IS : 10606 - 1983 ( Reaffirmed 1998 )

Indian Standard
CODE OF PRACTICE FOR CONSTRUCTION OF FLOORS AND ROOFS USING PRECAST CONCRETE WAFFLE UNITS
(First Reprint SEPTEMBER 1993)

UDC 69*024/*025 : 691.327 : 006.76

8 BUREAU
MANAK

Copyright INDIAN

1983 STANDARDS
ZAFAR MARG

OF
BHAVAN,

9 BAHADUR SHAH NBW DBLHI 110002

Gr 3

May 1983

IS :10505-1983

Indian Standard
CODE OF PRACTICE FOR CONSTRUCTION OF FLOORS AND ROOFS USING PRECAST CONCRETE WAFFLE UNITS
Prefabricated and Composite Construction Sectional Committee, BDC 32
Chairman SHIU A. RAMAKRISHNA Members SHRI S. SUBRAMANIAN ( Alternate to Shri A. Ramakrishna ) DR N. S. BHAL Structural Engineering Research Centre, Roorkee SHRI K. C. NAITHANI ( Alternate ) SHRI AJYA BI~ARADWAJ In personal capacity ( 207, Golf Links, New Delhi ) SHRT DAKSHA BHARADWAJ ( Alternate ) Central Building Research Institute, Roorkee SRRI S. C. CHAKRABARTI Housing and Urban Development Corporation, SKRI B. K. CHAKRABORYY New Delhi Gammon India Limited, Bombay SHRI A. K. CHATTERJEZ SHRI A. C. ROY ( /llternafe ) CHIEF ARCHITECT Central Public Works Department, New Delhi SENIOR ARCHITECT ( H&TP ) ( Alternate ) DIRECTOR ( C & MDD ) Central Water Commisssjon, New Delhi DEPUTY DIRECTOR ( C&MDD ) ( Al/emote ) SHRI A. GH~SHAL In personal capacity ( C/o hf/s S&b Consultants L&d, 12 Darga Road, Calcutta ) JOINT DIRECTOR STANDARDS Research, Designs and Standards Organization, ( Ministry of Railways ), Lucknow ( B&S ) CB DY DIRECTOR STANDARDS ( B&S ) CB ( Alkrnate) Structural Engineering Research Centre ( CSIR ), Dn A. G. MADHAVA KAO Madras SHRI G. ANNAM~LAI ( Alternafe ) Hindustan Prefab Limited, New Delhi SHRI G. K. MAJCMDAR SHRI M. KCNDU ( Alternate ) SHRI P. \. NA~K Hindustan Construction Co Ltd, Bombay SHR~ A. C. NARWANI ( Alternate ) DR M. Nalr.ir; The Concrete Association of India, Bombay SHRI P. SRINIVASAN ( Alternate ) ( Continued on page 2 ) Representing Engineering Construction Corporation Ltd, Madras

@ Copyrighl 1983
OF INDIAN STANDARDS This publication is protected under the Indian Copyright Acf ( XIV of 1957 ) and reproduction in whole or in part by any means except with written permissioa of the publisher shall be deemed to be an infringement of copyright under the raid Act. BUREAU

IS :10505- 1983

flw Prrfalwication

System

Suhcommittre,

BDC

32 : 1

IS :10505

- 1983

Indian Standard
CODE OF PRACTICE FOR CONSTRUCTION OF FLOORS AND ROOFS USJNG PRECAST CONCRETE WAFFLE UNITS

0.
0.1 This

FOREWORD
.

Indian Standard was adopted by _the Indian Standards Institution on 28 February 1983, after the draft finalized by the Prefabricated and Composite Construction Sectional Committee had been approved by the Civil Engineering Division Council. 0.2 The scheme consists of a nominally reinforced precast open box type concrete units called waffle units laid in a <grid pattern and cast-in-situ concrete in the joints between the units with the reinforcement provided Minimum thickness of top screed is provided depending in the joints. The finished slab has a upon structural and functional requirements. pleasant grid pattern in the ceiling. The scheme is suitable for roofs/floors spanning in two directions.

1. SCOPE 1.1 This standard covers tile details using precast concrete waffle units.
2. DETAILS of construction of floors and roofs

OF THE Unit

SCHEME

2.1 Precast

2.1.1 S/m/x -- The units are of the.shape of an inverted trough, square, lhe ribs of the units may be rectangular, triangular or any other shape. given an outward slope to enable the precast components to demould easily and also to enable them to act monolithically with cast-in-situ beams in joints between the units.
Typical details of cross-section section of floor/roof using waffle respectively. of square waffle slab unit and crossunits are shown in Fig. 1 and 2 3

IS :10505- 1983

*.
v .

FIG. 1

TYPICAL

SQUARE

WAFFLE

SLAB

UNIT

CAST IN StTU CONCRETE

i

TOP SCREEO

vPRECAST

WAFFLE

UNIT

FIG, 2 TYPICAL SECTIONOF FLOOR USING WAFFLE UNITS

IS: 10505- 1983 2.1.2 Size - The lateral dimensions of the units should be modular ( see IS : 6820-1972* ). The depth of the unit shall be as per structural design and will vary according to loads and spans. The minimum thickness of the flange and web of the units shall be 25 mm.
3. MATERIALS 3.1 General IS ; 456-1978f. 4. STRUCTURAL 4.1 The analysis. The material DESIGN by any of the accepted methods of used for the construction shall conform to

grid slab shall be analysed

4.2 The precast accordance with following stages: b) Handling,

units shall have adequate strength and stability in relevant code of practice ( IS : 456-19787 ) during th?

a) Demoulding; stacking, transporting and placing; and concrete c) With all design in joints. loads together with dead load of in-situ

NOTE - Where portland pozzolana cement is used delayed strength development at the early ages shall be considered.

4.3

Loads

shall be in accordance

with IS : 875-1964:.

4.4 For calculating the limit state of collapse at the critical cross sections, at stage of demoulding and handling, a load factor of at least 1.5 shall be applied for calculating the design limit state of collapse load. 5. MOULD 5.1 The mould used for manufacturing waffle slabs normally consists of two parts (a) bottom mould and (b) side moulds. The bottom mould can be made out of timber, masonry, concrete, steel FRP, plastic or any The side moulds simiother material acceptable to engineer-in-charge. When using masonry or larly can be timber, steel, FRP or plastic. concrete moulds, the top surface shall be finished to the required accuracy and made smooth. In case of masonry moulds, the use of chicken mesh or fibre reinforcement in the top surface will help in making the mould last Admixtures for higher strength of concrete longer for higher efficiency. can also be used. *Recommendations for modular co-ordination rules for modular planning. *Code of practice for plain and reinforced concrete ( thirdreuision). $&de of practice for structural safety of buildings : Loading standards (Jirst revision ). 5

IS : 10505 - 1983 6. REINFORCEMENT 6.1 Keinforcement

ments. Any metal/chicken be provided. 7. CONCRETE

IN PRECAST

UNIT

shall be provided according to the structural requiremesh/expanded mesh type of reinforcement/welded mesh with a maximum spacing of 100 mm both ways shall

7;l Mix - The concrete IS : 456-1978.

8. CASTING

mix shall be of minimum

grade

M 20

as per

AND

CURING

vibration either through mould/table vibrators or screed vibrator is essential to ensure good compaction. Needle vibrators can be used for compacting concrete in the ribs and screed vibrators can be used for compacting concrete in the flange. For larger factories, concrete placing machine which level, vibrate and finish the concrete units can be advantageously utilized. 8.2 Curing shall be done according to IS : 456-1978*. If necessary, low pressure steam curing may be provided to get early stripping/release strength. 9. TOLERANCES

8.1 Mechanical

9.1 Tolerances
a)

on the dimensions * &

shall be as follows: or f 0%1 percent whichever is

Length/breadth greater, and -

5 mm

b) Thickness

2 mm.

10. SAMPLING 10.1 Sampling Appendix A. -

AND TESTING
Sampling shall shall

OF UNITS
be done in accordance with with the

10.2 Load test on floor/roof provisions of IS : 456-1978*.

be carried

out in accordance

11. TRANSPORTATION ELEMENTS 11.1 Lifting

be provided and erection

AND

ERECTION

OF

PRECAST

Hooks - Wherever lifting hooks/holes are used these shall at structurally advantageous points to facilitate demoulding of the precast unit, The lifting hooks can be formed out of
( third r&ion ).

*Code of practice for plain and reinforced concrete 6

IS:10505 normal mild carry the self erection, the joint concrete

- 1983

steel reinforcing bars with adequate carrying capacity to I\-eight during tlcmoulding, hanclling and et crtiotr. i\ ii c , hooks can be either cut or bent do\vn insitlc the scr~cetl ot that will be laid subsequently.

11.2 Stacking of Units - After removal from moulds the precast units shall be stacked over support placetl at about l/6 of span from ends. Care shall be taken to set that no support is placed at the centre of span. the units, rope 11.3 Transportation - For transportin ,g ant1 erecting slings shall be tied near the ends at l/5 of the length from either end of In case the units are transported in trolleys, the overhang of the unit. the units from the trolley shall not be more than l/5 of length. The units shall be lifted rnanttally or with the lrtll) of chain l)ulley l.>locks or mechanically with a hoist or a crane. 11.4 The units shall be placetl and alignerl side hy side acsoss the span Ilacitrg of units shall be started from one end of the to be covered. building. 12. CURING OF IN-SITU CONCRETE IN JOINTS

12.1 The in-situ concrete in the joint shall he cured for at least 7 days The concrete shall be then allowed in accordance with IS : 456-1978*. to dry fcr at least a \veck. .\ coat. of cement slurry may be applied to the joints to fill the hairline cracks that might have developed. 13. FIXTURES 13.1 Designers shall indicate provisions for fixtures like fanhooks/inserts/ electric conduits, etc, to he incorporated within the precast units or the in-situ joint;/screed concrete. 13.1.1 In case of concealed wiring, conduits may be placed within the joints along the length or within the screed before concreting. If adequate thickness A avrailable this may be concealed within the floor/roofs finish. 13.1.2 Holes, openings and fixtures required to be provided within the precast units shall be fixed accurately with adequate embedment at the Drilling of holes/cutting of edges shall not be made precasting stage. otherwise permitted by the Engineer-in-Charge. 14. FLOOR FINISH

14.1 In case of floor slab, the floor finish shall be with relevant Indian Standard Code of practice.

done

in

accordance

*Code uf practice for plain and reinforced concrete ( third rm3on ). 7

IS : 10505- 1983 14.2 To provide adequate resistance against impact/acoustic the floor thickness at any place shall not be less than 75 mm. 15. ROOF TREATMENT
treatment

15.1 Adequate

and thermal insulation to suit local water proofing climatic conditions shall be adopted in acrordance with relevant Indian Standard Code of practice.

APPENDIX ( Clause 10. I )

SAMPLING A-l. LOT PROCEDURE

A
SLAB UNITS

FOR PRECAST

A-l.1 All the precast

slab units of the same size, manufactured from the same material under similar conditions of production shal! be grouped together to constitute a lot.

A-l.2 The number of units to be selected from each lot fo dimensional requirements shall depend upon the size of the lot and shall be in accordance with co1 1 and 2 of Table 1.
TABLE 1 SAMPLE SIZE AND REJECTION
I )

NUMBER

( Clauses A-l.2 and A-2.

LOT

SIZE

FIRST SAMPLE SIZE

SECOND SAMPLE SIZE

FIRST REJECTION NKWBER (4) 2 2 2 3

s wo:m R ,...I IXTION NCXBER

(5) 2 2 2 4

(1) up to 100 101 to 300 301 to 500 501 and above

12) 5 8 13 20

(3) 5 8 13 20

A-1.2.1 The units shall be selected to ensure the randomness of selection, may be followed.
*Methods for random sampling.

from the lot at random. In order procedure given in IS : 4905-1968*

IS:10505A-2. NUMBER OF TESTS AND CRITERIA FOR

1983

CONFORMITY

A-2.1 All the slab units selected Lat random in accordance with co1 1 and 2 of Table 1 shall be subjected to the dimensional requirements. A unit failing to satisfy any of the dimensional requirements shall be termed as defective. The lot shall be considered as conforming to the dimensional requirements if no defective is found in the sample, and shall be rejected if the number of defectives is greater than or equal to If the number of defectives is less than the the first rejection number. first rejection number, the second sample of the same size as taken in the first stage shall be selecte 1 from the lot at random and subjected to the dimensional requiremens. The number of defectives in the first sample and the second samph. shall be combined and if the combined number of defectives is less than the second rejection number, the lot shall be considered as conforming to the dimensional requirements; otherwise not.

IS :10505- 1983 (Continued-from page 2

Members ) Repesenting Engineering Consrdtants ( India ), New Delhi Central Bullding Rcscarch Institute, Roorkee
Enginrcring

I SHRI G. B. SIN(:JI ( Alternnfe I ; SHRI S. SEBRAM.I.\NI.XN( Alternate II ) SKRI A. N,rSox Civengers Enterprise Pvt Ltd, New Delhi SRnr B. V. B. PAI The Concrete Association of India, Bombay SHRI P. SRINIV.~SAN ( Akernate j DR N. R,4c;rrsvxx1n~.4 Cement Rrsearch Institute of India, New Delhi SHRI H. K. JLJLKA ( Allernate ) SHRI S. RAY Bridge and Roof Co ( India ) Ltd, Calcutta S~ltr AKUP KUXAR DUTTA ( Alternate ) SIiRr L. R. SAWRI Tamil Nadu Police Hpusing Corporation Ltd, Madras SHRI P. CIFELLAM ( Alternate ) SHnI P. V. SHAH Shah Construction Company, Bomhay SJXRI B. G. SHII;KE M/s B. G. Shirke and Co, Pune SARI D. V. K~JLK \IWI ( Aherntlte I ) SHRr I<. T. PAWAIL ( Alternate 11 ) SHRI K. S. SHINIVASAN National Buildings Organization, New Delhi SHRI SVNIL BERY ( Alternr,te ) SIJRVEYOIL OR \vOJlKS v Central Public Works Department, New Delhi SHBI R. K. SUN~~I~AM ( Akernate ) SHRI K. VRl~RARACJl4Vd7HARY Bharat Heavy Electricals Ltd, Ranipet SHRI V. MU,VIYA ( Alternate ) SHRI z~cIi.4~1.4 GEORGE Structural Engineering Research Centre, Madras DR A. G. M.~DHAVA RAO ( Ahernate )

Indian Institute of Architects, Bombay Construction Corporation MatlrZlS

Limited,

10

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OF

INDIAN

STANDARDS

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Printed at Dee Kay Printers. New Delhi. India

AblENDFWl- NO. 1 TO

MARCH 1986

IS: 10505-1983 CODEOF PRACTICEFOR CONSTRUCTION OF FLOORS AND ROOFS USING PRECAST CONCRETE WAFFLE UNITS

(Page

5,

c%ause 4.4 > - Add the following sentence

at the end of the clause: 'Guidelines for design of floors/roofs using waffle units is given at Appendix B.'
(Page 9, Appendix A) -

Ada the following new

Appendix B after A-2.1: APPENDIX B (CZause 4.4) GUIDELINES FOR DESIGN OF FLOORS/ROOFS USING WAFFLE UNI'l'S B-l, LOADS AND FORCES B-l.1 Loads and forces *shall be taken in accordance with clause 17 of IS:456-1978*. In addition,slab should be checked for incidental concentrated load which is likely to occur during the construction. B-2. ANALYSIS OF FLOORS/ROOFS

B-2.1 The floor/roof with waffle units up to a span of of width not less than 100 mm .* (excluding thickness of precast waffle ribs) spaced 'h' at not mre than 750 mm may be analysed as solid slab spanning in two direct ions at right angles in accordan with 23.4 of Is:456-1978" or as flat slab in accordant with 30 of 1~:456-1978".
6 metres having ribs

*Code of pmctice*for plain and reinforced concre

(third ., / retiion). -_.. _. 1 _ _

L&2.2 'l'llc floor/roof wit11 wnfflc units Im.vrI.ng span of lIore than 6 m and a rib spacing of more .thal)750 mm shall be designeli as slab and grid beam system. The shear at the interface of precast and in-s'itu concrete shall be calculated and suitable shear keys/shear 'reinforcenlent. shfA1 be provided . to avoid separation. -1 -. ._--0 -. NOTE - When the span of waffle unit is more than 750 mm, the structural design of ,tlie uni-1;sllould bc nludc . B-3. CONTROL OF DEFLECTION

B-3.1 If.the system is analysed as per E-2.1, the deflection shall be restricted in accordance with 23 of IS:ll56-1978* and the depth of rib of -the unit shall be considered as depttl of slub. R-3.2 If the system is analysed as per B-2.2, deflection should be restric-ted in accordance 22.1, 22.2 and 23 of IS:lb56-1978*. B-4. DETAILING OF REINFORCEMENT in the ribs

-the with

B-4.1 Shear stress per IS:456-1978*.

shall be calculated

as

B-Ii.2 Detailing of the reinforcement shall be done in accordance with clause 25 of IS:l156-lc)'(O*.

-_.._

___.

.-

*Code
.

of practice
..

for plain
__.

and reinforced

concrete
_

(t-l~izd revisio7~).
. . . _ .

(KC

32) 2
___--_________-_-_-_____-________c____

Renronaphy

Unit,

ISI, New Delhi,

India