From: International Prestressed Hollowcore Associations (Ipha)

From: INTERNATIONAL PRESTRESSED HOLLOWCORE ASSOCIATIONS (IPHA)
https://hollowcore.org/hollowcore/production/
1) DRAWING, DESIGN AND PLANNING

- Designed using 3D CAD software.
- Design loads are used to calculate the depth and wire patterns of the slabs. (depending
on the spans required)
- Transfer into production plan for the factory to maximize efficiency and minimize waste.
- Production plan include information such as:
o Cutting slabs to length
o Detailing requirements (insertion of lifting pins, notches and exposed cores)
2) BED PREPARATION
- Hollow core slab is cast onto beds that are typically upwards of 100m in length.
- Before casting, there are numbers operations required in order to prepare them:
o Must be cleaned of any debris from previous casting cycles Carried out by
o Sprayed with an oil release agent. multipurpose
- The pre-stressing tendons must lay down on the bed for preparations machine or bed
of tensioning. cleaner
3) PRE-STRESSING
- Involves the application of load into the high-strength, low-relaxation tendons prior to
casting
- Usually either single ply wire or multi-wire strand (ranging from 5mm-15mm diameter)
- The tendons are tensioned either individually or all at once. (known as multi-stressing)
- Accomplished using hydraulic pumps and jacks/cylinder, with the tendons anchored in
abutments at either end of the bed.
- Once the desired load is achieved (typically 70% of ultimate tensile strength), the
tendons are locked into place.
4) Concrete Batching and Distribution
- The concrete mix required to manufacture hollow core slabs varies depending on the
casting machine used.
- Planetary/ twin shaft mixers are typically used.
- High quality materials are desirable, and may be supplemented with additive (admix)
chemicals.
- Once batched and mixed, the concrete may be delivered to the casting machine via a
concrete skip using:
o Mobile plant
o Overhead/semi portal cranes
5) CASTING
- Once concrete has been delivered to the casting machine, the form of the hollow core
slab begins. There are 3 types on casting machine:
o Extruder
i. Casts the slab using a dry mix with low cement content
ii. Compacts the concrete with high frequency vibration
iii. The buildup of concrete and auger drive moves the extruder down the
casting bed.
o Slip former
i. Cast the slab in 2 or 3 stages, using a drive mechanism and vibration to
form the slab around moving steel cores.
ii. Have flexibility to cast other elements that have a continuous profile.
o Flow former
i. Casts the concrete without mechanisms or drive units.
ii. The concrete flows by gravity and vibration.
iii. The process uses plastic quality concrete for versatility of cross section
profile options with smooth, rough or indented surface finish.
6) DETAILING
- Hollow core slabs often require additional detailing, such as openings, shelf-angles,
narrow widths, and insertion of lifting pins.
- Some factories may use an automated Plotter (which is linked to the design/planning
software – to accurately mark out these details and record data)
- Vacuum suction machines/aspirators can be used to remove concrete and create
openings.
- Wet cut saws are used to make longitudinal or ‘rip cuts’ in the fresh concrete.
7) CURING
- Once cast, insulated covers are normally used to assist with curing of the slabs, and to
retain moisture.
- Additional water or steam heating under the casting beds may speed this process up
further.
8) DETENSIONING
- Once the appropriate strength has been reached, the concrete will have bonded
effectively with the pre-stressed tendons.
- They can then be de-tensioned, capturing the pre-stressing load within the slab.
9) CUTTING
- Saws are used to cut slabs to the correct length, and at different angles.
- Water is used to dampen the blade and reduce dust.
- Additional cutting stations can sometimes be utilised outside of the factory.
10) STRIPPING OF BEDS

- Slabs are removed from the casting bed using clamps and lifting beams, in conjunction
with cranes.
11) STORAGE
- Slabs may be removed from the factory on bogeys, using forklift trucks, or side loaders.
-
- They are stacked on timber bearers in the stockyard.

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From: International Prestressed Hollowcore Associations (Ipha)

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From: International Prestressed Hollowcore Associations (Ipha)

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From: INTERNATIONAL PRESTRESSED HOLLOWCORE ASSOCIATIONS (IPHA)

1) DRAWING, DESIGN AND PLANNING

10) STRIPPING OF BEDS

- They are stacked on timber bearers in the stockyard.

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