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Hollowcore is ideal for long unpropped spans which
are subjected to uniformly distributed loads, and is
used extensively in commercial buildings all around
the world. Hollowcore is manufactured using a
high-strength concrete which is processed through a
unique machine that extrudes the Hollowcore profile
onto a steel bed. This specialised manufacturing
process allows the product to be cut to any length,
making Hollowcore economical, quick to produce
and flexible to use on building sites. Hollowcore
can be used either as a solid floor or spaced out
(see page 14) to provide an even more economical
flooring solution.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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Architects
General
Spiroll
Depth (mm)
Solid
Spaced 1800
Spaced 2000
200
58
50
49
The Auckland branch has Echo in sizes 150, 200, 300 & 400mm deep
300
63
50
49
The Otaki branch has Spiroll in sizes 200 & 300mm deep
The Christchurch branch has Elematic in sizes 200, 300 & 400mm deep
As the different sections have some differing properties, individual
projects should be designed with location in mind to match the
nearest Hollowcore profile from the closest manufacturing plant.
1.1 Durability
Stahlton Hollowcore slabs meet exposure classifications A1, A2, B1 &
B2 as per table 3.6 in NZS 3101:Part 1:2006 for a 50-year life.
Spaced 1800
Spaced 2000
0.23
0.25 -
0.29 -
Depth (mm)
Solid
Spaced 1800
Spaced 2000
200
0.24
0.25 0.23
0.29 0.23
150
55
54
53
300
0.26
0.26 0.25
0.31 0.25
200
58
56
55
400
0.27
0.28 0.27
0.32 0.26
300
63
58
56
400
67
59
57
Depth (mm)
Solid
Spaced 1800
Spaced 2000
200
58
50
49
300
63
50
49
400
67
50
49
Elematic
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Consulting Engineers
2.0 Loadings
Hollowcore floors can sustain point loads and loads induced by some
truck wheels. However, significant loadings should be checked by one
of the Stahlton Engineers at the preliminary design stage. Generally for
vehicles loadings refer to table 3.1 in AS/NZS 1170.1 as well as the NZBC
Handbook Acceptable Solutions C/AS1 Part 8 Fire Fighting cl8.1.1a.
Loadings shown for medium trucks and the recommended fire truck
loadings are acceptable for Hollowcore floors but will depend on span,
UDL and load factors of the unit. Additional detailing at the ends may
be required to sustain high shear forces induced by wheel loadings or
point loads located at the ends of the units.
Intended load factors and uniformly distributed loads should be clearly
shown on the Consultants drawings to avoid any confusion throughout
the shop drawing and design process. Contact the Stahlton Technical
Department if you have special loading cases for design advice.
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Consulting Engineers
2.2 Topping
Depth (mm)
Echo (kPa)
Spiroll (kPa)
Elematic (kPa)
150
3.99
200
4.39
4.06
4.32
300
5.35
4.88
5.21
400
6.25
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6.10
Depth (mm)
Echo (kPa)
Spiroll (kPa)
Elematic (kPa)
150
3.61
200
4.00
3.45
3.55
300
4.62
4.00
4.11
400
5.19
4.69
Echo (kPa)
Spiroll (kPa)
Elematic (kPa)
150
3.46
200
3.86
3.14
3.22
300
4.42
3.63
3.73
400
4.93
4.26
Contractors
3.0 Temporary Propping
3.1 Camber
Depth (mm)
Echo (kg/m)
Spiroll (kg/m)
Elematic (kg/m)
Stahlton Hollowcore units will arrive at site with some positive camber
(hog). This is unavoidable due to the nature of prestressing. The
amount of hog will depend on a number of factors, including amount
of prestress, how long the units have been manufactured and exposed
to the elements and length of unit to name but a few variables. As a
rule of thumb allow 2-3mm of hog for every 1m of span (see page 16).
Generally half of the hog of the Hollowcore unit will come down after
the topping concrete is poured and any propping is removed. Half of
the remaining hog will eventually come out over time due to creep
and shrinkage.
150
274
200
316
303
321
300
427
402
422
400
530
527
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Contractors
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Specifications
Design
(i) The design of Stahlton Hollowcore shall be in accordance with
the requirements and recommendations of NZS 3101:2006 Concrete
Structures Standard Part 1 & 2 and/or any recognised international
Standard or part thereof, for example BS 8110:1007 The Structural Use of
Concrete.
(ii) The prestress strand pattern in the Stahlton Hollowcore shall be
designed to sustain the loadings shown on the Consulting Engineers
drawings and allowance will be made for self weight of the unit and
topping concrete.
Materials
(i) Concrete shall be specifically mixed depending on environmental
conditions and should have a 28 day cylinder strength of 50MPa as a
minimum.
(ii) All concrete shall show signs of thorough compaction otherwise be
rejected if repair cannot be undertaken to bring the unit back to the
original specification.
(iii) An air entraining agent complying with BS EN 934-2-2001 may be
included in the concrete mix to improve workability.
(iv) The strand reinforcement used in Stahlton Hollowcore shall be
12.7mm or 12.9mm diameter complying with the requirements of
AS/NZS 4671:2001
(v) Prestressing strand shall be clean and free from deleterious
substances. Superficial rust is acceptable, however strand with
corrosion that has caused surface pitting shall be rejected for the main
longitudinal reinforcement of the unit.
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Specifications
Manufacture
(i) Materials, execution of stressing prestress strand and workmanship
of the Stahlton Hollowcore units shall conform with Stahlton Engineered
Concrete ISO 9001 Quality Assurance Operating Procedures.
(ii) Stahlton Hollowcore units shall be nominally 1200mm wide and made
in the following profile and nominal depth; Echo (Auckland) 150mm,
200mm, 300mm & 400mm, Spiroll (Wellington) 200mm & 300mm,
Elematic (Christchurch) 200mm, 300mm & 400mm.
(iii) The top surface of the Stahlton Hollowcore unit shall have a nominal
roughness of 2mm or more as stipulated in NZS3101:2006 clause 18.5.4.1(c).
(iv) The tolerance for length of the Stahlton Hollowcore units shall be in
accordance with NZS 3109 (usually +/- 15mm).
Temporary Propping
(i) Design of temporary propping, back propping, bracing systems and
ground conditions to support prop loads shall be carried out by a suitably
qualified Engineer.
(ii) Propping shall not be removed until the topping concrete has reached
at least 75% of the 28 day strength.
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Topping Concrete
(i) The top surface of the Hollowcore units shall be clean and free of all
dust, oil or any deleterious substances which may adversely affect the
wet topping bond to the Hollowcore units.
(ii) Pre-wet precast concrete surfaces prior to placing the topping concrete.
(iii) Free water shall be broomed away before the topping is applied.
(iv) Topping reinforcement shall be laid and supported to the Specifying
Engineers requirements and shall be supported to prevent displacement
during concreting.
(v) Topping concrete shall have a minimum aggregate size of _______
(normally 13mm) and a 28 day strength of _______ (minimum of 25MPa)
and be well compacted with mechanical vibrators.
(vi) Topping concrete shall be poured to a true surface so that the
specified thickness of _______ (minimum of 65mm) is achieved at the
centre of the span. The key-ways between each Hollowcore unit must
also be filled with well-compacted topping concrete.
(vii) In-situ concrete shall be cured by the application of an approved
curing membrane or by being kept continuously wet for not less than
seven days.
Pg 11
Pg 14
Pg 11
Pg 13
Pg 14
Pg 12
Pg 13
Pg 12
Key Plan
Scale: NTS
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10
11
Section 1
Scale: NTS
Section 2
Scale: NTS
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**
**
Section 3
Scale: NTS
** 75mm minimum, wider may
be required by specific design'
Section 4
Scale: NTS
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12
13
Section 5
Scale: NTS
Section 6
Scale: NTS
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Section 7
Scale: NTS
Section 8
Scale: NTS
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14
15
Scale: NTS
Fixings to Hollowcore
Scale: NTS
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Scale: NTS
Support
Scale: NTS
Handling
Scale: NTS
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16
17
Scale: NTS
Scale: NTS
Scale: NTS
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Scale: NTS
Scale: NTS
Scale: NTS
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18
19
Scale: NTS
Scale: NTS
Scale: NTS
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20
Level/Grid:
Project Name:
12
16
20
24
Compare
factored
design load
with this axis
5.5
Date:
Project Number:
6.5
7.5
8.5
65mm topping
Span, m
2000mm module
1800mm module
90mm topping
Notes:
Superimposed Loads
21
Level/Grid:
Project Name:
12
16
20
24
Compare
factored
design load
with this axis
Date:
Project Number:
10
65mm topping
90mm topping
Span, m
2000mm module
1800mm module
Notes:
Superimposed Loads
22
Level/Grid:
Project Name:
12
16
20
24
Compare
factored
design load
with this axis
10
Date:
Project Number:
11
12
14
15
65mm topping
Span, m
13
2000mm module
1800mm module
90mm topping
Notes:
Superimposed Loads
23
Level/Grid:
Project Name:
12
16
20
24
Compare
factored
design load
with this axis
13
Date:
Project Number:
14
15
16
17
1800mm module
Span, m
2000mm module
18
65mm topping
90mm topping
Notes:
Superimposed Loads
0800 STAHLTON
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The recommendations in this literature are based on good engineering judgement and building practice, but are not an exhaustive statement of all relevant information that needs to be considered to comply with the NZBC.
Further, as the successful performance of the relevant system depends on numerous factors outside the control of Stahlton Engineered Concrete (eg quality of workmanship on site) Stahlton Engineered Concrete shall not
be liable for the recommendations in this literature and the performance of the relevant system, including its suitability for any purpose or ability to satisfy the relevant provisions of the NZBC, regulations and Standards.