Ceilings – types of concrete ceilings

ceilings

Ceilings are key structural elements of buildings, made as precast concrete products with different systems and parameters adapted to design requirements. They are produced in reinforced concrete technology, prestressed concrete technology or as dense-rib systems, ensuring high load-bearing capacity and durability of the structure. They are used in residential construction, industrial construction, public facilities and multi-story parking lots.

For each investment, the price of ceilings is calculated individually, taking into account the type of system, span, load and specifics of the project. We guarantee competitive business terms, comprehensive technical advice and timely delivery. We invite you to get a free quote tailored to your construction project.

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Technical characteristics of the ceilings

Ceilings are the basic structural element of any building, separating floors and carrying imposed loads. They are manufactured from structural concrete of class C30/37 to C50/60, depending on the required load-bearing capacity and span. In addition, each ceiling is protected against corrosion by an appropriate lagging of the reinforcement of at least 30-40 mm.

The production process takes place under controlled plant conditions, where the dense-rib or channel floor is formed to the highest standards. Then intensive compaction of the concrete mixture by vibrating or vibropressing is applied. At the same time, the geometry and surface quality of each floor element is controlled.

Prefabricated ceilings – advantages of the solution

Ready-mixed floors are characterized by much higher quality workmanship than elements poured on site. Production in hall conditions allows to obtain concrete of high strength classes. In addition, the types of ceilings available on offer allow optimal adaptation to any type of building.

The prefabrication system allows for the construction of floors with different parameters – from lightweight dense ribbed floors to massive hollow core floors. Standard spans range from 2.4 to 20 meters, depending on the type of construction. But at the same time, a reinforced concrete or prestressed concrete floor provides full rigidity and load-bearing capacity without additional supports.

Types of ceilings

Different types of ceilings require different production technologies adapted to their specific construction. In the case of dense-rib systems, support beams and infill blocks are produced, creating a lightweight structure. In contrast, channel floor types are formed as monolithic slabs with longitudinal openings to reduce weight. Each of the available types of ceilings is characterized by different parameters of load-bearing capacity, insulation and applicability.

The concrete floors exhibit excellent fire resistance at REI60 to REI240. The solid construction also provides effective sound insulation between floors. As a result, concrete ceilings meet the highest requirements of building and fire regulations.

Reinforcement is made of A-IIIN class steel (RB500W) or Y1860S7 prestressing steel for prestressed concrete floors. The amount and distribution of reinforcement in each ceiling is determined on the basis of static calculations. Then the filigree ceiling or any other type receives technical documentation with load-bearing parameters.

Advantages of ceilings

Speed of ceiling installation

The ceilings are supplied as prefabricated elements or systems for quick installation on site. Laying a hollow core or dense rib ceiling takes a few days instead of the weeks needed for traditional construction. In addition, the elimination or reduction of formwork significantly speeds up the progress of the work. This reduces the construction time by 60-70%.

High carrying capacity and strength

The use of high-grade concrete in production ensures a load-bearing capacity of 3.0 to 10.0 kN/m². Reinforced concrete ceiling made as a prefabricated product is characterized by homogeneity of structure and absence of execution defects. In addition, prestressed concrete ceilings, thanks to prestressing, eliminate scratching under service loads. As a result, the ceilings maintain their parameters throughout their service life.

Variety of floor systems

The types of floors available include hollow core, dense-rib, solid and filigree systems. Each dense-rib or hollow-core floor has its own optimal application depending on the type of building. In addition, the ability to combine different systems in a single building increases design flexibility. Thanks to this, ceilings are adapted to any requirements.

Fire resistance of the structure

Concrete floors are characterized by a fire resistance class ranging from REI60 for thinner elements to REI240 for massive slabs. A filigree or solid ceiling provides an effective barrier to the spread of fire between floors. Subsequently, the absence of combustible structural elements increases building safety. Such resistance makes the ceilings ideal for buildings with high fire protection requirements.

Sound insulation of ceilings

The dead weight of 250 to 500 kg/m² provides effective insulation against air and impact sounds. Hollow core ceilings with longitudinal openings further dampen sound due to their structure. In addition, a dense-rib ceiling with hollow block filling creates a natural acoustic barrier. As a result, the ceilings meet standards for residential construction.

Cost-effectiveness of the solution

The use of ready-made ceilings generates savings in the cost of formwork, reinforcement and labor. The reduction in construction time translates into a faster return on investment. In addition, concrete ceilings require no maintenance over their lifetime. As a result, the total life-cycle cost of ceilings is lower than traditional solutions.

Ability to perform installations

The design of the various types of ceilings makes it possible to run installations without weakening the load-bearing capacity. In ducted ceilings, pipes are routed in hollow channels. The filigree ceiling then allows free arrangement of installations before concreting. Such functionality facilitates subsequent finishing work.

Service life of ceilings

Prestressed concrete and reinforced concrete floors are designed for a minimum of 100 years of use. The use of concrete with exposure class XC3 ensures resistance to carbonation. In addition, adequate lagging of the reinforcement protects the steel from corrosion. Thanks to these protections, the ceilings retain their properties throughout the life of the building.

Application of ceilings

Ceilings are universally used in all types of construction as floor separating elements. The primary area of application is residential construction, where various types of ceilings are used. In addition, the dense-rib or hollow-core ceiling is used in public buildings.

In industrial construction, prestressed concrete floors make it possible to cross large spans of production halls. The ability to carry high imposed loads makes the reinforced concrete ceiling ideal for high-storage warehouses. Then, in commercial buildings, the floors create spacious sales areas without intermediate columns.

Channel floors are ideal for the construction of multi-story parking lots and garages. High load-bearing capacity allows truck traffic, and resistance to de-icing salts ensures durability. In addition, the filigree floor is used where monolithic construction is required. Thanks to the variety of systems, concrete floors meet the requirements of any type of building.

Special applications are found for ceilings in hospital and laboratory construction. The ability to carry loads from heavy medical equipment requires the use of reinforced structures. At the same time, the excellent sound insulation of ceilings ensures the comfort of patients. As a result, various types of ceilings are standard in modern medical facilities.

Increasingly, the dense-rib ceiling and other systems are used in energy-efficient construction. The possibility of additional insulation and the storage mass of the ceiling stabilize the temperature inside the building. In addition, integration with underfloor heating and cooling systems increases energy efficiency. Thus, the ceilings support the implementation of passive construction standards.

Technical parameters of ceilings

Ceilings are manufactured in accordance with PN-EN 13224 for floor slabs and PN-EN 15037 for floor joists. Standard concrete classes range from C30/37 for dense-rib floors to C50/60 for prestressed concrete floors. In addition, each reinforced concrete floor has a declaration of performance and CE marking.

The strength parameters of the various types of ceilings include a characteristic load capacity of 3.0 to 10.0 kN/m². Fire resistance is specified in the range from REI60 to REI240 depending on the type and thickness. Subsequently, the heat transfer coefficient U ranges from 0.70 to 2.50 W/m²K. The sound insulation of the ceilings is Rw = 50-60 dB for airborne sound.

Reinforcement of concrete ceilings is made of A-IIIN class steel (RB500W) with diameters from 8 to 25 mm. For prestressed concrete ceilings, Y1860S7 strands with diameters of 9.5-15.7 mm are used. In addition, the filigree floor contains space trusses as load-bearing reinforcement. The lagging of the reinforcement is a minimum of 30 mm from the bottom and 25 mm from the top.

The standard dimensions of hollow core ceilings are 600-2400 mm wide, 150-500 mm thick. A dense-rib ceiling has a typical thickness of 230-340 mm with a beam spacing of 600 mm. However, the lengths of the elements are adjusted individually, up to a maximum of 20 meters. The unit weight of ceilings ranges from 250 kg/m² for lightweight systems to 500 kg/m² for solid slabs.

Installation of ceilings

Preparation for the installation of ceilings begins with checking the level of bearing walls or support beams. First the height ordinates are verified with a tolerance of +/- 10 mm to ensure an even plane. Next, a layer of leveling mortar or elastomeric shims is laid at the support points. In addition, installation axes are determined to determine the position of the first floor elements.

Transport of different types of ceilings to the construction site requires the use of appropriate equipment. A dense-rib ceiling is delivered in the form of beams and hollow blocks laid by hand. In addition, hollow core floors or solid slabs require unloading with a crane with the appropriate lifting capacity. Before installation, each element is checked for compliance with the design.

The laying of prestressed concrete or channel floors is carried out according to the assembly design. The elements are lowered slowly onto the supports with a minimum support of 80-150 mm. At the same time, the adhesion to the support surface and the level of the upper plane are controlled. Filigree ceiling additionally requires the setting of mounting supports before concreting.

The assembly of ceilings is carried out by filling the joints with structural concrete. In the case of a dense-rib ceiling, a complete concreting of the ribs and superconcrete is performed. Then the reinforcement of the perimeter rims is joined to the floor elements. Correct bonding ensures monolithic and disc rigidity of the structure.

Quality control of the installation includes checking the correct support of each element. Joint widths, surface level and continuity of reinforcement are verified. In addition, for concrete floors, the quality of the concrete used for composite is checked. As-built documentation should include acceptance protocols and a layout plan of the elements with type designation.

Price of ceilings in 2024 and 2025

Ceilings price is shaped by the type of system, technical parameters and the size of the order. The calculation takes into account the type of construction – gooseneck, hollow or solid floor, and design requirements. In addition, the final pricing is affected by the location of construction and transportation costs. In 2024, prices of floor systems were observed to stabilize with increasing investment demand.

Ceiling price – cost structure

The cost of ceilings primarily includes the value of materials – high-quality concrete and reinforcing steel. Ceilings price also includes inputs for the production process, including energy, molds and labor. Then the costs of quality control, certification and preparation of technical documentation are added. In 2024, the share of materials in the price of different types of ceilings was 55-70% of the total cost.

Factors affecting the price of ceilings

The pricing of ceilings depends mainly on the type of system and its technical parameters. The price per m2 for a dense-rib floor is 30-40% lower than for a hollow-core floor. In addition, a monolithic reinforced concrete or filigree floor requires additional expenditures on formwork and concrete. Increased load-bearing capacity or span requirements significantly affect the final price.

Cost optimization in the purchase of ceilings

Ceilings pricing offers more favorable rates for orders of entire floors or buildings. Ceiling pricing for purchases over 500 m² can be 10-15% lower due to economies of scale. In addition, standardization of elements and ordering logistics reduce costs. Promotions are planned for large residential and industrial projects in 2025.

The calculation of concrete ceilings should take into account the total cost of the system including installation. Ceilings price of prefabricated solutions often turns out to be competitive when all components are taken into account. At the same time, savings come from the reduction in construction time and the elimination of formwork. It is worth comparing different types of ceilings for optimal value for money.

Additional costs in the implementation of ceilings

How much do ceilings cost with a complete service is a question that includes delivery, installation and assembly. Ceilings transport price depends on the type of elements – lightweight dense rib ceiling or heavy hollow core slabs. Then the cost of installation by crane is usually 15-25% of the value of the materials. In 2024, the average cost of complex implementation of prestressed concrete ceilings was 200-350 PLN/m².

The price offer of different types of ceilings often includes additional elements of the system. Ceiling prices may include perimeter beams, rims, lintels or special elements. In addition, manufacturers offer technical support, static calculations and installation designs. In 2025, comprehensive packages for entire buildings will be available.

Price comparison of different floor systems

The value of different types of ceilings varies significantly depending on the technology. Ceilings price of dense-rib systems like Teriva or Akerman is the lowest – 150-200 PLN/m². In addition, the filigree ceiling as a semi-prefabricated solution costs 180-250 PLN/m². The estimate should take into account not only the purchase price, but the total cost of construction.

The rate for hollow core ceilings in 2024 was in the range of 180-280 PLN/m² for standard thicknesses. Ceilings price for special elements with large spans could reach 400-500 PLN/m². However, it was possible to negotiate discounts for contracts for entire facilities. The forecast for 2025 assumes a price increase of 4-6% related to rising production costs.

The cost estimate for ceilings should be prepared individually for each project. Ceilings final price depends on the specifics of the project, the number of floors and the schedule of works. Then you should consider the possibility of optimizing the project or staging the delivery. Feel free to contact us for a personalized offer for ceilings tailored to your construction project.

Here are just some of our implementations of prefabricated ceilings. This list includes only large investments on which our prefabricated products have appeared.

What are ?

Precast concrete units are prefabricated building components produced off-site that can be assembled into larger structures at the project site. These are standard, repetitive modules produced in series at industrial plants, which greatly speed up and facilitate construction work in various construction sectors.

What are the types of ?

Reinforced concrete. prestressed concrete, post-tensioned concrete – 20+ types

What is the use of ?

Rapid modular construction of various structures

What are the properties of the ?

Repeatability, precision, speed of installation, durability

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