Precast Hollowcore & Solid Floors

Excellent sound-reducing qualities, durability and inherent fire resistance make our hollowcore slabs the solution of choice for apartments, care homes, hospitals and commercial projects.

Our precast hollowcore floors are available in sections 150, 200, 250 and 260mm deep. They can be delivered nationwide on a supply and install basis by specialised teams from Bison Precast, or supply only for installation by the main contractor.

Our precast hollowcore floor unit offers the ideal structural section, reducing deadweight whilst also providing maximum structural efficiency within the hollowcore slab depth.

Precast floors are available with a variety of factory-formed notches, slots and reinforcement arrangements to offer a range of structural design solutions.

 

Hollowcore Floors

Hollowcore floor slabs have excellent sound-reducing qualities, durability and inherent fire resistance making them the ideal solution for apartments, care homes, hospitals, schools, universities, hotels, custodial facilities, industrial and commercial projects.

Hollowcore Composite Floors

Our precast hollowcore composite combines hollowcore slab with a composite structural concrete topping. Ideal for applications where enhanced structural performance and lateral load distribution is required, such as in industrial buildings, and multi-storey buildings and car parks.

Solid Floors

Our solid floor prestressed units provide effective solutions for projects in a variety of sectors. They are manufactured in 100mm depths and are suitable for use in high-rise apartments, stadia, industrial and commercial projects.

Solid Composite Floors

Our solid composite floors combine solid prestressed units with a composite structural concrete topping that is applied after the solid slabs have been installed. Solid prestressed units are manufactured in 100mm depths and are suitable for many commercial applications

 

 

Insulated Hollowcore Floors

Our insulated hollowcore floor units feature expanded polystyrene bonded to the soffit of the unit. They are ideal for use at ground floor level construction and where increased U-values are required to meet Part L of Building Regulations.

Composite Steel Beams

Where hollowcore or solid flooring units bear onto structural steel work, significant economies can be achieved by designing the steel beam to act compositely with the precast units, enabling the possibility of a reduction in composite steel beam sizes, section weights of the steel frame, and the overall supporting structure.

 

All of the above product images are shown for illustration purposes only


CAMBER DETAILS

Bison Precast hollowcore units exhibit an upward curve known as camber which is a result of the compressive force near the bottom generated by the prestressing tendons.

An allowance of span/300 should be taken into account in floor finishes or bearing levels.

 

 

Design Benefits
  • Can be used in all types of structure – masonry, steel and concrete
  • Ideal structural section by reducing deadweight
  • Excellent sound reducing qualities and inherent fire resistance
  • Compatible with Robust Details for Part E of Building Regulations
  • Design support provided from concept through to project completion
  • Flexibility in design approach
  • Enhanced spans
  • Excellent sound and fire resistance
  • Pre-bonded insulation (insulated hollowcore)
  • Floor slabs and steel beams act compositely together to enhance load capacity of steel beams (composite steel beams).
  • Provides a structural and cost-efficient solution for steel frames (composite steel beams)
Suitable Applications
  • Residential – standard housing, retirement apartments, high-rise apartments, residential
    (single and multi-occupancy), care homes
  • Education – schools, universities
  • Industrial and commercial – office buildings, retail, distribution, manufacturing
  • Student accommodation
  • Stadia
  • Leisure – hotels, leisure centres
  • Custodial – prisons, custody suites
  • Healthcare – hospitals, healthcare centres
  • Car parks – steel frame, precast frame

 

Quality Benefits
  • Manufactured under factory-controlled conditions to maintain quality consistency
  • All precast concrete products and processes comply with all relevant standards and are manufactured in accordance with BS EN ISO 9001
  • Accredited to BS EN 14001 and BES 6001 responsible sourcing
  • Precast components are CE marked against BS EN 1168
  • Preformed site services

 

Construction Benefits
  • Clear, unpropped spans provide an immediate working platform
  • Fast and simple to erect
  • Cast in lifting hooks
  • Easier installation of services, with holes and notches pre-formed during manufacture
  • Virtually maintenance free – concrete is not subject to damage from rot or insect attack
  • Concrete floor eliminates squeaky floors
  • Precast floors are manufactured on high quality steel beds and, where appropriate, are suitable for direct decoration. Exposed soffits accommodated upon request.
  • Nationwide coverage
  • Supply only or supply and install services available
  • One or two-hour fire resistance
  • Type ‘A’ finished soffit
  • Shelf angle bearing
  • Sound resistance – noise transfer performance
  • Reduction of in-situ concrete
  • Design support provided from concept through to project completion
  • Can be used in all types of structure – masonry, steel and concrete
  • Reduces total tonnage of steel beams by up to 40% (composite steel beams)
  • Reduces the number of components to be erected (composite steel beams)
  • Reduced site operations (composite steel beams)
  • Optimisation of shear studs (composite steel beams)

 

Construction Details

Bearings can be taken from brickwork, blockwork, steel beam flanges or shelf angles and concrete.

Longitudinal joints: the sides of the slabs are cast with a shear key profile which when filled with C25/30 grade concrete distributes loads to adjacent units.

The nominal bearing for:
Masonry: 100mm

Steel: 75mm
Concrete: 75mm


BEARING ON MASONRY

Slabs are usually manufactured to have 100mm bearing onto a 100mm wide wall. However, where slabs share an intermediate wall, the wall must have a minimum thickness of 190mm.


SIDE BEARING

To provide effective lateral restraint, slabs are built into parallel spanning walls with a continuous bed of mortar between slab and wall. This not only seals the joint but ensures wall loads are transferred through the slab.

Where high wall line loads are present, the outer core can be filled solid to further enhance load transfer capacity of the slab.


NARROW WALL BEARING

For walls narrower than 190mm, slabs must be tied together to allow for construction and manufacturing tolerances. Typically, two cores per 1200mm-wide slab are formed open so that a reinforcement bar can be inserted across the slabs.

The cores are then filled in-situ with concrete to form the tie detail. The cores on opposing slabs must line up to facilitate this detail.

Note In order to satisfy the tolerances in this situation, this detail is only recommended where a full bearing is available at the other end of the slab.


BEARING ON SHELF ANGLES

Slabs can be formed with either reduced ends or a notched end to allow the slab to sit on the shelf angle.

The void between the unit and the steel beam is then filled with C25/30 grade concrete by the main contractor to tie the components together. The nominal bearing length is 75mm on steel work.


BEAMS WITHIN THE FLOOR DEPTH

To provide lateral restraint to the steel beam and to meet sound/fire requirements, it is necessary to fill the void between the hollowcore unit and the steel beam with C25/30 grade concrete.


BEARING ON TOP OF STEELWORK

Standard units can be provided for class 1 and 2A buildings with a nominal bearing of 75mm.


CONTINUITY OVER STEELWORK

Where the nominal bearing is less than 75mm, the same detail as used for masonry walls less than 190mm is required.


CONTINUITY WITH CONCRETE

Should continuity be required, then the same detail as for masonry walls less than 190mm can be used.

Note that the cores on opposing slabs need to line up to facilitate this detail.


TIE DETAILS

To comply with ‘disproportionate collapse requirement’, open cores can be provided to allow the slabs to be tied to shear studs.

This requires close co-operation to ensure that the setting out of the cores and shear studs align.


HOLES & NOTCHES

To accommodate service voids and column notches, the hollowcore can be pre-formed to individual requirements.

Large openings may require steel trimming supports. It is recommended that holes of less than 100mm diameter are drilled on site, on the centreline of cores.

 


CEILING FINISHES

A number of ceiling finishing options are suitable for hollowcore units: soffits can be plastered using a suitable bonding agent.

Proprietary suspended ceiling systems can be hung from supports located between units. Counter battens can be screw-fixed to the soffit for a plasterboard finish.


BALCONIES

Bison Precast is able to offer several solutions to incorporate balconies within a floor layout: additional reinforcement can be incorporated into hollowcore slabs to accept bolt-on steel balconies. 100mm-thick solid prestressed slabs can be used as permanent formwork for a cast in-situ balcony.

We have 150mm-thick solid prestressed slabs that incorporate top reinforcement to form the balcony and backspan slab as a single unit. Alternatively we can supply RC units cast with integrated thermal breaks.


COMPOSITE STEEL BEAMS

Where hollowcore or solid flooring units bear onto structural steel work, significant economies can be achieved by designing the steel beam to act compositely with the precast units.

This enables the possibility of a reduction in composite steel beam sizes and section weights of the steel frame, and the overall supporting structure.

Shear studs are welded onto the top flange of the steel beams and reinforced in-situ concrete enable the precast and the steel work to act in unison.

Composite steel beam design
technical guidance – download here

 

 

 

 

BIM Downloads

Loading of Hollowcore
Bearing requirements
Bedding of slabs
Deflection Head
Camber
Balconies
Corbelling of Masonry
Trimmer Angles
Floor U Value
Tolerances
Separating Wall
Solid Ends
Composite Steel Beam Design
Hollowcore Brochure
DOP HV Hollow Core
DOP Foundation Elements
DOP Floor Plates
Building Regulations - Part L
Building Regulations - Part E
Building Regulations - Part A and E
Building Regulations – Part A

Hollowcore Floors Load/Span Table

Largely because of fast on-site construction, Bison hollowcore floors are one of the most economic flooring solutions  for the widest variety of situations including masonry, steel and concrete structures for retail, commercial and  industrial buildings. The table is given as a guide only. When using maximum spans, consideration must be given to the effect of camber and deflection on partitions or finishes. Further advice is available on request. * 35mm screed required for 2 hour fire resistance.

Hollowcore - Non Composite with 2.1kN/m² for finishes

Note:
Max span based on minimum Natural Frequancy of 4.0Hz
live load of 3.0 is in congregation category as this will cover classrooms.

 

Section Details

 

Case Studies

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Etap Hotel Hounslow
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Sports City Apartments
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Arora International Hotel

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