PRECAST SOLUTIONS:

FILIGREE SLAB SYSTEMS

PRECAST CONCRETE EQUIPMENT

DESIGN
MANUFACTURING
&
INSTALLATION

YO U R LO NG TE RM PARTNE R
ABOUT US
At Moldtech we are at your disposal to provide innovative solutions to any
kind of need in the area of moulds for the prefabricated concrete industry,
ranging from a custom designed mould to the installation of fully equipped
plants on turn-key basis.

Our manufacturing process is certified under ISO standard 9002 and our
products comply with all European standards.

Our factory, covering more than 15.000 sqm, has the latest production
technology and our workforce consists of a highly skilled and motivated
production team. We have our own design department where our engineers
create new products and adapt existing designs to the specific needs of our
clients. In addition, as a specialised company, we have the ability to be flexible
and to have close and efficient communication channels with our customers.

We offer a full service approach that begins in the design stage and covers
aspects like on-site installation, test production and after-sales service.
Nowadays our products are exported to 4 continents and international sales
represent about 80% of our business revenue. This catalogue will give you a
first idea about what we do and who we are, but we´ll gladly provide you more
information in order to explore possibilities of future cooperation.
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4 TECHNICAL DOCUMENTS – FILIGREE SLAB

Introduction

Every designer, architect or engineer, knows the great advantages of the use of filigree slabs in the
construction of floors, mezzanines or roofs.

The filigree slab allows to work with many design variants: arches, elements in wedge or of various
formats, hollows, integration of beams and brackets, etc.

The system is very simple: first we have the filigree slab, which is produced in a precast plant under
strict controls of all the technical aspects like reinforcements and concrete. Then the final thickness
of the floor is obtained on site by pouring a layer of concrete on top which absorbs the compression.

The installation of the filigree slab is very fast, because no formwork is needed. Moreover, no heavy
lifting systems are required, as the filigree slabs are light. Large surfaces are covered at one time.
Reinforcements and metal meshes are reduced to a minimum quantity.

The result is a monolithic, solid slab, with a high resistance to fire and excellent behaviour against
the noise.

The filigree slabs are widely used in simple and multifamily housing construction, institutional and
commercial buildings (schools, hospitals, offices), and they have a complementary use in infrastructure
works (for example to cover spaces between beams in bridges, tunnels, other uses).

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Predalle classification

Depending on the steel reinforced system, we can classify the filigree slabs into two big groups: The
CLASSIC FILIGREE SLAB and the PRESTRESSED FILIGREE SLAB.

Other technical aspects allow to classify filigree slabs into: ISOLATED, LIGHT, RIBBED, etc.

1) THE CLASSIC FILIGREE SLAB

TECHNICAL DEFINITION:

The CLASSIC or simply reinforced FILIGREE SLAB is a thin plate-shaped element, composed of a
layer of concrete, rebars and / or an electro-welded steel mesh, and can incorporate the necessary
steel bars for connection with other structural elements and reinforcements.

THE CONCRETE PLATE OF THE FILIGREE SLAB:

The concrete plate has different functions. First, it transmits the efforts to the inner reinforcement,
which thanks to the concrete coating is protected against the external elements (environment, fire,
etc.). The roughness of the upper part of the concrete contributes to a solid connection with the
concrete poured on top.

THE THIKNESS OF THE FILIGREE SLAB:

The thickness of the FILIGREE SLAB is variable and ranges from 40 to 150 mm. We could define the
standard thickness at 50 mm. The thickness will be defined, among other conditions, by the required
steel bars coating, the calculation of the reinforcement, the final thickness of the slab to be built, the
constructive details that the project demands and, of course, the local regulations to be applied.

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6 TECHNICAL DOCUMENTS – FILIGREE SLAB

THE WIDTH OF THE FILIGREE SLAB:

The width of the FILIGREE SLAB varies between 1200 and 2400 mm. The width is generally defi-
ned by the prefabricator and by the equipment used for the production, the possibilities of hand-
ling, transport and lifting on site, the customer requirements and the project details.

Although the casting equipment allows normally to produce slabs of various widths the ideal is to
standardize the widths so production can be optimized.

LENGHT AND SHAPE OF FILIGREE SLABS:

The length and shape of the slabs correspond to a given project. It is in this context that the FILI-
GREE SLABS are adjusted to a customized design which constitutes the strength of the FILIGREE
SLAB, as it allows to incorporate all kinds of elements, such as:

• Holes for all kind of installations.

• Reservations in light weight concrete for future holes.
• The inclusion of electrical installations (ceiling light boxes, etc.) and other facilities during
the production process of the FILIGREE SLAB, which allows to accelerate and simplify the
assembly process and construction on site.

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JOINTS AND CONNECTIONS BETWEEN FILIGREE SLABS:

The connection systems between different types of FILIGREE SLABS are accomplished by creating
a joint with chamfer. The shape of this joint will depend on the prefabricator, the design and the
type of interior finish that the client requires. In general, at these joints an elastomeric sealant is
used, based on a high performance polyurethane with high humidity curing and mono component,
which advantages are:

• Being a one-component, ready-to-use sealant, it reduces time, effort and need for mixing
equipment.
• Fast drying to the touch and final curing.
• High elasticity, cures to a solid, durable and flexible consistency with exceptional cut and
tear resistance.
• Excellent adhesion to most building materials.
• Excellent resistance to aging.
• Tested in all climates around the world.

THE QUALITY OF THE CONCRETE:

Both the quality and dosage of concrete can be adapted and adjusted to the demands of the pro-
ject. Manipulation, loads and the span determine the minimum required resistance.

In practice, the resistance characteristics of the concrete used in non-prestressed FELIGREE

SLABS for flooring vary between 25 and 30 N / mm2.

THE STEEL REINFORCEMENT OF THE SLAB:

The steel reinforcement from the slab is executed by using high strength steel or structural steel,
generally BE500 type with improved adherence through the use of electro-welded mesh, individual
bars or a combination of both.

A variety of options in the use of stirrups, pins etc.. makes it possible to adapt the FILIGREE SLAB
to different kind of project requirements.

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8 TECHNICAL DOCUMENTS – FILIGREE SLAB

The steel reinforcement of the classis FILIGREE SLAB performs numerous functions:

• It gives the FILIGREE SLAB the necessary rigidity during handling, transport and the
manipulation on site.
• Ensures, through the roughness of the concrete, the perfect union between the FILIGREE
SLAB and the cast concrete on site.
• Acts as a point of attachment during handling.
• Can be used as a separator for the upper reinforcement and mesh.

The steel reinforcement is composed of three elements. The two lower bars are an integral part
of the FILIGREE SLAB’S reinforcement, continuous sinusoidal diagonal reinforcements transfer the
stresses to the upper bar and the shear stress between the FILGREE SLAB and the fresh concrete
layer on top. The upper bar maintains the balance of the forces.

THE COMPRESSION LAYER

From the constructive point of view, the compression layer is the most important part of the slab.
It is the active layer of the slab. Once the FILIGREE SLAB is in place, the compression concrete is
poured on top at site.

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For the pouring of the concrete it must be taken into account:

• The Steel reinforcement of joints and connections

On the joints or joints of the FILIGREE SLABS, between the reinforcements, small connecting rods
will be placed, whose function is that the forged work in monolithic form, and to avoid the appearance
of fissures in the layer of compression and in the completion of the inferior face (Interior) of the
ceiling.

• The upper steel reinforcement mesh.

The upper rebars are mounted in all sectors where negative moments must be absorbed. These
reinforcements can be mounted on the reinforcements and can serve as stirrups.

• Supplementary reinforcement
All other reinforcement, indicated in the details of rebars assembly, must be considered and installed
in its correct position. These additional reinforcements may be necessary for a variety of reasons,
for example by the creation of beams incorporated in the slab, to prevent the punching effect of
columns, or by the reinforcement of perimeters or edges.

EQUIPMENTS AND INSTALLATIONS

All types of equipment and installations can be assembled and incorporated into the compression
layer, such as electric pipes, heating, drainage pipes, as well as large elements.This allows to avoid the
construction of suspended ceilings, with the consequent improvement in free height of mezzanines
or the optimization of building heights.

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10 TECHNICAL DOCUMENTS – FILIGREE SLAB

2) PRESTRESSED IGREE SLAB

TECHNICAL DEFINITION:

The PRESTRESSED FILIGREE SLAB is a thin plate-shaped element, composed of a layer of concrete,
in which the classic reinforcement is replaced by strands or PRESTRESSED cables, which, taking
advantage of this technique, increase the loads, the distances between supports and reduction of the
arrow, with the same sections of concrete.

The characteristics of PRESTRESSED FILIGREE SLABS are similar to the classic ones in terms
of details of finishes, dimensions and uses. We can define PRESTRESSED FILIGREE SLAB as a
prefabricated compressed concrete element that forms part of the base or bottom of the section
of a slab.

In this type of PRESTRESSED FILIGREE SLAB there are no triangular reinforcements, as can be seen
in the photo.

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COMPOSITION AND MANUFACTURING:

The PRESTRESSED FILIGREE SLAB replaces the traditional reinforcement with prestressed steel
strands with a high elasticity limit.The strands are positioned on the fixed production table and ten-
sioned before casting the concrete.

Once the concrete has acquired the required resistance, the cables will be de-tensioned and cut,
with the consequent compression of the concrete section.

The PRESTRESSED FILIGREE SLABS will be produced with a particularly resistant concrete, type
C30 to C37 (compressive strength of 40 Mpa at approximately 28 days)

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12 TECHNICAL DOCUMENTS – FILIGREE SLAB

For demoulding, a minimum curing time of 6 to 12 hours (depending on the type of concrete used
and the climatic conditions of temperature and humidity) must be observed.
To increase productivity, curing acceleration systems are usually used with the implementation of
hot water or steam heating circuits under the production tables.

Demoulding is performed once the resistance of the concrete has been verified by laboratory tests.
Mobile cranes or gantry cranes are used for demoulding, after this the product is transported to a
storage yard.

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Transportation to site is done by truck, so it is very important to verify the dimensions of the
elements that we are going to produce and the local transport regulations.

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14 TECHNICAL DOCUMENTS – FILIGREE SLAB

3) OTHER FILIGREE SLAB TYPES

FILIGREE SLAB WITH INSULATION LAYERS

This type of FILIGREE SLAB allows the incorporation of a thermal insulation.

This insulation, generally of high density expanded polystyrene, is incorporated in the FILIGREE
SLAB at the factory, which allows to reduce the execution times on site and to guarantee the results
of their use, given the previous tests.

The distance between insulating elements allows the arrangement of reinforcements and installations.

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LIGHT WEIGHT FILIGREE SLABS:

In order to reduce the overall weight of the slab, lightweight elements may be incorporated as a filler
in the areas of the section where the concrete is not structurally necessary.

These blocks or ceramic elements, polystyrene or PVC spheres allow working with lightweight
ribbed slabs of great bearing capacity, and which has a smooth lower face with all the features of
the FILIGREE SLAB. As in any normal or ribbed slab it will be necessary to incorporate transverse
stiffeners in case of load concentration.

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16 TECHNICAL DOCUMENTS – FILIGREE SLAB

4) ADVANTAGES

FILIGREE SLAB ADVANTAGES

The FILIGREE SLAB constitutes an important structural element for any building or construction.
They form a mesh link or fundamental connection to give stability to the building, create
horizontal separation of spaces (visual, acoustic and thermal), ensure the supporting function and
largely determine the visual aspect of space.

If we analyse the precast slabs, the FILIGREE SLAB is the closest to the slab cast in-situ. The final
product forms a monolithic assembly that guarantees the rigidity of the building. Therefore, it not
is necessary to use other stiffening elements such as lift or stair boxes.

We could mention the following additional advantages:

• The forge or slab built with FILIGREE SLAB is more economical than the one built in
traditional way and cast in-situ or that constructed with “T beams”.
• The execution speed allows to install 100 m2 in 2 hours and concrete in 48 hours.
• The slab built with FILIGREE SLAB is more resistant than built and cast on site to
equivalent steel sections.
• Less use of material on site, no formwork required, less use of struts, reduction of
reinforcement to be erected.
• The “prefabricator” guarantees the customer the strength, lights, loads and arrows.
• Excellent seismic behaviour.
• Lower (inner) face is finished. No ceilings required.
• Pre-installation (electric, etc.) included to reduce Works on site.
• Guarantee in the protection of reinforcements and coatings. Corrosion of
reinforcements is eliminated.
• Shipment to the site by truck. Assembly with crane. Reduction of work times due to
adverse climatology.
• Consulting and technical support by the “prefabricater”.
• Certification of the production processes, which gives absolute guarantees to the final
consumer.

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5) PHYSICAL CHARACTERISTICS

FIRE RESISTANCE

The fire resistance of concrete slabs can be determined by test or calculation. Fire resistance is
defined by the total thickness of the floor and the concrete cover of the main reinforcement.
The minimum thickness of the slab “hs” is the sum of the non-combustible thicknesses.

DURABILITY

FILIGREE SLABS are produced in precast industrial plants, under strict control and ideal condi-
tions. Thanks to the superior quality of the concrete elaborated in plant under controlled condi-
tions, the prefabricated concrete elements offer better physical qualities and suffer less influences
of the environment.

ACOUSTIC ISOLATION

The high volumetric mass of the final slab responds perfectly to the regulations and offers a good
sound insulation between floors.

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6) INTERIOR FINISHES AND DECORATION

JOINT MASHING

As the FILIGREE SLABS are produced in precast plants under strict quality controls in fixed metal
tables without deformations and on steel plates of 8 to 10 mm polished like mirrors, the quality
of the underside surface is excellent and impossible to overcome by any other technical solution
performed on site.

The custom-made production respecting the projects, allows working with the joints to adapt the
design.

To give a correct interior finish, once the joints have been installed, a thin plaster type can be
applied on the FILIGREE SLAB’s surface, on which one can apply paints bases and finishing’s
colours.

Interior design using PREDALLE

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As can be seen in the photos above, the finishing quality of the FILIGREE SLAB surface, without
the application of plasters or mastics, is very high. A solution applicable to high-quality housing and
social housing, office buildings, shopping centres, hospitals, equipment buildings, etc.

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20 TECHNICAL DOCUMENTS – FILIGREE SLAB

7) EXAMPLES OF LOADS AND SPANS FOR DIFFERENT USES

These tables are only examples that must be verified for each local regulation.

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These tables show the great advantage of working with PRESTRESSED FILIGREE SLAB,
mainly in housing and office projects.

In the commercial sector, they move freely and are very competitive. In the industrial sector,
they are excellent covering mezzanines of offices or warehouses, decks, etc.

The PRESTRESSED FILIGREE SLAB compete with great advantages over T beam slabs,
hollow core slabs, post-tensioned slabs and slabs using steel plates.

MOLDTECH fixed tables, using hot water heating systems for

the production of precast slabs and panels.

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 Diseñamos,
desarrollamos y fabricamos
proyectos flexibles
adaptados a las necesidades de cada
cliente.
 SEVILLE, SPAIN, EUROPE

C/ Polysol Uno, 40
Pol. Industrial Piedra Hincada
41500 Alcalá de Guadaira, Sevilla

Ph_ +34 955 44 41 90

E_ info@moldtechsl.es

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