WELLS HOLLOWCORE

DESIGN DATA

INTRODUCTION 1
PRODUCT OVERVIEW 2
A. The Manufacturing Process 3
B. Plank Design Considerations 3
C. Bottom Finishes 3
D. Fire Ratings 3
E. Production and Erection Tolerances 7
F. Narrow Hollowcore Widths 8
SPECIFICATIONS FOR PRECAST, PRESTRESSED HOLLOWCORE PLANK 9
INTRODUCTION
The purpose of this technical data is to provide
assistance in selecting and detailing precast concrete
hollowcore plank manufactured by Wells Concrete.
The load tables presented herein are intended as
a guide only. Final design is determined by our
engineering department based on information
presented in the final plans and specifications. To
ensure the optimum selection for your application,
please contact Wells Concrete for assistance.
Although care has been taken to provide the most
accurate data possible, Wells Concrete does not assume
responsibility for errors and omissions.
Reinforced concrete members must carry their own
weight in addition to any applied superimposed loads.
Short spans and thick depths of section are common
limiting factors in conventionally reinforced members.
Efforts to overcome these limitations resulted in the
development of prestressing the precast concrete
members. The major advantage of prestressed concrete
is its ability to span longer distances with much thinner
sections while carrying heavier loads. Span and load
requirements determine the member thickness and the
amount of prestressing force. It is important to note
that camber is a result of the design and is not a design
parameter.

A. General 9
B. Products 11
C. Execution 13
LOAD TABLES 15
8” Ultra-Span Load Tables 16
10” Ultra-Span Load Tables 18
12” Ultra-Span Load Tables 20
DETAILS 22
ERECTION PROCEDURES AND RECOMMENDATIONS 26
A. Pre-Erection Stage 27
B. Erection Stage - Handling and Setting Ultra-Span 28
C. Leveling & Grouting 29
D. Cutting Openings 30
E. Precautions 30
F. Visual Installation Guide 31

ii 1
 PRODUCT OVERVIEW
Hollowcore is an extruded, prestressed concrete slab with continuous voids to reduce weight and cost. It is primarily used as
a floor and roof deck system. Hollowcore is very economical and provides great design flexibility. It is used in many different
building systems. This unique product is strong, durable, and allows for significant floor loading and clear spans.
Advantages of Hollowcore
• Provides clear spans in excess of 40 feet while maintaining
a very thin cross section. Available in depths of 8, 10, and
12 inches
• Compatible with steel, masonry, cast-in-place, and other
precast structures
• Indoor manufacturing ensures consistent quality and
allows for year-round production
• Speed of erection schedule reduces down time for other
trades and decreases the overall build time; speed of
construction can reduce overall project time, increasing
speed to market and reducing cost
• The steel form finish on the underside allows for a smooth
paintable surface for a finished ceiling
2 3
• Fire resistant-offering up to 3-hour fire ratings with no
additional fireproofing required, this can reduce insurance
cost and potential loss of life and property
• Sound resistant, providing STC ratings of 50 or more
• Provides economical and efficient floor and roof systems
• Costly repairs or replacement due to water damage or
other types of accidents are drastically reduced when
compared with wood construction
• Precast/Prestressed Concrete Institute (PCI) Certified
Plant insures a quality product manufactured under strict
regulations
A. The Manufacturing Process
Ultra-Span is a machine-extruded, precast, prestressed hollowcore
D. Fire Ratings
Fire Rating Specifications are an important part of any building
plank. The plank is manufactured on 500-foot long beds in a construction project and are often dealt with during the
standard width of 48 inches and thicknesses of 8, 10, and 12 beginning of the design process. They sometimes drive the
inches. Plank is cut to length for each project. High-strength materials selected for the structure, its framing and exterior
prestressing strands are cast into the plank at the spacing and components for the need to protect the new structure from a
location required for the given span, loading, and fire cover fire event in an adjacent structure. Depending on the area of the
requirements. project, there are a few different methods that can be utilized
to determine the requirements. This is a brief overview of what
All Ultra-Span materials equal or exceed the requirements of is common in our area, however each project is unique and local
applicable ASTM specifications. The concrete mix is designed to codes should be consulted to ensure that the method selected
have a release strength of 3,500 psi and a 28-day compressive is allowed. There is also a difference between Fire Rating and
strength of 7,000 psi. The prestressing strands are uncoated, seven- Fire Separation. A fire rating typically means the duration for
wire, low-lax with a minimum ultimate strength of 270,000 psi. which a passive fire protection system can withstand a standard
fire resistance test. Fire Separation is a floor or wall having a fire
rating required by appropriate authorities that acts as a barrier
B. Plank Design Considerations against the spread of fire within a building. Another factor in the
The following items will affect the selection of appropriate plank fire rating of floors and roof members is the use of end conditions.
sizes and should be carefully reviewed by the architect/engineer Plank can be considered restrained by the Architect or Engineer
while developing the plans and specifications for a project: of Record based on if thermal expansion is resisted by adjacent
construction. Restrained bearing conditions offer longer fire
1. Fire Rating
endurances due to the restriction of the ends of the plank to move
• The fire rating requirement should be clearly specified in the during an event.
contract documents. RESTRAINED
2. Loading Conditions
• Specify all uniform loading requirements
on structural plans.
• Identify line and point loads resulting
from bearing walls, masonry walls,
columns, mechanical equipment, etc.
• Identify diaphragm forces and lateral
loads resulting from wind or earth
pressures.
• Review roof plans for vertical protrusions
such as parapets, penthouses, and
adjacent buildings that could require designing for snow UNRESTRAINED
drift loads.
• Size and number of openings can affect design.
• Plank supporting stairs require special loading
considerations.
C. Bottom Finishes
Bottom finish is the result of the extrusion process. Wells
hollowcore is produced on a smooth steel form resulting in a flat,
paintable finish.
 Typical Methods to Determine Fire Endurance in Plank:
Table 722.2.3 (2)
1. 2012 International Building Code (IBC) Cover Thickness for Prestressed Concrete Floor or Roof Slabs (inches)
2. Rational Design Method as defined by PCI MNL-124, “Design for
Concrete Fire-Resistance Rating (hours)
Fire Resistance of Precast Concrete” *Industry-preferred method
of design Aggregate Restrained Unrestrained
Type 1 1.5 2 3 4 1 1.5 2 3 4
International Building Code (IBC):
Siliceous 0.75 0.75 0.75 0.75 0.75 1.125 1.5 1.75 2.375 2.75
There are two requirements that have to be met in this code to achieve the desired fire endurance. They are the minimum total slab
thickness and strand clear cover. Below is a step by step process on how Wells’ hollowcore can perform under the IBC code. Carbonate 0.75 0.75 0.75 0.75 0.75 1 1.375 1.625 2.2125 2.25

Wells Hollowcore Values Sand-lightweight

0.75 0.75 0.75 0.75 0.75 1 1.375 1.5 2 2.25
Hollowcore Cross-Sectional Equivalent Strand or lightweight
Cross Section Area, (in2) Thickness, (in2/in) Clear Cover (in) IBC, 2012, pp. 174
8” 226 4.70
10” 248 5.17 1.50 PCI Design by Rational Analysis
12” 275 5.74 PCI MNL-124 allows a method defined as “rational analysis” for determining the fire rating of the precast and prestressed mem-
bers. This is the preferred method for determining a fire rating of our precast cross sections for both walls and floor members.
1. Equivalent concrete thickness. All Wells’ hollowcore sections are made with a siliceous concrete type. This value can be found Actual practice has provided evidence that this method is conservative when compared to the IBC method. This method utiliz-
in the table above under “Equivalent Thickness”. Equivalent thicknesses can be calculated by dividing the cross-sectional area es elevated temperatures in the prestressing strands to determine the moment capacities based on reduced capacities in the
by the nominal plank width (48”). To obtain a higher slab thickness, normal carbonate concrete field topping can be added strand. Those reductions are compared to the moments required
to gain a higher total slab thickness. Other topping materials such as gypcrete can be added to achieve a fire endurance Wells Concrete Examples of 3 for service
Hour PCI loads. Prestressing
Resistance strand temperatures are based
Systems
on the amount of cover provided and the standard fire exposure as defined by the time-temperature relationship provided in
using different tables. 350
ASTM E-119. Unlike the IBC rating, the PCI design does not require the distinction of restrained vs unrestrained.
Example: Slab thickness = 8” Hollowcore + 2” of topping = 4.70 in + 2.0 in = 6.70 in ≥ 6.2 in. Therefore, we meet the requirement for a 3 hour slab thickness, but
the strand clear cover needs to be met too!

Table 722.2.2.1 298

300
Minimum Slab Thickness (inches) 288

Fire-Resistance Rating (hours)

Concrete Type 1 1.5 2 3 4
250
Siliceous 3.5 4.3 5 6.2 7

Total Uniform Superimposed Load (psf)

245
Carbonate 3.2 4 4.6 5 6.6 233
204
Sand-lightweight 2.7 3.3 3.8 4.6 5.4
200 8" Standard
Lightweight 2.5 3.1 3.6 4.4 5.1
8" HC + 2" Tpg
IBC, 2012, pp. 172 185
10" Standard
150 10" HC + 2" Tpg
150
2. Bottom strand clear cover over the prestressing strand is 1.5”. Fire ratings utilizing this method are also impacted by the 132 122 12" Standard
bearing condition, which can be restrained or unrestrained.
12" HC + 2" Tpg
Example: Unrestrained hollowcore bays that requires a 3 hour rating. Strand cover = 1.50 in ≤ 2.25 in. Therefore, we only meet the requirement for a 1.5 hour 129
cover thickness. 115
100
Example: Restrain every hollowcore bay that requires a 3 hour rating. Standard strand cover = 1.50 in ≥ 0.75 in. Therefore, we meet the requirement for a 3 hour
104 76 70
cover thickness.
51
71 70
39
50
34
44

31 34
4 5
0
10 15 20 25 30 35 40 45 50
 E. Production and Erection Tolerances Hollowcore Slabs Erection Tolerances

Hollowcore Slabs Product Tolerances The primary control surfaces are usually as shown. A majority of the time there is no designated vertical primary control surface, and in
some scenarios there are no primary control surfaces at all. This needs to be determined on a job-by-job basis.
a = Length............................................................................................±1/2 in. [±13 mm]
a = Plan location from building grid datum..............................................±1 in. [±25 mm]
b = Width (overall)................................................................................±1/4 in. [±6 mm]
a1 = Plan location from centerline of steel support*..................................±1 in. [±25 mm]
b1 = Web width:
The total web width defined by the sum of the actual measured values of “b1” b = Top elevation from building elevation datum at member ends:
shall not Covered with topping.........................................................................±3/4 in. [±19 mm]
be less than 85% of the sum of the nominal web widths “b1, nominal” Pretopped tee/carpet direct hollowcore.............................................±1/4 in. [±6 mm]
Untopped roof....................................................................................±3/4 in. [±19 mm]
C = Depth (overall).................................................................................±1/4 in [±6 mm]
c = Maximum jog alignment of matching edges
c1 = Top flange depth:
(both topped and untopped construction).............................................1 in. [25 mm]
Top flange area defined by the actual measured values of average”c1” x “b” shall
not d = Joint width:
be less than 85% of the nominal area calculated by “c1, nominal” x “bnominal” 0 to 40 ft. member.............................................................................±1/2 in. [±13 mm]
41 to 60 ft. member............................................................................±3/4 in. [±19 mm]
c2 = Bottom flange depth:
61 ft. plus member.................................................................................±1 in. [±25 mm]
Top flange area defined by the actual measured values of average”c2” x “b”
shall not e = Differential top elevation as erected (for units of same design and length):
be less than 85% of the nominal area calculated by “c2, nominal” x “bnominal” Field topped.............................................................................................3/4 in. [19 mm]
Pretopped tees at driving lanes/carpet direct hollowcore......................1/4 in. [6 mm]
d = Variation from specified plan end squareness or skew..............±1/2 in. [±13 mm]
Untopped roof**.....................................................................................3/4 in. [19 mm]
e = Variation from specified elevation end squareness or skew.......................±1/8 in.
f = Bearing length***(span-direction)......................................................±3/4 in. [±19 mm]
per 12 in., ±1/2 in. maximum
[±3 mm per g = Differential bottom elevation of
300 mm, ±13 mm maximum] exposed hollowcore slabs****.,,..............................................................1/4 in. [6 mm]
f = Sweep........................................................................±3/8 in. in 10 ft. [6 mm in 3 m] Note: When bearing pads are used at unarmored edges they should be set back a minimum of 1/2 in. [13mm] from the face of the support
g = Applications requiring close control of differential camber between adjacent or at least the chamfered dimension at chamfered edges.
members should be * For precast concrete erected on a steel frame building, this tolerance takes precedence over tolerance on dimension “a”.
discussed with the producer to determine applicable tolerances.
** It may be necessary to feather the edges to ±1/4 in. [±6mm] to properly apply some roof membranes.
h = Local smoothness of any surface...............................1/4 in. in 10 ft. [6 mm in 3 m]
***This is a setting tolerance and should not be confused with structural performance requirements set by the architect/engineer. The
k = Center of gravity (CG) of strand group...................................... ±1/4 in . [±13 mm] nominal bearing dimensions and the allowable variations in the bearing length and width should be specified by the engineer and shown
k1 = Location of strand perpendicular to plane of panel...................±1/2 in. [±13 mm] on the erection drawings.
Minimum cover..................................................................................3/4 in. [19 mm] ****Untopped installations will require a larger tolerance.
k2 = Location of strand parallel to plane of panel..................................3/4 in. [19 mm]
Minimum cover..................................................................................3/4 in. [19 mm]
l1 = Location of embedment*................................................................±2 in. [±50 mm]
l2 = Tipping and flushness of embedment............................................±1/4 in. [±6 mm]
n1 = Location of blockout........................................................................±2 in. [±50 mm]
n2 = Size of blockouts...........................................................................±1/2 in. [±13 mm]
x = Weight:
Actual measured value shall not exceed 110 percent of the nominal published
unit weight used in the design.

6 7
 F. Narrow Hollowcore Widths
SPECIFICATIONS FOR PRECAST,
Wells Concrete’s standard manufactured hollowcore width is 4 feet. Most building layouts require a small amount of plank to be
delivered in widths less than the standard 4 feet. Refer to the guidelines below for allowable ranges of narrow hollowcore widths. PRESTRESSED HOLLOWCORE PLANK
Note that not all narrow width slabs are available due to safety concerns during handling and erection.

A. General
1.01 Description

A. Work Included:

1. These specifications cover manufacture, transportation, and erection of precast/prestressed concrete hollowcore plank,
including grouting of joints between adjacent units.

B. Related Work Specified Elsewhere:

1. Cast-in-place concrete; architectural precast concrete; precast structural concrete; underlayments (floor and/or roof leveling);
caulking and sealants; small holes for mechanical/plumbing; cast-in-place embedments; steel bearing lintels; insulation in plank
cores.

1.02 Quality Assurance D. Welder Qualifications: In accordance with AWS D1.1

A. All precast/prestressed concrete shall be designed to
support the loads shown on the drawings.
B. Manufacturer Qualifications: The precast concrete
manufacturing plant shall be certified by the Prestressed
Concrete Institute (PCI) Plant Certification Program prior
to the start of production.
The manufacturer shall retain a registered structural
engineer to certify that manufacturing is in accordance
with design requirements; or the manufacturer shall, at
his expense, meet the following requirements:
E. Testing: In general compliance with applicable provisions
of Prestressed Concrete Institute MNL-116, “Manual
for Quality Control for Plants and Production of Precast
Prestressed Concrete Products.”
F. Requirements of Regulatory Agencies: All local codes plus
the following specifications, standards and codes are a
part of these specifications:
1. ACI 318-89 – “Building Code Requirements for
Structural Concrete”. All definitions of terms and
symbols shall be defined in ACI 318-89

1. The basis of inspection shall be the Prestressed Concrete 2. AWS D1.1 – Structural Welding Code-Steel
Institute’s “Manual for Quality Control for Plants
and Production of Precast and Prestressed Concrete 3. AWS D1.4 – Structural Welding Code-Reinforcing Steel
Products,” MNL-116, and the criteria for acceptance
4. ACI 301-84 (Revised 1987) – “Specifications for
shall be the same as the Plant Certification Program.
Structural Concrete Buildings”
2. Retain a full-time structural engineer to certify that
5. PCI-MNL 116 – “Manual of Quality Control for Plant
manufacturing is in accordance with design
and Products of Precast”
requirements.
6. ASTM Specifications – As referred to in Part 2-Products,
C. Erector Qualifications: Must be a PCI certified erector and
of this Specification
regularly engaged for at least five years in the erection
of precast structural concrete similar to the requirements 7. 2nd Edition “PCI Manual for the Design of Hollowcore
of this project. Retain a registered structural engineer Slabs”
to certify that erection is in accordance with design
requirements.

8 9
 1.03 Submittals and Design
A. Shop Drawings:
1. Erection Drawings:
a. Plans locating and defining all hollowcore plank
furnished by manufacturer, with all major openings
shown.
b. Sections and details showing connections, weld
plates, edge conditions and support conditions of the
hollowcore plank units.
c. All dead, live and other applicable loads used in the
design.
d. Fire rating.
2. Shop drawings shall be checked for compliance by the
general contractor. All drawings shall be marked with
any necessary corrections, initialed by the contractor and
returned to the prestressed concrete manufacturer.
3. Shop drawings shall be complete and shall include a layout
plan, fabrication details, connections and anchorage details,
and member identification marks. The identification marks
shall appear on the manufactured units to facilitate correct
field placement.
4. The general contractor shall provide size and location of all
rough openings required that must be cut into the precast
prestressed concrete units. The openings should
be marked on the hollowcore shop drawings by the general
contractor and/or sub-contractors during the submittal
approval process.
5. Openings may not be cut in the field without prior approval
from manufacturer, unless the opening can be cut in a
hollow void and no prestressed strand will be cut.
6. In addition to the above shop drawing requirements. The
shop drawings shall include:
a. Dimensions of all members.
1.04 Quality Control and Inspection
b. Dimensional location of all reinforcing steel and
prestressing steel.
c. Size, type, and location of all accessories.
10
B. Approvals:
1. Submit erection drawings for approval prior to fabrication.
Fabrication not to proceed prior to receipt of approved
drawings. Any changes made after approval may delay
delivery schedule.
C. Product Design Criteria:
1. Loadings for design:
a. Initial handling and erection stresses.
b. All dead and live loads as specified on the
contract documents.
c. All other loads specified for Hollowcore plank
where applicable
2. Fire rating shall be a ___-hour.
3. Design steel plank support headers when such headers are
determined necessary by manufacturer’s engineer.
4. Design calculations shall be performed by a registered
engineer experienced in precast/prestressed concrete design
and submitted for approval upon request.
5. Design shall be in accordance with ACI 318 and
applicable codes.
D. Permissible Design Deviations:
1. Design deviations will be permitted only after the architect/
engineer’s written approval of the manufacturer’s proposed
design supported by complete design calculations and
drawings.
2. Design deviations shall provide an installation equivalent
to the basic intent without incurring additional cost to the
owner.
E. Test Reports: Test reports on concrete and other materials
shall be submitted upon request.
A. Release strength must be a minimum of 3,500 psi with
minimum of 7,000 psi at 28 days. Panel design may require
higher strengths due to project requirements.
B. All products in this section shall be inspected prior to
shipment by the manufacturer for conformance to these
specifications.
B. Products
2.01 Materials
A. Slabs shall be manufactured by the continuous
extrusion process.
B. Concrete for precast/prestressed concrete shall be by
central batching plant operated or controlled by the
manufacturer to insure specified quality.
C. Materials used shall conform to ACI 318-89.
D. Use of calcium chloride will not be allowed.
E. Portland Cement:
1. ASTM C150-Type I or III.
F. Admixtures:
1. Water Reducing, Retarding, Accelerating, High-
Range Water Reducing Admixtures: ASTM C494
G. Aggregates:
1. ASTM C33 or C330
H. Water:
1. Potable or free from foreign materials in amounts
harmful to concrete and embedded steel.
I. Reinforcing Steel:
1. Uncoated, 7-wire strand complying with ASTM A-416,
Grade 270K.
2. Bars: Deformed Billet Steel: ASTM A615.
Deformed Rail Steel: ASTM A616.
Deformed Axle Steel: ASTM A617.
Deformed Low Alloy Steel: ASTM A706.
3. Wire: Cold Drawn Steel: ASTM A82.
J. Prestressing Strand:
1. Uncoated, 7-wire, Low Lax strand: ASTM A416 –
Grade 270K.
K. Welded Studs: In accordance with AWS D1.1.
L. Structural Steel Plates and Shapes: ASTM A36.
M. Grout:
1. Grout shall be a mixture of not less than one
part Portland cement to three parts fine sand,
and the consistency shall be such that joints can
be completely filled but without seepage over
adjacent surfaces. The grout shall achieve a
minimum 28-day compressive strength of 3,000
psi. Any grout that seeps from the joint shall be
completely removed before it hardens.
N. Bearing Stripes:
1. Plastic: Multi-monomer plastic strips shall be
non-leaching and support construction loads
with no visible overall expansion.
2. Install bearing pads where indicated on the
shop drawings. Set pads on level and uniform
bearing surface.
3. Bearing pads shall be 1/8” by 3” Korolath® or
equal hard plastic with one side non-skid.
O. Opening, Inserts & Fastenings:
1. All openings shall be located on
structural drawings.
2. Other openings shall be located and field drilled
or cut by trade requiring them after slabs have
been erected and grout has been allowed to cure.
Openings and/or cutting of prestress strand shall
be approved by Architect/Engineer and
Manufacturer before drilling or cutting.
P. Weep holes will be provided at each core location at both
ends of plank to allow drainage of any rainwater or water
resulting form other construction activities.
11
 2.02 Concrete Mixes
A. 28-day compressive strength: minimum of 7,000 psi.
B. Release strength: minimum of 3.500 psi.
C. Use of calcium chloride or admixtures containing chlorides
is not permitted.
2.03 Manufacture
A. Hollowcore plank shall be machine-cast in 48-inch widths as
3.01 Product Delivery, Storage, and Handling
manufactured by Wells Concrete under the trade
name Ultra-Span®.
B. Manufacturing procedures and tolerances shall be in
general compliance with PCI MNL 116.
C. Openings: Manufacturer shall provide for rectangular
openings 10 inches or larger on all sides and as clearly
shown on the architectural and structural drawings. They
shall be located by the trade requiring them and field
cut by the erector. Round and small openings (less than
10 inches) shall be drilled or cut by the respective trades
after grouting. Openings requiring cutting of prestressing
strand shall be approved by manufacturer before drilling
or cutting.
D. Finishes: Bottom surface shall be flat and uniform as
resulting from an extrusion process cast on a smooth
steel form, without major chips, spalls and imperfections.
Top Surface shall be machine troweled. Finish shall be
standard grade. The steel form finish on the underside
allows for a smooth paintable surface for a finished ceiling.
3.02 Erection
E. Patching: Will be acceptable providing the structural
adequacy of the hollowcore unit is not impaired.
C. Execution
A. Delivery and Handling:
1. Hollowcore plank shall be lifted and supported
during manufacturing, stockpiling, transporting and manufacturer. Bearing strips shall be set where
erection operations only at the lifting or supporting required. Grout keys shall be filled. Openings shall be
points designated by manufacturer.
2. Transportation, site handling, and erection shall be
performed with acceptable equipment and methods,
and by qualified personnel.
B. Storage:
1. Store all units off ground on firm, level surfaces with
dunnage placed at bearing points.
2. Place stored units so that identification marks
are discernible.
3. Separate stacked units by dunnage across full width
of each plank.
A. Site Access: Erection access suitable for cranes and
trucks to move unassisted from public roads to all
crane working areas as required by erector, or
otherwise indicated herein, will be provided and
maintained by the general contractor. Obstructing
wires shall be shielded or removed and, when
applicable, snow removal and winter heat will be
provided by the general contractor.
B. Preparation: The general contractor shall be
responsible for:
3. All pipes, stacks, conduits and other such items shall
be stubbed off at a level lower than the bearing
plane until the plank is in place.
C. Installation: Installation of hollowcore slab units
shall be performed by manufacturer. Members shall
be lifted with slings at points determined by
field cut only after grout has cured, unless authorized
by manufacturer’s engineer.
D. Alignment: Members shall be properly aligned.
Variations between adjacent members shall be
reasonably leveled out by jacking, loading or any other
feasible method as recommended by manufacturer.
3.03 Field Welding
A. Field welding is to be done by qualified welders
using equipment and materials compatible to the
base material.
3.04 Attachments and Small Holes
A. Subject to approval of the architect/engineer,
hollowcore plank units may be drilled or “shot”
provided no contact is made with the prestressing
steel. Round holes and those less than 10 inches on
any side shall be drilled or cut by the respective trades.
Should spalling occur, it shall be repaired by the trade
doing the drilling, shooting, or cutting.
3.05 Clean Up
A. Remove rubbish and debris resulting from hollowcore
plank work from premises upon completion.
3.06 Safety

1. Providing true, level, bearing surfaces on all
field-placed bearing walls and other field-placed
supporting members. Masonry wall bearing surfaces
shall be bond beams with properly filled and
cured concrete.
A. All safety barricades and opening covers will be
provide by Wells Concrete during the precast
installation process. Once installation is complete, this
becomes the responsibility of the general contractor.

2. Assuring that all structural framing to support

precast/prestressed concrete is braced against
horizontal displacement or any other movement
during erection.

12 13
 HOLLOWCORE LOAD TABLES
The tables herein list allowable live loads in pounds per
square foot for uniformly distributed loading. Non-uniform
loading conditions resulting from point loads, line loads,
openings, and cantilevers require special design consideration.
The allowable load is sometimes governed by the ultimate
capacity of the section. As a design aid, the ultimate moment
capacities in foot-kips per foot of width are listed in the
tables.
Short span allowable live loads for untopped plank may be
governed by the shear capacity of the section. For topped
plank, the governing criterion for short spans
may be the horizontal shear stress between the plank
and the topping.
14
Allowable live loads for long-span, heavily reinforced sections
are limited to loads that result in a bottom-tension stress
equal to the cracking stress, assumed to be 7.5√(F’)c. Loads
beyond this limit may result in deflections that exceed the
allowable value set forth in the ACI Code.
The load tables are based on a plank concrete strength of
7,000 psi. Tables for topped sections are based on a topping
strength of 3,000 psi and a minimum thickness
of 2 inches.
Maximum spans and loads shown are not absolutes. Longer
spans or heavier loads may be achieved under certain
conditions or different criteria than assumed in the tables.
Contact Wells Concrete for design assistance.
15
 If hollowcore can be considered restranded, use
1.5 Hour Fire Rating, 2” Minimum Composite Topping this load chart for fire ratings up to 3 hours
8” Wells Hollowcore Load Tables Area of
Mn (kip- Span in Feet
Series Steel
Allowable load in PSF. These tables are for general descriptive ft.) 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
(In2)
purposes only. Actual design load tables are dependent on local 8804T 0.612 92.79 431 390 356 324 295 258 227 200 176 156 138 122 108 96 85 75 65 57 50 43 37 31
codes and standards, material properties and product end usage.
8805T 0.765 112.9 546 493 447 410 372 328 289 257 228 203 182 162 145 130 117 104 93 83 74 66 59 52
• Blue shaded values are controlled by shear. Filling of cores 8807T 1.071 149.8 687 633 569 506 452 406 367 333 304 278 255 235 214 193 175 159 145 131 119 109 99 90
may be requested

2 Hour Fire Rating, 2” Minimum Composite Topping

Area of
Mn (kip- Span in Feet
Series Steel
ft.)
Series Designation Example (In2) 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
8804T 0.612 39.12 356 299 252 213 181 153 130 109 92 77 63 51 41 32
8808T
8805T 0.765 48.32 460 390 332 284 244 210 181 156 134 115 99 84 71 60 49 40 32
INDICATES COMPOSITE TOPPING 8807T 1.071 65.96 660 564 485 419 365 318 279 245 215 189 167 147 129 113 99 87 75 65 55 47 39 32
NUMBER OF STRANDS
STRAND DIAMETER (16THS) 3 Hour Fire Rating, 2” Minimum Composite Topping
PLANK THICKNESS Area of Span in Feet
Mn (kip-
Series Steel
ft.) 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
(In2)
1.5 Hour Fire Rating, No Topping If hollowcore can be considered restranded, use this load chart for fire ratings up to 3 hours 8804T 0.612 22.83 171 138 111 88 69 53 39
Area of
Mn (kip- Span in Feet 8805T 0.765 28.32 233 192 158 130 107 87 70 55 42 31
Series Steel
ft.) 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
(In2)
8807T 1.071 39.01 355 298 251 212 180 152 129 109 91 76 63 51 41 31
8804 0.612 72.36 340 306 278 253 231 206 182 161 142 126 112 100 89 79 71 63

8805 0.765 88.84 427 385 350 319 293 263 233 207 185 165 148 133 120 108 97 87 79 71 64 57 51 46
Estimated Camber at erection, cambers in inches
8807 1.071 119.6 530 486 440 392 352 318 289 263 241 222 204 189 175 161 146 133 122 101 92 83 75 68
Span in Feet
Series
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
2 Hour Fire Rating, No Topping 8804 0.19 0.21 0.23 0.24 0.26 0.27 0.27 0.27 0.27 0.26 0.24 0.22 0.18 0.14 0.09 0.02

Area of
Mn (kip- Span in Feet 8805 0.25 0.28 0.31 0.33 0.36 0.38 0.4 0.41 0.42 0.42 0.42 0.41 0.4 0.37 0.33 0.29 0.23 0.16 0.07 -.07 -.15 -.28
Series Steel
ft.) 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
(In2)
8807 0.37 0.41 0.46 0.51 0.55 0.6 0.64 0.68 0.72 0.75 0.78 0.8 0.82 0.82 0.82 0.81 0.79 0.76 0.71 0.66 0.58 0.49
8804 0.612 30.01 278 234 198 168 143 122 104 89 75 63 53 44 36

8805 0.765 37.19 359 305 260 223 192 166 144 125 108 94 81 70 60 51 43 36
Selection Properties
8807 1.071 51.16 517 443 381 331 288 252 222 195 172 152 135 119 105 93 82 72 64 56 48 42 36 30
Net Area 225.78 IN2 Strength of Concrete 7,000 psi
Moment of Inertia 1767.9 IN4 Unit Weight of Concrete 150 PCF
3 Hour Fire Rating, No Topping
Centoid From Slab Bottom 4.00 IN Ultimate Steel Strength 270 KSI
Area of
Mn (kip- Span in Feet
Series Steel
ft.) Section Modules. Top 442.22 IN3 Strand Jacking Stress 202.5 KSI
(In2) 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
8804 0.612 17.44 135 110 89 71 57 45 34 Section Modules. Bottom 442.22 IN3 Strand Type Low Relaxation

8805 0.765 21.67 183 151 125 104 86 71 58 47 37 Web Width 12.94 IN Thermal Resistance R = 1.34

8807 1.071 29.98 277 233 198 168 143 122 104 88 75 63 53 44 36 V/S Ratio 2.13 IN Sound Transmission Class STC = 50
Self Weight 63 PSF Impact Insulation Class IIC = 28
Strength at Transfer 3,500 PSI

16 17
 If hollowcore can be considered restranded, use
10” Wells Hollowcore Load Tables 1.5 Hour Fire Rating, 2” Minimum Composite Topping this load chart for fire ratings up to 3 hours
Area of
Mn Span in Feet
Allowable load in PSF. These tables are for general Series Steel
(kip-ft.) 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
(In2)
descriptive purposes only. Actual design load tables are
10804 0.612 117.2 116 99 84 71 60 50 41 33
dependent on local codes and standards, material properties
10806 0.918 169.1 389 366 336 306 279 256 235 216 199 184 167 152 139 126 115 105 95 87 79 71 64 58 52 47 41 37 32
and product end usage.
10808 1.224 217.2 389 366 345 326 309 293 279 259 239 221 205 190 177 164 153 142 133 124 116 109 101 94 86 79 72 66 61 55 50 45 41
• Blue shaded values are controlled by shear. Filling of 10810 1.53 262.3 389 366 345 326 309 293 279 259 253 241 231 221 206 192 179 167 156 146 136 128 119 112 105 99 92 87 82 76 72 67 63
cores may be requested.
• Bold or gray shaded values: live load deflection exceeds 2 Hour Fire Rating, 2” Minimum Composite Topping
L/360 or total deflection exceeds L/240. Area of
Mn Span in Feet
Series Steel
(kip-ft.) 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
(In2)

10804T 0.612 49.05 116 99 84 71 60 50 41 33

10806T 0.918 72.19 308 270 238 210 185 163 144 127 111 97 85 73 63 54 45 37 30
Series Designation Example 10808T 1.224 94.35 389 366 340 303 270 242 217 194 174 156 139 125 111 99 88 78 68 60 52 44 38 31
10810T 1.53 115.4 389 366 345 326 309 293 279 258 234 211 191 173 157 142 128 116 104 94 84 75 67 59 52 45 39 33
10808T

INDICATES COMPOSITE TOPPING 3 Hour Fire Rating, 2” Minimum Composite Topping

NUMBER OF STRANDS Area of
Mn Span in Feet
Series Steel
(kip-ft.) 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
STRAND DIAMETER (16THS) (In2)

10804T 0.612 28.54 65 50 38

PLANK THICKNESS
10806T 0.918 42.28 141 120 101 84 70 57 45 35
10808T 1.224 55.64 216 187 162 140 121 104 89 76 64 54 44 35
1.5 Hour Fire Rating, No Topping If hollowcore can be considered restranded, use this load chart for fire ratings up to 3 hours 10810T 1.53 68.59 288 252 221 195 171 150 132 116 101 88 76 65 55 46 38 31
Area of
Mn Span in Feet
Series Steel
(kip-ft.) 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
(In2)
Estimated Camber at erection, cambers in inches
10804 0.612 97.21 103 89 77 66 56 48 41 34
Span in Feet
10806 0.918 142.0 316 297 279 255 234 216 199 184 171 159 148 136 124 114 105 96 88 81 74 68 62 57 52 47 43 39 Series
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
10808 1.224 184.0 316 297 281 266 252 240 228 217 202 188 175 163 152 143 134 125 118 110 104 98 92 87 81 75 70 65 60 55 51 47 43
10804 0.27 0.29 0.29 0.3 0.3 0.3 0.29 0.28
10810 1.53 221.6 316 297 281 266 252 240 228 217 208 198 190 182 174 164 154 145 136 128 120 113 107 101 95 90 85 81 76 72 68 65 61
10806 0.48 0.51 0.54 0.57 0.6 0.62 0.64 0.66 0.67 0.67 0.67 0.66 0.65 0.62 0.59 0.55 0.49 0.43 0.35 0.26 0.16 0.04 -0.09 -0.24 -0.41 -0.59
10808 0.68 0.73 0.79 0.84 0.89 0.94 0.98 1.02 1.06 1.1 1.13 1.15 1.17 1.18 1.18 1.17 1.16 1.13 1.1 1.05 0.99 0.91 0.82 0.72 0.6 0.46 0.31 0.14 -0.06 -0.27 -0.51
2 Hour Fire Rating, No Topping
10810 0.87 0.95 1.02 1.1 1.17 1.24 1.31 1.38 1.45 1.51 1.57 1.62 1.67 1.72 1.75 1.78 1.8 1.82 1.82 1.81 1.79 1.76 1.71 1.66 1.58 1.49 1.39 1.26 1.12 0.96 0.78
Area of
Mn Span in Feet
Series Steel
(kip-ft.) 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
(In2)

10804 0.612 39.94 103 89 77 66 56 48 41 34 Selection Properties

10806 0.918 59.17 260 230 203 180 160 142 126 112 99 88 78 68 60 52 45 39 33 Net Area 247.99 IN2 Strength of Concrete 7,000 psi
10808 1.224 77.87 316 297 281 266 232 208 187 169 152 137 124 112 100 90 81 73 65 58 51 45 40 34 30
Moment of Inertia 3262.4IN4 Unit Weight of Concrete 150 PCF
10810 1.53 96.02 316 297 281 266 252 239 216 195 176 160 145 131 119 108 98 88 80 72 64 58 52 46 40 35 31
Centoid From Slab Bottom 5.00 IN Ultimate Steel Strength 270 KSI
3 Hour Fire Rating, No Topping Section Modules. Top 652.46 IN3 Strand Jacking Stress 202.5 KSI
Area of
Mn Span in Feet
Series Steel
(kip-ft.) 20 Section Modules. Bottom 652.46 IN3 Strand Type Low Relaxation
(In2) 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
10804 0.612 23.14 60 48 38 Web Width 9.25 IN Thermal Resistance R = 1.74
10806 0.918 34.42 123 105 90 76 64 54 45 36 V/S Ratio 2.28 IN Sound Transmission Class STC = 52
10808 1.224 45.51 184 161 140 123 107 93 81 70 61 52 44 37 30
Self Weight 69.0 PSF Impact Insulation Class IIC = 33
10810 1.53 56.38 245 216 190 168 149 132 117 103 91 80 71 62 54 47 40 34
Strength at Transfer 3,500 PSI

18 19
 If hollowcore can be considered restranded, use
12” Wells Hollowcore Load Tables 1.5 Hour Fire Rating, 2” Minimum Composite Topping this load chart for fire ratings up to 3 hours
Area of
Mn Span in Feet
Allowable load in PSF. These tables are for general descriptive Series Steel
(kip-ft.) 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
(In2)
purposes only. Actual design load tables are dependent on
12805T .765 175.0 47 39 32 26
local codes and standards, material properties and product end
12807T 1.071 237.1 235 218 203 188 176 164 153 142 131 120 111 102 94 86 79 72 66 60 54 49 44 39 35 31
usage.
12809T 1.337 292.8 251 240 230 220 206 192 179 168 157 147 138 129 121 114 107 100 94 88 83 78 72 66 61 56
• Blue shaded values are controlled by shear. Filling of cores 12811T 1.683 341.7 246 235 225 216 207 198 191 183 176 166 156 147 138 129 122 114 107 101 95 89 84 79 74 70 65
may be requested.
2 Hour Fire Rating, 2” Minimum Composite Topping
Area of
Mn Span in Feet
Series Steel
(kip-ft.) 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
(In2)

Series Designation Example 12805T .765 73.14 47 39 32 26

12807T 1.071 100.8 146 131 116 103 91 80 70 61 53 45 38 31
12808T 12809T 1.337 143.6 251 230 209 191 174 158 144 131 119 107 97 87 78 70 62 55 48 42 36 30
12811T 1.683 208.4 246 235 225 216 207 198 191 183 176 166 156 147 138 129 122 114 107 101 95 89 83 76 69 62 56
INDICATES COMPOSITE TOPPING
NUMBER OF STRANDS
STRAND DIAMETER (16THS)
3 Hour Fire Rating, 2” Minimum Composite Topping
Area of
Mn Span in Feet
PLANK THICKNESS Series Steel
(kip-ft.) 30
(In2) 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1.5 Hour Fire Rating, No Topping If hollowcore can be considered restranded, use this load chart for fire ratings up to 3 hours 12805T .765 42.58
12807T 1.071 58.99 43 34
Area of
Mn Span in Feet
Series Steel 12809T 1.337 92.7 126 112 99 87 76 66 56 48 40 33
(kip-ft.) 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
(In2)
12811T 1.683 124.0 204 184 167 151 136 122 110 99 88 79 70 61 54 47 40 34
12805 0.765 151 49 42 36 31
12807 1.071 207 209 194 181 169 158 149 140 131 123 114 106 98 91 84 78 72 67 61 57 52 48 44 40 36
Estimated Camber at erection, cambers in inches
12809 1.337 256.4 209 206 197 189 182 172 161 152 143 135 127 120 113 107 101 95 90 86 81 77 62 67 63 58 54
Span in Feet
12811 1.683 297.7 209 201 192 184 177 170 164 158 152 146 141 134 127 120 113 107 101 96 91 86 82 78 74 70 66 Series
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
12805 0.41 0.4 0.39 0.37

2 Hour Fire Rating, No Topping 12807 0.76 0.77 0.79 0.79 0.8 0.79 0.79 0.77 0.75 0.72 0.68 0.63 0.58 0.51 0.43 0.35 0.25 0.13 0.01 -0.13 -0.28 -0.45 -0.64 -0.84
12809 1.05 1.08 1.12 1.15 1.17 1.19 1.21 1.22 1.22 1.22 1.2 1.18 1.16 1.12 1.07 1.01 0.95 0.87 0.77 0.67 0.55 0.42 0.27 0.1 -0.08
Area of
Mn Span in Feet
Series Steel 12811 1.28 1.33 1.38 1.43 1.47 1.51 1.55 1.57 1.6 1.61 1.62 1.63 1.62 1.61 1.58 1.55 1.51 1.45 1.39 1.31 1.22 1.11 0.99 0.86 0.7
(kip-ft.) 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
(In2)
12805 0.765 62.04 49 42 36 31 26
12807 1.071 86.03 135 121 109 98 88 79 70 62 55 48 42 36 31
Selection Properties
12809 1.337 123.5 209 206 191 175 160 147 134 123 113 103 94 86 78 71 64 58 52 47 42 37 32 Net Area 275.35 IN2 Strength of Concrete 7,000 psi
12811 1.683 181.6 209 201 192 184 177 170 164 158 152 146 141 134 127 120 113 107 101 96 91 86 82 78 72 66 61 Moment of Inertia 5352.7 IN4 Unit Weight of Concrete 150 PCF
Centoid From Slab Bottom 6.00 IN Ultimate Steel Strength 270 KSI
3 Hour Fire Rating, No Topping
Section Modules. Top 892.12 IN3 Strand Jacking Stress 202.5 KSI
Area of
Mn Span in Feet
Series Steel Section Modules. Bottom 892.12 IN3 Strand Type Low Relaxation
(kip-ft.) 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
(In2)
12805 0.765 35.94 Web Width 8.50 IN Thermal Resistance R = 1.91
12807 1.071 49.99 46 38 31 V/S Ratio 2.47 IN Sound Transmission Class STC = 54
12809 1.337 78.99 117 105 94 84 74 66 58 51 44 38 32
Self Weight 78.0 PSF Impact Insulation Class IIC = 38
12811 1.683 106.2 185 168 153 139 127 115 105 95 86 78 70 63 56 50 44 39 34
Strength at Transfer 3,500 PSI

20 21
 DETAILS

BEARING DETAIL PRECAST WALL NON-BEARING DETAIL PRECAST WALL BEARING DETAIL MASONRY WALL BEARING DETAIL MASONRY WALL WITH CANTILEVER

BEARING DETAIL MASONRY WALL NON-BEARING DETAIL MASONRY WALL BEARING & LAP CONDITION ON CMU DETAIL BEARING DETAIL PRECAST BEAM

22 23
 BEARING DETAIL STEEL BEAM BEARING DETAIL STEEL BEAM THRU-BOLT DETAIL NON-BEARING DETAIL INTERIOR WALLS

BEARING DETAIL STEEL BEAM WITH CANTILEVER BEARING DETAIL STEEL ANGLE

24 25
 ERECTION PROCEDURES AND RECOMMENDATIONS
The following recommendations are provided as a guide to assist in the proper and efficient installation of the hollowcore
roof and floor assembly. Some projects may have special applications that will need to be addressed on a per-job basis.
When erecting Ultra-Span, use the right tools, correct procedures, and work safely.
These recommendations are furnished in the interest of good construction practice for typical installation. Job
requirements and conditions will vary. Wells Concrete assumes no liability for any claim, loss, or injury arising from
installation practices or procedures conducted by others, whether or not in accordance with these recommendations.
If you plan to set Ultra-Span plank instead of
having Wells Concrete do it, be aware of two
important points:
• You are accepting full responsibility for
installing the plank properly, including
all of the work normally handled by
Wells Concrete.
• Wells Concrete will not be responsible for
any problems or damage which result from
incorrect procedures once the material is
loaded on your trucks or delivered to the
job-site.
To erect Ultra-Span with a minimum of delays
and problems, follow the suggestions and
instructions provided on these pages. Additional
help is available from Wells Concrete.
26
A. Pre-Erection Stage
PRIOR TO SCHEDULING DELIVERY, GO OVER THIS LIST CAREFULLY
1. The erector should familiarize themselves with shop drawings
(provided by Wells Concrete), the architectural and structural
plans and specifications as well as the job-site conditions.
Access for erectors crane and suppliers rigs should be pre-
planned paying close attention to overhead clearance, surface
stability and underground obstacles. The general contractor is
responsible for providing access to job-site.
2. Erect all materials strictly in accordance with the shop
drawings.
3. Other trades should be made aware of the requirements for
dimensional accuracy of supporting walls and beams, uniform
level bearing surfaces and anchorage locations.
4. The general contractor must determine which point of the
structure to use as a starting point and sequence of erection.
This information should be given to Wells prior to scheduling
delivery time so as to allow Wells to prepare a load list.
5. Coordinate delivery times with Wells Concrete and/or the
trucking company in advance.
6. Check product weights and determine the crane size required.
7. Make sure access is available for the crane and trucks.
8. Determine that the proper equipment is available for erecting
the plank.
9. Have all erecting equipment sized by a competent rigger.
10. Check building dimensions and lay out the job. Become
familiar with plank tolerances, and note that plank will have
camber, and may gain or lose in dimensions. Make sure all
bearing supports are in place.
11. Review the load lists and shipping sequence with
Wells Concrete.
12. Insure that the crew, crane, delivery, grout or grout materials,
and required tools are coordinated with the job schedule.
Ultra-Span plank can usually be hoisted directly from the
delivery truck into final position on the structure in one
smooth, efficient operation. The allowable off-loading time
per delivery truck is one hour. Trucks can be off loaded well
within this amount of time with proper coordination. A typical
shipping schedule would provide for sequential delivery trucks
to arrive in one- to two-hour intervals after the first. This will
be coordinated between the general contractor, erector, and
Wells Concrete.
13. Be sure that personnel supervising and performing the
erection are qualified.
14. INSIST ON SAFE WORKING CONDITIONS AND SAFE
PROCEDURES AT ALL TIMES.
27
 B. Erection Stage - Handling and Setting Ultra-Span
Ultra-Span plank must be shipped, lifted, and handled properly to ensure good results.
1. Make sure dunnage and pickup points line up when plank are
being shipped or stacked.
2. To avoid unnecessary handling or stockpiling, lift and place
plank directly off the truck.
3. Your plank will be delivered with the correct side up. Always
handle with this side up.
4. When lifting, make sure slings or chokers are located no more
than 12 inches from the ends. NEVER LIFT FROM THE MIDDLE.
One exception would be a cantilevered plank. Consult Wells
Concrete in this instance.
5. Never cantilever (overhang) plank unless it has been designed
as a cantilever.
6. Allow sufficient bearing. Minimum bearing is shown on the
approved shop drawings.
7. Place bearing strips in accordance with the shop drawings.
8. Set each plank as close as possible to its final position,
allowing just enough room to remove the slings. After
removing slings, skid the plank into final position against the
adjacent one.
9. Split or saw plank to obtain special widths as shown on shop
drawings.
10. Be sure that the plank is being set squarely.
11. Make connections carefully. Bend and place bars or make
welds per shop drawings and/or construction documents.
12. Depending on individual job requirements, erector shall
arrange for crane of adequate capacity with two-way cable
rigging of sufficient length and capacity to handle the
maximum length and weight of the hollowcore plank.
28
13. General contractor or responsible subcontractor shall check
for readiness of structure for hollowcore units. This includes
accessibility by crane, delivery trucks, checking bearing
surfaces, and dimensions of shop drawings.
14. Erector shall place Ultra-Span planks on supporting structure
in conformance with shop drawings. All details indicated on
shop drawings must be adhered to. Any deviation must be
approved by Wells Concrete engineers.
15. Erector shall notify Wells Concrete if any plank is damaged
upon arrival at job-site. This will insure that the unit can be
taken care of or replaced in a timely manner.
16. Hollowcore units should never be lifted into place by any
means other than as shown in the Visual Installation Guide.
This includes placing bars into the hollow voids, using lift
trucks, etc.
17. Any notching or cutting of the units shall be done in a
workmanlike manner and in accordance with the Wells plans
and drawings. Notching or cutting may be necessary around
building members that interfere with unit placement. If the
erector is unfamiliar with hollowcore erection and cutting, call
Wells Concrete for general and specific guidelines.
18. Erection shall proceed in workmanlike manner until
completion of erection phase. Check for proper alignment of
the plank according to the shop drawings before leveling or
grouting takes place.
19. Erector shall furnish all material required for erection, leveling,
grouting or patching.
20. Erector shall install bearing pads and steel hangers (when
required). Bearing pad and hangers are usually furnished by
Wells Concrete.
C. Leveling & Grouting
1. Erector should be alert to replace defective units prior
to grouting and to conduct a final check of leveling and
alignment prior to grouting.
2. All keyway joints between adjacent planks should be fully
grouted by erector or responsible parties with a 3:1 sand
cement grout having an approximate 6-inch slump. Grout
may be mixed with portable mixer or purchased from ready
mix suppliers. Wheel-barrows are normally used for delivery
to grout box or trough which is used to place grout in to the
keyways.
3. The erector shall remove excess grout from the top of the
keyway joints with care as not to effect the bonding of the
composite topping, leaving a flush and finished appearance to
the joint.
4. Erector shall remove excess grout from the bottom chamber
portion of the plank joints.
5. Erector is responsible for cleaning up any grout that flows
through keyway joint and falls to floor below. This can be
greatly reduced by utilizing a foam backer rod.
6. When “feathering” of keyway joints is required as part of the
job specifications, the erector shall taper the keyway grout
pour away from the keyway so as to present a surface without
sharp or noticeable vertical rises between slabs. The correction
of “grout shrinkage” is the responsibility of the erector.
7. Erector shall properly form any openings as required to
prevent grout from falling through using plywood and hilti
shots or other method.
8. Prior to grouting the keyways, variations between adjacent
members should be reasonably leveled out by jacking,
loading or other feasible methods in accordance with
recommendations provided by Wells Concrete.
9. Clear keyways of debris.
10. To assure a good bond, wet down the keyways prior to
grouting. This is especially important in hot weather.
11. Make sure grout is cured prior to placing loads of construction
materials on the deck.
12. Standard procedure for grouting plank keyways during cold
weather is as follows:
a) No grouting will be done at temperatures below 20° F.
unless the desk is covered and heated. Grouting will be
done when the temperature is at least 20° F (and rising),
with the following precautions.
• Keyways must be clean and free of ice and snow.
• A warm grout mix with an appropriate accelerator
will be used.
• Freezing of the grout after it has reached its initial
set is acceptable, but care must be taken to insure
that the in-place grout is not subjected to repeated
freeze/thaw cycles.
b) Above 32 degrees, normal grouting procedures will
be used.
13. When concrete topping is required, the plank must be grouted
first. Unless specified otherwise, the Ultra-Span deck surface
must be clean and thoroughly damp with no standing water.
Precautions must be taken to clean the Ultra-Span surface of
all laitance.
29
 D. Cutting Openings
1. All hole cutting should be approved by Wells Concrete.
2. Plank is designed to support the required loads with the
openings shown on the approved shop drawings. Do not cut
openings that are not shown.
3. Openings should not be cut until the joints are grouted and the
grout has reached 85% of its design strength (normally design
strength is 3,000 psi). Holes are generally laid out by the trades
requiring them.
4. Holes that are drilled or cut through the voids are acceptable.
Holes or openings that cannot be shifted to miss all prestressed
strands must be approved by Wells. This should be done during
the shop drawing process. Additional cost may be incurred if
this is done after shop drawings have been engineered.
30
E. Precautions F. Visual Installation Guide
1. Good construction practice must be maintained during erection
and related operations.
2. Do not lift planks with hooks in end cores.
3. Do not lift planks by means other than support at both ends.
Units are not designed to be lifted at or near the center of the
span. Lifting points shall not be more than 18 inches from each
end of panel.
4. If restacking of the planks is necessary, planks must be
supported only at the dunnage points at or near the ends.
Dunnage must be kept in close vertical alignment and only
identical units stacked together.
5. End walls or other supports should be adequately braced to
accommodate temporary loads if required.
6. Planks must not be inverted or turned upside down.
7. Prestress strands must not be cut unless shown on shop
drawings or approved by a Wells Concrete engineer.
31
 PCI Certified
in plant operations
and field installation

Wells, MN / Albany, MN
800.658.7049
Maple Grove, MN / Rosemount, MN
763.425.5555
Grand Forks, ND
800.732.4261
Fargo, ND
701.478.2100
Des Moines, IA
515.981.4624
Winnipeg, MB
204.509.6383

WELLSCONCRETE.COM

32
 WELLSCONCRETE.COM

ALBANY, MN | DES MOINES, IA | FARGO, ND | GRAND FORKS, ND | MAPLE GROVE, MN | ROSEMOUNT, MN | WELLS, MN | WINNIPEG, MB