Duct plates

ceiling hollow core slabs

Hollow core slabs are prestressed concrete floor elements with longitudinal channels, produced as precast prestressed elements with high load-bearing capacity. They are produced by continuous molding method from concrete of C50/60 class with prestressing steel, providing exceptional strength and the ability to cross large spans. They are used as floor elements in residential and industrial construction, public buildings and multi-story parking lots.

For each investment hollow core slabs price is calculated individually, taking into account the length of the elements, thickness and design requirements. We guarantee competitive business conditions, professional technical advice and timely delivery. We invite you to request a free quote tailored to your construction project.

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Technical characteristics of hollow core panels

Hollow core slabs are a modern structural solution in floor systems of modern construction. They are manufactured from high-strength concrete of C50/60 or C45/55 class, using Y1860S7 prestressing steel. In addition, each hollow core slab is characterized by a section with longitudinal openings that reduce the dead weight of the element.

The production process is carried out on tension tracks up to 150 meters long, where hollow floor slabs are formed using a continuous method. Then prestressing with steel tendons with a force of up to 1860 MPa is applied. At the same time, the concrete is compacted with high-frequency vibrators, ensuring a homogeneous structure of the material.

Prefabricated hollow core slabs – advantages of the solution

Prefabricated hollow core slabs have much better strength parameters than traditional cast-in-place floors. Production under controlled hall conditions makes it possible to obtain concrete of C50/60 grade with a minimum w/c ratio. In addition, the hollow core slab undergoes thermal treatment to accelerate the maturation of the concrete.

The channel system in hollow core floor slabs reduces the dead weight of the floor by up to 40% while maintaining full load-bearing capacity. Standard thicknesses of hollow core slabs range from 150 to 500 mm, allowing spans of up to 20 meters to be crossed. But at the same time, the design of the hollow core slabs provides excellent acoustic and thermal insulation.

Pre-stressed concrete hollow core slabs exhibit minimal deflection due to prestressing. Pre-tensioning compensates for service loads, eliminating cracks and excessive deflection. As a result, the hollow core slab floor maintains its geometry throughout the life of the building.

The prestressing reinforcement is made of Y1860S7 seven-strand strand with diameters from 9.5 to 15.7 mm. The number and arrangement of tendons in each hollow floor slab is determined on the basis of static calculations. Subsequently, the hollow floor slabs receive technical documentation with parameters of load capacity and permissible loads.

Advantages of hollow core panels

Large span of hollow core slabs without supports

Hollow core slabs allow spans of up to 20 meters to be crossed without the need for intermediate columns. High-strength steel prestressing technology provides load-bearing capacity with minimal structural ceiling height. In addition, the elimination of intermediate supports increases the functionality of the usable space. This makes hollow floor slabs ideal for industrial halls and parking lots.

Speed of ceiling installation

Prefabricated hollow core slabs are delivered as ready-made components for immediate installation. Laying a hollow core slab floor using a crane takes a few days instead of the weeks needed for a poured floor. In addition, the lack of the need for formwork and waiting for the concrete to mature significantly speeds up the progress of the work. As a result, the construction time is reduced by 60-70%.

Fire resistance of hollow core panels

Concrete hollow core slabs are characterized by a fire resistance class of REI60 to REI240, depending on the thickness. The solid structure of the concrete provides an effective barrier to the spread of fire between floors. In addition, the absence of combustible structural elements increases the fire safety of the building. Thanks to these properties, the hollow core slab meets the highest requirements of fire regulations.

Load-bearing capacity and structural strength

The use of C50/60 grade concrete in the channel floor slabs provides a service load capacity of up to 10 kN/m². Compression eliminates scratching under service loads, preserving the tightness of the ceiling. Subsequently, the corresponding rigidity of the hollow core slabs minimizes vibration and deflection. This design guarantees comfort for decades.

Sound insulation of hollow core panels

The structure of the hollow core slabs with longitudinal air channels attenuates impact and airborne sounds. The ceiling’s own weight of about 300-400 kg/m² provides effective noise insulation. In addition, the possibility of filling the channels with sound-absorbing material further improves the acoustic performance. As a result, the hollow core slab ceiling meets acoustic standards for residential construction.

Cost-effectiveness of the solution

The use of hollowcore slab generates savings in the cost of labor and auxiliary materials. Elimination of formwork, site reinforcement and ready-mixed concrete reduces expenditures by 30-40%. In addition, the shorter execution time translates into a faster return on investment. This makes hollow floor slabs the optimal economic solution.

Ability to drill holes in hollowcore panels

The prefabrication system makes it possible to make installation holes in hollow core slabs as early as the production stage. Precision cutouts are made according to the installation design without weakening the load-bearing capacity. It is then possible to drill additional holes of up to 150 mm in diameter in the ducts. This flexibility makes it easier to guide the installation in the ceiling.

Service life of channel floors

The prestressed concrete channel slabs are designed for a minimum of 100 years of use. The use of concrete with exposure class XC3 and XD1 ensures resistance to carbonation. In addition, an adequate reinforcement cover of at least 35 mm protects the steel from corrosion. Thanks to these protections, the hollow core slab floor maintains its parameters throughout the life of the building.

Application of hollow core panels

Hollow core slabs are widely used in all types of construction as universal floor elements. The main purpose is the implementation of interstorey floors in multi-family residential buildings. In addition, hollow core floor slabs are an optimal solution for buildings with large spans and loads.

In industrial construction, the hollow core slab floor is used in production and warehouse halls. The ability to cross spans of up to 20 meters eliminates the need for internal columns. Then, in commercial buildings, hollow core slabs form high load-bearing ceilings for sales areas.

The hollow slab is ideal for the construction of multi-story parking lots and underground garages. The high load-bearing capacity allows truck and bus traffic. In addition, resistance to the aggressive environment of de-icing salts ensures the durability of the structure. Thanks to its fire-resistant properties, hollow floor slabs meet the requirements for closed garages.

Special use is found for hollow core panels in public construction. They are used in schools, hospitals, office buildings and sports centers. At the same time, the excellent sound insulation of hollow core slabs provides comfort in classrooms and conference rooms. As a result, hollow core ceilings are a standard in modern public construction.

Increasingly, ducted floor slabs are being used in green and energy-efficient construction. The ability to use ducts to run ventilation systems increases energy efficiency. In addition, the thermal mass of the hollow core slab ceiling stabilizes the temperature inside the building. Thus, the hollow core slab supports the implementation of passive construction standards.

Technical parameters of hollow core panels

Channel slabs are manufactured in accordance with PN-EN 1168 for prestressed concrete precast units. The standard concrete class is C50/60 with a characteristic compressive strength of 60 MPa. In addition, each hollow core slab has a declaration of performance, CE marking and ITB technical approval.

The strength parameters of hollow core floor slabs include characteristic load capacity from 3.5 to 10.0 kN/m². Fire resistance is specified in the range from REI60 to REI240, depending on the thickness of the element. Subsequently, the heat transfer coefficient U ranges from 0.90 to 2.50 W/m²K. The sound insulation of hollow core panels is Rw = 52-58 dB for airborne sound.

The prestressing reinforcement of the channel plates is made of Y1860S7 strands with diameters of 9.5; 12.5 or 15.7 mm. The prestressing force of a single strand ranges from 100 to 280 kN, depending on the diameter. In addition, plain reinforcement in the form of welded mesh fi 5-8 mm is used. The lagging of the reinforcement is a minimum of 35 mm from the bottom and 30 mm from the top of the slab.

The standard dimensions of hollow floor slabs are modular widths of 600, 1200 or 2400 mm. Typical thicknesses are 150, 200, 220, 265, 320, 400 and 500 mm. However, the lengths of the elements are individually adapted to the project, up to a maximum of 20 meters. The unit weight of a hollow core slab floor ranges from 230 kg/m² for 150 mm thickness to 475 kg/m² for 500 mm thickness.

Installation of hollowcore panels

Preparation of the support structure for hollowcore slabs requires the construction of reinforced concrete rims or steel beams. First, the leveling of the support surface is checked with a tolerance of +/- 5 mm. Then a layer of 10-20 mm thick leveling mortar or elastomeric shims is laid. In addition, the installation axes determining the position of the first hollowcore slab are determined.

Transport of hollow floor slabs to the construction site is carried out using low-loader sets. Unloading is carried out with a crane of appropriate capacity using forklifts or belt slings. In addition, the elements are stored on level ground with wooden shims at the support points. Prior to installation, each hollowcore panel is checked for compliance with the design.

The laying of hollow core slabs starts from the outermost bay, maintaining the designed direction of installation. The element is lifted at points located 0,2L from the ends of the slab, where L is the length. At the same time, the channel floor slabs are lowered slowly onto the supports with a minimum support of 80-120 mm. The gaps between the elements should be 10-20 mm.

The assembly of the floor of hollow core slabs is carried out by filling the joints with concrete of minimum class C20/25. The reinforcement of the perimeter rim is anchored in the filled channels of the edge slabs. This is followed by a layer of over-concrete with a minimum thickness of 40 mm with an anti-shrinkage mesh. Correct bonding of the channel slabs ensures the disc stiffness of the floor.

Quality control of the installation includes verification of the correct support of each hollow core slab. The widths of the joints, the level of the top surface of the ceiling and the filling of the channels are verified. In addition, the continuity of the reinforcement in the tie beams and the correctness of the over concrete are checked. As-built documentation should include acceptance protocols and a layout plan of the hollow floor slabs with type designation.

Price of hollow core slabs in 2024 and 2025

Hollow core slabs price is shaped by technical parameters such as thickness, length and floor load class. The calculation also takes into account the cost of specialized transportation and on-site installation services. In addition, the final pricing is affected by the size of the order and the complexity of the project. In 2024, it was observed that the price of prefabricated floor elements stabilized at a competitive level.

Hollow core slabs price – cost structure

The cost of hollow core slabs primarily includes the value of high-strength C50/60 concrete and prestressing steel. The hollowcore slabs price also includes expenditures for the energy-intensive process of prestressing and heat treatment of the concrete. Then the costs of cutting to size, making holes and certifying each batch are added. In 2024, the share of materials in the price of hollow floor slabs was about 55-65% of the total cost.

Factors affecting the price of hollow core slabs per m2

The pricing of hollow core slabs depends mainly on the thickness of the element that determines the load capacity and span. Hollow core slabs price per m2 for 200 mm thickness is 25-30% lower than for 320 mm thickness. In addition, the length of the elements above 12 meters generates additional costs for special transportation. Individual requirements such as installation holes or unusual dimensions increase the price of hollow core slab.

Cost optimization in the purchase of hollow floor slabs

The price list for hollow core slabs offers more favorable rates for orders of entire floors or buildings. The price of hollow core slabs for purchases of more than 1,000 m² can be lower by 5-10% due to production optimization. In addition, unifying the types of slabs in a project reduces production preparation costs. Promotions are planned for residential and industrial projects in 2025.

The calculation of a hollow slab floor should take into account the total cost of the floor system. Hollow core slabs price per m2 often turns out to be competitive with monolithic ceilings after labor is taken into account. At the same time, savings result from the elimination of formwork and a 70% reduction in construction time. It is worth comparing the offers of different manufacturers paying attention to the class of concrete and load-bearing parameters.

Additional costs when implementing hollow core slab floors

How much does hollow core slabs cost with a complete service is a question that includes delivery, installation and bonding. Hollow core slabs transport price depends on the distance and the need for low-loader vehicles. Then the cost of assembly by crane is usually 15-20% of the value of prefabricated elements. In 2024, the average cost of comprehensive implementation of hollow floor slabs was 150-280 PLN/m² net.

The price offer of hollow core slabs often includes additional elements of the floor system. Hollow core slabs price per m2 may include perimeter beams, levelling plates or lintel elements. In addition, many manufacturers offer free static calculations and technical advice. In 2025, comprehensive packages for entire buildings will be available.

Price comparison of hollow core panels of different types

The value of hollow core floor slabs varies depending on the system – HC, SP or SPK. Hollow core slabs price type HC (hollow core) is standard and the most competitive. In addition, SP type slabs with increased load-bearing capacity are 15-20% more expensive than standard ones. Cost estimates should take into account the optimal selection of the type for the project requirements.

The rate for hollow core slabs in 2024 was at PLN 150-250/m² for standard thicknesses of 200-265 mm. Hollow core slabs price per m2 for elements thicker 400-500 mm could reach 300-400 PLN/m². However, with large contracts it was possible to negotiate volume discounts. The forecast for 2025 assumes a price increase of 3-5% related to rising energy and steel costs.

The cost estimate for hollow floor slabs should be prepared individually for each project. Hollow core slabs final price depends on the specifics of the project, construction location and delivery schedule. Then it is worth considering the possibility of staging the delivery or financing the purchase. Feel free to contact us for a personalized offer for hollow core slabs tailored to your construction project.

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

Frequently asked questions by our customers about hollow core panels

What are hollow plates?

Hollow core slabs are prefabricated floor elements made of concrete, containing longitudinal hollow channels. They are characterized by quick and easy installation, do not require supports and allow immediate loading of the floor, which speeds up the construction process.

What is the price of hollow core panels in 2025?

150-350 PLN net/m²

What are the types of hollow core panels?

Zheran, compressed (HC)

What is the use of hollow core panels?

Residential, commercial, industrial construction

What are the properties of hollow core panels?

Dry mounting without mounting supports, quick installation in all conditions

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