MANUFACTURE

Hanson hollowcore wall panels are manufactured using slipform technology and are cast as a continuous length on 170-metre-long steel casting beds (FIGURE 1). After curing and drilling of erection holes, the panels are cut to the required length by means of a diamond-tipped saw. Because the saw does not go through to the steel casting bed, the cuts are rough along the off-form edge. Tolerance on length cuts is ± 10 mm.


Table 1 Properties of hollowcore wall panels

STANDARD TYPES AND PROPERTIES

Hanson hollowcore wall panels are designated according to their thickness and fire-resistance-level (FRL). There are four standard types. Their typical sections are shown in FIGURE 2 and their corresponding properties in TABLE 1.

DESIGN PROCEDURE
  • Determine a feasible arrangement for the basic structure, columns, beams and wall panels
  • Establish the basic design data:

    - Occupancy of building

    - Fire resistance level(building regulations)

    - Sound transmission requirements (building regulations)

    - Exposure classification and durability requirements(AS 3600)

  • Select a suitable panel type from TABLE 1, to satisfy the handling and serviceability requirements established above.
  • Determine the dead, live, wind and any other loads acting on the wall. Any concentrated loads or large openings should be assessed separately.
  • Check the strength capacity of the panel and the connections. In practice, the standard Hanson hollowcore wall panels when used as simple panels, subject to nominal vertical and wind loads, will automatically comply.

For further assistance with design, see Other Data for a link to Hollow Core Walling - A Technical Manual produced by the National Precast Concrete Association Australia and available free online as PDF.

FIXING DETAILS

Generally panels are simply fixed directly to steel supporting structures by clips, or to concrete footings and the like by grouted dowels in the cores. When connected to steel frames, to guard against outward collapse of wall panels during a fire and to comply with the Building Code of Australia, Clause C1.11, some clips will require welding as shown in the details (FIGURES 3 and 4).


FIGURE 3 TYPICAL fixing details for panels in horizontal configuration


FIGURE 4 Typical fixing details for panels in vertical configuration

GABLE ENDS AND CORNER PANELS

When vertically-oriented panels are used at a sloping gable end, the end of the panels can be cut at an angle to match.

At corners,where less than full-width panels are needed to close, longitudinal cuts can be used to produce narrow-width closing panels. Also at corners, panels can have a matching finish (usually exposed aggregate) applied to one edge.

JOINTS

Joints between panels are a nominal 10 mm wide and are sealed on the outer face with a two-part polyurethane sealant placed against a closed-cell foam backing rod. The inner face is not normally sealed but may may be similarly sealed if required.

SERVICE OPENINGS

A standard 820 mm wide personnel door which fits into the 1200 mm modular panel width is available.

Various size window openings can be cut to order. However, it is recommended where possible, window openings of 1200 mm width be used.

Roller door openings are best prepared at the design stage, with panels precut prior to delivery.

Penetrations for other service openings can be cut on-site or precut to order.

SPECIFICATION

A specification is provided in Other Data as a guide to preparing a general project specification or as a stand-alone specification.