Stahlton Prospekt NZS3101
Stahlton Prospekt NZS3101
Stahlton Prospekt NZS3101
Contents
Hollowcore is ideal for long unpropped spans which 2 Introduction & Contents
are subjected to uniformly distributed loads, and is 3 Architects
used extensively in commercial buildings all around General
the world. Hollowcore is manufactured using a 1.0 Acoustic Rating
high-strength concrete which is processed through a 1.1 Durability
1.2 Thermal Rating
unique machine that extrudes the Hollowcore profile
1.3 Fire Rating
onto a steel bed. This specialised manufacturing
process allows the product to be cut to any length,
4 Consulting Engineers
2.0 Loadings
making Hollowcore economical, quick to produce 2.1 End Seating
and flexible to use on building sites. Hollowcore 5 Consulting Engineers
can be used either as a solid floor or spaced out 2.2 Topping
(see page 14) to provide an even more economical 2.3 Design Weight Including Topping Concrete
flooring solution. 6 Contractors
3.0 Temporary Propping
3.1 Camber
3.2 Handling & Storage
7 Contractors
3.4 Penetrations & Fixings
8 Specifications
4.0 Drawing Call-up
4.1 Written Specification Clauses
9 Specifications
4.1 Written Specification Clauses
10 Key Plan
11 Hollowcore Sections 1 & 2
12 Hollowcore Sections 3 & 4
13 Hollowcore Sections 5 & 6
14 Hollowcore Sections 7 & 8
15 Fixings to Hollowcore
16 Camber Allowances, Support & Handling
17 150, 200 & 300 Deep Echo Slab
18 400 Deep Echo Slab and 200 & 300 Deep Spiroll Slab
19 200, 300 & 400 Deep Elematic Slab
20 Load Span Graph, 150 Stahlton Hollowcore
21 Load Span Graph, 200 Stahlton Hollowcore
22 Load Span Graph, 300 Stahlton Hollowcore
23 Load Span Graph, 400 Stahlton Hollowcore
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Architects
General Spiroll
Stahlton Engineered Concrete has three different profiles of Hollowcore Depth (mm) Solid Spaced 1800 Spaced 2000
made in different locations around New Zealand: 200 58 50 49
The Auckland branch has Echo in sizes 150, 200, 300 & 400mm deep 300 63 50 49
The Otaki branch has Spiroll in sizes 200 & 300mm deep With the inclusion of a 10mm Gibraltar board fixed ceiling suspended
The Christchurch branch has Elematic in sizes 200, 300 & 400mm deep 100mm beneath the soffit of the Hollowcore, an extra 8dB increase
can be expected.
As the different sections have some differing properties, individual
projects should be designed with location in mind to match the
nearest Hollowcore profile from the closest manufacturing plant. 1.1 Durability
Stahlton Hollowcore slabs meet exposure classifications A1, A2, B1 &
1.0 Acoustic Rating B2 as per table 3.6 in NZS 3101:Part 1:2006 for a 50-year life.
Elematic
1.3 Fire Rating
Depth (mm) Solid Spaced 1800 Spaced 2000
All Stahlton Hollowcore floors with a minimum of 65mm of on-site
200 58 50 49 topping have a 60-minute Fire Resistance Rating (FRR). Increased
FRR can be achieved in some circumstances; please contact Stahlton
300 63 50 49
Technical Department if you wish to discuss further. Any penetrations
400 67 50 49 through the Stahlton Hollowcore floors must also be fire rated, see page
15. Advice should be sought from the fire protection suppliers regarding
suitability of their tested products with the Hollowcore floor systems.
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Consulting Engineers
Intended load factors and uniformly distributed loads should be clearly In some structures, simply increasing the seating length to 80 or
shown on the Consultants drawings to avoid any confusion throughout 90mm would add an extra safety factor into the design for minimal
the shop drawing and design process. Contact the Stahlton Technical cost. Alternatively, armouring the edge of the beam the Hollowcore
Department if you have special loading cases for design advice. is sitting on would allow for extra tolerance with regard to horizontal
movement. As always, applying an engineering common sense
approach to detailing will provide the best result in the design of a
building until further definitive testing is completed. In the meantime
the details described above and in section 18 of the Concrete Standard
are to be applied to all buildings in New Zealand, regardless of size,
location and building type.
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Consulting Engineers
The topping concrete strength should be specified as a minimum of Depth (mm) Echo (kPa) Spiroll (kPa) Elematic (kPa)
25MPa as per cl 5.2.1 NZS 3101:2006. The minimum topping depth for 150 3.61
Stahlton Hollowcore at midspan is 65mm. Additional topping depth
will usually be required feathered out to the ends of the units to 200 4.00 3.45 3.55
allow for an even finished floor level. Floor reinforcement and saddle 300 4.62 4.00 4.11
bars should be designed and shown on the Consulting Engineers
400 5.19 4.69
drawings. Steps in the topping can be formed using suitable density
polystyrene, however the extra topping thickness needs to be
2000mm Spaced System
accounted for as a gravity load and allowed for in the design.
Depth (mm) Echo (kPa) Spiroll (kPa) Elematic (kPa)
Care should be taken when pouring topping not to mound up the
concrete in one place as this can produce large point loads. The 150 3.46
mounding of in situ concrete should not exceed the construction 200 3.86 3.14 3.22
loadings the units are designed to sustain. Topping concrete should
also not be poured directly onto the timber infill sections for spaced 300 4.42 3.63 3.73
Hollowcore but rather raked into place. 400 4.93 4.26
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Contractors
3.1 Camber Depth (mm) Echo (kg/m) Spiroll (kg/m) Elematic (kg/m)
Stahlton Hollowcore units will arrive at site with some positive camber 150 274
(hog). This is unavoidable due to the nature of prestressing. The 200 316 303 321
amount of hog will depend on a number of factors, including amount
of prestress, how long the units have been manufactured and exposed 300 427 402 422
to the elements and length of unit to name but a few variables. As a 400 530 527
rule of thumb allow 2-3mm of hog for every 1m of span (see page 16).
Generally half of the hog of the Hollowcore unit will come down after
the topping concrete is poured and any propping is removed. Half of 3.4 Penetrations & Fixings
the remaining hog will eventually come out over time due to creep Stahlton Hollowcore units can have penetrations core drilled through
and shrinkage. the unit in specific locations (see page 15). No more than one
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Contractors
penetration per 750mm of span or width of the unit is permitted, as Units can be designed with additional prestressing tendons to allow
too many holes will reduce the load capacity of the Hollowcore unit. for cutting of occasional tendons. However, this needs to be thought
The area of concrete around the strand must be avoided altogether. about at the start of the project and built into the design before the
If a strand is cut onsite, temporary prop either side of the penetration units are cast, bearing in mind that extra strand will induce more hog
immediately, then contact Stahlton Engineered Concrete as a design in the slab.
check will need to be done to ascertain whether the unit is still
The infill sections of Stahlton Spaced Hollowcore are the ideal place
structurally sound.
to accommodate penetrations and services. Care should still be taken
There are very few fixings specifically designed for use in Hollowcore with placing of penetrations so as not to cause weakness in the floor
floors. The Hilti HCC and HLC anchors are specifically designed for diaphragm. Fixings can be made into the timber infill for light loads or
Hollowcore. Please note powder actuated shot fired nails are not into the topping concrete for heavier loads. These fixings should be
permitted to be used with Stahlton Hollowcore unless specially checked by a suitably qualified Engineer.
designed and tested by the fixing supplier. Advice should be sought
from the fixing manufacturer as to the suitability and load-carrying
capacity of their products in Hollowcore.
An alternative is to use fixings such as threaded rod that pass through
the void area of the Stahlton Hollowcore, see page 15. Again fixings
cannot be situated so as to interfere with the prestressing strand.
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Specifications
4.0 Drawing Call-Up (iii) The Stahlton Hollowcore shall be designed for exposure
classification A1/A2/B1/B2 as per table 3.6 in NZS 3101:2006.
To specify the Stahlton Hollowcore system on your drawings we
suggest you use the following designation: (iv) The Stahlton Hollowcore unit shall have a FRR (Fire Resisting Rating)
of 60/60/60. Penetrations through the flooring system shall be reinstated
Stahlton depth Echo / Spiroll / Elematic / Hollowcore with 65mm to the required FRR by an approved fire protection system.
topping
(v) Stahlton Hollowcore shall be designed to have a maximum crack
For example if the project is to be erected in Christchurch, made from width of 0.3mm under full live load conditions.
200mm-deep Stahlton Hollowcore with a 90mm-deep topping, then
the specification would read: (vi) The acoustic STC (Sound Transmission Class) and IIC rating of
the floor system shall meet or exceed 55dB as tested at a registered
Stahlton 200 Elematic Hollowcore with 90mm topping institution or a field test of 50dB measured in on-site conditions. These
If 2.0m module Spaced Stahlton Hollowcore made in Auckland with ratings apply to the finished floor system, including any carpeting and
65mm topping is desired then: suspended ceiling systems.
Stahlton 200 Spaced 2.0m Echo Hollowcore with 65mm topping (vii) The Stahlton Hollowcore units shall have a minimum of 75mm
end seating of L/180, whichever is greater, as per clause 18.7.4 in NZS
4.1 Written Specification Clauses 3101:2006 plus tolerance of 15mm if seated on an unarmoured concrete
beam.
Stahlton Hollowcore products in general comply with the following
standards:
Materials
NZS 3101:2006 Concrete Structures Standard Part 1 & 2
(i) Concrete shall be specifically mixed depending on environmental
NZS 3109:1997 Concrete Construction conditions and should have a 28 day cylinder strength of 50MPa as a
minimum.
AS/NZS 4671:2001 Steel Reinforcing Materials
(ii) All concrete shall show signs of thorough compaction otherwise be
BS 5896:1980 Specification for High Tensile Steel Wire and Standard for
rejected if repair cannot be undertaken to bring the unit back to the
the Prestressing of Concrete
original specification.
Design (iii) An air entraining agent complying with BS EN 934-2-2001 may be
included in the concrete mix to improve workability.
(i) The design of Stahlton Hollowcore shall be in accordance with
the requirements and recommendations of NZS 3101:2006 Concrete (iv) The strand reinforcement used in Stahlton Hollowcore shall be
Structures Standard Part 1 & 2 and/or any recognised international 12.7mm or 12.9mm diameter complying with the requirements of
Standard or part thereof, for example BS 8110:1007 The Structural Use of AS/NZS 4671:2001
Concrete. (v) Prestressing strand shall be clean and free from deleterious
(ii) The prestress strand pattern in the Stahlton Hollowcore shall be substances. Superficial rust is acceptable, however strand with
designed to sustain the loadings shown on the Consulting Engineers corrosion that has caused surface pitting shall be rejected for the main
drawings and allowance will be made for self weight of the unit and longitudinal reinforcement of the unit.
topping concrete.
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Specifications
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Pg 11
Pg 14
Pg 11
Pg 13 Pg 14
Pg 12
Pg 13
Pg 12
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Section 1 Scale: NTS
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**
**
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Section 5 Scale: NTS
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Section 7 Scale: NTS
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Fixings to Hollowcore (Echo profile shown) Scale: NTS
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Camber (hog) Allowances Scale: NTS
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150 Deep Echo Slab (Ex Akl) Scale: NTS
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400 Deep Echo Slab (Ex Akl) Scale: NTS
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200 Deep Elematic Slab (Ex Chc) Scale: NTS
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Compare
Load Span Graph 150 Stahlton Hollowcore
factored
design load
with this axis Superimposed Loads
G: 1.2 x ________________ = _______ kPa
24
Q: 1.5 x ________________ = _______ kPa
Factored Design Load = _______ kPa
Notes:
20 1. Refer to section 2.0 for more information.
2. If your design is close to the line, please
contact Stahlton to discuss options.
3. If G>1/2Q, or if G>0.5kPa for maximum span
and near maximum loads, please contact
Stahlton to discuss further.
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4. Self weight and 65mm topping have been
allowed for.
5. Specied loads on engineers drawings
need to be shown unfactored.
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90mm topping
0
5.5 6.5 7.5 8.5
Span, m
20 Level/Grid: Date:
0800 STAHLTON | www.stahlton.co.nz
Compare
Load Span Graph 200 Stahlton Hollowcore
factored
design load
with this axis Superimposed Loads
G: 1.2 x ________________ = _______ kPa
24
Q: 1.5 x ________________ = _______ kPa
Factored Design Load = _______ kPa
Notes:
20 1. Refer to section 2.0 for more information.
2. If your design is close to the line, please
contact Stahlton to discuss options.
3. If G>1/2Q, or if G>0.5kPa for maximum span
and near maximum loads, please contact
Stahlton to discuss further.
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4. Self weight and 65mm topping have been
allowed for.
5. Specied loads on engineers drawings
need to be shown unfactored.
12
0
7 8 9 10
Span, m
21 Level/Grid: Date:
0800 STAHLTON | www.stahlton.co.nz
Compare
Load Span Graph 300 Stahlton Hollowcore
factored
design load
with this axis Superimposed Loads
G: 1.2 x ________________ = _______ kPa
24
Q: 1.5 x ________________ = _______ kPa
Factored Design Load = _______ kPa
Notes:
20 1. Refer to section 2.0 for more information.
2. If your design is close to the line, please
contact Stahlton to discuss options.
3. If G>1/2Q, or if G>0.5kPa for maximum span
and near maximum loads, please contact
Stahlton to discuss further.
16
4. Self weight and 65mm topping have been
allowed for.
5. Specied loads on engineers drawings
need to be shown unfactored.
12
0
10 11 12 13 14 15
Span, m
22 Level/Grid: Date:
0800 STAHLTON | www.stahlton.co.nz
Compare
Load Span Graph 400 Stahlton Hollowcore
factored
design load
with this axis Superimposed Loads
G: 1.2 x ________________ = _______ kPa
24
Q: 1.5 x ________________ = _______ kPa
Factored Design Load = _______ kPa
Notes:
20 1. Refer to section 2.0 for more information.
2. If your design is close to the line, please
contact Stahlton to discuss options.
3. If G>1/2Q, or if G>0.5kPa for maximum span
and near maximum loads, please contact
Stahlton to discuss further.
16
4. Self weight and 65mm topping have been
allowed for.
5. Specied loads on engineers drawings
need to be shown unfactored.
12
0
13 14 15 16 17 18
Span, m
23 Level/Grid: Date:
0800 STAHLTON | www.stahlton.co.nz
A Division of Fulton Hogan Limited
The recommendations in this literature are based on good engineering judgement and building practice, but are not an exhaustive statement of all relevant information that needs to be considered to comply with the NZBC.
Further, as the successful performance of the relevant system depends on numerous factors outside the control of Stahlton Engineered Concrete (eg quality of workmanship on site) Stahlton Engineered Concrete shall not
be liable for the recommendations in this literature and the performance of the relevant system, including its suitability for any purpose or ability to satisfy the relevant provisions of the NZBC, regulations and Standards.