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Concrete Slabs Good Practice
Concrete Slabs Good Practice
Concrete Slabs Good Practice
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Sathiyaseelan Subramani

PRECAST CONCRETE SLABS ON LOAD BEARING MASONRY WALLS G o o d P r a c t i c e G u i

d e 1 INTRODUCTION This technica

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PRECAST CONCRETE SLABS ON LOAD BEARING MASONRY WALLS G o o d

P r a c t i c e

G u i d e

INTRODUCTION This technical note covers sound and accepted design and construction
principles for masonry walls which support precast concrete slabs used for floors
and roofs. As such the publication is aimed at the developer, the building
professionals, architects, structural engineers, quantity surveyors and the
builder. It is based on SABS standards for the types of materials used and required
for design and construction. Each building situation is unique – these notes are
guidelines for all those involved in the building process to determine optimum
conditions – the balance of costs, ease and speed of construction, life costing
etc.

BENEFITS OF LOAD BEARING MASONRY WALLS WITH PRECAST CONCRETE SLABS AS A BUILDING
SYSTEM AND THE IMPORTANCE OF PREPLANNING The use of masonry walls to support floor
and roof slabs is not only based on its ability to carry safely the loads imposed
but to provide the envelope that encloses the building. Building a structural
framework to support the loads and then use exterior masonry infill panels,
duplicates the structural requirement, increases costs and is time consuming. In
the interior of the building the use of structural masonry means that there is
improved resistance to the spread of fire, generally an improvement in acoustic
properties (less absorption and transmission of noise) and thermal comfort
(improved capacity to store heat and reduction in heat movement) reducing insurance
and operating costs of the building. Flexibility for possible re-arrangement of
structural masonry supports can be improved by building in initially of continuous
masonry bond beams at door/window height permitting some openings, say up to 2.0m
in width, to be made at a subsequent date. Also at the preplanning stage decisions
should be made on imposed loadings on floors and roofs to be used in design. Though
the building might initially be designed for office loading, say 2.5kN/m² it might
be more economical, at some later stage to use the building for storage purposes
with imposed loading of 5.0kN/m2. Normally this would not require any major
strengthening of the walls but requires the design of a stronger slab at a
relatively small increase in the total cost of the building. Initial planning can
permit the accommodation and location of services (electrical, water, sewerage,
etc) required initially and possibly in the future in optimum positions in the
structure. In masonry walls horizontal chasing significantly reduces strength and
is not normally permitted without special detailing. Installing suitable ducting is
a possible answer to the problem. Holes in precast concrete slabs should be planned
for, especially important in factory made slabs and beams. The coring of precast
slabs has become a common and cost efficient procedure for any additional service
holes that may be required. Control joints in walls must be in the same position in
the slab. The cost effectiveness of masonry/slab structures is in appreciating at
the preplanning and design stage the advantages of the construction in reducing
costs and time, improving the soundness and durability of the structure, and
reducing initial operating and maintenance costs. The aesthetically pleasing façade
of masonry buildings is an added bonus.

TYPES OF BUILDINGS AND ASSOCIATED ECONOMICS The benefits of the use of precast
prestressed slabs as compared to in-situ concrete are mainly quicker and easier
construction, reduced site problems and supervision, greater confidence in the slab
structure and

better span to depth ratios. Suspended slabs are suitable for use in all types of
building e.g. residential, commercial, industrial, educational, recreational etc.
Commercial office buildings often have a basement with the slab supported on a RC
or structural steel framework structure based on a car parking module.
Longitudinally columns are at 5m

MAX SPAN,

THICKNESS,

metres

mm

120

Domestic building

150

Office loading / Domestic

8.5

200

School loading/Office

10

250

Offices

12.0
250

Roof loading + any of above

(2 car) or 7.5m (3 car) spacing and transversally at say 7.5m spacing. With hollow
core slabs a guide to the relationship between thickness, span and type of
structure is given in table 1.

NORMAL USE

Table 1

A typical cost comparison of an

RC

office block (Johannesburg 2001/02)

CONSTRUCTION

comparing a reinforced concrete frame of in-situ cast columns and

Time required for

beams supporting a post tensioned

construction, weeks

slab, with a precast concrete

Cost, R

LOAD BEARING MASONRY AND PRECAST SLAB

15

931 000

802 000

suspended floor supported on external masonry walls with

Note: The office block was 3600m² in plan and

internally in-situ cast concrete

comparison covered basement, ground and first floor slabs as

columns supporting reinforced

at June 2002.

precast beams is shown in table 2.

Table 2
SUSPENDED SLABS FOR FLOORS AND ROOFS: THE FUTURE In South Africa an overall design
consideration is to reduce costs in the building and operation of residential,
educational, community and health, industrial and commercial buildings. Low rise
buildings, say up to three storeys where lifts are not normally required, increase
the density in the use of land saving costs on services i.e. roads, water,
sewerage, electricity etc. Low-rise buildings of masonry construction use local
material and are a traditional form of construction. Suspended slabs use readily
available materials and techniques of construction that are cost effective, while
the higher strength concrete used with increased prestressing can reduce the mass
and handling of suspended slabs. The overall consideration in development is
“buildability” – ease of construction, which reduce costs. Future developments will
involve better preplanning, construction planning, easier and firm access to site,
cheaper and safer lifting equipment, better detailing of the beam/slab/wall
intersection, while reducing site work to a minimum. Suspended slabs on masonry
walls is a recognized and proven system. It is time saving and economical. New
technical developments together with improved construction management techniques
will ensure that this is a sound and viable form of construction for the 21st
century.

TYPES OF SUSPENDED SLABS The hollow core slab (HCS) is a reinforced or prestressed
concrete slab, containing cores, generally varying in thickness from 120mm to 250mm
and, depending on loading, spanning up to 12m. The width is normally 900 or 1200mm.
A rib and block slab (RB) is composed of rectangular shaped (generally) precast
concrete reinforced or prestressed ribs supporting rebated filler blocks placed
between two ribs. This system is sometimes referred to as plank and block or beam
and block. In-situ concrete is poured between and over the blocks. Slab depths vary
from 170 to 380mm with clear span up to 10m. Beams with a width of 100–200mm and
minimum depth 60mm are used with infill blocks 200–250mm long, 440 to 485mm width
and 100–355mm deep.

The choice of which type of suspended slab to use depends on a number of factors
and consideration should be given to the following. The HCS is manufactured in the
quality-controlled conditions of a factory and the only site work involved is the
placing of a levelling screed 30 to 45mm thick. HCS fitting into non-modular widths
(module normally 1200mm) are cut to size in the factory while concrete is fresh.
HCS are cut to length to suit as built building dimensions immediately after the
concrete has reached the required strength. Propping is usually not required on HCS
and following trades can start work immediately after erection. The RB system is
more flexible in coping with irregular shapes. Spans are smaller and the lifting
capacity required to place beams is less. It is significantly slower than HCS in
construction time as in-situ concrete must be poured and cured. Propping of the
system during construction is required with a RB system.

TYPES OF WALLS Single leaf, collar jointed, cavity and diaphragm walls and walls
with fins are suitable structural walls. Horizontal and vertical dimensions
together with economic considerations will influence the wall type chosen. Single
leaf external walls are normally 140–190mm in thickness and collar-jointed walls
190 and 230mm. With cavity and diaphragm walls (if the suspended slab rests on the
inner leaf only) the external leaf is sometimes of face units 90, 110 or 140mm in
thickness, while the inner leaf if supporting the slab, should have a minimum
thickness of 110mm. Loading and the eccentricity of loading, and the slenderness
ratio, vertical and horizontal, will dictate wall thickness. Hollow units are
easier to reinforce both vertically and horizontally. Solid units can only be
reinforced horizontally, unless the cavity of a cavity wall or special pockets are
used to house vertical reinforcement.

DESIGN OF LOAD BEARING MASONRY WALLS AND PRECAST CONCRETE SLABS Structural masonry
walls give strength and stability to the structure. To ensure that the structure
has satisfactory resistance to collapse, the layout arrangements of all components
and their interaction to resist destabilising forces must be considered. Sometimes
a designer will be responsible only for the structural masonry, or the suspended
floors, or the roof. There should be a single designer responsible for overall
design, including foundations and stability. Structural components/elements of the
structure should be effectively tied together such that in the longitudinal,
transverse and vertical direction the whole structure is of robust construction.
Consideration of the interaction between the masonry elements and other parts of
the structure required to provide continuity is essential. The position of
intersecting walls, piers and control (movement) joints must be assessed to ensure
that they do not affect lateral stability adversely. Overall masonry design
covering accommodation of movement, design for stability, exclusion of moisture,
fire resistance, thermal properties, sound absorption, sound insulation and noise
reduction are covered in SANS 10021, SANS 10145 and SANS 10249. Empirical
structural design or design of reinforced masonry by simple rules have been
developed by SABS (refer SANS 10400) and the National Home Builders Registration
Council (refer Home Building Manual) where a rigorous design procedure is not
warranted. They are normally conservative to ensure that the empirical design will
have an adequate factor of safety against failure. Limitations and the type, size
and wall configuration, which are covered in the design, are stated.

Rational design is based on assumed loading (SANS 10160) and resistance of the
structural masonry to this loading (SANS 10164-1 and 2), codes of practice, which
cover un-reinforced, reinforced and prestressed masonry. Suspended precast concrete
slabs should comply with the requirements of SANS 1879 and the design code SANS
10100.

MATERIALS Masonry Masonry units, solid or hollow, brick or block size, of burnt
clay or concrete of adequate compressive strength (usually 10.5 to 21MPa for solid
units or 7.0 to 14.0MPa for hollow units) are satisfactory. Class II mortar (50kg
common cement, 0–40 l lime, 200 l sand) is normally used. Fine and coarse
aggregates should comply with the relevant SABS standard, particularly in respect
of the fines content.

Precast slabs, ribs and blocks Ribs, infill blocks and slabs should be manufactured
to satisfy the requirements of SANS 1879. The standard specifies requirements for
tolerances of dimensions of ribs, blocks and hollow core slab. The design and
manufacture of ribs and slabs must ensure that under proof load the deflection, and
recovery after removal of the test load satisfy the requirements of SANS 1879.

CONSTRUCTION Masonry walls Accuracy in the building of walls in the plan position
to ensure satisfactory bearing length support for beams and slabs, and to the
designated level (bedding joints thicker than 15mm reduce wall strength
significantly) are vital for the success of the structure to perform its intended
service. Packing pieces of fibre cement sheeting can be used under slabs or beams
to achieve the correct level but gaps between shims must be filled with a suitable
mortar mix. SANS 10155 covers accuracy in building and SANS 10164-1 states
permissible deviations in accuracy for structural walls.

Hollow core slabs Slabs are placed on the masonry walls with a minimum bearing of
100mm as per drawing details. On roofs or exposed balconies, install the specified
material to accommodate thermal movement (e.g. bituminised softboard or similar).
Such provision must make allowance for changes in camber or deflection,
particularly where light parapet walls are built on prestressed HCS. In such
situations a light mesh reinforcement should also be placed in the finishing screed
or topping.
Rib and block system Ribs are placed on the masonry walls with a minimum bearing of
100mm as per drawing details at approximate centres, their position being finally
adjusted to suit the width of the filler block with a 35mm minimum bearing of block
on rib. Closed end filler blocks are placed at the end of each line. Temporary
propping of beams not exceeding 1800mm centres are erected to suitable level and
camber. If transverse stiffener ribs are detailed then blocks are left out to
accommodate reinforcement and concrete. Services should be installed over blocks
and not ribs and the specified mesh is placed throughout. Before grade 25 (minimum)
concrete is cast, all rubble should be removed and the blocks thoroughly wetted.
Concreting should be continuous. Removal of the temporary propping before the
compressive strength of the in-situ concrete reaches 17MPa will lead to an increase
in the long term deflections.

Transport and lifting equipment For HCS a crane is required to place the slabs into
position directly from the delivery truck. Tower cranes give maximum reach but on
normal 2 and 3 storey buildings mobile cranes are used. They have a lifting
capacity of 30 tonnes with a 31m boom, and operate easily over a 17m radius. Larger
cranes are available where required. With HCS the placing of 600m2 to 700m2 of
finished floor area per shift can be achieved. With the RB system the ribs and
blocks are usually stored on site and placed in position by hand when required.

Details of some intersections of masonry slabs The connection between the masonry
and the slabs is obviously critical to the structural strength, aesthetics and
water resistant properties of the building.

It is part of the role of the professional team in conjunction with the technical
department of the manufacturer to develop details that best suit the needs of the
various situations. A few of the typical details most commonly used follow.

Roof slab parapet wall detail

Slope to inside to avoid streaking of paint Waterproofing membrane

DPC on top of slab Expansion joint Screed/foam cement to fall

Ref 100 mesh

Brickforce in every course Jointex

V-joint in external plaster

Approved stretch paint

Slip joint 2 layers DPC or 2 ply Malthoid

V-joint in plaster

Brickforce in every course above door/window height

NB A 110mm wide parapet wall is recommended, but a 230mm wide parapet wall can be
used on the height of the parapet wall.

Suspended floors on external 140mm walls 140

140 Plaster Topping if required

Concrete slab V-shaped joint in plaster Slip joint – see note

Slip joint– see note Bond beam/U-beam

Bedding reinforcement to suit – maximum diameter 6mm

NOTE: 1. If floor slab span exceeds 6m spanning on to wall and large movements
expected consider a slip joint on top of wall, such as two layers of DPC or 2 ply
Malthoid. Structural stability & robustness may preclude use of slip joint. 2.
Consider use of U- or bond beams below slab. 3. If designer assumes wall laterally
restrained by slab then slip joint not advisable.

TYPICAL MASONRY SLAB CONNECTION DETAILS Control joints in walls and slabs At the
design stage the position of control joints, to reduce the likelihood of cracking
due to movement (mainly due to temperature changes) is determined by the project
engineer. Joints in slabs must coincide with the

control joints in the masonry walls. Long lengths of freestanding walls are most
susceptible. The addition of brickwork reinforcement and a concrete slab gives some
restraint and the interruption of long facades by deep recesses also helps to
reduce the incidence of cracking. The inclusion of a continuous reinforcing mesh in
a screed or topping on a precast slab will increase the degree of restraint
provided by the slab.

SUPERVISION AND INSPECTION Supervision and inspection during construction will

ensure that the final structure is of acceptable quality. This involves Ensuring
walls built to acceptable plumb, line and level Ensuring position of holes or slots
for services will not compromise structural integrity or durability. Adequate
bearing length for beams/slabs Bearing surface is smooth and plane. Thickness of
mortar joint is less than 15mm otherwise packing pieces to be used. Placing of
ribs/slabs so walls are not damaged and ensure continuity of wall control joints
into slabs Ensure that placing and compaction of concrete in a RB slab and
structural topping in a reinforced hollow core slab is satisfactory. Prestressed
hollow core slabs only require a 40mm levelling screed of river sand and cement.
For guidance on the correct application of screeds and toppings see the C & CI
publication “Recommendations for screeds and toppings”.

Standards and references on precast concrete slab construction SANS number

Title

50197-1

Common cement composition, specification and conformity

227

Burnt clay masonry units

1083

Aggregates from natural sources – aggregates for concrete

1090

Aggregates from natural sources – fine aggregates for plaster and mortar
1215

Concrete masonry units

1879

Precast concrete suspended slabs

10145

Concrete masonry constructions

10155

Accuracy in building

10100

The structural use of concrete

10160

The general procedures and loadings to be adopted for the design of buildings

10164-1

The structural use of masonry un-reinforced masonry walling.

10164-2

The structural use of masonry – reinforced and prestressed masonry.

10249

Masonry walling

10400

Application of the National Building Regulations

National Home Builders Registration Council’s Home Building manual Concrete

Manufacturers Association publications: Detailing of concrete masonry: Volume 1

Solid units – 140

Volume 2

Hollow units – 140/190

Volume 3

Cavity wall – 240/290

Masonry manual – 2000 Structural concrete masonry. A design guide. F.S. Crofts and
J.W. Lane

Some definitions Masonry:

An assemblage of masonry units bonded together with mortar

Solid masonry unit:

A masonry unit containing cores not exceeding 25% of the gross volume of the unit.

Hollow masonry unit:

A masonry unit containing cores that exceed 25% but do not exceed 60% of the gross
volume of the unit.

APPENDIX A Accuracy in building masonry walls and manufacture of precast concrete

suspended slabs Masonry PERMISSIBLE DEVIATION

ITEM

mm

Straightness, line

10 in 5m

Level, bed joints

± 5 in < 5m ± 10 in 5m to 10m ±15 in 10m to 20m

Plumb, vertical

± 5 in 3m ± 10 in 3m to 6m ± 20 in over 6m

Surface of supporting elements

– 10 + 5

Position on plan of any edge or marking measured from the nearest grid line or
agreed centreline

± 10

Level (deviation) from designed level with reference to the nearest transferred
datum of the average top surface of an element.

– 10 + 0

Bed joint thickness (normally 10 – 13mm)

±3

• First joint above supporting element (includes foundation)

– 5 + 10

Suspended slabs To l e r a n c e s o n d i m e n s i o n s o f r i b s , blocks and

hollow core slabs UNIT

DIMENSION

Rib
Block

Hollow core slab (full panel) Width:

TOLERANCES mm

Length

± 20

Width

±3

Depth

±3

Length

±5

Width

±3

Depth

±3

Length

± 10

Width

±4

splitter (a)

± 20

Depth: 120 – 150mm

±5

200 – 250mm

±7

(a) A splitter is any slab less than the product standard width

8 Portland Park, Old Pretoria Road, Halfway House 1685, South Africa. PO Box 168
Halfway House 1685 Tel +27 11 805 6742, Fax +27 11 315 4683 e-mail: [email protected]
website: www.cma.org.za

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