HOLLOW CORE FLAT FLOOR PLANKS Design and application guide

Fast installation regardless of weather.

Immediately loadable. No temporary supports needed.

High load bearing capacity. Span up to 18 m. Can be cut to desired length.

Flat and smooth top and bottom surface, no plasterwork needed.

Recommended top and intermediate slab system for family and apartment houses, factory halls.

1. Product brochure
In 1999 SW Umwelttechnik ptelemgyr Kft. started to manufacture slab elements introduced in application guide. The products are manufactured by modern, extrusion technology. Planks of great span and various load bearing capacity can be manufactured by extrusion technology. Planks are made on 1.2 m wide and 130/170 m long line and can be cut into pieces of arbitrarily sizes after manufacturing. Planks are cut with diamond disc cutters. Elements with the same height may have different reinforcements. The hollow core plank product family has Building Technical Permit, with number: A-50/2003. The hollow core plank product family has European trade certificate. Number of certificate: 1831-89/106/CEE-1999/94/CEE-94-07 Fire resistance limit of slabs: FR = 1,5 h.

2. Technical data, available elements

Pre-strained MF floor planks have constant cross sections, but the elements width can be reduced by cutting. Six different slab thicknesses are available. Available span ranges and cross sections. MF-200 L=4,0 - 9,0 m MF-265 L=6,0 - 12,0 m MF-320 L=7,0 - 15,0 m MF-400 L=9,0 - 18,0 m MF-450 L=10,0 - 19,0 m MF-500 L=13,0 - 22,0 m

Annotation schema for the elements is as follows: E.g.: MF 200 B 7,10 MF-200/B-7,10 SW Umwelttechnik slab thickness in mm reinforcement schema B full length of the panel in meters

If bearing for the ordered element is not yet specified, clear width between walls should be also specified (see 3. Installation regulations)

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Concrete quality of panels: Pre-stressing tendons used:

C50/60XC1 Fp-100/1770-R2 Fp-55/1770-R2

Masses of elements are given by manufacturing parameters. Load bearing capacities were determined according to present structural regulations and standards: MSZ EN 1992-1-1:2004. 1. Serviceability limit state: qser

Load level for Wk<=0.2 mm crack width limit (qser2) Load level for deflection of L/250 limit (qc).

2. Load bearing limit state (limit load): qrd Limit load is determined from moment (MRd) and shearing (Vrd) resistances. Loads in the diagrams are in kN/m2 and apply for properly installed slabs. Warning During calculations, extreme values of loads (multiplied by the safety coefficient) shall be compared to values of the diagram. When examining serviceability limit state, relevant EC impact-combinations (frequent and quasi-static) shall be used for design values of loads. Outer dimensions and load bearing diagrams are shown in Appendix 1. SW Umwelttechnik hollow core planks
Mrd (kNm) MF-200/B MF-200/D MF-265/A MF-265/B MF-265/C MF-320/A MF-320/B MF-320/C MF-320/D MF-320/E MF-400/A MF-400/B MF-400/C MF-400/D MF-400/E MF-450/A MF-450/B MF-450/C MF-450/D MF-450/E MF-500/A MF-500/B MF-500/C MF-500/D 101,01 140,05 169,06 225,54 278,41 210,26 280,19 350,18 404,61 462,08 269,01 358,56 527,44 608,73 760,65 305,57 407,37 509,26 600,77 697,56 667,14 782,85 887,92 1037,41 Vrd (kN) 69,96
83,65 84,28 98,09 110,31 93,00 109,24

dead weight of planks (kN/m2) 2,36 2,36 3,28 3,28 3,28 3,65 3,65 3,65 3,65 3,65 4,15 4,15 4,15 4,15 4,15 4,80 4,80 4,80 4,80 4,80 6,00 6,00 6,00 6,00

Positions of tendons 5Fp100/1770-R2 7Fp100/1770-R2 6Fp100/1770-R2 2Fp55+8Fp100/1770-R2 2Fp55+10Fp100/1770-R2 2Fp55+6Fp100/1770-R2 2Fp55+8Fp100/1770-R2 2Fp55+10Fp100/1770-R2 2Fp55+12Fp100/1770-R2 2Fp55+14Fp100/1770-R2 3Fp55+6Fp100/1770-R2 3Fp55+8Fp100/1770-R2 3Fp55+12Fp100/1770-R2 3Fp55+14Fp100/1770-R2 3Fp55+16Fp100/1770-R2 3Fp55+6Fp100/1770-R2 3Fp55+8Fp100/1770-R2 3Fp55+10Fp100/1770-R2 3Fp55+12Fp100/1770-R2 3Fp55+14Fp100/1770-R2 3Fp55+12Fp100/1770-R2 6Fp55+14Fp100/1770-R2 6Fp55+16Fp100/1770-R2 6Fp55+19Fp100/1770-R2

123,74
135,23

145,98
104,45

123,30
154,04 167,56

187,70
108,61

128,35
146,18

161,00
175,50 184,48 198,96 214,58 236,99

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3. Regulations for installation

Planks are to be installed by structural plans, considering the following: Planks must not be used as continuous structures, with intermediate supports. MF planks must be laid on structures which are able to bear loads of the slab, meeting requirements of deformation limits specified in the relevant standard. Bearing of planks is L/100, minimum 10 cm Planks are to be laid on even surfaces. If the surface that planks to be laid on is uneven, it must be level before installation. Planks can be laid on grouting or NEOPERN strips with minimum thickness of 5 mm. Thickness of grouting must exceed 10 mm, with minimum H25 quality. Load bearing parameters of elements are shown in attached diagrams and tables. If specific loads calculated by the Engineer do not exceed values in diagrams and tables, and calculated operating loads do not exceed the maximum value, it is not necessary to examine deformations and crack width of elements by calculations. Lateral stress sharing can be considerd, but only if quality of grouting meets the specified requirements. Load distribution schema between neighboring planks is shown on Figure 1. If the Engineer does not use more precise calculations, this schema is to be applied. A maximum of 15 % of loads of a plank is allowed to carry over to a neighboring plank. In-situ concrete topping is necessary if loads are unevenly distributed on the slab, or the Engineer prescribes, or because of the arrangement of building. (Minimum thickness: 5cm, strength: C20/25)

Figure 1

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Typical details at ring beams are shown on Figure 2.

L/100 min. 10cm L/100 min. 10cm

L/100

min. 10cm

Figure 2 1. MF floor plank 3. Plastic plug of cores 5. Load bearing wall 7. Tieback rod 9. Precast reinforced concrete girder * Cast in-situ if needed) 2. Dewatering hole 4. Grouting 10 mm 6. Engineered ring beam reinforcement 8. Thermo insulation

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Dewatering holes are necessary when cores of planks of non damp proof floors are filled up with water, mostly in winter months, during constant rain or snow melting. Water content of the cores of the planks can be checked by boring the planks; if water was found, dewatering holes are to be bored for all cores, at the end of the elements. The Manufacturer closes cores of the planks with plastic plugs preventing concrete from getting in the cores during building the ring beams. Planks shall be tied into ring beams. Diameter of the tying bars depends on the span: Recommended minimum values: up to 6 m span between 6-9 m span 8 mm 10 mm 12 mm tying bars are to be installed at the panels ends (B60.50 or Bst500)

above 9 m span

Gaps between the planks shall be cleaned, and reinforcement specified in structural plans shall be installed in prior to casting ring beams and grouting gaps. When aesthetic factors are involved, before pouring concrete, undersides of planks shall be checked if they share the same plane. Installation of neighboring planks of different strength may result in vertical differences between bottom levels of the elements. Appropriate propping can provide the same level for the bottoms of the planks. Ring beams and fill in gaps shall be cast of concrete: min. C20/25

During building, planks shall be protected from stormwater. Planks do not need rendering, joints of the slab can be smoothed by special works. Electrical cables, pipes and ducts can be fastened to the underside of the planks. However, these cables, pipes and ducts can be only fastened if the load bearing capacity of the floor is sufficient for additional loads. Bottom of planks can be drilled, dubeled in centerline of cores. Figure 4 Screws can be driven through planks in line of cores. Figure 5 Suspension screws can be fixed in installation gaps, before grouting. Figure 6

Figure 4

dbel

Figure 5

Figure 6

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Floor openings During manufacturing and installation, holes and openings are allowed to be drilled in the planks only after discussions with the Manufacturer. After manufacturing, openings are cut in the elements by diamond disc cutter. Cantilevered installation After discussions with the Manufacturer, floor planks can be installed cantilevered with a maximum cantilever length of 1.2 m Suspension After discussions with the Manufacturer, floor planks can be installed suspended on the neighboring planks, with maximum plank width of 1.2 m., providing larger floor openings. MF floor planks are applicable: -- for precast frame structures and traditional or monolithic reinforced concrete systems, which provide required bearing and structural strength -- for locations where loads of planks do not exceed load bearing limits. -- suitable structural joints can be built -- limit of fire resistance of planks meets required values -- where environment is not aggressive for concrete and steel, and sufficient corrosion protection, waterproofing and thermal insulation of structures is provided by plans of the Engineer

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4. Quality requirements
Since no plasterwork is to be applied, the following are not allowed on the bottom of planks: bulges, knobs hardly removable contamination showing Size tolerances Length: Width: Hight: Concrete thickness above/beneath hollow core: Axis of pre-stressing tendons: Tendon pulled in: Slant of faces: Upward camber max: Deviation from calculated upward camber: Size of bites: Minimum concrete cover on tendons: 15 mm 5 mm h/30 mm 20 % 10 mm max 4 mm 10 mm l/300 15 mm 25 mm Cmin 2,5D (D: tendon diameter)

5. Transportation, lifting and storage of the elements

Since planks are manufactured by extrusion technology and the elements have no lifting ears, special lifting straps with clamps are to be used for lifting (see Figure 7). The equipment is available for sale or rent from the manufacturer.

60 max. 100 cm

Figure 7

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Lifted planks must remain horizontally stable. During lifting, elements must be protected from bumping against structures or other objects. Safety chains are to be driven under the planks at clamps, and chains are to be removed only after planks had been laid. Removal of the chain is followed by precise installation of the element. Equipment shown on Figure 7 are not to be used to lift thin or greatly bitten elements. For these cases, the Manufacturer installs lifting ears in the precast product: in place of the ears, walls of cores are opened, ears are installed, then cores are filled with concrete (see Figure 8). Safety chains are to be used in these cases too, similarly to when the planks are lifted by straps and clamps.
lifting hook

lifting hook concrete fill

lifting hook

lifting hook

Figure 8 Elements are to be stored in a flat, hard area. Elements are to be stacked in maximum five rows, separated with spacers installed along the same vertical line. Recommended distance of spacers from ends of the elements is 30 cm. During transportation, elements are to be supported in an identical way. Transported elements are to be protected from tilting and slipping.

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Area of cross section: 1182 cm2

Mass: 236 kg/m2

Volumetric density: 2400 kg/m3

PCE_EC2_09 15_200_Diag EC2-EN

Limit load

2007.10.08; 10:27

[kN/m2] L [m]
PCE_EC2_09 15_200_Diag; Limit load

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PCE_EC2_09 15_200_Diag EC2-EN

Cracking load

2007.10.08; 10:27

[kN/m2] L [m]
PCE_EC2_09 15_200_Diag; Cracking load

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PCE_EC2_09 15_200_Diag EC2-EN

Cracking limit wk=0,2 mm

2007.10.08; 10:27

[kN/m2] L [m]
PCE_EC2_09 15_200_Diag; Cracking limit

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PCE_EC2_09 15_200_Diag EC2-EN

Deflection L/250

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2007.10.08; 10:27

[mm] L [m]
PCE_EC2_09 15_200_Diag; Deflection

PCE_EC2_09 15_200_Diag EC2-EN

Upward cambering

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2007.10.08; 10:27

[mm] L [m]
PCE_EC2_09 15_200_Diag; Upward cambering

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Area of cross section: 1642 cm2

Mass: 328 kg/m2

Volumetric density: 2400 kg/m3

PCE_EC2_09 15_265_Diag EC2-EN

Limit load

2007.10.08; 10:34

[kN/m2] L [m]
PCE_EC2_09 15_265_Diag; Limit load

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PCE_EC2_09 15_265_Diag EC2-EN

Cracking load

2007.10.08; 10:34

[kN/m2] L [m]
PCE_EC2_09 15_265_Diag; Cracking load

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PCE_EC2_09 15_200_Diag EC2-EN

Cracking limit wk=0,2 mm

2007.10.08; 10:34

[kN/m2] L [m]
PCE_EC2_09 15_200_Diag; Cracking limit

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PCE_EC2_09 15_265_Diag EC2-EN

Deflection L/250

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2007.10.08; 10:34

[mm] L [m]
PCE_EC2_09 15_265_Diag; Deflection

PCE_EC2_09 15_265_Diag EC2-EN

Upward cambering

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2007.10.08; 10:34

[mm] L [m]
PCE_EC2_09 15_265_Diag; Upward cambering

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Area of cross section: 1830 cm2

Mass: 365 kg/m2

Volumetric density: 2400 kg/m3

PCE_EC2_09 15_320_Diag EC2-EN

Limit load

2007.10.08; 10:37

[kN/m2] L [m]
PCE_EC2_09 15_320_Diag; Limit load

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PCE_EC2_09 15_320_Diag EC2-EN

Cracking load

2007.10.08; 10:37

[kN/m2] L [m]
PCE_EC2_09 15_320_Diag; Cracking load

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PCE_EC2_09 15_320_Diag EC2-EN

Cracking limit wk=0,2 mm

2007.10.08; 10:37

[kN/m2] L [m]
PCE_EC2_09 15_320_Diag; Cracking limit

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PCE_EC2_09 15_320_Diag EC2-EN

Deflection L/250

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2007.10.08; 10:37

[mm] L [m]
PCE_EC2_09 15_320_Diag; Deflection

PCE_EC2_09 15_265_Diag EC2-EN

Upward cambering

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2007.10.08; 10:34

[mm] L [m]
PCE_EC2_09 15_265_Diag; Upward cambering

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Area of cross section: 2074 cm2

Mass: 415 kg/m2

Volumetric density: 2400 kg/m3

PCE_EC2_09 15_400_Diag EC2-EN

Limit load

2007.10.09;18:14

[kN/m2] L [m]
PCE_EC2_09 15_400_Diag; Limit load

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PCE_EC2_09 15_400_Diag EC2-EN

Cracking load

2007.10.09; 18:14

[kN/m2] L [m]
PCE_EC2_09 15_400_Diag; Cracking load

- 29 -

PCE_EC2_09 15_400_Diag EC2-EN

Cracking limit wk=0,2 mm

2007.10.09; 18:14

[kN/m2] L [m]
PCE_EC2_09 15_400_Diag; Cracking limit

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PCE_EC2_09 15_400_Diag EC2-EN

Deflection L/250

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2007.10.09; 18:14

[mm] L [m]
PCE_EC2_09 15_400_Diag; Deflection

PCE_EC2_09 15_400_Diag EC2-EN

Upward cambering

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2007.10.09; 18:14

[mm] L [m]
PCE_EC2_09 15_400_Diag; Upward cambering

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Area of cross section: 2390 cm2

Mass: 480 kg/m2

Volumetric density: 2400 kg/m3

PCE_EC2_09 15_450_Diag EC2-EN

Limit load

2007.10.09; 18:32

[kN/m2] L [m]
PCE_EC2_09 15_450_Diag; Limit load

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PCE_EC2_09 15_450_Diag EC2-EN

Cracking load

2007.10.09; 18:32

[kN/m2] L [m]
PCE_EC2_09 15_450_Diag; Cracking load

- 35 -

PCE_EC2_09 15_450_Diag EC2-EN

Cracking limit wk=0,2 mm

2007.10.09; 18:32

[kN/m2] L [m]
PCE_EC2_09 15_450_Diag; Cracking limit

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PCE_EC2_09 15_450_Diag EC2-EN

Deflection L/250

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2007.10.09; 18:32

[mm] L [m]
PCE_EC2_09 15_450_Diag; Deflection

PCE_EC2_09 15_450_Diag EC2-EN

Upward cambering

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2007.10.09; 18:32

[mm] L [m]
PCE_EC2_09 15_450_Diag; Upward cambering

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Area of cross section: 3040 cm2

Mass: 600 kg/m2

Volumetric density: 2400 kg/m3

PCE_EC2_09 15_500_Diag EC2-EN

Limit load

2007.10.08; 10:45

[kN/m2] L [m]
PCE_EC2_09 15_500_Diag; Limit load

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PCE_EC2_09 15_500_Diag EC2-EN

Cracking load

2007.10.08; 10:45

[kN/m2] L [m]
PCE_EC2_09 15_500_Diag; Cracking load

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PCE_EC2_09 15_500_Diag EC2-EN

Cracking limit wk=0,2 mm

2007.10.08; 10:45

[kN/m2] L [m]
PCE_EC2_09 15_500_Diag; Cracking limit

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PCE_EC2_09 15_500_Diag EC2-EN

Deflection L/250

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2007.10.08; 10:45

[mm] L [m]
PCE_EC2_09 15_500_Diag; Deflection

PCE_EC2_09 15_500_Diag EC2-EN

Upward cambering

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2007.10.08; 10:45

[mm] L [m]
PCE_EC2_09 15_500_Diag; Upward cambering

Sales management 2339 Majoshza Tkzi u. 10. Pf. 7 Tel.: +36 24 620 401 Fax: +36 24 620 473 ertekesites@sw-umwelttechnik.hu www.sw-umwelttechnik.hu

RO-305307 Ortisoara Str. Principala nr. 680, jud. Timis Tel.: +40 256 296 168 Fax: +40 256 247 509 office@sw-umwelttechnik.ro www.sw-umwelttechnik.ro

Jun trieda 125, 040 01 Koice Tel.: +421 55 677 0655 Fax: +421 55 677 0655 office@sw-umwelttechnik.sk www.sw-umwelttechnik.sk

. 107045 . 4 8 .: +7 909 675 8092 /: +7 499 243 5560 laszlo.esztergalyos@sw-umwelttechnik.ru www.sw-umwelttechnik.ru

04053. . . 11-, 1. .: +38 067 131 4341 : +38 044 486 6241 nora.juhasz@sw-umwelttechnik.hu www.sw-umwelttechnik.hu

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