N STRESS FLOOR SLAB

2.)Interspan Floor Slab

The Interspan flooring system
consists of 200mm wide precast prestressed
concrete ribs spaced generally
at 900mm centres with timber infills
placed between them. The ribs have
variable depth to suit the projects
load/span requirements. This multi piece
system is tied together with a 75mm in
situ concrete topping and mesh
reinforcing. This system has the benefit
of being suitable for those tricky sites
where access is a problem or poor foundation conditions dictate the use of a comparatively lightweight
floor.
Flexible
Interspan is easily adapted to circular floor plans, where the use of other suspended flooring
systems is difficult. Large floor openings of up to 700mm between ribs are easily accommodated.
Timber Infills
Timber infill planks are merchant grade rough sawn timber. Timber infills should be dampened prior
to placing the concrete topping. Alternative timber types can be left with an exposed underside finish to
create an architectural feature, e.g. polyurethaned macrocarpa or rimu.
Sound Transmission
One of the major features of a concrete floor is the low sound transmission. The table below shows
sound transmission ratings achieved by Interspan.
Transport
Interspan Ribs must be handled and stacked at two points, at, or directly beside the lifting eyes.
Erection
It is recommended that Interspan ribs be ideally seated 75mm onto the supporting walls/beams, and
bedded on wet mortar, vinyl or plastic bearing strips to ensure an even bearing at the correct level.
Fire Resistance Rating
Standard Interspan provides a 1 hour fire resistance rating. An increased fire rating can be achieved
with specific design.
Alternative Flooring Systems
Hollowcore and Double Tees, are available for longer spans, and/or heavier loads.
Materials
Rib Strength= 42 MPa at 28 days Topping strength = 20 MPa minimum at 28 days
General
Topping thickness =75mm
Propping = from 1-4 props
Rib centres = 900mm
Fire rating 60 minutes

SPAN STRESS FLOOR SLAB

3.) Hallowcore Floors
Hollowcore is a 1200mm wide extruded, pre-stressed,
voided slab unit with a reinforced concrete topping.
Standard unit depths are 200, 300 and 400mm. Units are
cut to a c Hollowcore is a 1200mm wide extruded, prestressed,
voided slab unit with a reinforced concrete
topping. Standard unit depths are 200, 300 and 400mm.
Units are cut to a customised length and may have raking
ends. Hollowcore is ideally suited for large floor spans with
commercial loading.ustomised length and may have raking
ends. Hollowcore is ideally suited for large floor spans with
commercial loading.

Sound Transmission
One of the major features of a concrete floor is the low
sound transmission. The table below shows sound
transmission ratings achieved by Hollowcore floors.
Lifting and Handling
Hollowcore floor slabs must be handled and supported
near their ends at all times. Fabric strops, purpose made
clamps or lifting forks are recommended for installation.
Chains or wire strops can be used but may cause some
edge damage. Safety chains must always be used under
units where clamps are used.
Erection/End Seating
A seating length of 75mm is recommended. Top surface of support should be packed using either
damp mortar or a plastic bearing strip. Slabs must be positioned in contact with neighbouring units
(unless otherwise noted). It is recommended to start placement working from the centre of the building
out (where possible) as any construction tolerance can be spread over both sides of the slab area.
Props
End props must be provided where they are required for stability of edge loaded beams.
Fire Resistance Rating
A standard fire resistance rating of Hollowcore units in the load span tables is 2 hours. Fire
resistance ratings are unrestrained ratings and are based on minimum strand cover and equivalent
concrete thickness requirements.
Shear Capacity
The shear capacity of extruded floor slabs is adequate for the uniformly distributed loads given in
the load/span graphs. Concentrated loads near supports may result in high shear or strand bond
stresses. Extruded slabs are not recommended for highway loadings, in truck docks or similar areas
with high shear loads.
Fastenings and Suspensions
Light fastenings can be fixed in the area between strands by means of different anchors, bolts and
screws. No fastenings must be attached within a 30mm radius of the pre-stressing strands. Heavier
fastenings can be attached either in the joint between slabs or through the slab itself. The extra load
due to suspension must be taken into account in the design calculations.
A suspension point can be made at the joint between slabs by anchoring
a steel rod into the joint concrete using a hook or welded steel piece on
the end of the rod.
Penetrations
Small holes and recesses between strands at the position of the
voids are usually made on the building site. Holes may be circular or
rectangular, and up to three are permitted in the same cross section
(two for 300mm and 400mm units). Holes are considered to be in the
same cross-section if they are less than 750mm apart in the longitudinal slab direction. When making
holes, great care must be taken not to damage the slab. It is particularly important that the pre-stressing
strands are not cut or exposed.
Water in Cores
Some construction practices and weather conditions can result in water being trapped in the cores.
Holes may be drilled in the ends of all units to drain this water.
Materials
Strand - Stress relieved 7 wire strand to BS 5896 Topping strength = 20 MPa minimum at 28 days.
Unit strength = 42 MPa at 28 days minimum.
Hollowcore may be designed for other uses such as wall cladding, and retaining wall structures.

4.) Double Tee Floors

Double Tee flooring units consist
of two pre-stressed ribs and a
connecting top slab. The ribs can
vary in depth from 200 to
500mm.The connecting slab is

2400mm wide x 50mm thick. Double

Tees are ideally suited for larger
spanning floors with a wide variety of
services suspended from the flooring
system. Double Tees can easily
accommodate large floor
voids/penetrations through the slab
region.
Sound Transmission
A major practical benefit of a
concrete floor is its ability to reduce
noise transmission. Double Tee
concrete floors are quiet and do not
creak with temperature and moisture
changes. The table below shows
sound transmission ratings achieved
by Double Tees.
Material
Double Tee concrete strength = 42 MPa.
Topping concrete strength = 20MPa.
Topping thickness = 65 mm

SPAN STRESS FLOOR SLAB

Fire Resistance Rating
2400 wide unit = 90 minutes.
Bearing Capacity
Where high shear loads are combined with support beams or walls of low material strength, a
bearing capacity check according to NZS3101 should be made; e.g. masonry bearing walls.
Lifting
Lift Double Tees only at the lifting points provided. Chains or strops must be of correct length to
carry equal load and must not be more than 300 off vertical.
Storage
Double Tees if stored on site must be supported at their ends on firm ground. Bearers between
layers in a stockpile must be vertically above each other and units of varying length should not be
stacked upon each other. Ensure the bottom bearers are not pushed into the ground, resulting in the
bottom unit being supported near mid span.
Seating
Flange supported Double Tees must be bedded on a sand cement mortar (the consistency of block
laying mortar). This must be evenly spread just prior to the unit being placed. Double Tee legs should
be placed on cement mortar or on plastic bearing pads. Double Tees are designed as pre-stressed
sections as per NZS3101: Part 1:1995. For minimum seating requirements refer to NZS3101: Part
1:1995, section .3.6.4.
When choosing the right flooring unit for your project, you may need to consider the following:
Ceiling Profile
Unispan and Hollowcore have a flat unit profile, which may be left uncovered eliminating the need
for a suspended ceiling to achieve a flat look.
Interspan and Double Tees have a stepped profile and are easily fitted with a suspended ceiling to
achieve a flat look. A stepped profile has the advantage of being able to run services parallel between
the vertical ribs.
Floor Loading And Design Services
Each floor unit is individually designed to comply with the requirements of the New Zealand
standards and Building Code. To ensure best practice, our staff maintains contacts with international
professional groups and industry leaders.
Overall Floor Depth
The overall depth of the flooring system will vary depending on the concrete topping thickness
(typically a minimum of 65 mm), flooring unit depth (dependant on span and load) and the ceiling cavity
depth. For residential construction, Unispan is typically the shallowest flooring unit followed by

Interspan. For commercial construction, Hollowcore is typically the shallowest flooring unit followed by
Double Tee's.
Floor Penetrations / Openings
Interspan and Double Tee's can easily accommodate large floor penetrations. Most penetrations,
both large and small can be allowed for in the flooring units with forward planning and specific design. It
is more difficult to accommodate large penetrations in Unispan and Hollowcore because of the number
and location of the pre-stressing strands in the units. Our designers are able to offer you advice on how
best to deal with each situation.

SPAN STRESS FLOOR SLAB

Floor Finishes
All of the flooring units are typically designed to have a cast in situ concrete topping. The quality of
finish and treatment of the concrete topping surface should be specified and be compatible with any
secondary finishes.
Transportation
Individual flooring units vary in weight and size and normally require trucking and craneage
On Site Installation And Handling
All of our units require some form of on site mechanical handling. Crane capacity and site access
should be considered when choosing a flooring unit. Interspan is the easiest and lightest unit to install,
followed by Unispan, Hollowcore and Double Tee's.
Durability
Our standard flooring units can be designed for interior and exterior use. We should be made aware
of the particular conditions at time of placing order.
Fire Resistance
Flooring units require different fire ratings depending on their utilisation and location within the
structure. We should be made aware of any special fire rating requirements and our design team will
incorporate these requirements into our design.
Precamber
All of the flooring units are pre-stressed concrete elements. The pre-stressing force causes the unit
to have an upward (positive) precamber. Once the topping concrete is placed, the precamber will
normally reduce to a more level (neutral) position.