade panels are usually stored in vertical position
supporting their own weight using racks with stabilizing wall.

An installation plan shall be prepared well in advance and agree on the order of the delivery of the
slabs. Select a lifting device that is suitable for the site conditions and the weight of the hollow core
slabs. Compare each slab with the plan. Inspect the slab levels in the level drawings, the supports for
the installation phase, the lifting necks, the number of strands,the location of deep-plugs and the
slippage of the strand. Mark the location of the slabs and set installation shims or a neoprene bearing
strip in place. Inspect the length of the bearing surface, level, and location of the installation shims at
the web of the slab. Assemble the temporary supports for the work phase according to the plan, prior
to the installation of the slabs. The hollow core slabs are installed by using a spreader beam and lifting
clamps. A slab that is shorter than three meters can be lifted with long lifting chains without a spreader
beam. The angle between the legs of the lifting chains must be less than 60 degrees. Level out
differences in the slab camber according to the plan, by using supports, adjuster bolts or installation
shims. Reinforce the joints and install an electrical conduit according to the plan. Carry out the joint
grouting and seal it. Carry out protection and curing according to the conditions. Inspect and open
drainage holes after joint grouting.

6.1.5 Handling, Lifting and Delivery

Hollow core slabs units shall be lifted and supported during manufacturing, stockpiling, transporting
and erection operations only at the lifting or supporting points, or both, as specified by the company.

The on-site lifting and erection operations shall be in accordance with the method statement for
erection of Hollow core slabs which is based on PCI MNL, 126 and or as per project requirements.

Full width Hollow core slabs shall be hoisted by using specially designed lifting equipment’s clamp
with spreader beam to ensure- vertical lifting of slab.

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683549.Ernakulam.

Hollow core slabs shall be stored off ground by placing them on plywood runner, etc. The slabs should
be stored in such a way that identification marks are describable. The stacked hollow core slabs shall
be separated by patterns across full width of each hollow core slab. The upper slab of the stacked tier-
should not be used as storage area for shorter members or heavy equipment.

Hollow core slabs are handled in the flat horizontal position. Slabs are not turned-on edge or end
unless approved by design engineer. While lifting narrow slabs (width less than 120 mm), and slabs
with cut-offs near the end, sling belts of adequate capacity properly tightened around the hollow core
Slabs, are used for lifting process.

Hollow core slabs are transported from the factory to the site on the flat bed trailers. Slabs are secured
to the trailer, using latching chains. Loading is governed by trailer capacity and slabs geometry.

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 SCMS COLLEGE OF POLYTECHNICS, Vaikkara, Perumbavoor–
683549.Ernakulam.

CHAPTER 7
PRINCIPLES OF HOLLOW CORE SLABS

The principles of hollow core slabs are classified as:

I. Extrusion
II. Slip form

Extrusion
In extrusion system a very low slump concrete is forced through the machine. The cores are formed
with augers or tubes with the concrete being compacted around the cores. Extrusion is known for the
high compaction capabilities and excellent structural capacity of the hollow core slab. One of the
advantages in the modern extrusion is the silent and automatic operation.

The key to an optimum compaction on dry cast is the frequency of vibration since the absence of water
makes it more difficult for the concrete particles to flow. Some of the Extruders manufactured today
do not use the high frequency vibrators, instead they operate based on pressing extrusion screws,
which usually requires more water to achieve the same level of compaction than the Hollow Core
Extruders based on high frequency of vibration.

Slip form
This system uses a higher slump concrete. Sides are formed either with stationary, fixed forms or
with forms attached to the machine with the sides being slip formed. This is a relatively simple
principle where concrete is flowing on to the product in two to three phases (layers) each phase is
compacted typically by vibrators. The Slip form system is used mainly for shallower hollow core cross
sections and various other cross sections like inverted T-beams. However, there are slip formers,
which can form 700mm hollow core sections. The production speed for each of the system varies
depending on raw materials, depth of products and machine types being used. The speed ranges
between 1 to 3 meters/min. Hollow core slabs can be manufactured in different thicknesses such
as150mm, 200m, 240mm, 265mm, 280mm,300mm,320mm,350mm,400mm etc. as required.

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 SCMS COLLEGE OF POLYTECHNICS, Vaikkara, Perumbavoor–
683549.Ernakulam.

CHAPTER 8
ADVANTAGES AND DISADVANTAGES

8.1 Advantages

In recent years, many studies have been conducted for the design of concrete structures, most of which
are related to style roof construction has led to the presentation of roofs that, in addition to maintaining
high strength, have a significantly lower dead load Compared to traditional roofs. Reducing the dead
load of the roof has great benefits for the whole structure, the most important of which is to reduce the
strength.
An earthquake falls on the structure, which, in turn, reduces the partitions and reduces the dead load
of the structure

i. This system, because it is hollow compared to traditional solid surfaces, and with the same
load capacity, it is reduced by 35% in concrete consumption and dead load, resulting in a
reduction of the vertical load-bearing members.
ii. Reducing the dead load and being the double-sided slab results in smaller deformations of the
slab, which is of particular importance.
iii. Increased floor height due to beam removal
iv. After reducing the weight and reducing the number of columns, it. creates an ideal space for
architects to design the interior space
v. In the case of seismic force in such systems, the collective acceleration. of these members is
reduced due to the large reduction in dead load As a result, the strength of the earthquake also
decreases
vi. As a result of reducing the consumption of concrete in this system by about 35% considering
that the consumption of each ton of cement causes emissions the emission of this gas, which
has an environmental aspect, is largely prevented. in 700 kg of gas co2 it is 300 Each cubic
meter of concrete consumes about 300 kg of cement which emits about 200 kg of gas
vii. The outstanding resistance to fire and sound insulation are other features of Hollow core slab
viii. Easy to install and requires less labor

8.2 Disadvantages
i. Not economical for small spans
ii. If not handled properly, hollow slab units may break or become damaged
iii. It is necessary to arrange special equipment for lifting and transporting precast units

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 SCMS COLLEGE OF POLYTECHNICS, Vaikkara, Perumbavoor–
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CONCLUSION

• The main conclusion is as follows;

a) Feasibility to use Hollow core slab as a roofing member for buildings. It was proved also that
these slabs efficient after rehabilitation using carbon fiber (CFRP) strips.

b) by eliminating bubbles at the center of the slab at distance 2D and 3D the failure load
increased by about (14.72 and 8.76%), respectively for slabs with (D/t = 0.6) compared to
slabs with bubbles at all slab area, and for slabs with (D/t = 0.7) the ultimate load increased
by (30.85 and 27.65%), for bubbles at distance 2D and 3D, respectively.

c) The NSM-CFRP strengthening method majorly supports the bending and shear load capacity
of Hollow core slabs. The increase in failure flexural capacity was minimized in slabs that
failed by shear before reaching their full bending capacity.

d) The greatest percentage of decreasing in the cross-sectional area is extending between 29%-
35% for styropor block slabs.

e) Hollow core is extremely durable, retaining its structural capacity for a lifespan of 100 years
or more. Production of elements in a controlled factory environment reduces waste, noise,
and emissions.

f) Prestressed concrete hollow-core slabs have been widely used throughout the world in
concrete and steel structures they were developed in the 1950s when long-line techniques
evolved with the extrusion method.

g) Designing for sustainable development not only involves using recyclable building materials
and reducing energy consumption while building, but it also implies better use of available
building materials, production systems with less environmental burden, products with higher
performances, design systems in line with new demands for flexibility and adaptability to
future needs. Hollow core slabs enable a very efficient industrialized production.

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 SCMS COLLEGE OF POLYTECHNICS, Vaikkara, Perumbavoor–
683549.Ernakulam.

REFERENCES
1. Foubert S. Mahmoud K. and El-Salakawy E. 2016. Behavior of Prestressed Hollow-Core Slabs
Strengthened in Flexure with NearSurface Mounted Carbon Fiber-Reinforced Polymer
Reinforcement. ASCE, Journal of Composites for Construction. 20(6).

2. Ibrahim I.S., K.S. Elliott, b. Abdullah, R. Kueh A.B.H., Sarbini N.N. 2016. Experimental
Study on the Shear Behavior of Precast Concrete Hollowcore Slabs with Concrete Topping.
Engineering Structures.

3. Abdul Al-Aziz B. M. 2017.Behavior of Reinforced Lightweight Aggregate Concrete Hollow

Core Slabs. MSc. Thesis, Al-Nahrain University/Civil Engineering Department .

4. Wariyatno N. G., and Haryanto Y. and Sudiboyo G. H. 2017. Flexural behavior of precast how
core slab using PVC pipe and Styrofoam with different reinforcement.

5. PrakashanL.V. George, J., Edayadiyil, J. B., George, J. M. 2017. Experimental Study on the
Flexural Behavior of Hollow Core Concrete Slabs. Applied Mechanics and Materials.

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