Integration of services in Hollow Core Slab Systems

Introduction

Hollow Core slabs are among the most usable precast slab systems available for the construction
industry. Modular by design, they have standard width, depth and length combinations and offer a
wide range of possibilities for quick construction. As per the demand, they can be manufactured to
specifications, transported on flat-back trailer trucks, carried to the site and hoisted using a site
crane. The presence of hollow cores brings in the possibility of integrating service layouts into the
slab systems itself. The area of scrutiny, thus, explores the various ways or systems which enable
services integration in Hollow Core Slabs systems.

Keywords

Hollow Core Slabs, Service Layouts, Efficiency, Construction Technology, Cost and Maintenance

Aim

The study is concerned with investigating the various ways in which services can be integrated into
prefab hollow core slab systems

Objectives

-To explore scope of services integration with hollow core slabs

-To consider construction challenges and solutions

-To find out about the issues of cost and maintenance

Methodology

The approach would be primarily through literature study and case studies from secondary sources.
The method of analysis would majorly be qualitative in nature and the paper will be suggestive in
prescribing construction techniques and identifying cost-maintenance issues.

Anshuman Abhisek Mishra 2013BARC010

Gaurav Kumar 2013BARC040

Introduction

Hollow Core slabs are among the most usable precast slab systems available for the construction
industry. Modular by design, they have standard width, depth and length combinations and offer a
wide range of possibilities for quick construction. As per the demand, they can be manufactured to
specifications, transported on flat-back trailer trucks, carried to the site and hoisted using a site
crane. The presence of hollow cores brings in the possibility of integrating service layouts into the
slab systems itself. The area of scrutiny, thus, explores the various ways or systems which enable
services integration in Hollow Core Slabs systems.

Contents

 History
 Standards sizes
 Advantages highlighted by Manufacturers
 Usage and Application
 Cost, Life cycle & logistical benefits
 Scope for services integration
 Ducts and piping systems through
 Thermal

History

A hollow core slab, also known as a voided slab, hollow core plank or simply a concrete plank is a
precast slab of prestressed concrete typically used in the construction of floors in multi-story
apartment buildings. The slab has been especially popular in countries where the emphasis of home
construction has been on precast concrete, including Northern Europe and former socialist
countries of Eastern Europe. Precast concrete popularity is linked with low-seismic zones and more
economical constructions because of fast building assembly, lower self weight (less material), etc.
(rephrase_From wiki)

The precast concrete slab has tubular voids extending the full length of the slab, typically with a
diameter equal to the 2/3-3/4 of the slab. This makes the slab much lighter than a massive solid
concrete floor slab of equal thickness or strength. The reduced weight is important because it
lowers the costs of transportation as well as material (concrete) costs. (rephrase_From wiki)

Slabs in prestressed concrete are usually produced in lengths of up to 200 meters. The process
involves extruding wet concrete along with the prestressed steel wire rope from a moving mold.
The continuous slab is then cut by big diamond circular saw according to the lengths (and width)
required on blueprint. Factory production provides the obvious advantages of reduced time, labor
and training. (rephrase_From wiki)
Another fabrication system produces hollow-core floor slabs in Reinforced Concrete (not
prestressed). These are made on carousel production lines, directly to exact length, and as a stock
product. Especially in Belgium, this method is widely used in private housing. (rephrase_From wiki)

To meet modern standards (both hollow-core and massive slab) of soundproofing the floor needs to
be covered with a soft floor covering that is able to dampen the sound of footsteps or a floating
floor screed should be installed. An alternative is to put a strip of rubber underneath the floor slabs.

The voids of the hollow core can be used as conduit for installations. The interior of the core can be
coated in order to use it as a ventilation duct. (rephrase_From wiki)

Dimensions

The slabs are typically 120 cm wide with standard thicknesses between 15 cm and 50 cm.
Reinforcing steel wire rope provides resistance to bending moment from loads. The ones made on
carousel production lines are limited in length to about 7-8 metre.

Hollow-core slabs and wall elements without prestressed steel wire can be formed by extruders.
The size of these elements will typically range in width from 600 to 2400 mm, in thickness from 160
to 500 mm, and can be delivered in lengths of up to 24 m. (rephrase_From wiki)

In practice, a 75mm concrete screed is applied on top to give an even finish. This hides all
indications of the use of a precast slab system.

(source- https://precast.ag.uk.com/media/3950/hollowcore-live-loads-drawings-comp.png as
accessed on 18-11-17 at 1300hrs)

Site Installation

Hollow core slabs are quick and easy to install using mobile cranes or typical on-site tower cranes.

The erection time for a pre-fabricated building compared to a conventional cast in situ concrete
building can be reduced by up to 30%.

Factory produced hollow core slabs enable installation to take place during all weather conditions.
( https://www.termodeck.com/how.html )

(Source-
https://www.countymaterials.com/media/zoo/images/hollowcore_1_4a81dd8ee115509b8f1ad3a5
0ca6b551.jpg as accessed on 18/11/17 at 1245hrs)

Role of concrete in keeping a building cool

Concrete partially absorbs heat from the structure and its occupants, essentially removing heat
from the space and helping naturally cool the building. At some point during the day, the
supplementary cooling may be required, but for a relatively short time compared to conventional
systems.

By design, hollow-core slabs can intake and store cooler nighttime air, then release it when
required. The slab acts as a thermal ‘battery’, which can harness free cooling when available, and
can be mechanically charged at night when conditions are favorable (i.e.) when required. The slab
acts as a thermal ‘battery’, which can harness free cooling when available, and can be mechanically
charged at night when conditions are more favorable (i.e. when the sun is down and lights are off).
As well, for most of the year, the integration of hollow-core slabs with a ventilation system can
increase overall air quality by providing an increased flow of fresh air without the need for
supplementary heating or cooling.
In summer, cool night air (i.e. between 10 and 15 oC [50-50 oF]) can not only be circulated but also
stored in precast floors. In places, where the nighttime air is not cool enough, offpeak air
refrigeration may be needed to precool buildings.

When cooling or heating a building, dynamic energy exchange between exterior and interior should
be considered. The body heat generated by occupants is highly valuable thermal energy in winter,
and can be easily harnessed to maintain temperatures in the desired comfort zone without
overheating. When the thermal mass of a building is engaged through a hollow-core slab ventilation
system, heat gain generated from occupants, lights and appliances can be stored for later use. Air is
kept clean via filtration and is delivered at slightly lower velocities than with a conventional system,
which helps ensure concrete particles are not lifted. Hollow-core slab manufacturing also creates
minimal concrete particles in the core area. (rephrase_Hollow Core Slab Integration in Buildings
)

Activating Thermal Mass of Concrete

Using concrete in commercial, institutional, and residential buildings is ideal for low-energy design, and
for allowing a building to absorb and store energy, thanks to the material’s high thermal mass. This
quality also means a large amount of energy is required to alter concrete’s temperature, making it ideal
for a building where the goal is to maintain a consistent interior environment. Concrete works well in
passive structures that use an alternative energy source (e.g. solar or geothermal), as well as in active
building integrating hollow-core slabs with the HVAC system to store energy.
A hollow-core concrete building’s thermal mass also makes it more resilient than lighter structure,
allowing it to withstand extreme temperature changes and maintain comfort even during failure or
heating or cooling systems. The large surface area of these slabs helps preserve the building’s core
temperature for an extended period of time. The volumetric thermal capacity of concrete with a density
of 2300 kg/cum (143 lb/cf) is 2.07 MJ/cum per K (30.89 Btu/cf per F). In other words, if a building
requires the temperature of 1 cum (35 cf) concrete to be raised to 1 K (1.8F), it requires approximately
575 W-h (1962 Btu). The benefit of this is if the HVAC system fails, the building can still function and
remain comfortable.

In fact, the heat capacity of precast hollow-core slabs is estimated to be about 100 W-h/sqm per K (17.6
Btu/sf per F). In a conventional system (e.g. steel studs and drywall), the thermal exchange between a
room’s air and walls has a heat-transfer value of only about 10W/sqm per K (1.76Btu/hr/sf per F).
(rephrase_Hollow Core Slab Integration in Buildings )

Advantages

1) The long hollow cores (voids) can be used to run mechanical and electrical equipment.

2) The long span capabilities in hollow-core slab provides long and clear spans, opening interior
spaces in projects and allows designers to maximize functional layouts.

3) The high-strength hollow-core slabs can provide floors that support heavy loads.

4) Buildings (esp. tall buildings) that use hollow-core slabs have less vibrations than conventional
allow, along with a strong acoustical performance.

5) Hollow-core slabs are most helpful in meeting the requirement of separating parking and other
functional areas of the mixed-usage facility.
6) Cantilevered hollow-core slabs can provide monolithic balconies that are secure and quick to
construct.

7) Hollow-core slabs act as a ceiling and flooring unit and reduces the building height while saving
the cost.

8) The ducts in the Hollow-core slabs can save material and time by eliminating ductwork.

9) The Hollow-core slab can also be used as vertical or horizontal wall panels.

( http://preca.in/blog/9-uses-of-hollow-core-slab/ )

Advantages in cost savings

On average, about 75 per cent of the thermal energy available from tempered ventilation air can be
absorbed by a hollow-core slab. Consequently, using thermal properties of floors and ceiling as an active
battery is less expensive than alternative conventional mechanical systems. At the same time, these
systems naturally lend themselves to cost effective, net-zero construction.

Radiant air-conditioning systems with thermal storage work intuitively with fan-assisted ventilation
systems. The ventilation will push treated fresh air through a series of main ducts, fed into branch ducts
formed within the hollow-core slabs of ceiling or floors. As air passes along the ducts, the concrete
warms or cools the fresh air before supplying it to the occupied space. The building residents will benefit
from both better air quality and controlled temperatures.

Precast, prestressed hollow-core planks can be seamlessly integrated into a building distributing air
through their cores. They can be tied into various conventional HVAC systems to store energy for later
use, helping reduce greenhouse gas (GHG) emission and overall energy costs. Incorporating systems
with a high thermal mass is one way to adapt to the impact of rising temperatures and unstable weather
patterns directly linked to climate change.

Building implementing these methods can typically withstand significant outdoor temperature changes
and even energy disruptions with minimal impact, as the energy storage feature of hollow-core slabs
enables building occupants to remain ‘off-grid’ for extended periods. Commonly used in floors and
roofs, these systems can be paired with a ventilation system to provide both the thermal mass valued in
concrete and an energy storage solution. This type of material adapts well to hot, cold, and humid
environments, as it responds to the needs of various occupancy types and climatic zones.

Effectively, hollow-core slabs are an economical solution that can move an inert floor or roof from an
idle state to an intelligent one by capturing, storing, and releasing low-grade energy upon demand. This
can reduce or eliminate the need for heating and cooling from non-renewable sources and spread the
release of energy over a longer time. In case of a power failure or other climate-change-related events,
hollow-core concrete slabs will continue to release stored energy, ensuring the building is habitable and
providing a sustainable operation solution. (rephrase_Hollow Core Slab Integration in Buildings )

References

 ( http://preca.in/blog/9-uses-of-hollow-core-slab/ )
 Hollow Core Slab Integration in Buildings, Jack Lacken, Construction Canada
 https://www.countymaterials.com/media/zoo/images/hollowcore_1_4a81dd8ee115509b8f
1ad3a50ca6b551.jpg as accessed on 18/11/17 at 1245hrs

 ( https://www.termodeck.com/how.html )
 https://precast.ag.uk.com/media/3950/hollowcore-live-loads-drawings-comp.png as
accessed on 18-11-17 at 1300hrs